1999-2002 ISUZU EXP UBS WORKSHOP MANUAL – PDF DOWNLOAD
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1999-2002 ISUZU EXP UBS WORKSHOP MANUAL
1999-2002 ISUZU EXP UBS WORKSHOP MANUAL
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1999-2002 ISUZU EXP UBS WORKSHOP MANUAL – PDF DOWNLOAD
- recommended. Park vehicle on level ground, “block” front or rear wheels, set jack against the recommended lifting points (see “Lifting Instructions” in this section), raise vehicle and support with chassis stands and then perform the service operations. 2. Before performing service operations, disconnect ground cable from the battery to reduce the chance of cable damage and burning due to short circuiting. 3.
- Use a cover on body, seats and floor to protect them against damage and contamination. 4. Brake fluid and anti–freeze solution must be handled with reasonable care, as they can cause paint damage. 5. The use of proper tools and recommended essential and available tools, where specified, is important for efficient and reliable performance of service repairs. 6. Use genuine Isuzu parts. 7. Used cotter pins, plastic clips, gaskets, O–rings, oil seals, lock washers and self–locking nuts should be discarded and new ones should be installed, as normal function of the parts cannot be maintained if these parts are reused.
- 8.To facilitate proper and smooth reassembly operation, keep disassembled parts neatly in groups. Keeping fixing bolts and nuts separate is very important, as they vary in hardness and design depending on position of installation. 9. Clean the parts before inspection or reassembly. Also clean oil ports, etc. using compressed air, and make certain they are free from restrictions. 10.
- Lubricate rotating and sliding faces of the parts with oil or grease before installation. 11. When necessary, use a sealer on gaskets to prevent leakage. 12. Carefully observe all specifications for bolt and nut torques. 13. When removing or replacing parts that require refrigerant to be discharged from the air conditioning system, be sure to use the Vehicle Refrigerant Recovery and Recycling Equipment (VRRRE) to recover and recycle Refrigerant–134a. 14.
- When a service operation is completed, make a final check to be sure the service has been done properly and the problem has been corrected. 15.SUPPLEMENTAL RESTRAINT SYSTEM The vehicle is equipped with a Supplemental Restraint System (SRS) – Air Bags. This system is not to be serviced without consulting the appropriate service information.
- Consult Section 9J “SRS System” if work is to be done on the front of the vehicle such as bumper, sheet metal, seats, wiring, steering wheel or column. Also review SRS system information if any arc welding is to be done on the vehicle. The SRS system equipped vehicle can be identified by: 1. “AIR BAG” warning light on the instrument cluster. 2. A Code “J” for fifth digit of Vehicle Identification Number.
TABLE OF CONTENTS:
1999-2002 ISUZU EXP UBS WORKSHOP MANUAL – PDF DOWNLOAD
TOP............................................................................................................................................................. 0 US VERSION.................................................................................................................................................. 2 1999 MODEL.............................................................................................................................................. 2 (UX) TROOPER........................................................................................................................................ 2927 Sec.0 GENERAL INFORMATION..................................................................................................................... 2928 0A GENERAL INFORMATION.................................................................................................................... 2928 General Repair Instruction.............................................................................................................. 2928 Illustration Arrows..................................................................................................................... 2929 Identification.......................................................................................................................... 2930 Theft Prevention Standard............................................................................................................... 2932 Lifting Instructions.................................................................................................................... 2937 Standard Bolts Torque Specifications.................................................................................................... 2940 Abbreviations Charts.................................................................................................................... 2941 Service Parts Identification Plate...................................................................................................... 2942 0B MAINTENANCE AND LUBRICATION............................................................................................................ 2943 Maintenance Schedule List............................................................................................................... 2943 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 2946 Recommended Fluids and Lubricants................................................................................................... 2949 Lubricant Viscosity Chart............................................................................................................... 2950 Recommended Liquid Gasket........................................................................................................... 2952 Recommended Thread Locking Agents................................................................................................... 2953 Maintenance Service Data................................................................................................................ 2954 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 2955 1A HVAC SYSTEMS........................................................................................................................... 2955 Service Precaution...................................................................................................................... 2956 Heating and Ventilation System.......................................................................................................... 2956 General Description..................................................................................................................... 2956 Wiring Diagram.......................................................................................................................... 2961 Diagnosis............................................................................................................................... 2962 Individual Inspection................................................................................................................... 2965 Heater Unit............................................................................................................................. 2968 Heater Unit and Associated Parts.................................................................................................... 2968 Removal............................................................................................................................. 2968 Installation........................................................................................................................ 2969 Heater Core and / or Mode Door.......................................................................................................... 2970 Disassembled View................................................................................................................... 2970 Removal............................................................................................................................. 2970 Inspection.......................................................................................................................... 2971 Installation........................................................................................................................ 2971 Heater Mode Control Link Unit........................................................................................................... 2972 Disassembled View................................................................................................................... 2972 Removal............................................................................................................................. 2972 Installation........................................................................................................................ 2973 Heater Temperature Control Link Unit.................................................................................................... 2973 Disassembled View................................................................................................................... 2973 Removal............................................................................................................................. 2973 Installation........................................................................................................................ 2973 Blower Assembly......................................................................................................................... 2974 Blower Assembly and Associated...................................................................................................... 2974 Removal............................................................................................................................. 2974 Installation........................................................................................................................ 2975 Blower Link Unit and / or Mode door..................................................................................................... 2975 Disassembled View................................................................................................................... 2975 Removal............................................................................................................................. 2975 Installation........................................................................................................................ 2976 Blower Motor............................................................................................................................ 2977 Blower Motor and Associated Parts................................................................................................... 2977 Removal............................................................................................................................. 2977 Installation........................................................................................................................ 2977 Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 2978 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 2978 Removal............................................................................................................................. 2978 Installation........................................................................................................................ 2979 Center and / or Drive Side Vent......................................................................................................... 2979 Center Vent, Drive Side Vent and Associated Parts................................................................................... 2979 Removal............................................................................................................................. 2979 Installation........................................................................................................................ 2979 Control Lever Assembly and / or Control Cable........................................................................................... 2980 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 2980 Removal............................................................................................................................. 2980 Installation........................................................................................................................ 2981 Control Panel Illumination Bulb......................................................................................................... 2982 Control Panel Illumination Bulb and Associated Parts................................................................................ 2982 Removal............................................................................................................................. 2982 Installation........................................................................................................................ 2982 Resistor................................................................................................................................ 2983 Resistor and Associated Parts....................................................................................................... 2983 Removal............................................................................................................................. 2983 Installation........................................................................................................................ 2983 Air Conditioning System................................................................................................................. 2984 General Description................................................................................................................. 2984 Wiring Diagram...................................................................................................................... 2990 Diagnosis........................................................................................................................... 2993 Individual Inspection............................................................................................................... 3001 General Repair Procedure............................................................................................................ 3002 Compressor Assembly..................................................................................................................... 3009 Compressor Assembly and Associated Parts............................................................................................ 3009 Removal............................................................................................................................. 3009 Installation........................................................................................................................ 3010 Condenser Assembly...................................................................................................................... 3011 Condenser Assembly and Associated Parts............................................................................................. 3011 Removal............................................................................................................................. 3011 Installation........................................................................................................................ 3011 Receiver / Drier........................................................................................................................ 3012 Receiver / Drier and Associated Parts............................................................................................... 3012 Removal............................................................................................................................. 3012 Installation........................................................................................................................ 3012 Pressure Switch......................................................................................................................... 3013 Pressure Switch and Associated Parts................................................................................................ 3013 Removal............................................................................................................................. 3013 Installation........................................................................................................................ 3013 Evaporator Assembly..................................................................................................................... 3014 Evaporator Assembly and Associated Parts............................................................................................ 3014 Removal............................................................................................................................. 3014 Installation........................................................................................................................ 3015 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 3015 Disassembled View................................................................................................................... 3015 Removal............................................................................................................................. 3015 Installation........................................................................................................................ 3016 Air Conditioning Switch and Illumination Bulb........................................................................................... 3017 Air Conditioning Switch, Illumination Bulb and Associated Parts..................................................................... 3017 Removal............................................................................................................................. 3017 Installation........................................................................................................................ 3017 Refrigerant Line........................................................................................................................ 3018 Refrigerant Line and Associated Parts............................................................................................... 3018 Removal............................................................................................................................. 3018 Installation........................................................................................................................ 3019 Main Data And Specifications............................................................................................................ 3020 Compressor.............................................................................................................................. 3022 Service Precaution.................................................................................................................. 3022 General Description................................................................................................................. 3022 Metric Thread Size Information...................................................................................................... 3024 Compressor Clutch Plate and Hub Assembly................................................................................................ 3024 Removal............................................................................................................................. 3024 Installation........................................................................................................................ 3024 Compressor Clutch Rotor and/or Bearing.................................................................................................. 3025 Removal............................................................................................................................. 3025 Installation........................................................................................................................ 3025 Compressor Clutch Coil.................................................................................................................. 3026 Removal............................................................................................................................. 3026 Installation........................................................................................................................ 3027 Compressor Shaft Seal................................................................................................................... 3028 Service Precaution.................................................................................................................. 3028 Seal Leak Detection................................................................................................................. 3028 Removal............................................................................................................................. 3028 Cleaning............................................................................................................................ 3029 Installation........................................................................................................................ 3029 Compressor Pressure Relief Valve........................................................................................................ 3030 Removal............................................................................................................................. 3030 Installation........................................................................................................................ 3030 Compressor Oil.......................................................................................................................... 3030 Compressor Oil Check................................................................................................................ 3030 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 3030 Checking and Adjusting for Compressor Replacement................................................................................... 3030 Contamination of Compressor Oil..................................................................................................... 3031 Oil Return Operation................................................................................................................ 3031 Replacement of Component Parts...................................................................................................... 3031 Bench-Check Procedure............................................................................................................... 3031 Special Tools........................................................................................................................... 3033 Sec.2 STEERING................................................................................................................................ 3035 2A POWER ASSISTED SYSTEM.................................................................................................................. 3035 Service Precaution...................................................................................................................... 3036 General Description..................................................................................................................... 3036 Diagnosis............................................................................................................................... 3039 Power Steering System Test.............................................................................................................. 3045 Maintenance............................................................................................................................. 3046 Fluid Level............................................................................................................................. 3046 Bleeding The Power Steering System...................................................................................................... 3046 Bleeding Procedure...................................................................................................................... 3046 Flushing The Power Steering System...................................................................................................... 3046 Steering Wheel Free Play Adjustment..................................................................................................... 3047 Front End Alignment Inspection and Adjustment........................................................................................... 3047 Main Data and Specifications............................................................................................................ 3052 Special Tools........................................................................................................................... 3053 Power Steering Gear..................................................................................................................... 3054 Power Steering Gear and Associated Parts............................................................................................ 3054 Removal............................................................................................................................. 3054 Installation........................................................................................................................ 3055 Steering Gear Disassembled View..................................................................................................... 3056 Disassembly......................................................................................................................... 3057 Inspection and Repair............................................................................................................... 3058 Reassembly.......................................................................................................................... 3059 Main Data and Specifications........................................................................................................ 3061 Power Steering Pump..................................................................................................................... 3062 Power Steering Pump and Associated Parts............................................................................................ 3062 Removal............................................................................................................................. 3062 Installation........................................................................................................................ 3063 Power Steering Pump Disassembled View............................................................................................... 3064 Disassembly......................................................................................................................... 3064 Inspection and Repair............................................................................................................... 3065 Reassembly.......................................................................................................................... 3066 Main Data and Specifications........................................................................................................ 3067 Center Track Rod Assembly............................................................................................................... 3068 Center Track Rod Assembly and Associated Parts...................................................................................... 3068 Removal............................................................................................................................. 3069 Inspection and Repair............................................................................................................... 3069 Installation........................................................................................................................ 3069 Outer Track Rod Assembly................................................................................................................ 3070 Outer Track Rod Assembly and Associated Parts....................................................................................... 3070 Removal............................................................................................................................. 3071 Inspection and Repair............................................................................................................... 3071 Installation........................................................................................................................ 3072 Relay Lever............................................................................................................................. 3073 Relay Lever and Associated Parts.................................................................................................... 3073 Removal............................................................................................................................. 3073 Installation........................................................................................................................ 3074 Steering Linkage and Associated Parts................................................................................................... 3075 Main Data and Specifications........................................................................................................ 3075 Special Tools........................................................................................................................... 3076 Supplemental Restraint System Steering Wheel & Column................................................................................... 3077 Service Precaution.................................................................................................................. 3077 SRS Connectors...................................................................................................................... 3077 Inflator Module......................................................................................................................... 3079 Inflator Module and Associated Parts................................................................................................ 3079 Removal............................................................................................................................. 3079 Inspection and Repair............................................................................................................... 3080 Installation........................................................................................................................ 3080 Steering Wheel.......................................................................................................................... 3081 Steering Wheel and Associated Parts................................................................................................. 3081 Removal............................................................................................................................. 3081 Installation........................................................................................................................ 3083 Combination Switch...................................................................................................................... 3084 Combination Switch and Associated Parts............................................................................................. 3084 Removal............................................................................................................................. 3084 Installation........................................................................................................................ 3086 Lock Cylinder........................................................................................................................... 3088 Lock Cylinder and Associated Parts.................................................................................................. 3088 Removal............................................................................................................................. 3088 Installation........................................................................................................................ 3090 System Inspection................................................................................................................... 3091 Steering Column......................................................................................................................... 3092 Steering Column and Associated Parts................................................................................................ 3092 Removal............................................................................................................................. 3092 Inspection.......................................................................................................................... 3094 Installation........................................................................................................................ 3096 System Inspection................................................................................................................... 3097 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 3098 Main Data and Specifications........................................................................................................ 3098 Special Tools........................................................................................................................... 3099 Sec.3 SUSPENSION.............................................................................................................................. 3100 3C FRONT SUSPENSION....................................................................................................................... 3100 Service Precaution...................................................................................................................... 3100 General Description..................................................................................................................... 3101 General Diagnosis....................................................................................................................... 3102 Shock Absorber.......................................................................................................................... 3105 Shock Absorber and Associated Parts................................................................................................. 3105 Removal............................................................................................................................. 3105 Inspection and Repair............................................................................................................... 3105 Installation........................................................................................................................ 3105 Stabilizer Bar.......................................................................................................................... 3106 Stabilizer Bar and Associated Parts................................................................................................. 3106 Removal............................................................................................................................. 3106 Inspection and Repair............................................................................................................... 3106 Installation........................................................................................................................ 3106 Torsion Bar............................................................................................................................. 3107 Torsion Bar and Associated Parts.................................................................................................... 3107 Removal............................................................................................................................. 3107 Inspection and Repair............................................................................................................... 3108 Installation........................................................................................................................ 3108 Knuckle................................................................................................................................. 3110 Knuckle and Associated Parts........................................................................................................ 3110 Removal............................................................................................................................. 3110 Inspection and Repair............................................................................................................... 3111 Installation........................................................................................................................ 3111 Upper Control Arm....................................................................................................................... 3113 Upper Control Arm and Associated Parts.............................................................................................. 3113 Removal............................................................................................................................. 3113 Inspection and Repair............................................................................................................... 3114 Installation........................................................................................................................ 3115 Lower Control Arm....................................................................................................................... 3117 Lower Control Arm and Associated Parts.............................................................................................. 3117 Removal............................................................................................................................. 3117 Inspection and Repair............................................................................................................... 3119 Installation........................................................................................................................ 3119 Upper Ball Joint........................................................................................................................ 3121 Upper Ball Joint and Associated Parts............................................................................................... 3121 Removal............................................................................................................................. 3121 Inspection and Repair............................................................................................................... 3122 Installation........................................................................................................................ 3122 Lower Ball Joint........................................................................................................................ 3123 Lower Ball Joint and Associated Parts............................................................................................... 3123 Removal............................................................................................................................. 3123 Inspection and Repair............................................................................................................... 3124 Installation........................................................................................................................ 3124 Main Data and Specifications............................................................................................................ 3125 Special Tools........................................................................................................................... 3126 3D REAR SUSPENSION........................................................................................................................ 3127 Service Precaution...................................................................................................................... 3127 General Description..................................................................................................................... 3128 Coil Spring............................................................................................................................. 3129 Coil Spring and Associated Parts.................................................................................................... 3129 Removal............................................................................................................................. 3129 Inspection and Repair............................................................................................................... 3130 Installation........................................................................................................................ 3130 Shock Absorber.......................................................................................................................... 3131 Shock Absorber and Associated Parts................................................................................................. 3131 Removal............................................................................................................................. 3131 Inspection and Repair............................................................................................................... 3131 Installation........................................................................................................................ 3131 Trailing Link........................................................................................................................... 3132 Trailing Link and Associated Parts.................................................................................................. 3132 Removal............................................................................................................................. 3132 Inspection and Repair............................................................................................................... 3132 Installation........................................................................................................................ 3133 Center Link............................................................................................................................. 3134 Center Link and Associated Parts.................................................................................................... 3134 Removal............................................................................................................................. 3134 Inspection and Repair............................................................................................................... 3134 Installation........................................................................................................................ 3135 Lateral Rod............................................................................................................................. 3136 Lateral Rod and Associated Parts.................................................................................................... 3136 Removal............................................................................................................................. 3136 Inspection and Repair............................................................................................................... 3136 Installation........................................................................................................................ 3137 Stabilizer Bar.......................................................................................................................... 3138 Stabilizer Bar and Associated Parts................................................................................................. 3138 Removal............................................................................................................................. 3138 Inspection and Repair............................................................................................................... 3138 Installation........................................................................................................................ 3139 Main Data and Specifications............................................................................................................ 3140 Special Tools........................................................................................................................... 3142 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 3143 Service Precaution...................................................................................................................... 3143 General Description..................................................................................................................... 3144 Diagnosis............................................................................................................................... 3145 Wheel................................................................................................................................... 3151 Wheel and Associated Parts.......................................................................................................... 3151 Removal............................................................................................................................. 3151 Installation........................................................................................................................ 3151 Tire.................................................................................................................................... 3152 Tire Replacement.................................................................................................................... 3152 General Balance Procedure........................................................................................................... 3152 Balancing Wheel and Tire............................................................................................................ 3153 Main Data and Specifications............................................................................................................ 3154 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 3155 4A1 DIFFERENTIAL (FRONT)................................................................................................................... 3155 Service Precaution...................................................................................................................... 3155 Front Drive Axle........................................................................................................................ 3156 Diagnosis............................................................................................................................... 3156 Pinion Shaft Oil Seal................................................................................................................... 3157 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 3157 Removal............................................................................................................................. 3157 Inspection and Repair............................................................................................................... 3158 Installation........................................................................................................................ 3158 Front Drive Axle Assembly............................................................................................................... 3159 Front Drive Axle Assembly and Associated Parts...................................................................................... 3159 Removal............................................................................................................................. 3159 Installation........................................................................................................................ 3161 Differential Assembly................................................................................................................... 3163 Disassembled View................................................................................................................... 3163 Disassembly......................................................................................................................... 3163 Reassembly.......................................................................................................................... 3166 Differential Cage Assembly.............................................................................................................. 3175 Disassembled View................................................................................................................... 3175 Disassembly......................................................................................................................... 3175 Inspection and Repair............................................................................................................... 3176 Reassembly.......................................................................................................................... 3177 Main Data and Specifications............................................................................................................ 3179 Special Tools........................................................................................................................... 3181 4A2 DIFFERENTIAL (REAR).................................................................................................................... 3183 Service Precaution...................................................................................................................... 3183 General Description..................................................................................................................... 3184 Diagnosis............................................................................................................................... 3185 Axle Housing............................................................................................................................ 3186 Axle Housing and Associated Parts................................................................................................... 3186 Removal............................................................................................................................. 3186 Oil Seal Replacement................................................................................................................ 3187 Installation........................................................................................................................ 3187 Axle Shaft.............................................................................................................................. 3188 Axle Shaft and Associated Parts..................................................................................................... 3188 Removal............................................................................................................................. 3188 Inspection and Repair............................................................................................................... 3189 Oil Seal Replacement................................................................................................................ 3190 Installation........................................................................................................................ 3190 Pinion Oil Seal......................................................................................................................... 3191 Pinion Oil Seal and Associated Parts................................................................................................ 3191 Removal............................................................................................................................. 3191 Inspection and Repair............................................................................................................... 3192 Installation........................................................................................................................ 3192 Differential Assembly................................................................................................................... 3193 Differential Assembly and Associated Parts.......................................................................................... 3193 Removal............................................................................................................................. 3193 Installation........................................................................................................................ 3194 Disassembled View................................................................................................................... 3195 Disassembly......................................................................................................................... 3196 Reassembly.......................................................................................................................... 3198 Differential Cage Assembly.............................................................................................................. 3205 Disassembled View................................................................................................................... 3205 Disassembly......................................................................................................................... 3206 Inspection and Repair............................................................................................................... 3206 Reassembly.......................................................................................................................... 3206 Locking Differential Assembly........................................................................................................... 3208 Disassembled View................................................................................................................... 3208 Disassembly......................................................................................................................... 3208 Inspection and Repair............................................................................................................... 3210 Reassembly.......................................................................................................................... 3210 Main Data and Specifications............................................................................................................ 3212 Special Tools........................................................................................................................... 3213 4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)............................................................................................ 3216 Service Precaution...................................................................................................................... 3216 Shift On The Fly System................................................................................................................. 3217 Outline of Shift on The Fly System.................................................................................................. 3217 Functions of Indicator Lamp............................................................................................................. 3221 Diagnosis............................................................................................................................... 3222 Front Axle Diagnosis.................................................................................................................... 3232 Shift On The Fly Vacuum Piping And Electric Equipment................................................................................... 3234 Vacuum piping diagram............................................................................................................... 3234 VSV Assembly, Actuator Assembly..................................................................................................... 3234 Vacuum Tank......................................................................................................................... 3234 Inspection And Repair............................................................................................................... 3235 4WD Control Unit........................................................................................................................ 3238 4WD Control Unit Associated Parts....................................................................................................... 3238 Removal................................................................................................................................. 3239 Installation............................................................................................................................ 3239 4B2 DRIVELINE CONTROL SYSTEM (TOD)......................................................................................................... 3240 Service Precaution...................................................................................................................... 3240 General Description..................................................................................................................... 3241 System Components....................................................................................................................... 3243 Parts Location...................................................................................................................... 3243 Functions of Indicator Lamp............................................................................................................. 3247 Diagnosis............................................................................................................................... 3251 Basic Diagnostic Flow Chart............................................................................................................. 3255 Parts Location.......................................................................................................................... 3256 Circuit Diagram......................................................................................................................... 3257 Connector List.......................................................................................................................... 3260 Checking Failed Pin..................................................................................................................... 3262 Checking Failed TOD Control Unit Pin.................................................................................................... 3265 Diagnostic Trouble Codes................................................................................................................ 3269 Fault Diagnosis from Trouble Codes...................................................................................................... 3270 Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 3297 Fault Diagnosis from Symptom............................................................................................................ 3324 4C DRIVE SHAFT SYSTEM..................................................................................................................... 3334 Service Precaution...................................................................................................................... 3334 General Description..................................................................................................................... 3334 Diagnosis............................................................................................................................... 3335 Front Hub and Disc...................................................................................................................... 3336 Disassembled View................................................................................................................... 3336 Disassembly......................................................................................................................... 3336 Inspection and Repair............................................................................................................... 3337 Reassembly.......................................................................................................................... 3338 Main Data and Specifications........................................................................................................ 3341 Special Tools....................................................................................................................... 3342 Front Drive Shaft Joint................................................................................................................. 3343 Front Drive Shaft Joints Replacement................................................................................................ 3343 Front Axle Drive Shaft.................................................................................................................. 3344 Front Axle Drive Shaft and Associated Parts......................................................................................... 3344 Disassembly......................................................................................................................... 3345 Inspection and Repair............................................................................................................... 3346 Bushing Replacement................................................................................................................. 3346 Reassembly.......................................................................................................................... 3347 Shift On The Fly System................................................................................................................. 3349 Shift On The Fly System and Associated Parts........................................................................................ 3349 Disassembly......................................................................................................................... 3349 Inspection and Repair............................................................................................................... 3351 Main Data and Specifications........................................................................................................ 3356 Special Tools....................................................................................................................... 3357 Front Propeller Shaft................................................................................................................... 3358 General Description................................................................................................................. 3358 Front Propeller Shaft and Associated Parts.......................................................................................... 3359 Removal............................................................................................................................. 3359 Installation........................................................................................................................ 3360 Disassembly (Except TOD 4ﾗ4)........................................................................................................ 3361 Universal Joint Disassembly......................................................................................................... 3362 Inspection and Repair............................................................................................................... 3363 Universal Joint Reassembly.......................................................................................................... 3366 Reassembly (Except TOD 4ﾗ4)......................................................................................................... 3367 Main Data and Specifications........................................................................................................ 3368 Rear Propeller Shaft.................................................................................................................... 3369 General Description................................................................................................................. 3369 Rear Propeller Shaft and Associated Parts........................................................................................... 3369 Removal............................................................................................................................. 3369 Installation........................................................................................................................ 3370 Disassembly......................................................................................................................... 3371 Universal Joint Disassembly......................................................................................................... 3372 Inspection and Repair............................................................................................................... 3373 Universal Joint Reassembly.......................................................................................................... 3374 Reassembly.......................................................................................................................... 3375 Main Data and Specifications........................................................................................................ 3376 4D1 TRANSFER CASE (STANDARD TYPE).......................................................................................................... 3377 Service Precaution...................................................................................................................... 3377 General Description..................................................................................................................... 3378 Transfer Rear Oil Seal.................................................................................................................. 3380 Removal............................................................................................................................. 3380 Installation........................................................................................................................ 3380 Transfer Case Assembly.................................................................................................................. 3381 Removal............................................................................................................................. 3381 Installation........................................................................................................................ 3381 Transfer Rear Case Assembly............................................................................................................. 3383 Removal............................................................................................................................. 3383 Installation........................................................................................................................ 3384 Disassembly......................................................................................................................... 3387 Inspection and Repair............................................................................................................... 3388 Reassembly.......................................................................................................................... 3388 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 3390 Disassembled View................................................................................................................... 3390 Disassembly......................................................................................................................... 3390 Inspection and Repair............................................................................................................... 3392 Reassembly.......................................................................................................................... 3392 Transfer Case Assembly.................................................................................................................. 3394 Disassembled View................................................................................................................... 3394 Disassembly......................................................................................................................... 3395 Inspection and Repair............................................................................................................... 3397 Reassembly.......................................................................................................................... 3401 Main Data and Specifications............................................................................................................ 3407 Special Tools........................................................................................................................... 3410 4D2 TRANSFER CASE (TOD).................................................................................................................... 3412 Service Precaution...................................................................................................................... 3412 Transfer Case Assembly.................................................................................................................. 3413 Removal............................................................................................................................. 3413 Installation........................................................................................................................ 3414 Transfer Rear Oil Seal.................................................................................................................. 3416 Transfer Rear Oil Seal and Associated Parts......................................................................................... 3416 Removal............................................................................................................................. 3416 Installation........................................................................................................................ 3416 TOD ECU................................................................................................................................. 3418 Removal............................................................................................................................. 3418 Installation........................................................................................................................ 3418 Unit Repair............................................................................................................................. 3419 Inspection.......................................................................................................................... 3419 Transfer Case........................................................................................................................... 3420 Disassembled View................................................................................................................... 3420 Disassembly......................................................................................................................... 3420 Reassembly.......................................................................................................................... 3421 Transfer Cover Assembly................................................................................................................. 3423 Disassembled View................................................................................................................... 3423 Disassembly......................................................................................................................... 3423 Reassembly.......................................................................................................................... 3425 Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 3427 Disassembled View................................................................................................................... 3427 Disassembly......................................................................................................................... 3427 Sprocket and Mechanical Lock............................................................................................................ 3429 Disassembled View................................................................................................................... 3429 Disassembly......................................................................................................................... 3429 Output Shafts and Shift Control Shaft................................................................................................... 3431 Disassembled View................................................................................................................... 3431 Disassembly......................................................................................................................... 3432 Transfer Case........................................................................................................................... 3434 Disassembled View................................................................................................................... 3434 Disassembly......................................................................................................................... 3435 Inspection and Repair............................................................................................................... 3437 Transfer Case........................................................................................................................... 3441 Disassembled View................................................................................................................... 3441 Reassembly.......................................................................................................................... 3441 Output Shafts and Shift Control Shaft................................................................................................... 3444 Disassembled View................................................................................................................... 3444 Reassembly.......................................................................................................................... 3444 Sprocket and Mechanical Lock............................................................................................................ 3447 Disassembled View................................................................................................................... 3447 Reassembly.......................................................................................................................... 3447 Clutch Pack and Clutch Cam.............................................................................................................. 3449 Disassembled View................................................................................................................... 3449 Reassembly.......................................................................................................................... 3449 Main Data and Specifications............................................................................................................ 3451 Special Tools........................................................................................................................... 3453 Sec.5 BRAKES.................................................................................................................................. 3454 5A BRAKE CONTROL SYSTEM................................................................................................................... 3454 Service Precaution...................................................................................................................... 3455 General Description..................................................................................................................... 3456 System Components................................................................................................................... 3456 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 3456 ABS Warning Light................................................................................................................... 3457 Wheel Speed Sensor.................................................................................................................. 3457 G-Sensor............................................................................................................................ 3457 Normal and Anti-lock Braking........................................................................................................ 3457 Brake Pedal Travel.................................................................................................................. 3457 Acronyms and Abbreviations.......................................................................................................... 3457 General Diagnosis....................................................................................................................... 3458 General Information................................................................................................................. 3458 ABS Service Precautions............................................................................................................. 3458 Computer System Service Precautions................................................................................................. 3458 General Service Precautions......................................................................................................... 3458 Note on Intermittents............................................................................................................... 3458 Test Driving ABS Complaint Vehicles................................................................................................. 3458 "ABS" Warning Light................................................................................................................. 3459 Normal Operation.................................................................................................................... 3459 Basic Diagnostic Flow Chart......................................................................................................... 3459 Basic Inspection Procedure.......................................................................................................... 3460 Tech 2 Scan Tool.................................................................................................................... 3461 Getting Started..................................................................................................................... 3462 Operating Procedure................................................................................................................. 3462 Data List........................................................................................................................... 3464 EHCU Connector Pin-out Checks........................................................................................................... 3465 Circuit Diagram..................................................................................................................... 3466 Connector List...................................................................................................................... 3469 Part Location....................................................................................................................... 3471 Symptom Diagnosis....................................................................................................................... 3472 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 3472 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 3473 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 3473 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 3474 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 3474 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 3475 Diagnostic Trouble Codes................................................................................................................ 3476 Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 3477 Diagnostic Trouble Codes (DTCs)..................................................................................................... 3477 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 3480 Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 3480 Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 3481 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 3481 Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 3481 Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 3482 Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 3483 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 3483 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 3484 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 3484 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 3484 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 3485 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 3485 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 3485 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 3486 Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 3486 Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 3487 Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 3487 Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 3488 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 3489 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 3490 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 3491 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 3492 Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 3493 Unit Inspection Procedure............................................................................................................... 3494 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 3494 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 3495 Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 3495 Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 3496 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 3496 Chart C-2 Transmission Input Inspection Procedure................................................................................... 3497 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 3498 Special Tools........................................................................................................................... 3499 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 3500 Service Precaution...................................................................................................................... 3500 Electronic Hydraulic Control Unit....................................................................................................... 3501 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 3501 Removal............................................................................................................................. 3501 Installation........................................................................................................................ 3501 G-Sensor................................................................................................................................ 3502 Removal............................................................................................................................. 3502 Inspection and Repair............................................................................................................... 3502 Installation........................................................................................................................ 3502 Front Wheel Speed Sensor................................................................................................................ 3503 Front Wheel Speed Sensor and Associated Parts....................................................................................... 3503 Removal............................................................................................................................. 3503 Inspection and Repair............................................................................................................... 3504 Installation........................................................................................................................ 3504 Rear Wheel Speed Sensor................................................................................................................. 3505 Rear Wheel Speed Sensor and Associated Parts........................................................................................ 3505 Removal............................................................................................................................. 3505 Inspection and Repair............................................................................................................... 3505 Installation........................................................................................................................ 3505 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 3506 Service Precaution...................................................................................................................... 3507 General Description..................................................................................................................... 3507 Diagnosis............................................................................................................................... 3510 General Diagnosis....................................................................................................................... 3511 Hydraulic Brakes........................................................................................................................ 3514 Filling Master Cylinder Reservoir................................................................................................... 3514 Deterioration of Brake Fluid........................................................................................................ 3514 Leakage of Brake Fluid.............................................................................................................. 3514 Bleeding Brake Hydraulic System..................................................................................................... 3514 Flushing Brake Hydraulic System..................................................................................................... 3515 Brake Pipes and Hoses............................................................................................................... 3515 Brake Hose Inspection............................................................................................................... 3515 Front / Rear Caliper Brake Hose......................................................................................................... 3516 Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 3516 Removal............................................................................................................................. 3516 Installation........................................................................................................................ 3516 Rear Axle Brake Hose.................................................................................................................... 3517 Rear Axle Brake Hose and Associated Parts........................................................................................... 3517 Removal............................................................................................................................. 3517 Installation........................................................................................................................ 3517 Brake Pipe.............................................................................................................................. 3518 Removal............................................................................................................................. 3518 Installation........................................................................................................................ 3518 P & B (Proportioning and Bypass) Valve.................................................................................................. 3519 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 3519 Removal............................................................................................................................. 3519 Installation........................................................................................................................ 3519 Main Data and Specifications........................................................................................................ 3520 Brake Pedal............................................................................................................................. 3521 Checking Pedal Height............................................................................................................... 3521 Checking Pedal Travel............................................................................................................... 3521 Brake Pedal and Associated Parts.................................................................................................... 3522 Removal............................................................................................................................. 3522 Installation........................................................................................................................ 3522 Stoplight Switch........................................................................................................................ 3523 Removal............................................................................................................................. 3523 Installation........................................................................................................................ 3523 Main Data and Specifications........................................................................................................ 3524 Fluid Reservoir......................................................................................................................... 3525 Fluid Reservoir Tank and Associated Parts........................................................................................... 3525 Removal............................................................................................................................. 3525 Installation........................................................................................................................ 3525 Master Cylinder Assembly................................................................................................................ 3526 Master Cylinder Assembly and Associated Parts....................................................................................... 3526 Removal............................................................................................................................. 3526 Inspection and Repair............................................................................................................... 3526 Installation........................................................................................................................ 3527 Main Data and Specifications........................................................................................................ 3528 Special Tools....................................................................................................................... 3529 Vacuum Booster Assembly................................................................................................................. 3530 Vacuum Booster Assembly and Associated Parts........................................................................................ 3530 Removal............................................................................................................................. 3530 Inspection and Repair............................................................................................................... 3530 Installation........................................................................................................................ 3531 Exterior Components..................................................................................................................... 3533 Exterior Components and Associated Parts............................................................................................ 3533 Removal............................................................................................................................. 3533 Inspection and Repair............................................................................................................... 3534 Installation........................................................................................................................ 3534 Vacuum Booster Overhaul................................................................................................................. 3534 Vacuum Booster...................................................................................................................... 3534 Main Data and Specifications........................................................................................................ 3535 Special Tools....................................................................................................................... 3536 Front Disc Brake Pads................................................................................................................... 3537 Front Disc Brake Pads Inspection.................................................................................................... 3537 Front Disc Brake Pads and Associated Parts.......................................................................................... 3537 Removal............................................................................................................................. 3538 Installation........................................................................................................................ 3538 Front Disc Brake Rotor.................................................................................................................. 3540 Inspection.......................................................................................................................... 3540 Replacing Brake Rotors.............................................................................................................. 3540 Refinishing Brake Rotors............................................................................................................ 3540 Front Disc Brake Caliper Assembly....................................................................................................... 3542 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 3542 Removal............................................................................................................................. 3542 Installation........................................................................................................................ 3543 Front Disc Brake Caliper................................................................................................................ 3545 Front Disc Brake Caliper Disassembled View.......................................................................................... 3545 Disassembly......................................................................................................................... 3545 Inspection and Repair............................................................................................................... 3546 Reassembly.......................................................................................................................... 3546 Main Data and Specifications........................................................................................................ 3548 Rear Disc Brake Pads.................................................................................................................... 3549 Brake Pads Inspection............................................................................................................... 3549 Brake Pads and Associated Parts..................................................................................................... 3549 Removal............................................................................................................................. 3550 Installation........................................................................................................................ 3550 Rear Disc Brake Rotor................................................................................................................... 3552 Inspection.......................................................................................................................... 3552 Replacing Brake Rotors.............................................................................................................. 3552 Refinishing Brake Rotors............................................................................................................ 3552 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 3553 Rear Disc Brake Caliper Assembly........................................................................................................ 3554 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 3554 Removal............................................................................................................................. 3554 Installation........................................................................................................................ 3555 Rear Disc Brake Caliper................................................................................................................. 3557 Rear Disc Brake Caliper Disassembled View........................................................................................... 3557 Disassembly......................................................................................................................... 3557 Inspection and Repair............................................................................................................... 3558 Reassembly.......................................................................................................................... 3558 Main Data and Specifications........................................................................................................ 3560 5D PARKING BRAKE SYSTEM................................................................................................................... 3561 Service Precaution...................................................................................................................... 3561 General Description..................................................................................................................... 3561 Operation............................................................................................................................... 3562 Parking Brake Lever and Front Cable..................................................................................................... 3563 Parking Brake Lever, Front Cable and Associated Parts............................................................................... 3563 Removal............................................................................................................................. 3563 Installation........................................................................................................................ 3564 Parking Brake Rear Cable................................................................................................................ 3565 Parking Brake Rear Cable and Associated Parts....................................................................................... 3565 Removal............................................................................................................................. 3565 Installation........................................................................................................................ 3566 Inspection and Repair............................................................................................................... 3567 Parking Brake Adjustment............................................................................................................ 3567 Main Data and Specifications............................................................................................................ 3568 Sec.6 ENGINE.................................................................................................................................. 3569 6A ENGINE MECHANICAL...................................................................................................................... 3569 Service Precaution...................................................................................................................... 3570 General Description..................................................................................................................... 3571 Engine Diagnosis........................................................................................................................ 3572 Cylinder Head Cover LH.................................................................................................................. 3586 Removal............................................................................................................................. 3586 Installation........................................................................................................................ 3587 Cylinder Head Cover RH.................................................................................................................. 3589 Removal............................................................................................................................. 3589 Installation........................................................................................................................ 3590 Common Chamber.......................................................................................................................... 3592 Removal............................................................................................................................. 3592 Installation........................................................................................................................ 3592 Exhaust Manifold LH..................................................................................................................... 3594 Removal............................................................................................................................. 3594 Installation........................................................................................................................ 3594 Exhaust Manifold RH..................................................................................................................... 3595 Removal............................................................................................................................. 3595 Installation........................................................................................................................ 3595 Crankshaft Pulley....................................................................................................................... 3596 Removal............................................................................................................................. 3596 Installation........................................................................................................................ 3596 Timing Belt............................................................................................................................. 3597 Removal............................................................................................................................. 3597 Installation........................................................................................................................ 3598 Camshaft................................................................................................................................ 3601 Removal............................................................................................................................. 3601 Installation........................................................................................................................ 3601 Cylinder Head........................................................................................................................... 3605 Removal............................................................................................................................. 3605 Installation........................................................................................................................ 3605 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 3607 Removal............................................................................................................................. 3607 Installation........................................................................................................................ 3607 Piston, Piston Ring and Connecting Rod.................................................................................................. 3608 Removal............................................................................................................................. 3608 Installation........................................................................................................................ 3609 Crankshaft and Main Bearings............................................................................................................ 3610 Removal............................................................................................................................. 3610 Installation........................................................................................................................ 3611 Rear Oil Seal........................................................................................................................... 3615 Removal............................................................................................................................. 3615 Installation........................................................................................................................ 3615 Engine Assembly......................................................................................................................... 3616 Removal............................................................................................................................. 3616 Installation........................................................................................................................ 3616 Cylinder Head........................................................................................................................... 3620 Cylinder Head and Associated Parts.................................................................................................. 3620 Disassembly......................................................................................................................... 3620 Clean............................................................................................................................... 3621 Inspection and Repair............................................................................................................... 3621 Reassembly.......................................................................................................................... 3621 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 3624 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 3624 Disassembly......................................................................................................................... 3624 Inspection and Repair............................................................................................................... 3625 Reassembly.......................................................................................................................... 3628 Valve Clearance Adjustments......................................................................................................... 3629 Camshaft................................................................................................................................ 3631 Camshaft and Associated Parts....................................................................................................... 3631 Disassembly......................................................................................................................... 3631 Inspection and Repair............................................................................................................... 3632 Reassembly.......................................................................................................................... 3634 Crankshaft.............................................................................................................................. 3637 Crankshaft and Associated Parts..................................................................................................... 3637 Disassembly......................................................................................................................... 3637 Inspection and Repair............................................................................................................... 3638 Inspection and Repair............................................................................................................... 3639 Reassembly.......................................................................................................................... 3641 Piston and Connecting Rod............................................................................................................... 3645 Piston, Connecting Rod and Associate Parts.......................................................................................... 3645 Disassembly......................................................................................................................... 3645 Inspection and Repair............................................................................................................... 3646 Reassembly.......................................................................................................................... 3650 Cylinder Block.......................................................................................................................... 3653 Cylinder Block and Associated Parts................................................................................................. 3653 Disassembly......................................................................................................................... 3653 Inspection and Repair............................................................................................................... 3654 Reassembly.......................................................................................................................... 3655 Main Data and Specification............................................................................................................. 3658 Special Tool............................................................................................................................ 3664 6B ENGINE COOLING......................................................................................................................... 3666 Service Precaution...................................................................................................................... 3666 General Description..................................................................................................................... 3667 Diagnosis............................................................................................................................... 3670 Draining and Refilling Cooling System................................................................................................... 3671 Water Pump.............................................................................................................................. 3672 Water Pump and Associated Parts..................................................................................................... 3672 Removal............................................................................................................................. 3672 Inspection.......................................................................................................................... 3672 Installation........................................................................................................................ 3672 Thermostat.............................................................................................................................. 3673 Thermostat and Associated Parts..................................................................................................... 3673 Removal............................................................................................................................. 3673 Inspection.......................................................................................................................... 3673 Installation........................................................................................................................ 3673 Radiator................................................................................................................................ 3674 Radiator and Associated Parts....................................................................................................... 3674 Removal............................................................................................................................. 3674 Inspection.......................................................................................................................... 3675 Installation........................................................................................................................ 3676 Drive Belt and Cooling Fan.............................................................................................................. 3677 Drive Belt and Associated Parts..................................................................................................... 3677 Inspection.......................................................................................................................... 3677 Installation........................................................................................................................ 3677 Main Data and Specifications............................................................................................................ 3678 Special Tool............................................................................................................................ 3679 6C ENGINE FUEL............................................................................................................................ 3680 Service Precaution...................................................................................................................... 3680 General Description..................................................................................................................... 3681 Fuel Metering........................................................................................................................... 3682 Fuel Filter............................................................................................................................. 3683 Fuel Filter and Associated Parts.................................................................................................... 3683 Removal............................................................................................................................. 3683 Inspection.......................................................................................................................... 3683 Installation........................................................................................................................ 3683 Inspection.......................................................................................................................... 3684 In-Tank Fuel Filter................................................................................................................. 3684 Fuel Pump Flow Test................................................................................................................. 3684 Fuel Pump............................................................................................................................... 3685 Fuel Pump and Associated Parts...................................................................................................... 3685 Removal............................................................................................................................. 3685 Installation........................................................................................................................ 3685 Fuel Pump Relay......................................................................................................................... 3686 General Description................................................................................................................. 3686 Fuel Tank............................................................................................................................... 3686 Fuel Tank and Associated Parts...................................................................................................... 3686 Removal............................................................................................................................. 3686 Installation........................................................................................................................ 3687 Fuel Tube / Quick-Connect Fittings...................................................................................................... 3687 Precautions......................................................................................................................... 3687 Cautions During Work................................................................................................................ 3687 Removal............................................................................................................................. 3687 Reuse of Quick-Connector............................................................................................................ 3689 Assembling Advice................................................................................................................... 3689 Fuel Gauge Unit......................................................................................................................... 3690 Fuel Gauge Unit and Associated Parts................................................................................................ 3690 Removal............................................................................................................................. 3690 Installation........................................................................................................................ 3690 Fuel Filler Cap......................................................................................................................... 3691 General Description................................................................................................................. 3691 Inspection.......................................................................................................................... 3691 Main Data and Specifications............................................................................................................ 3691 6D1 ENGINE ELECTRICAL...................................................................................................................... 3692 Battery................................................................................................................................. 3692 General Description................................................................................................................. 3692 Diagnosis........................................................................................................................... 3692 Battery Charging.................................................................................................................... 3693 Jump Starting....................................................................................................................... 3693 Battery Removal..................................................................................................................... 3694 Battery Installation................................................................................................................ 3694 Main Data and Specifications........................................................................................................ 3695 6D2 IGNITION SYSTEM........................................................................................................................ 3696 Service Precaution...................................................................................................................... 3696 General Description..................................................................................................................... 3697 Diagnosis............................................................................................................................... 3697 Ignition Coil........................................................................................................................... 3698 Removal............................................................................................................................. 3698 Inspection and Repair............................................................................................................... 3698 Installation........................................................................................................................ 3698 Spark Plug.............................................................................................................................. 3699 Removal............................................................................................................................. 3699 Inspection and Repair............................................................................................................... 3699 Installation........................................................................................................................ 3699 Crankshaft Angle Sensor................................................................................................................. 3700 Removal............................................................................................................................. 3700 Installation........................................................................................................................ 3700 Main Data and Specifications............................................................................................................ 3701 6D3 STARTING AND CHARGING SYSTEM........................................................................................................... 3702 Service Precaution...................................................................................................................... 3702 Starting System......................................................................................................................... 3703 General Description..................................................................................................................... 3703 Diagnosis............................................................................................................................... 3705 Starter................................................................................................................................. 3706 Removal............................................................................................................................. 3706 Installation........................................................................................................................ 3706 Disassembled View................................................................................................................... 3707 Disassembly......................................................................................................................... 3708 Inspection and Repair............................................................................................................... 3710 Reassembly.......................................................................................................................... 3714 Main Data and Specifications........................................................................................................ 3716 Charging System......................................................................................................................... 3719 General Description..................................................................................................................... 3719 General On-Vehicle Inspection........................................................................................................... 3719 Generator............................................................................................................................... 3720 Removal............................................................................................................................. 3720 Inspection.......................................................................................................................... 3720 Installation........................................................................................................................ 3720 Disassembled View................................................................................................................... 3721 Disassembly......................................................................................................................... 3722 Inspection and Repair............................................................................................................... 3724 Reassembly.......................................................................................................................... 3726 Reassembly.......................................................................................................................... 3726 Main Data and Specifications........................................................................................................ 3727 6E 3.5L ENGINE DRIVEABILITY AND EMISSIONS................................................................................................. 3728 Specifications.......................................................................................................................... 3733 Tightening Specifications........................................................................................................... 3733 Diagrams and Schematics................................................................................................................. 3734 PCM Wiring Diagram (1 of 8)......................................................................................................... 3734 PCM Wiring Diagram (2 of 8)......................................................................................................... 3735 PCM Wiring Diagram (3 of 8)......................................................................................................... 3736 PCM Wiring Diagram (4 of 8)......................................................................................................... 3737 PCM Wiring Diagram (5 of 8, Automatic Transmission Only)............................................................................ 3738 PCM Wiring Diagram (6 of 8, Manual Transmission Only)............................................................................... 3739 PCM Wiring Diagram (7 of 8)......................................................................................................... 3740 PCM Wiring Diagram (8 of 8)......................................................................................................... 3741 PCM Pinouts............................................................................................................................. 3742 PCM Pinout Table, 32-Way Red Connector-Row "A"...................................................................................... 3742 PCM Pinout Table, 32-Way Red Connector-Row "B"...................................................................................... 3744 PCM Pinout Table, 32-Way White Connector-Row "C".................................................................................... 3745 PCM Pinout Table, 32-Way White Connector-Row "D".................................................................................... 3746 PCM Pinout Table, 32-Way Blue Connector-Row "E"..................................................................................... 3748 PCM Pinout Table, 32-Way Blue Connector-Row "F"..................................................................................... 3749 Component Locators...................................................................................................................... 3750 Engine Component Locator Table...................................................................................................... 3751 Undercarriage Component Locator..................................................................................................... 3752 Undercarriage Component Locator Table (Automatic Transmission)...................................................................... 3752 Undercarriage Component Locator Table (Manual Transmission)......................................................................... 3753 Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 3753 Sensors and Miscellaneous Component Locators........................................................................................ 3754 Diagnosis............................................................................................................................... 3757 Strategy-Based Diagnostics.......................................................................................................... 3757 DTC Stored.......................................................................................................................... 3757 No DTC.............................................................................................................................. 3757 No Matching Symptom................................................................................................................. 3757 Intermittents....................................................................................................................... 3757 No Trouble Found.................................................................................................................... 3757 Verifying Vehicle Repair............................................................................................................ 3757 General Service Information............................................................................................................. 3758 OBD II Serviceablity Issues......................................................................................................... 3758 Emissions Control Information Label................................................................................................. 3758 Maintenance Schedule................................................................................................................ 3759 Visual / Physical Engine Compartment Inspection..................................................................................... 3759 Basic Knowledge of Tools Required................................................................................................... 3759 Serial Data Communications.............................................................................................................. 3759 Class II Serial Data Communications................................................................................................. 3759 On-Board Diagnostic (OBD II)............................................................................................................ 3759 On-Board Diagnostic Tests........................................................................................................... 3759 Comprehensive Component Monitor Diagnostic Operation................................................................................ 3759 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 3760 Common OBD II Terms................................................................................................................. 3760 The Diagnostic Executive............................................................................................................ 3761 DTC Types........................................................................................................................... 3762 Decimal/Binary/Hexadecimal Conversions.............................................................................................. 3763 Verifying Vehicle Repair............................................................................................................ 3763 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 3763 Tech 2.............................................................................................................................. 3764 Tech 2 Features..................................................................................................................... 3765 Getting Started..................................................................................................................... 3765 Operating Procedure (For Example)................................................................................................... 3766 DTC Modes........................................................................................................................... 3767 DTC Information Mode................................................................................................................ 3767 Miscellaneous Test.................................................................................................................. 3768 Lamps Test.......................................................................................................................... 3768 Relays Test......................................................................................................................... 3769 EVAP Test........................................................................................................................... 3770 Idle Air Control System Test........................................................................................................ 3772 Fuel System Test.................................................................................................................... 3773 EGR Control Test.................................................................................................................... 3775 Variable Intake Manifold Solenoid Test.............................................................................................. 3775 Injector Balance Test............................................................................................................... 3776 Plottong Snapshot Graph................................................................................................................. 3777 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 3778 Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 3779 Primary System-Based Diagnostic......................................................................................................... 3780 Fuel Control Heated Oxygen Sensor................................................................................................... 3780 HO2S Heater......................................................................................................................... 3780 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 3780 Evaporative Emission (EVAP) Purge System Vacuum Switch.............................................................................. 3781 Misfire Monitor Diagnostic Operation.................................................................................................... 3781 Misfire Counters.................................................................................................................... 3781 Fuel Trim System Monitor Diagnostic Operation........................................................................................... 3782 Fuel Trim Cell Diagnostic Weights................................................................................................... 3782 On-Board Diagnostic (OBD II) System Check............................................................................................... 3783 A/C Clutch Control Circuit Diagnosis.................................................................................................... 3786 Electronic Ignition System Diagnosis.................................................................................................... 3792 EVAP Canister Purge Solenoid and EVAP Vacuum Switch..................................................................................... 3792 Visual Check of The Evaporative Emission Canister....................................................................................... 3792 Fuel Metering System Check.............................................................................................................. 3792 Idle Air Control (IAC) Valve............................................................................................................ 3792 Fuel System Pressure Test............................................................................................................... 3792 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.............................................................. 3792 Knock Sensor Diagnosis.................................................................................................................. 3797 Powertrain Control Module (PCM) Diagnosis............................................................................................... 3797 Multiple PCM Information Sensor DTCS Set................................................................................................ 3797 Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 3800 Engine Tech 2 Data Definitions and Ranges............................................................................................... 3800 Typical Scan Data Values................................................................................................................ 3803 No Malfunction Indicator Lamp (MIL)..................................................................................................... 3809 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 3812 Engine Cranks But Will Not Run.......................................................................................................... 3814 Fuel System Electrical Test............................................................................................................. 3820 Fuel System Diagnosis................................................................................................................... 3823 Idle Air Control (IAC) System Check..................................................................................................... 3828 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................ 3831 Exhaust Gas Recirculation (EGR) System Check............................................................................................ 3833 Manifold Absolute Pressure (MAP) Output Check........................................................................................... 3835 Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 3837 Upshift Lamp System Check (Manual Transmission Only).................................................................................... 3840 PCM Diagnostic Trouble Codes............................................................................................................ 3843 Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 3847 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 3850 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 3853 Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 3856 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 3859 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 3862 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 3865 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 3868 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 3871 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 3874 Diagnostic Trouble Code (DTC) P0121 TP System Performance............................................................................... 3877 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....................................................................... 3880 Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage...................................................................... 3883 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 3886 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 3889 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 3892 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 3895 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit I........ 3899 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 3902 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 3905 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 3908 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 3911 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 3914 Diagnostic Trouble Code (DTC) P0143 HO2S Circuit Low Voltage Bank 1 Sensor 3............................................................ 3917 Diagnostic Trouble Code (DTC) P0144 HO2S Circuit High Voltage Bank 1 Sensor 3........................................................... 3920 Diagnostic Trouble Code (DTC) P0146 HO2S Circuit Insufficient Activity Bank 1 Sensor 3.................................................. 3923 Diagnostic Trouble Code (DTC) P0147 HO2S Heater Circuit Bank 1 Sensor 3................................................................. 3926 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 3930 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 3933 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 3936 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 3940 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor................................................................... 3943 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 3946 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 3949 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 3952 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 3955 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 3958 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 3962 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 3966 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 3970 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 3974 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 3977 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 3980 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 3983 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 3986 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 3989 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 3992 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 3996 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 3998 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 4000 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 4002 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 4004 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 4006 Diagnostic Trouble Code (DTC) P0325 KS Module Circuit................................................................................... 4008 Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit................................................................................... 4010 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 4013 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 4016 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 4019 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 4023 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 4027 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 4030 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 4033 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 4036 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 4039 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 4042 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 4045 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.............................................................................. 4048 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck...................................................................................... 4050 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 4052 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 4055 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1 with Automatic Transmission........................................ 4058 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1 with Manual Transmission........................................... 4061 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2 with Automatic Transmission........................................ 4064 Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 4066 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 4070 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 4074 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage............................................................... 4077 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.............................................................. 4080 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................ 4083 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.............................................................. 4086 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 4088 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 4091 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 4094 Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 4097 Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 4099 Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 4100 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 4101 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 4103 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 4105 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 4108 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 4110 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 4112 Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage......................................................... 4115 Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage.......................................................... 4117 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 4119 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 4123 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 4127 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 4131 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 4135 Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault..................................................................... 4138 Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................ 4139 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 4140 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 4143 Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.................................................................................. 4146 Diagnostic Trouble Code (DTC) P1509 IAC System High RPM................................................................................. 4149 Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................ 4152 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 4153 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 4154 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 4157 Symptom Diagnosis....................................................................................................................... 4160 Default Matrix Table.................................................................................................................... 4188 On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 4191 Crankshaft Position (CKP) Sensor........................................................................................................ 4192 Engine Coolant Temperature (ECT) Sensor................................................................................................. 4192 Heated Oxygen Sensor (HO2S)............................................................................................................. 4193 Intake Air Temperature (IAT) Sensor..................................................................................................... 4196 Knock Sensor (KS)....................................................................................................................... 4197 Mass Air Flow (MAF) Sensor.............................................................................................................. 4198 Manifold Absolute Pressure (MAP) Sensor................................................................................................. 4198 Malfunction Indicator Lamp (MIL)........................................................................................................ 4199 Powertrain Control Module (PCM)......................................................................................................... 4199 EEPROM.................................................................................................................................. 4201 Throttle Position (TP) Sensor........................................................................................................... 4201 Vehicle Speed Sensor (VSS).............................................................................................................. 4202 Air Cleaner/Air Filter.................................................................................................................. 4203 Idle Air Control (IAC) Valve............................................................................................................ 4205 Common Chamber.......................................................................................................................... 4206 Accelerator Cable Assembly.............................................................................................................. 4206 Accelerator Pedal Replacement........................................................................................................... 4209 Fuel Filter Cap......................................................................................................................... 4211 Fuel Filter............................................................................................................................. 4211 Fuel Gauge Unit......................................................................................................................... 4214 Fuel Injectors.......................................................................................................................... 4215 Fuel Pressure Regulator................................................................................................................. 4216 Fuel Metering System.................................................................................................................... 4218 Fuel Pump Assembly...................................................................................................................... 4219 Fuel Pump Relay......................................................................................................................... 4219 Fuel Rail Assembly...................................................................................................................... 4220 Fuel Tank............................................................................................................................... 4221 Throttle Body (TB)...................................................................................................................... 4223 Electronic Ignition System.............................................................................................................. 4225 Catalytic Converter..................................................................................................................... 4226 Air Conditioning Relay.................................................................................................................. 4226 EVAP Canister Hoses..................................................................................................................... 4227 EVAP Canister........................................................................................................................... 4227 EVAP Canister Vent Solenoid............................................................................................................. 4228 Fuel Tank Pressure Sensor............................................................................................................... 4229 EVAP Canister Purge Solenoid............................................................................................................ 4229 Fuel Tank Vent Valve.................................................................................................................... 4230 Linear Exhaust Gas Recircula-tion (EGR) Valve........................................................................................... 4230 Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 4231 Wiring and Connectors................................................................................................................... 4232 PCM Connectors and Terminals............................................................................................................ 4232 Wire Harness Repair: Twisted Shielded Cable............................................................................................. 4232 Twisted Leads........................................................................................................................... 4233 Weather-Pack Connector.................................................................................................................. 4234 Com-Pack III............................................................................................................................ 4235 Metri-Pack.............................................................................................................................. 4236 General Description (PCM and Sensors)................................................................................................... 4237 58X Reference PCM Input............................................................................................................. 4237 A/C Request Signal.................................................................................................................. 4237 Crankshaft Position (CKP) Sensor.................................................................................................... 4237 Camshaft Position (CMP) Sensor and Signal........................................................................................... 4237 Engine Coolant Temperature (ECT) Sensor............................................................................................. 4237 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 4238 Fuel Control Heated Oxygen Sensors.................................................................................................. 4238 Catalyst Monitor Heated Oxygen Sensors.............................................................................................. 4238 Intake Air Temperature (IAT) Sensor................................................................................................. 4239 Knock Sensor........................................................................................................................ 4239 Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 4240 Mass Air Flow (MAF) Sensor.......................................................................................................... 4240 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 4240 Powertrain Control Module (PCM)..................................................................................................... 4241 PCM Function........................................................................................................................ 4241 PCM Components...................................................................................................................... 4241 PCM Voltage Description............................................................................................................. 4241 PCM Input/Outputs................................................................................................................... 4242 PCM Service Precautions............................................................................................................. 4242 Reprogramming The PCM............................................................................................................... 4242 Throttle Position (TP) Sensor....................................................................................................... 4242 Transmission Fluid Temperature (TFT) Sensor......................................................................................... 4242 Transmission Range Switch........................................................................................................... 4243 Vehicle Speed Sensor (VSS).......................................................................................................... 4243 Use of Circuit Testing Tools........................................................................................................ 4243 Aftermarket Electrical and Vacuum Equipment......................................................................................... 4243 Electrostatic Discharge Damage...................................................................................................... 4243 Upshift Lamp........................................................................................................................ 4244 General Description (Air Induction)..................................................................................................... 4244 Air Induction System................................................................................................................ 4244 General Description (Fuel Metering)..................................................................................................... 4244 Acceleration Mode................................................................................................................... 4244 Accelerator Controls................................................................................................................ 4244 Battery Voltage Correction Mode..................................................................................................... 4244 CMP Signal.......................................................................................................................... 4244 Clear Flood Mode.................................................................................................................... 4244 Deceleration Mode................................................................................................................... 4244 Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................ 4244 Fuel Cutoff Mode.................................................................................................................... 4244 Fuel Injector....................................................................................................................... 4244 Fuel Metering System Components..................................................................................................... 4245 Fuel Metering System Purpose........................................................................................................ 4245 Fuel Pressure Regulator............................................................................................................. 4245 Fuel Pump Electrical Circuit........................................................................................................ 4245 Fuel Rail........................................................................................................................... 4245 Idle Air Control (IAC) Valve........................................................................................................ 4246 Run Mode............................................................................................................................ 4246 Starting Mode....................................................................................................................... 4246 Throttle Body Unit.................................................................................................................. 4247 General Description (Electronic Ignition System)........................................................................................ 4247 Camshaft Position (CMP) Sensor...................................................................................................... 4247 Crankshaft Position (CKP) Sensor.................................................................................................... 4247 Electronic Ignition................................................................................................................. 4247 Ignition Coils...................................................................................................................... 4248 Ignition Control.................................................................................................................... 4248 Ignition Control PCM Output......................................................................................................... 4249 Knock Sensor (KS) PCM Input......................................................................................................... 4249 Powertrain Control Module (PCM)..................................................................................................... 4249 Spark Plug.......................................................................................................................... 4249 A/C Clutch Diagnosis.................................................................................................................... 4251 A/C Clutch Circuit Operation........................................................................................................ 4251 A/C Clutch Circuit Purpose.......................................................................................................... 4251 A/C Request Signal.................................................................................................................. 4251 General Description (Evaporative (EVAP) Emission System)................................................................................ 4251 EVAP Emission Control System Purpose................................................................................................ 4251 EVAP Emission Control System Operation.............................................................................................. 4252 Enhanced Evaporative Emission Control System........................................................................................ 4252 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 4255 EGR Purpose......................................................................................................................... 4255 Linear EGR Valve.................................................................................................................... 4256 Linear EGR Control.................................................................................................................. 4256 Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 4256 EGR Pintle Position Sensor.......................................................................................................... 4256 General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 4256 Crankcase Ventilation System Purpose................................................................................................ 4256 Crankcase Ventilation System Operation.............................................................................................. 4256 Special Tools........................................................................................................................... 4258 6F ENGINE EXHAUST......................................................................................................................... 4260 General Description..................................................................................................................... 4261 Front Exhaust Pipe (Manual Transmission Only)........................................................................................... 4262 Front Exhaust Pipe and Associated Parts............................................................................................. 4262 Removal............................................................................................................................. 4262 Installation........................................................................................................................ 4262 Three Way Catalytic Converter LH (Automatic Transmission)............................................................................... 4263 Removal............................................................................................................................. 4263 Installation........................................................................................................................ 4263 Three Way Catalytic Converter RH........................................................................................................ 4264 Removal............................................................................................................................. 4264 Installation........................................................................................................................ 4264 Exhaust Silencer........................................................................................................................ 4265 Exhaust Silencer and Associated Parts............................................................................................... 4265 Removal............................................................................................................................. 4265 Installation........................................................................................................................ 4265 Rear Exhaust pipe....................................................................................................................... 4266 Rear Exhaust pipe and Associated Parts.............................................................................................. 4266 Removal............................................................................................................................. 4266 Installation........................................................................................................................ 4266 Main Data and Specifications............................................................................................................ 4267 6G ENGINE LUBRICATION..................................................................................................................... 4268 Service Precaution...................................................................................................................... 4268 General Description..................................................................................................................... 4269 Oil Pump................................................................................................................................ 4270 Oil Pump and Associated Parts....................................................................................................... 4270 Disassembly......................................................................................................................... 4270 Inspection and Repair............................................................................................................... 4271 Reassembly.......................................................................................................................... 4272 Oil Pan and Crankcase................................................................................................................... 4274 Removal............................................................................................................................. 4274 Installation........................................................................................................................ 4274 Oil Pump................................................................................................................................ 4277 Removal............................................................................................................................. 4277 Installation........................................................................................................................ 4277 Oil Pump Oil Seal....................................................................................................................... 4279 Removal............................................................................................................................. 4279 Installation........................................................................................................................ 4279 Oil Filter.............................................................................................................................. 4280 Removal............................................................................................................................. 4280 Installation........................................................................................................................ 4280 Main Data and Specification............................................................................................................. 4281 6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 4282 Service Precaution...................................................................................................................... 4282 Accelerator Pedal Control Cable......................................................................................................... 4283 Removal............................................................................................................................. 4283 Inspection.......................................................................................................................... 4283 Installation........................................................................................................................ 4283 Adjustment.......................................................................................................................... 4283 Accelerator Pedal....................................................................................................................... 4284 Accelerator Pedal and Associated Parts.............................................................................................. 4284 Removal............................................................................................................................. 4284 Installation........................................................................................................................ 4284 Adjustment.......................................................................................................................... 4284 6J INDUCTION.............................................................................................................................. 4285 Service Precaution...................................................................................................................... 4285 Air Cleaner Element..................................................................................................................... 4286 Removal............................................................................................................................. 4286 Inspection.......................................................................................................................... 4286 Installation........................................................................................................................ 4286 Sec.7 TRANSMISSION............................................................................................................................ 4287 7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 4287 Service Precaution...................................................................................................................... 4289 Construction............................................................................................................................ 4289 Range Reference Chart................................................................................................................... 4290 Normal Operation Of 1999 4L30-E Transmission............................................................................................ 4291 Diagnosis............................................................................................................................... 4291 Driver Information...................................................................................................................... 4291 General Diagnosis Procedure............................................................................................................. 4294 Preliminary Inspection Chart............................................................................................................ 4295 Checking Transmission Fluid Level and Condition......................................................................................... 4296 Test Driving............................................................................................................................ 4297 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 4298 Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 4299 Stall Test.............................................................................................................................. 4309 Line Pressure Test...................................................................................................................... 4309 Shift Speed Chart....................................................................................................................... 4310 Lockup Speed Chart...................................................................................................................... 4312 Changing Transmission Fluid............................................................................................................. 4313 Selector Lever.......................................................................................................................... 4313 Inspection.......................................................................................................................... 4313 Removal............................................................................................................................. 4313 Installation........................................................................................................................ 4314 Mode Switch............................................................................................................................. 4315 Removal............................................................................................................................. 4315 Installation........................................................................................................................ 4315 Transmission (With Transfer Case)....................................................................................................... 4317 Transmission And Associated Parts................................................................................................... 4317 Removal............................................................................................................................. 4317 Installation........................................................................................................................ 4319 Solenoid (Main Case Valve Body)......................................................................................................... 4323 Removal............................................................................................................................. 4323 Installation........................................................................................................................ 4323 Solenoid (Adapter Case Valve Body)...................................................................................................... 4324 Removal............................................................................................................................. 4324 Installation........................................................................................................................ 4324 Valve Body Assembly (Main Case)......................................................................................................... 4325 Removal............................................................................................................................. 4325 Installation........................................................................................................................ 4325 Valve Body Assembly (Adapter Case)...................................................................................................... 4327 Removal............................................................................................................................. 4327 Installation........................................................................................................................ 4327 Powertrain Control Module (PCM)......................................................................................................... 4327 Removal............................................................................................................................. 4327 Installation........................................................................................................................ 4327 Speed Sensor (Extension Housing)........................................................................................................ 4328 Removal............................................................................................................................. 4328 Installation........................................................................................................................ 4328 Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 4328 Removal............................................................................................................................. 4328 Installation........................................................................................................................ 4329 Front Oil Seal (Converter Housing)...................................................................................................... 4329 Removal............................................................................................................................. 4329 Installation........................................................................................................................ 4329 Rear Oil Seal (Extension Housing)....................................................................................................... 4329 Removal............................................................................................................................. 4329 Installation........................................................................................................................ 4330 Transmission (4L30-E)................................................................................................................... 4330 Disassembly......................................................................................................................... 4330 Reassembly.......................................................................................................................... 4334 Converter Housing And Oil Pump Assembly................................................................................................. 4345 Disassembled View................................................................................................................... 4345 Disassembly......................................................................................................................... 4345 Inspection And Repair............................................................................................................... 4345 Reassembly.......................................................................................................................... 4345 Oil Pump................................................................................................................................ 4346 Disassembled View................................................................................................................... 4346 Disassembly......................................................................................................................... 4346 Inspection And Repair............................................................................................................... 4346 Reassembly.......................................................................................................................... 4346 Main Case Valve Body.................................................................................................................... 4347 Disassembled View................................................................................................................... 4347 Disassembly......................................................................................................................... 4347 Inspection And Repair............................................................................................................... 4348 Reassembly.......................................................................................................................... 4348 Adapter Case Valve Body................................................................................................................. 4349 Disassembled View................................................................................................................... 4349 Disassembly......................................................................................................................... 4349 Inspection And Repair............................................................................................................... 4349 Reassembly.......................................................................................................................... 4349 Third Clutch And Sprag Unit............................................................................................................. 4351 Disassembled View................................................................................................................... 4351 Disassembly......................................................................................................................... 4351 Inspection And Repair............................................................................................................... 4352 Reassembly.......................................................................................................................... 4352 Third Clutch............................................................................................................................ 4353 Disassembled View................................................................................................................... 4353 Disassemble......................................................................................................................... 4353 Inspection And Repair............................................................................................................... 4353 Reassembly.......................................................................................................................... 4353 Sprag Unit.............................................................................................................................. 4355 Disassembled View................................................................................................................... 4355 Disassembly......................................................................................................................... 4355 Inspection And Repair............................................................................................................... 4355 Reassembly.......................................................................................................................... 4355 Second Clutch........................................................................................................................... 4356 Disassembled View................................................................................................................... 4356 Disassembly......................................................................................................................... 4356 Inspection And Repair............................................................................................................... 4357 Reassembly.......................................................................................................................... 4357 3-4 Accumulator Piston.................................................................................................................. 4358 Disassembled View................................................................................................................... 4358 Disassembly......................................................................................................................... 4358 Inspection And Repair............................................................................................................... 4358 Reassembly.......................................................................................................................... 4359 Reverse Clutch Piston And Center Support................................................................................................ 4360 Disassembled View................................................................................................................... 4360 Disassembly......................................................................................................................... 4360 Inspection And Repair............................................................................................................... 4361 Reassembly.......................................................................................................................... 4361 Overrun Clutch And Turbine Shaft........................................................................................................ 4362 Disassembled View................................................................................................................... 4362 Disassembly......................................................................................................................... 4362 Inspection And Repair............................................................................................................... 4363 Reassembly.......................................................................................................................... 4363 Main Data And Specification............................................................................................................. 4365 Special Tools........................................................................................................................... 4369 4L30-E Parts List....................................................................................................................... 4372 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 4380 Service Precaution...................................................................................................................... 4381 General Description..................................................................................................................... 4381 Electronic Control Diagram.......................................................................................................... 4382 Powertrain Control Module (PCM)..................................................................................................... 4383 Control System Diagram.............................................................................................................. 4384 Shift Control....................................................................................................................... 4385 Band Apply Control.................................................................................................................. 4385 Torque Converter Clutch Control..................................................................................................... 4385 Line Pressure Control............................................................................................................... 4385 On-Board Diagnostic System.......................................................................................................... 4385 Fail Safe Mechanism................................................................................................................. 4385 Torque Management Control........................................................................................................... 4385 ATF Warning Control................................................................................................................. 4385 ABS Control......................................................................................................................... 4385 Shift Mode Control.................................................................................................................. 4386 Gear Shift Control.................................................................................................................. 4387 Winter Drive Mode................................................................................................................... 4388 Backup Mode......................................................................................................................... 4388 Functions of Input / Output Components.............................................................................................. 4389 Diagnosis............................................................................................................................... 4390 Electronic Diagnosis................................................................................................................ 4390 How To Diagnose The Problem......................................................................................................... 4390 Check Trans Indicator............................................................................................................... 4390 Diagnostic Check.................................................................................................................... 4390 "Check Trans" Check................................................................................................................. 4391 Tech2 OBD II Connection............................................................................................................. 4392 F0: Transmission Data............................................................................................................... 4396 F1: PC Solenoid Data................................................................................................................ 4397 OBD II Diagnostic Management System................................................................................................. 4398 16-Terminal Data Link Connector (DLC)............................................................................................... 4399 Malfunction Indicator Lamp (MIL).................................................................................................... 4400 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 4400 Clear DTC........................................................................................................................... 4400 DTC Check........................................................................................................................... 4401 PCM Precaution...................................................................................................................... 4401 Information On PCM.................................................................................................................. 4401 Intermittent Conditions............................................................................................................. 4401 Transmission And PCM Identification................................................................................................. 4402 Diagnostic Trouble Code (DTC) Identification........................................................................................ 4403 DTC P0218 Transmission Fluid Over Temperature........................................................................................... 4404 DTC P0560 System Voltage Malfunction.................................................................................................... 4406 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 4409 DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 4412 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 4415 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 4418 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 4421 DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 4424 DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 4427 DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 4430 DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 4433 DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 4435 DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 4438 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 4440 DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 4442 DTC P0753 Shift Solenoid A Electrical................................................................................................... 4444 DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 4447 DTC P0758 Shift Solenoid B Electrical................................................................................................... 4449 DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 4453 DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 4454 DTC P1835 Kickdown Switch Always On..................................................................................................... 4455 DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 4457 DTC P1860 TCC Solenoid Electrical....................................................................................................... 4461 DTC P1870 Transmission Component Slipping............................................................................................... 4464 7B MANUAL TRANSMISSION.................................................................................................................... 4466 Service Precaution...................................................................................................................... 4466 General Description..................................................................................................................... 4467 Diagnosis............................................................................................................................... 4468 Manual Transmission Assembly............................................................................................................ 4469 Removal............................................................................................................................. 4469 Installation........................................................................................................................ 4473 Disassembled View................................................................................................................... 4478 Disassembly......................................................................................................................... 4481 Main Data and Specifications............................................................................................................ 4527 Special Tools........................................................................................................................... 4529 7C CLUTCH................................................................................................................................. 4531 Service Precaution...................................................................................................................... 4531 General Description..................................................................................................................... 4532 Diagnosis............................................................................................................................... 4536 Clutch Assembly......................................................................................................................... 4537 Clutch Assembly and Associated Parts................................................................................................ 4537 Removal............................................................................................................................. 4537 Inspection and Repair............................................................................................................... 4538 Installation........................................................................................................................ 4542 Clutch Control.......................................................................................................................... 4545 Clutch Control Parts................................................................................................................ 4545 Removal............................................................................................................................. 4545 Inspection and Repair............................................................................................................... 4545 Installation........................................................................................................................ 4546 Adjustment.......................................................................................................................... 4546 Master Cylinder......................................................................................................................... 4549 Inspection and Repair............................................................................................................... 4549 Slave Cylinder.......................................................................................................................... 4550 Disassembled View................................................................................................................... 4550 Disassembly......................................................................................................................... 4550 Inspection and Repair............................................................................................................... 4550 Reassembly.......................................................................................................................... 4551 Main Data and Specifications............................................................................................................ 4552 Special Tools........................................................................................................................... 4554 Sec.8 BODY AND ACCESSORIES.................................................................................................................... 4555 8A LIGHTING SYSTEM........................................................................................................................ 4555 Service Precaution...................................................................................................................... 4556 Headlight Bulb.......................................................................................................................... 4556 Removal............................................................................................................................. 4556 Installation........................................................................................................................ 4556 Headlight............................................................................................................................... 4557 Headlight and Associated Parts...................................................................................................... 4557 Removal............................................................................................................................. 4557 Installation........................................................................................................................ 4557 Headlight Adjustment................................................................................................................ 4557 Fog Light Bulb.......................................................................................................................... 4558 Removal............................................................................................................................. 4558 Installation........................................................................................................................ 4558 Fog Light Assembly...................................................................................................................... 4559 Removal............................................................................................................................. 4559 Installation........................................................................................................................ 4559 Fog Light Adjustment................................................................................................................ 4559 Front Side Marker Light Bulb............................................................................................................ 4559 Removal............................................................................................................................. 4559 Installation........................................................................................................................ 4559 Parking Light Bulb...................................................................................................................... 4560 Removal and Installation............................................................................................................ 4560 Taillight Bulb.......................................................................................................................... 4560 Removal............................................................................................................................. 4560 Installation........................................................................................................................ 4560 License Plate Light Bulb................................................................................................................ 4561 Removal............................................................................................................................. 4561 Installation........................................................................................................................ 4561 Stoplight Bulb.......................................................................................................................... 4561 Removal and Installation............................................................................................................ 4561 High Mount Stoplight.................................................................................................................... 4561 Removal............................................................................................................................. 4561 Installation........................................................................................................................ 4562 Front Turn Signal Light Bulb............................................................................................................ 4562 Removal............................................................................................................................. 4562 Installation........................................................................................................................ 4562 Rear Turn Signal Light Bulb............................................................................................................. 4563 Removal............................................................................................................................. 4563 Installation........................................................................................................................ 4563 Cornering Light Bulb.................................................................................................................... 4563 Removal............................................................................................................................. 4563 Installation........................................................................................................................ 4563 Backup Light Bulb....................................................................................................................... 4564 Removal............................................................................................................................. 4564 Installation........................................................................................................................ 4564 Dome Light Bulb......................................................................................................................... 4564 Removal............................................................................................................................. 4564 Installation........................................................................................................................ 4564 Luggage Room Light Bulb................................................................................................................. 4565 Removal............................................................................................................................. 4565 Installation........................................................................................................................ 4565 Courtesy Light Bulb..................................................................................................................... 4565 Removal............................................................................................................................. 4565 Installation........................................................................................................................ 4565 Map Light Switch/Bulb................................................................................................................... 4566 Removal............................................................................................................................. 4566 Installation........................................................................................................................ 4566 Cigarette Lighter Illumination Bulb..................................................................................................... 4566 Removal............................................................................................................................. 4566 Installation........................................................................................................................ 4566 Ashtray Illumination Bulb............................................................................................................... 4567 Removal............................................................................................................................. 4567 Installation........................................................................................................................ 4567 Glove Box Illumination Bulb............................................................................................................. 4567 Removal............................................................................................................................. 4567 Installation........................................................................................................................ 4567 Vanity Mirror Illumination Bulb......................................................................................................... 4568 Removal............................................................................................................................. 4568 Installation........................................................................................................................ 4568 Starter Switch.......................................................................................................................... 4568 Removal............................................................................................................................. 4568 Installation........................................................................................................................ 4569 Lighting Switch (Combination Switch).................................................................................................... 4569 Removal............................................................................................................................. 4569 Installation........................................................................................................................ 4570 Fog Light Switch........................................................................................................................ 4570 Removal............................................................................................................................. 4570 Installation........................................................................................................................ 4571 Stoplight Switch (W/O Cruise Control)................................................................................................... 4571 Removal............................................................................................................................. 4571 Installation........................................................................................................................ 4571 Brake Switch (W/Cruise Control)......................................................................................................... 4572 Removal............................................................................................................................. 4572 Installation........................................................................................................................ 4572 Turn Signal Switch/Cornering Light Switch (Combination Switch).......................................................................... 4572 Removal and Installation............................................................................................................ 4572 Hazard Warning Switch................................................................................................................... 4572 Removal............................................................................................................................. 4572 Installation........................................................................................................................ 4573 Tailgate Switch......................................................................................................................... 4573 Removal............................................................................................................................. 4573 Installation........................................................................................................................ 4573 Door Switch............................................................................................................................. 4574 Removal............................................................................................................................. 4574 Installation........................................................................................................................ 4574 Rear Defogger Switch.................................................................................................................... 4574 Removal............................................................................................................................. 4574 Installation........................................................................................................................ 4575 Seat Heater Switch...................................................................................................................... 4575 Removal............................................................................................................................. 4575 Installation........................................................................................................................ 4575 Key Remind Switch (Starter Switch)...................................................................................................... 4575 Removal and Installation............................................................................................................ 4575 Illumination Controller................................................................................................................. 4576 Removal............................................................................................................................. 4576 Installation........................................................................................................................ 4576 Main Data and Specifications............................................................................................................ 4577 8B WIPER / WASHER SYSTEM.................................................................................................................. 4579 Service Precaution...................................................................................................................... 4579 Windshield Wiper/Washer System.......................................................................................................... 4580 General Description................................................................................................................. 4580 Windshield Wiper And Washer Switch...................................................................................................... 4580 Removal and Installation............................................................................................................ 4580 Windshield Wiper Motor.................................................................................................................. 4580 Removal............................................................................................................................. 4580 Installation........................................................................................................................ 4580 Windshield Washer Motor................................................................................................................. 4581 Removal............................................................................................................................. 4581 Installation........................................................................................................................ 4581 Windshield Wiper Linkage................................................................................................................ 4582 Windshield Wiper Linkage and Associated Parts....................................................................................... 4582 Removal............................................................................................................................. 4582 Installation........................................................................................................................ 4582 Windshield Wiper Arm/Blade.............................................................................................................. 4583 Removal............................................................................................................................. 4583 Installation........................................................................................................................ 4583 Windshield Wiper Blade Rubber........................................................................................................... 4584 Removal............................................................................................................................. 4584 Installation........................................................................................................................ 4584 Rear Wiper/Washer System................................................................................................................ 4585 General Description................................................................................................................. 4585 Rear Wiper and Washer Switch............................................................................................................ 4585 Removal............................................................................................................................. 4585 Installation........................................................................................................................ 4585 Rear Wiper Motor........................................................................................................................ 4586 Removal............................................................................................................................. 4586 Installation........................................................................................................................ 4586 Alarm & Relay Control Unit.............................................................................................................. 4587 Removal............................................................................................................................. 4587 Installation........................................................................................................................ 4587 Rear Washer Motor....................................................................................................................... 4587 Removal............................................................................................................................. 4587 Installation........................................................................................................................ 4587 Rear Wiper Arm/Blade.................................................................................................................... 4588 Removal............................................................................................................................. 4588 Installation........................................................................................................................ 4588 Rear Washer Nozzle...................................................................................................................... 4588 Removal............................................................................................................................. 4588 Installation........................................................................................................................ 4588 Rear Washer Nozzle Angle Adjustment................................................................................................. 4588 Rear Wiper Blade Rubber................................................................................................................. 4589 Removal and Installation............................................................................................................ 4589 Main Data and Specifications............................................................................................................ 4589 8C ENTERTAINMENT.......................................................................................................................... 4590 Service Precaution...................................................................................................................... 4590 Cigarette Lighter....................................................................................................................... 4591 General Description................................................................................................................. 4591 Removal............................................................................................................................. 4591 Installation........................................................................................................................ 4591 Digital Clock........................................................................................................................... 4591 Removal............................................................................................................................. 4591 Installation........................................................................................................................ 4592 Rod Type Antenna........................................................................................................................ 4592 Removal............................................................................................................................. 4592 Installation........................................................................................................................ 4592 Diversity Glass Antenna................................................................................................................. 4593 Glass Antenna System Parts Location................................................................................................. 4593 Glass Antenna Pattern............................................................................................................... 4594 Glass Antenna Amplifier Removal..................................................................................................... 4594 Glass Antenna Amplifier Installation................................................................................................ 4594 Radio................................................................................................................................... 4595 Removal............................................................................................................................. 4595 Installation........................................................................................................................ 4595 Front Speaker........................................................................................................................... 4596 Removal............................................................................................................................. 4596 Installation........................................................................................................................ 4596 Tweeter Assembly........................................................................................................................ 4596 Removal............................................................................................................................. 4596 Installation........................................................................................................................ 4596 Rear Speaker............................................................................................................................ 4597 Removal............................................................................................................................. 4597 Installation........................................................................................................................ 4597 8D WIRING SYSTEM.......................................................................................................................... 4598 Service Precaution...................................................................................................................... 4599 General Description..................................................................................................................... 4600 Notes for Working on Electrical Items............................................................................................... 4600 Symbols and Abbreviations........................................................................................................... 4606 Parts for Electrical Circuit........................................................................................................ 4610 Reading the Circuit Diagram......................................................................................................... 4619 Main Data and Specifications............................................................................................................ 4622 Fuse, Fusible Link and Circuit Breaker Location..................................................................................... 4622 Relay and Fuse Box.................................................................................................................. 4623 Fuse Box............................................................................................................................ 4623 Reference Table of Fuse, Fusible Link and Circuit Breaker........................................................................... 4624 Relay Location...................................................................................................................... 4627 Diode Location...................................................................................................................... 4629 Grounding Point..................................................................................................................... 4631 Cable Harness Routing............................................................................................................... 4637 Fuse Block Circuit...................................................................................................................... 4641 Circuit Diagram..................................................................................................................... 4641 Parts Location...................................................................................................................... 4645 Start and Charging...................................................................................................................... 4646 General Description................................................................................................................. 4646 Circuit Diagram..................................................................................................................... 4647 Parts Location...................................................................................................................... 4649 Powertrain Control Module (PCM)......................................................................................................... 4650 General Description................................................................................................................. 4650 Circuit Diagram..................................................................................................................... 4651 Parts Location...................................................................................................................... 4663 Headlight and Fog Light................................................................................................................. 4666 General Description................................................................................................................. 4666 Circuit Diagram..................................................................................................................... 4667 Parts Location...................................................................................................................... 4669 Diagnosis........................................................................................................................... 4670 Front Side Marker Light, Parking Light, Taillight and License Plate Light............................................................... 4678 General Description................................................................................................................. 4678 Circuit Diagram..................................................................................................................... 4679 Parts Location...................................................................................................................... 4681 Diagnosis........................................................................................................................... 4682 Interior Illumination Light............................................................................................................. 4687 General Description................................................................................................................. 4687 Circuit Diagram..................................................................................................................... 4688 Parts Location...................................................................................................................... 4692 Diagnosis........................................................................................................................... 4693 Turn Signal Light, Hazard Warning Light and Cornering Light............................................................................. 4694 General Description................................................................................................................. 4694 Circuit Diagram..................................................................................................................... 4695 Parts Location...................................................................................................................... 4698 Diagnosis........................................................................................................................... 4699 Stoplight............................................................................................................................... 4705 General Description................................................................................................................. 4705 Circuit Diagram..................................................................................................................... 4706 Parts Location...................................................................................................................... 4707 Diagnosis........................................................................................................................... 4708 Backup Light............................................................................................................................ 4711 General Description................................................................................................................. 4711 Circuit Diagram..................................................................................................................... 4712 Parts Location...................................................................................................................... 4713 Diagnosis........................................................................................................................... 4714 Horn.................................................................................................................................... 4717 General Description................................................................................................................. 4717 Circuit Diagram..................................................................................................................... 4718 Parts Location...................................................................................................................... 4719 Diagnosis........................................................................................................................... 4720 Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 4722 General Description................................................................................................................. 4722 Circuit Diagram..................................................................................................................... 4723 Parts Location...................................................................................................................... 4725 Diagnosis........................................................................................................................... 4726 Power Door Lock......................................................................................................................... 4727 General Description................................................................................................................. 4727 Circuit Diagram..................................................................................................................... 4728 Parts Location...................................................................................................................... 4732 Diagnosis........................................................................................................................... 4733 Power Window............................................................................................................................ 4737 General Description................................................................................................................. 4737 Circuit Diagram..................................................................................................................... 4738 Parts Location...................................................................................................................... 4739 Diagnosis........................................................................................................................... 4740 Cruise Control.......................................................................................................................... 4746 General Description................................................................................................................. 4746 Circuit Diagram..................................................................................................................... 4747 Parts Location...................................................................................................................... 4749 Diagnosis........................................................................................................................... 4750 Anti-Lock Brake System (ABS)............................................................................................................ 4756 General Description................................................................................................................. 4756 Circuit Diagram..................................................................................................................... 4757 Parts Location...................................................................................................................... 4760 A/T Shift Lock.......................................................................................................................... 4761 General Description................................................................................................................. 4761 Circuit Diagram..................................................................................................................... 4762 Parts Location...................................................................................................................... 4763 Windshield Wiper and Washer............................................................................................................. 4764 General Description................................................................................................................. 4764 Circuit Diagram..................................................................................................................... 4765 Parts Location...................................................................................................................... 4766 Diagnosis........................................................................................................................... 4767 Rear Wiper/Washer....................................................................................................................... 4775 General Description................................................................................................................. 4775 Circuit Diagram..................................................................................................................... 4776 Parts Location...................................................................................................................... 4778 Diagnosis........................................................................................................................... 4779 Rear Defogger........................................................................................................................... 4786 General Description................................................................................................................. 4786 Circuit Diagram..................................................................................................................... 4787 Parts Location...................................................................................................................... 4788 Diagnosis........................................................................................................................... 4789 Audio................................................................................................................................... 4792 General Description................................................................................................................. 4792 Circuit Diagram..................................................................................................................... 4793 Parts Location...................................................................................................................... 4795 Cigarette Lighter and Digital........................................................................................................... 4796 General Description................................................................................................................. 4796 Circuit Diagram..................................................................................................................... 4797 Parts Location...................................................................................................................... 4798 Diagnosis........................................................................................................................... 4799 Power Door Mirror....................................................................................................................... 4801 General Description................................................................................................................. 4801 Circuit Diagram..................................................................................................................... 4802 Parts Location...................................................................................................................... 4805 Diagnosis........................................................................................................................... 4806 Anti-Theft System with Keyless Entry.................................................................................................... 4814 Circuit Diagram..................................................................................................................... 4814 Parts Location...................................................................................................................... 4819 Diagnosis........................................................................................................................... 4821 Meter and Warning/Indicator Light....................................................................................................... 4827 General Description................................................................................................................. 4827 Circuit Diagram..................................................................................................................... 4828 Parts Location...................................................................................................................... 4839 Diagnosis........................................................................................................................... 4840 A/T Shift Indicator..................................................................................................................... 4852 General Description................................................................................................................. 4852 Circuit Diagram..................................................................................................................... 4853 Parts Location...................................................................................................................... 4855 Heater and Air Conditioning............................................................................................................. 4856 General Description................................................................................................................. 4856 Circuit Diagram..................................................................................................................... 4857 Parts Location...................................................................................................................... 4860 Sun Roof................................................................................................................................ 4861 General Description................................................................................................................. 4861 Circuit Diagram..................................................................................................................... 4862 Parts Location...................................................................................................................... 4863 Diagnosis........................................................................................................................... 4864 Power Seat.............................................................................................................................. 4867 General Description................................................................................................................. 4867 Circuit Diagram..................................................................................................................... 4868 Parts Location...................................................................................................................... 4870 Diagnosis........................................................................................................................... 4871 Seat Heater............................................................................................................................. 4879 General Description................................................................................................................. 4879 Circuit Diagram..................................................................................................................... 4880 Parts Location...................................................................................................................... 4881 Diagnosis........................................................................................................................... 4882 Supplemental Restraint System (SRS)-Air Bag............................................................................................. 4884 General Description................................................................................................................. 4884 Circuit Diagram..................................................................................................................... 4885 Parts Location...................................................................................................................... 4886 Shift on the Fly System................................................................................................................. 4887 Circuit Diagram..................................................................................................................... 4887 Parts Location...................................................................................................................... 4889 Torque on Demand (T.O.D.)............................................................................................................... 4890 Circuit Diagram..................................................................................................................... 4890 Parts Location...................................................................................................................... 4893 Harness Connector Faces................................................................................................................. 4894 8E METER AND GAUGE........................................................................................................................ 4916 Service Precaution...................................................................................................................... 4916 General Description..................................................................................................................... 4916 Meter Assembly.......................................................................................................................... 4917 General Description................................................................................................................. 4917 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 4917 Table for Meter/Gauge Connector Terminal Connections................................................................................ 4921 Removal............................................................................................................................. 4925 Installation........................................................................................................................ 4925 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 4925 Removal............................................................................................................................. 4925 Installation........................................................................................................................ 4925 Vehicle Speed Sensor.................................................................................................................... 4926 Removal............................................................................................................................. 4926 Installation........................................................................................................................ 4926 Fuel Tank Unit.......................................................................................................................... 4926 Removal............................................................................................................................. 4926 Installation........................................................................................................................ 4926 Multi Meter............................................................................................................................. 4927 Removal............................................................................................................................. 4927 Installation........................................................................................................................ 4927 Ambient Sensor.......................................................................................................................... 4927 Removal............................................................................................................................. 4927 Installation........................................................................................................................ 4927 Main Data and Specifications............................................................................................................ 4928 8F BODY STRUCTURE......................................................................................................................... 4929 Service Precaution...................................................................................................................... 4931 Frame................................................................................................................................... 4931 General Description................................................................................................................. 4931 Frame Dimensions.................................................................................................................... 4932 General Description................................................................................................................. 4933 Front Bumper............................................................................................................................ 4933 Parts Location...................................................................................................................... 4933 Removal............................................................................................................................. 4934 Installation........................................................................................................................ 4934 Front Bumper Slider Bracket............................................................................................................. 4934 Removal............................................................................................................................. 4934 Installation........................................................................................................................ 4934 Rear Bumper............................................................................................................................. 4935 Parts Location...................................................................................................................... 4935 Removal............................................................................................................................. 4935 Installation........................................................................................................................ 4936 Rear Bumper Slider...................................................................................................................... 4937 Removal............................................................................................................................. 4937 Installation........................................................................................................................ 4937 General Description................................................................................................................. 4938 Cowl Cover.............................................................................................................................. 4938 Parts Location...................................................................................................................... 4938 Removal............................................................................................................................. 4938 Installation........................................................................................................................ 4939 Engine Hood............................................................................................................................. 4939 Removal............................................................................................................................. 4939 Installation........................................................................................................................ 4939 Engine Hood Hinge....................................................................................................................... 4940 Parts Location...................................................................................................................... 4940 Removal............................................................................................................................. 4940 Installation........................................................................................................................ 4940 Engine Hood Lock........................................................................................................................ 4941 Parts Location...................................................................................................................... 4941 Removal............................................................................................................................. 4941 Installation........................................................................................................................ 4942 Radiator Grille And Front End Lower Panel............................................................................................... 4942 Parts Location...................................................................................................................... 4942 Removal............................................................................................................................. 4942 Installation........................................................................................................................ 4943 Front Fender Panel...................................................................................................................... 4944 Parts Location...................................................................................................................... 4944 Removal............................................................................................................................. 4944 Installation........................................................................................................................ 4945 Body Mounting........................................................................................................................... 4946 Parts Location...................................................................................................................... 4946 Removal (No.1-No. 2)................................................................................................................ 4946 Removal (No. 3-No. 6)............................................................................................................... 4947 Installation........................................................................................................................ 4948 General Description..................................................................................................................... 4949 Body Dimension.......................................................................................................................... 4950 Instrument Panel Assembly............................................................................................................... 4968 Parts Location...................................................................................................................... 4968 Removal............................................................................................................................. 4968 Installation........................................................................................................................ 4973 Cross Beam Assembly..................................................................................................................... 4974 Parts Location...................................................................................................................... 4974 Removal............................................................................................................................. 4974 Installation........................................................................................................................ 4975 Front Door Assembly..................................................................................................................... 4976 Parts Location...................................................................................................................... 4976 Removal............................................................................................................................. 4976 Installation........................................................................................................................ 4976 Rear Door Assembly...................................................................................................................... 4977 Parts Location...................................................................................................................... 4977 Removal............................................................................................................................. 4977 Installation........................................................................................................................ 4978 Door Strikers........................................................................................................................... 4978 Adjustment.......................................................................................................................... 4978 Door Check Arm Assembly (Front & Rear).................................................................................................. 4979 Parts Location...................................................................................................................... 4979 Removal............................................................................................................................. 4979 Installation........................................................................................................................ 4980 Front Window Regulator, Glass And Glass Run............................................................................................. 4980 Parts Location...................................................................................................................... 4980 Removal............................................................................................................................. 4980 Installation........................................................................................................................ 4982 Rear Window Regulator And Glass......................................................................................................... 4983 Parts Location...................................................................................................................... 4983 Removal............................................................................................................................. 4983 Installation........................................................................................................................ 4984 Rear Door Fixed Glass And Glass Run..................................................................................................... 4985 Parts Location...................................................................................................................... 4985 Removal............................................................................................................................. 4985 Installation........................................................................................................................ 4986 Front Door Sash Moulding................................................................................................................ 4987 Parts Location...................................................................................................................... 4987 Removal............................................................................................................................. 4987 Installation........................................................................................................................ 4987 Rear Door Moulding...................................................................................................................... 4988 Parts Location...................................................................................................................... 4988 Removal............................................................................................................................. 4988 Installation........................................................................................................................ 4988 Front Door Waist Seal................................................................................................................... 4989 Parts Location...................................................................................................................... 4989 Removal............................................................................................................................. 4989 Installation........................................................................................................................ 4989 Rear Door Waist Seal.................................................................................................................... 4990 Parts Location...................................................................................................................... 4990 Removal and Installation............................................................................................................ 4990 Front Door Weatherstrip................................................................................................................. 4991 Parts Location...................................................................................................................... 4991 Removal............................................................................................................................. 4991 Installation........................................................................................................................ 4992 Rear Door Weatherstrip.................................................................................................................. 4993 Parts Location...................................................................................................................... 4993 Removal and Installation............................................................................................................ 4993 Front Door Seal Finisher................................................................................................................ 4994 Parts Location...................................................................................................................... 4994 Removal............................................................................................................................. 4994 Installation........................................................................................................................ 4994 Rear Door Seal Finisher................................................................................................................. 4995 Parts Location...................................................................................................................... 4995 Removal............................................................................................................................. 4995 Installation........................................................................................................................ 4995 Tailgate Assembly (LH).................................................................................................................. 4996 Parts Location...................................................................................................................... 4996 Removal............................................................................................................................. 4996 Installation........................................................................................................................ 4997 Tailgate Assembly (RH).................................................................................................................. 4998 Parts Location...................................................................................................................... 4998 Removal............................................................................................................................. 4998 Installation........................................................................................................................ 4999 Tailgate Strikers....................................................................................................................... 5000 Adjustment.......................................................................................................................... 5000 Tailgate Stopper Assembly............................................................................................................... 5000 Parts Location...................................................................................................................... 5000 Removal............................................................................................................................. 5000 Installation........................................................................................................................ 5000 Tailgate Dove-Tail...................................................................................................................... 5001 Parts Location...................................................................................................................... 5001 Removal............................................................................................................................. 5001 Installation........................................................................................................................ 5001 Tailgate Dove-Tail Striker.............................................................................................................. 5002 Adjustment.......................................................................................................................... 5002 Tailgate Frame Cover (LH)............................................................................................................... 5003 Parts Location...................................................................................................................... 5003 Removal............................................................................................................................. 5003 Installation........................................................................................................................ 5003 Tailgate Frame Cover (RH)............................................................................................................... 5004 Removal............................................................................................................................. 5004 Installation........................................................................................................................ 5004 Tailgate Sash Trim Cover................................................................................................................ 5005 Parts Location...................................................................................................................... 5005 Removal............................................................................................................................. 5005 Installation........................................................................................................................ 5005 Tailgate Outer Weatherstrip............................................................................................................. 5006 Parts Location...................................................................................................................... 5006 Removal............................................................................................................................. 5006 Installation........................................................................................................................ 5006 Tailgate Center Weatherstrip............................................................................................................ 5007 Parts Location...................................................................................................................... 5007 Removal............................................................................................................................. 5007 Installation........................................................................................................................ 5007 Tailgate Main Weatherstrip.............................................................................................................. 5008 Parts Location...................................................................................................................... 5008 Removal............................................................................................................................. 5008 Installation........................................................................................................................ 5008 Spare Tire Carrier...................................................................................................................... 5009 Parts Location...................................................................................................................... 5009 Removal............................................................................................................................. 5009 Installation........................................................................................................................ 5009 Headlining.............................................................................................................................. 5010 Parts Location...................................................................................................................... 5010 Removal............................................................................................................................. 5010 Installation........................................................................................................................ 5011 Rear Air Deflector...................................................................................................................... 5012 Parts Location...................................................................................................................... 5012 Removal............................................................................................................................. 5012 Installation........................................................................................................................ 5012 Roof Moulding........................................................................................................................... 5014 Parts Location...................................................................................................................... 5014 Removal............................................................................................................................. 5014 Installation........................................................................................................................ 5014 Windshield.............................................................................................................................. 5016 Parts Location...................................................................................................................... 5016 Removal............................................................................................................................. 5016 Installation........................................................................................................................ 5017 Rear Quarter Side Glass................................................................................................................. 5021 Parts Location...................................................................................................................... 5021 Removal............................................................................................................................. 5021 Installation........................................................................................................................ 5021 Tailgate Glass.......................................................................................................................... 5023 Parts Location...................................................................................................................... 5023 Removal............................................................................................................................. 5023 Installation........................................................................................................................ 5024 Main Data and Specifications............................................................................................................ 5025 Special Tools........................................................................................................................... 5035 8G SEATS.................................................................................................................................. 5036 Service Precaution...................................................................................................................... 5036 Front Seat Assembly..................................................................................................................... 5037 Front Seat Assembly and Associated Parts............................................................................................ 5037 Removal............................................................................................................................. 5037 Installation........................................................................................................................ 5037 Disassembled View................................................................................................................... 5038 Disassembly......................................................................................................................... 5039 Reassembly.......................................................................................................................... 5040 Power Seat Assembly..................................................................................................................... 5041 General Description................................................................................................................. 5041 Disassembled View................................................................................................................... 5041 Disassembly......................................................................................................................... 5042 Reassembly.......................................................................................................................... 5044 Power Seat Switch....................................................................................................................... 5044 Removal............................................................................................................................. 5044 Installation........................................................................................................................ 5044 Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....................................................................... 5045 Parts Location...................................................................................................................... 5045 Removal and Installation............................................................................................................ 5045 Seat Heater System...................................................................................................................... 5046 General Description................................................................................................................. 5046 Seat Heater Switch Removal and Installation......................................................................................... 5046 Heat Unit Parts Location............................................................................................................ 5046 Heat Unit Removal and Installation.................................................................................................. 5046 Rear Seat Assembly...................................................................................................................... 5047 Rear Seat Assembly and Associated Parts............................................................................................. 5047 Removal............................................................................................................................. 5047 Installation........................................................................................................................ 5047 Disassembled View (Split Type)...................................................................................................... 5048 Disassembly (Split Type)............................................................................................................ 5049 Reassembly (Split Type)............................................................................................................. 5050 Disassembled View (Bench Type)...................................................................................................... 5051 Disassembly (Bench Type)............................................................................................................ 5052 Reassembly (Bench Type)............................................................................................................. 5053 Rear Seat Foot Rest..................................................................................................................... 5053 Rear Seat Foot Rest and Associated Parts............................................................................................ 5053 Removal............................................................................................................................. 5054 Installation........................................................................................................................ 5054 Main Data and Specifications............................................................................................................ 5054 8H SECURITY AND LOCKS..................................................................................................................... 5056 Service Precaution...................................................................................................................... 5057 Front Door Lock Assembly................................................................................................................ 5057 Front Door Lock Assembly and Associated Parts....................................................................................... 5057 Removal............................................................................................................................. 5057 Installation........................................................................................................................ 5058 Front Outside Handle and Door Lock Cylinder............................................................................................. 5059 Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 5059 Removal............................................................................................................................. 5059 Installation........................................................................................................................ 5061 Rear Door Lock Assembly................................................................................................................. 5062 Rear Door Lock Assembly and Associated Parts........................................................................................ 5062 Removal............................................................................................................................. 5062 Installation........................................................................................................................ 5063 Rear Outside Handle..................................................................................................................... 5064 Rear Outside Handle and Associated Parts............................................................................................ 5064 Removal............................................................................................................................. 5064 Installation........................................................................................................................ 5065 Rear Door Inside Lock Knob Link......................................................................................................... 5065 Removal............................................................................................................................. 5065 Installation........................................................................................................................ 5065 Door Inside Lock Knob................................................................................................................... 5066 Removal............................................................................................................................. 5066 Installation........................................................................................................................ 5066 Door Inside Handle...................................................................................................................... 5066 Removal and Installation............................................................................................................ 5066 Tailgate Lock Assembly (LH)............................................................................................................. 5067 Tailgate Lock Assembly (LH) and Associated Parts.................................................................................... 5067 Removal............................................................................................................................. 5067 Installation........................................................................................................................ 5068 Tailgate Lock Assembly (RH)............................................................................................................. 5069 Tailgate Lock Assembly (RH) and Associated Parts.................................................................................... 5069 Removal............................................................................................................................. 5069 Installation........................................................................................................................ 5070 Tailgate Inside Lock Knob............................................................................................................... 5070 Removal............................................................................................................................. 5070 Installation........................................................................................................................ 5070 Tailgate Outside Handle and/or Tailgate Lock Cylinder................................................................................... 5071 Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts.......................................................... 5071 Removal............................................................................................................................. 5071 Installation........................................................................................................................ 5072 Key..................................................................................................................................... 5073 Key Coding.......................................................................................................................... 5073 Key Styles.......................................................................................................................... 5073 Power Door Lock System.................................................................................................................. 5074 General Description................................................................................................................. 5074 Front Door Lock Actuator Removal.................................................................................................... 5074 Front Door Lock Actuator Installation............................................................................................... 5074 Rear Door Lock Actuator Removal..................................................................................................... 5074 Rear Door Lock Actuator Installation................................................................................................ 5075 Tailgate Lock Actuator Removal...................................................................................................... 5075 Tailgate Lock Actuator Installation................................................................................................. 5075 Anti-theft System....................................................................................................................... 5076 General Description................................................................................................................. 5076 Anti-theft & Keyless Entry Control Unit Removal..................................................................................... 5076 Anti-theft & Keyless Entry Control Unit Installation................................................................................ 5076 Anti-theft Indicator Removal........................................................................................................ 5076 Anti-theft Indicator Installation................................................................................................... 5077 Anti-theft Horn Removal............................................................................................................. 5077 Anti-Theft Horn Installation........................................................................................................ 5077 Engine Hood Switch Removal.......................................................................................................... 5077 Engine Hood Switch Installation..................................................................................................... 5077 Keyless Entry System.................................................................................................................... 5078 ID Code Registration................................................................................................................ 5078 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 5081 Main Data and Specifications............................................................................................................ 5082 8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 5083 Service Precaution...................................................................................................................... 5083 Sun Roof Glass.......................................................................................................................... 5084 Sun Roof Glass and Associated Parts................................................................................................. 5084 Removal............................................................................................................................. 5084 Installation........................................................................................................................ 5085 Sun Roof Deflector...................................................................................................................... 5086 Removal............................................................................................................................. 5086 Installation........................................................................................................................ 5086 Sunshade................................................................................................................................ 5086 Disassembled View................................................................................................................... 5086 Removal............................................................................................................................. 5087 Installation........................................................................................................................ 5087 Sun Roof Frame Complete Assembly........................................................................................................ 5088 Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 5088 Removal............................................................................................................................. 5088 Installation........................................................................................................................ 5089 Disassembled View................................................................................................................... 5089 Disassembly......................................................................................................................... 5089 Reassembly.......................................................................................................................... 5090 Sun Roof Drain Hose (Front Side)........................................................................................................ 5091 Sun Roof Drain Hose (Front Side) and Associated Parts............................................................................... 5091 Removal............................................................................................................................. 5091 Installation........................................................................................................................ 5091 Sun Roof Drain Hose (Rear Side)......................................................................................................... 5092 Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................ 5092 Removal............................................................................................................................. 5092 Installation........................................................................................................................ 5092 Sun Roof Switch......................................................................................................................... 5093 General Description................................................................................................................. 5093 Removal............................................................................................................................. 5093 Installation........................................................................................................................ 5093 Sun Roof Control Unit................................................................................................................... 5094 General Description................................................................................................................. 5094 Removal............................................................................................................................. 5094 Installation........................................................................................................................ 5094 Safety Stop Switch...................................................................................................................... 5094 General Description................................................................................................................. 5094 Removal............................................................................................................................. 5094 Installation........................................................................................................................ 5094 Limit Switch............................................................................................................................ 5095 General Description................................................................................................................. 5095 Removal............................................................................................................................. 5095 Installation........................................................................................................................ 5095 Sun Roof Motor.......................................................................................................................... 5095 Removal............................................................................................................................. 5095 Installation........................................................................................................................ 5095 Main Data and Specifications............................................................................................................ 5096 8J EXTERIOR / INTERIOR TRIM............................................................................................................... 5097 Service Precaution...................................................................................................................... 5098 Dash Side Trim Panel.................................................................................................................... 5099 Removal............................................................................................................................. 5099 Installation........................................................................................................................ 5099 Assist Grip............................................................................................................................. 5099 Parts Location...................................................................................................................... 5099 Removal and Installation............................................................................................................ 5099 Consoles................................................................................................................................ 5100 Consoles and Associated Parts....................................................................................................... 5100 Removal............................................................................................................................. 5100 Installation........................................................................................................................ 5101 Front Door Trim Panel................................................................................................................... 5102 Front Door Trim Panel and Associated Parts.......................................................................................... 5102 Removal............................................................................................................................. 5102 Installation........................................................................................................................ 5105 Rear Door Trim Panel.................................................................................................................... 5106 Rear Door Trim Panel and Associated Parts........................................................................................... 5106 Removal............................................................................................................................. 5106 Installation........................................................................................................................ 5107 Door Wood Panel Assembly................................................................................................................ 5109 Door Wood Panel Assembly and Associated Parts....................................................................................... 5109 Removal............................................................................................................................. 5109 Installation........................................................................................................................ 5109 Door Mirror............................................................................................................................. 5110 Door Mirror and Associated Parts.................................................................................................... 5110 Removal............................................................................................................................. 5110 Installation........................................................................................................................ 5110 Interior Trim Panels Luggage Side and Quarter Upper Trim Cover...................................................................... 5111 Interior Trim Panels Luggage Side, Quarter Upper Trim Cover and Associated Parts.................................................... 5111 Removal............................................................................................................................. 5111 Installation........................................................................................................................ 5113 Center Pillar and Roof Side Trim Cover.................................................................................................. 5113 Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................ 5113 Removal............................................................................................................................. 5114 Installation........................................................................................................................ 5115 Front Pillar Trim Cover................................................................................................................. 5115 Front Pillar Trim Cover and Associated Parts........................................................................................ 5115 Removal............................................................................................................................. 5115 Installation........................................................................................................................ 5116 Center Pillar Assist Grip............................................................................................................... 5116 Parts Location...................................................................................................................... 5116 Removal and Installation............................................................................................................ 5116 Assist Grip............................................................................................................................. 5117 Parts Location...................................................................................................................... 5117 Removal and Installation............................................................................................................ 5117 Fuel Filler Lid Opener Cable............................................................................................................ 5118 Fuel Filler Lid Opener Cable and Associated Parts................................................................................... 5118 Removal............................................................................................................................. 5118 Installation........................................................................................................................ 5119 Fuel Filler Door........................................................................................................................ 5119 Parts Location...................................................................................................................... 5119 Removal............................................................................................................................. 5119 Installation........................................................................................................................ 5119 Rocker Protector (Without Wheel Opening Extension)...................................................................................... 5120 Rocker Protector (Without Wheel Opening Extension) and Associated Parts............................................................. 5120 Removal............................................................................................................................. 5120 Installation........................................................................................................................ 5120 Wheel Opening Extension and Rocker Protector Assembly................................................................................... 5121 Wheel Opening Extension, Rocker Protector Assembly and Associated Parts............................................................. 5121 Removal............................................................................................................................. 5121 Installation........................................................................................................................ 5122 Mud Flaps (With Wheel Opening Extension)................................................................................................ 5123 Mud Flaps (With Wheel Opening Extension) and Associated Parts....................................................................... 5123 Removal............................................................................................................................. 5123 Installation........................................................................................................................ 5123 Ventilation Assembly.................................................................................................................... 5124 Ventilation Assembly and Associated Parts........................................................................................... 5124 Removal............................................................................................................................. 5124 Installation........................................................................................................................ 5124 Tailgate Trim Panel (LH)................................................................................................................ 5125 Tailgate Trim Panel (LH) and Associated Parts....................................................................................... 5125 Removal............................................................................................................................. 5125 Installation........................................................................................................................ 5125 Tailgate Trim Panel (RH)................................................................................................................ 5126 Parts Location...................................................................................................................... 5126 Removal............................................................................................................................. 5126 Installation........................................................................................................................ 5126 Luggage Floor Box....................................................................................................................... 5127 Luggage Floor Box and Associated Parts.............................................................................................. 5127 Remove.............................................................................................................................. 5127 Installation........................................................................................................................ 5127 Rope Hook Set........................................................................................................................... 5127 Rope Hook Set and Associated Parts.................................................................................................. 5127 Removal............................................................................................................................. 5127 Installation........................................................................................................................ 5127 Power Door Mirror System................................................................................................................ 5128 General Description................................................................................................................. 5128 Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................ 5128 Installation........................................................................................................................ 5128 Power Door Mirror....................................................................................................................... 5128 General Description................................................................................................................. 5128 Removal and Installation............................................................................................................ 5128 Power Window System..................................................................................................................... 5129 General Description................................................................................................................. 5129 Power Window Switch Removal and Installation........................................................................................ 5129 Power Window Motor Removal and Installation......................................................................................... 5130 Main Data and Specifications............................................................................................................ 5131 Sec.9 RESTRAINTS.............................................................................................................................. 5132 9A SEAT BELT SYSTEM....................................................................................................................... 5132 Service Precaution...................................................................................................................... 5132 Seat Belt............................................................................................................................... 5133 Front Seat Belt and Associated Parts................................................................................................ 5133 Removal............................................................................................................................. 5133 Inspection.......................................................................................................................... 5133 Installation........................................................................................................................ 5134 Rear Seat Belt and Associated Parts................................................................................................. 5134 Removal............................................................................................................................. 5135 Inspection.......................................................................................................................... 5135 Installation........................................................................................................................ 5135 Front Seat Buckle Assembly.............................................................................................................. 5135 Removal............................................................................................................................. 5135 Installation........................................................................................................................ 5135 Rear Center Seat Belt / Buckle Assembly................................................................................................. 5136 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 5136 Removal............................................................................................................................. 5136 Installation........................................................................................................................ 5136 Rear Seat Lock Assembly................................................................................................................. 5137 Removal............................................................................................................................. 5137 Installation........................................................................................................................ 5137 Rear Seat Lock Assembly (Bench Type).................................................................................................... 5137 Removal............................................................................................................................. 5137 Installation........................................................................................................................ 5137 Rear Seat Strikers...................................................................................................................... 5138 Removal............................................................................................................................. 5138 Installation........................................................................................................................ 5138 Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 5138 General Description................................................................................................................. 5138 Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 5138 Installation........................................................................................................................ 5138 Main Data and Specifications............................................................................................................ 5139 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).................................................................................................... 5140 Service Precaution...................................................................................................................... 5140 General Description..................................................................................................................... 5141 SRS Component And Wiring Location View.................................................................................................. 5143 Component Description................................................................................................................... 5143 Definitions............................................................................................................................. 5146 Diagnosis............................................................................................................................... 5147 SRS Connector Body Face Views........................................................................................................... 5148 Repairs And Inspections Required After An Accident...................................................................................... 5148 On-Vehicle Service...................................................................................................................... 5149 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 5150 Special Tools........................................................................................................................... 5159 Service Precautions for SRS Component Service........................................................................................... 5163 SRS Connectors.......................................................................................................................... 5164 Sensing And Diagnostic Module (SDM)..................................................................................................... 5166 Service Precautions................................................................................................................. 5166 Removal............................................................................................................................. 5166 Installation........................................................................................................................ 5166 Driver Air Bag Assembly................................................................................................................. 5168 Service Precautions................................................................................................................. 5168 Removal............................................................................................................................. 5168 Installation........................................................................................................................ 5169 Steering Wheel.......................................................................................................................... 5170 Service Precautions................................................................................................................. 5170 Removal............................................................................................................................. 5170 Installation........................................................................................................................ 5171 SRS Coil Assembly....................................................................................................................... 5173 Service Precautions................................................................................................................. 5173 Removal............................................................................................................................. 5173 Installation........................................................................................................................ 5174 Steering Column......................................................................................................................... 5176 Service Precautions................................................................................................................. 5176 Removal............................................................................................................................. 5176 Installation........................................................................................................................ 5178 Passenger Air Bag Assembly.............................................................................................................. 5180 Service Precautions................................................................................................................. 5180 Removal............................................................................................................................. 5180 Installation........................................................................................................................ 5181 Main Data and Specifications............................................................................................................ 5181 9J1 RESTRAINT CONTROL SYSTEM............................................................................................................... 5182 Service Precaution...................................................................................................................... 5182 Diagnostic Information.................................................................................................................. 5183 System Schematic........................................................................................................................ 5185 SRS Diagnostic System Check............................................................................................................. 5185 Chart A SDM Integrity Check............................................................................................................. 5187 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 5189 Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady (1/2).......................................................................... 5191 DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 5194 DTC 16 Passenger Deployment loop Resistance Low......................................................................................... 5196 DTC 17 Passenger Deployment Loop Open................................................................................................... 5198 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 5200 DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 5202 DTC 21 Driver Deployment Loop Resistance High........................................................................................... 5204 DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 5207 DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 5209 DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 5211 DTC 26 Driver Deployment Loop Open...................................................................................................... 5213 DTC 51 Deployment Event Commanded....................................................................................................... 5215 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 5217 DTC 61 Warning Lamp Circuit Failure..................................................................................................... 5219 DTC 71 Internal SDM Fault............................................................................................................... 5221 Sec.10 CONTROL SYSTEM.......................................................................................................................... 5223 10A CRUISE CONTROL SYSTEM.................................................................................................................. 5223 Service Precaution...................................................................................................................... 5223 General Description..................................................................................................................... 5223 Diagnosis............................................................................................................................... 5224 Brake Switch............................................................................................................................ 5224 Removal............................................................................................................................. 5224 Installation........................................................................................................................ 5224 Adjustment.......................................................................................................................... 5225 Clutch Switch........................................................................................................................... 5225 Removal and Installation............................................................................................................ 5225 Adjustment.......................................................................................................................... 5225 Starter Switch.......................................................................................................................... 5226 Removal............................................................................................................................. 5226 Installation........................................................................................................................ 5226 Cruise Control Main Switch.............................................................................................................. 5227 Removal............................................................................................................................. 5227 Installation........................................................................................................................ 5227 Cruise Control Switch (Combination Switch).............................................................................................. 5227 Removal and Installation............................................................................................................ 5227 Cruise Control Unit..................................................................................................................... 5228 Removal............................................................................................................................. 5228 Installation........................................................................................................................ 5228 Cruise Actuator......................................................................................................................... 5228 Actuator Cable Diagram.............................................................................................................. 5228 Removal............................................................................................................................. 5229 Installation........................................................................................................................ 5229 Adjustment.......................................................................................................................... 5229 Mode Switch............................................................................................................................. 5230 Removal and Installation............................................................................................................ 5230 (UE) RODEO.......................................................................................................................................... 3 Sec.0 GENERAL INFORMATION..................................................................................................................... 4 0A GENERAL INFORMATION.................................................................................................................... 4 General Repair Instruction.............................................................................................................. 4 Illustration Arrows..................................................................................................................... 5 Identification.......................................................................................................................... 6 Theft Prevention Standard............................................................................................................... 8 Lifting Instructions.................................................................................................................... 13 Standard Bolts Torque Specifications.................................................................................................... 15 Abbreviations Charts.................................................................................................................... 16 Service Parts Identification Plate...................................................................................................... 17 0B MAINTENANCE AND LUBRICATION............................................................................................................ 18 Maintenance Schedule List............................................................................................................... 18 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 22 Recommended Fluids and Lubricants................................................................................................... 25 Lubricant Viscosity Chart............................................................................................................... 26 Recommended Liquid Gasket........................................................................................................... 28 Recommended Thread Locking Agents................................................................................................... 29 Maintenance Service Data................................................................................................................ 30 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 31 1A HVAC SYSTEMS........................................................................................................................... 31 Service Precaution...................................................................................................................... 32 Heating and Ventilation System.......................................................................................................... 32 General Description................................................................................................................. 32 Wiring Diagram...................................................................................................................... 36 Diagnosis........................................................................................................................... 37 Individual Inspection............................................................................................................... 41 Heater Unit............................................................................................................................. 43 Heater Unit and Associated Parts.................................................................................................... 43 Removal............................................................................................................................. 43 Installation........................................................................................................................ 44 Heater Core and / or Mode Door.......................................................................................................... 44 Disassembled View................................................................................................................... 44 Removal............................................................................................................................. 44 Inspection.......................................................................................................................... 45 Installation........................................................................................................................ 45 Heater Mode Control Link Unit........................................................................................................... 46 Disassembled View................................................................................................................... 46 Removal............................................................................................................................. 46 Installation........................................................................................................................ 47 Heater Temperature Control Link Unit.................................................................................................... 47 Disassembled View................................................................................................................... 47 Removal............................................................................................................................. 47 Installation........................................................................................................................ 48 Blower Assembly......................................................................................................................... 48 Blower Assembly and Associated Parts................................................................................................ 48 Removal............................................................................................................................. 48 Installation........................................................................................................................ 49 Blower Link Unit and / or Mode door..................................................................................................... 49 Disassembled View................................................................................................................... 49 Removal............................................................................................................................. 49 Installation........................................................................................................................ 50 Blower Motor............................................................................................................................ 51 Blower Motor and Associated Parts................................................................................................... 51 Removal............................................................................................................................. 51 Installation........................................................................................................................ 51 Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 52 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 52 Removal............................................................................................................................. 52 Installation........................................................................................................................ 53 Control Lever Assembly and / or Control Cable........................................................................................... 53 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 53 Removal............................................................................................................................. 54 Installation........................................................................................................................ 55 Control Panel Illumination Bulb......................................................................................................... 56 Control Panel Illumination Bulb and Associated Parts................................................................................ 56 Removal............................................................................................................................. 56 Installation........................................................................................................................ 56 Resistor................................................................................................................................ 56 Resistor and Associated Parts....................................................................................................... 56 Removal............................................................................................................................. 56 Installation........................................................................................................................ 56 Air Conditioning System................................................................................................................. 57 General Description..................................................................................................................... 57 Diagnosis............................................................................................................................... 65 Individual Inspection................................................................................................................... 74 General Repair Procedure............................................................................................................ 75 Leak Check.......................................................................................................................... 77 Compressor Assembly..................................................................................................................... 82 Compressor Assembly and Associated Parts............................................................................................ 82 Removal............................................................................................................................. 82 Installation........................................................................................................................ 83 New Compressor Installation......................................................................................................... 83 Condenser Assembly...................................................................................................................... 84 Condenser Assembly and Associated Parts............................................................................................. 84 Removal............................................................................................................................. 84 Installation........................................................................................................................ 84 Condenser Fan Motor..................................................................................................................... 85 Condenser Fan Motor and Associated Parts............................................................................................ 85 Removal............................................................................................................................. 85 Installation........................................................................................................................ 85 Receiver / Drier........................................................................................................................ 86 Receiver / Drier and Associated Parts............................................................................................... 86 Removal............................................................................................................................. 86 Installation........................................................................................................................ 86 Pressure Switch......................................................................................................................... 87 Pressure Switch and Associated Parts................................................................................................ 87 Removal............................................................................................................................. 87 Installation........................................................................................................................ 87 Evaporator Assembly..................................................................................................................... 88 Evaporator Assembly and Associated Parts............................................................................................ 88 Removal............................................................................................................................. 88 Installation........................................................................................................................ 89 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 89 Disassembled View................................................................................................................... 89 Removal............................................................................................................................. 90 Installation........................................................................................................................ 90 Refrigerant Line........................................................................................................................ 91 Refrigerant Line and Associated Parts............................................................................................... 91 Removal............................................................................................................................. 92 Installation........................................................................................................................ 92 Main Data And Specifications............................................................................................................ 92 Compressor.............................................................................................................................. 95 Service Precaution.................................................................................................................. 95 General Description..................................................................................................................... 95 Diagnosis............................................................................................................................... 96 Magnetic Clutch Assembly (DKV-14D Type)................................................................................................. 97 Parts Location View................................................................................................................. 97 Removal............................................................................................................................. 97 Inspection and Repair............................................................................................................... 98 Installation........................................................................................................................ 99 Compressor Oil.......................................................................................................................... 100 Oil Specification................................................................................................................... 100 Handling of Oil..................................................................................................................... 100 Compressor Oil Check................................................................................................................ 100 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 100 Checking and Adjusting for Compressor Replacement................................................................................... 101 Contamination of Compressor Oil..................................................................................................... 101 Oil Return Operation................................................................................................................ 101 Replacement of Component Parts...................................................................................................... 101 Main Data and Specifications............................................................................................................ 102 Special Tools........................................................................................................................... 104 Sec.2 STEERING................................................................................................................................ 105 2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 105 Service Precaution...................................................................................................................... 106 Diagnosis............................................................................................................................... 106 General Description..................................................................................................................... 112 Power Steering System Test.............................................................................................................. 114 Maintenance............................................................................................................................. 115 Fluid Level............................................................................................................................. 115 Bleeding The Power Steering System...................................................................................................... 115 Bleeding Procedure...................................................................................................................... 115 Flushing The Power Steering System...................................................................................................... 115 Steering Wheel Free Play Inspection..................................................................................................... 116 Front End Alignment Inspection and Adjustment........................................................................................... 116 Main Data and Specifications............................................................................................................ 120 Special Tools........................................................................................................................... 121 Power Steering Unit..................................................................................................................... 122 Power Steering Unit and Associated Parts............................................................................................ 122 Removal............................................................................................................................. 122 Installation (4ﾗ2 Model)............................................................................................................ 123 Installation (4ﾗ4 Model)............................................................................................................ 123 Power Steering Unit Disassembled View............................................................................................... 124 Disassembly......................................................................................................................... 124 Inspection and Repair............................................................................................................... 124 Reassembly.......................................................................................................................... 124 Main Data and Specifications........................................................................................................ 125 Special Tools....................................................................................................................... 125 Power Steering Pump..................................................................................................................... 126 Power Steering Pump and Associated Parts............................................................................................ 126 Removal............................................................................................................................. 126 Installation........................................................................................................................ 126 Power Steering Pump Disassembled View............................................................................................... 127 Disassembly......................................................................................................................... 127 Inspection and Repair............................................................................................................... 128 Reassembly.......................................................................................................................... 128 Main Data and Specifications........................................................................................................ 130 Transfer Gear Assembly.................................................................................................................. 131 Transfer Gear Assembly and Associated Parts......................................................................................... 131 Removal............................................................................................................................. 131 Inspection and Repair............................................................................................................... 131 Installation........................................................................................................................ 131 Supplemental Restraint System Steering Wheel & Column................................................................................... 132 Service Precaution.................................................................................................................. 132 SRS Connectors...................................................................................................................... 132 Inflator Module......................................................................................................................... 134 Inflator Module and Associated Parts................................................................................................ 134 Removal............................................................................................................................. 134 Inspection and Repair............................................................................................................... 135 Installation........................................................................................................................ 135 Steering Wheel.......................................................................................................................... 136 Steering Wheel and Associated Parts................................................................................................. 136 Removal............................................................................................................................. 136 Installation........................................................................................................................ 138 Combination Switch...................................................................................................................... 139 Combination Switch and Associated Parts............................................................................................. 139 Removal............................................................................................................................. 139 Installation........................................................................................................................ 141 Lock Cylinder........................................................................................................................... 143 Lock Cylinder and Associated Parts.................................................................................................. 143 Removal............................................................................................................................. 143 Installation........................................................................................................................ 145 System Inspection................................................................................................................... 146 Steering Column......................................................................................................................... 147 Steering Column and Associated Parts................................................................................................ 147 Removal............................................................................................................................. 147 Insepction.......................................................................................................................... 150 Installation........................................................................................................................ 151 System Inspection................................................................................................................... 152 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 153 Main Data and Specifications........................................................................................................ 153 Special Tools....................................................................................................................... 153 Sec.3 SUSPENSION.............................................................................................................................. 154 3C FRONT SUSPENSION....................................................................................................................... 154 Service Precaution...................................................................................................................... 154 General Description..................................................................................................................... 155 Diagnosis............................................................................................................................... 155 Shock Absorber.......................................................................................................................... 158 Shock Absorber and Associated Parts..................................................................................................... 158 Removal............................................................................................................................. 158 Inspection and Repair............................................................................................................... 158 Installation........................................................................................................................ 158 Stabilizer Bar.......................................................................................................................... 159 Stabilizer Bar and Associated Parts................................................................................................. 159 Removal............................................................................................................................. 159 Inspection and Repair............................................................................................................... 159 Installation........................................................................................................................ 159 Torsion Bar............................................................................................................................. 160 Torsion Bar and Associated Parts.................................................................................................... 160 Removal............................................................................................................................. 160 Inspection and Repair............................................................................................................... 161 Installation........................................................................................................................ 161 Knuckle................................................................................................................................. 163 Knuckle and Associated Parts........................................................................................................ 163 Removal............................................................................................................................. 163 Inspection and Repair............................................................................................................... 164 Installation........................................................................................................................ 164 Upper Control Arm....................................................................................................................... 166 Upper Control Arm and Associated Parts.............................................................................................. 166 Removal............................................................................................................................. 166 Inspection and Repair............................................................................................................... 167 Installation........................................................................................................................ 167 Lower Control Arm....................................................................................................................... 169 Lower Control Arm and Associated Parts.............................................................................................. 169 Removal............................................................................................................................. 169 Inspection and Repair............................................................................................................... 170 Installation........................................................................................................................ 171 Upper Ball Joint........................................................................................................................ 172 Upper Ball Joint and Associated Parts............................................................................................... 172 Removal............................................................................................................................. 172 Inspection and Repair............................................................................................................... 173 Installation........................................................................................................................ 173 Lower Ball Joint........................................................................................................................ 174 Lower Ball Joint and Associated Parts............................................................................................... 174 Removal............................................................................................................................. 174 Inspection and Repair............................................................................................................... 175 Installation........................................................................................................................ 175 Main Data and Specifications............................................................................................................ 176 Special Tools........................................................................................................................... 177 3D REAR SUSPENSION........................................................................................................................ 178 Service Precaution...................................................................................................................... 178 General Description..................................................................................................................... 178 Diagnosis............................................................................................................................... 179 Coil Spring............................................................................................................................. 182 Coil Spring and Associated Parts.................................................................................................... 182 Removal............................................................................................................................. 182 Inspection and Repair............................................................................................................... 183 Installation........................................................................................................................ 183 Shock Absorber.......................................................................................................................... 184 Shock Absorber and Associated Parts................................................................................................. 184 Removal............................................................................................................................. 184 Inspection and Repair............................................................................................................... 184 Installation........................................................................................................................ 184 Trailing Link........................................................................................................................... 185 Trailing Link and Associated Parts.................................................................................................. 185 Removal............................................................................................................................. 185 Inspection and Repair............................................................................................................... 185 Installation........................................................................................................................ 186 Upper Link.............................................................................................................................. 187 Upper Link and Associated Parts..................................................................................................... 187 Removal............................................................................................................................. 187 Inspection and Repair............................................................................................................... 187 Installation........................................................................................................................ 188 Lateral Rod............................................................................................................................. 189 Lateral Rod and Associated Parts.................................................................................................... 189 Removal............................................................................................................................. 189 Inspection and Repair............................................................................................................... 189 Installation........................................................................................................................ 190 Stabilizer Bar.......................................................................................................................... 191 Stabilizer Bar and Associated Parts................................................................................................. 191 Removal............................................................................................................................. 191 Inspection and Repair............................................................................................................... 191 Installation........................................................................................................................ 192 Main Data and Specifications............................................................................................................ 193 Special Tools........................................................................................................................... 195 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 196 Service Precaution...................................................................................................................... 196 General Description..................................................................................................................... 197 Diagnosis............................................................................................................................... 198 Wheel................................................................................................................................... 206 Wheel and Associated Parts.......................................................................................................... 206 Removal............................................................................................................................. 206 Installation........................................................................................................................ 206 Tire.................................................................................................................................... 207 Tire Replacement.................................................................................................................... 207 General Balance Procedure............................................................................................................... 207 Balancing Wheel and Tire................................................................................................................ 208 Main Data and Specifications............................................................................................................ 209 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 210 4A1 DIFFERENTIAL (FRONT)................................................................................................................... 210 Service Precaution...................................................................................................................... 210 Front Drive Axle........................................................................................................................ 211 Diagnosis............................................................................................................................... 211 Pinion Shaft Oil Seal................................................................................................................... 212 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 212 Removal............................................................................................................................. 212 Inspection and Repair............................................................................................................... 213 Installation........................................................................................................................ 213 Front Drive Axle Assembly............................................................................................................... 214 Front Drive Axle Assembly and Associated Parts...................................................................................... 214 Removal............................................................................................................................. 215 Installation........................................................................................................................ 216 Differential Assembly................................................................................................................... 217 Disassembled View................................................................................................................... 217 Disassembly......................................................................................................................... 218 Reassembly.......................................................................................................................... 220 Differential Cage Assembly.............................................................................................................. 228 Disassembled View................................................................................................................... 228 Disassembly......................................................................................................................... 228 Inspection and Repair............................................................................................................... 229 Reassembly.......................................................................................................................... 229 Main Data and Specifications............................................................................................................ 231 Special Tools........................................................................................................................... 234 4A2 DIFFERENTIAL (REAR).................................................................................................................... 236 Service Precaution...................................................................................................................... 236 General Description..................................................................................................................... 237 Diagnosis............................................................................................................................... 238 Axle Housing............................................................................................................................ 240 Axle Housing and Associated Parts................................................................................................... 240 Removal............................................................................................................................. 240 Installation........................................................................................................................ 242 Axle Shaft, Oil Seal and Bearing........................................................................................................ 242 Axle Shaft and Associated Parts..................................................................................................... 242 Removal............................................................................................................................. 243 Inspection.......................................................................................................................... 243 Installation........................................................................................................................ 243 Pinion Oil Seal......................................................................................................................... 245 Pinion Oil Seal and Associated Parts................................................................................................ 245 Removal............................................................................................................................. 245 Inspection and Repair............................................................................................................... 246 Installation........................................................................................................................ 246 Differential Assembly................................................................................................................... 248 Disassembled View................................................................................................................... 248 Inspecting the Axle Before Disassembly.............................................................................................. 249 Disassembly......................................................................................................................... 249 Inspection and Repair............................................................................................................... 251 Reassembly.......................................................................................................................... 251 Side Bearing Preload Adjustment..................................................................................................... 255 Pinion Installation................................................................................................................. 256 Determination of Backlash & Preload Shims........................................................................................... 257 Backlash Adjustment................................................................................................................. 258 Gear Tooth Pattern Check............................................................................................................ 258 Adjustments Affecting Tooth Contact................................................................................................. 259 Differential Case Assembly.............................................................................................................. 260 Disassembled View................................................................................................................... 260 Disassembly......................................................................................................................... 261 Inspection and Repair............................................................................................................... 261 Reassembly.......................................................................................................................... 261 Limited Slip Differential Assembly...................................................................................................... 262 Disassembled View................................................................................................................... 262 Disassembly......................................................................................................................... 262 Inspection and Repair............................................................................................................... 264 Reassembly.......................................................................................................................... 264 Main Data And Specifications............................................................................................................ 266 Special Tools........................................................................................................................... 268 4B DRIVELINE CONTROL SYSTEM............................................................................................................... 270 Service Precaution...................................................................................................................... 270 Shift On The Fly System................................................................................................................. 271 Outline of Shift on The Fly System...................................................................................................... 271 System Diagrams..................................................................................................................... 271 Normal Operation.................................................................................................................... 272 Retrial............................................................................................................................. 273 Functions of Indicator Lamp............................................................................................................. 275 Diagnosis............................................................................................................................... 276 Before Judging That Troubles Occur (Unfaulty mode).................................................................................. 276 Parts Location...................................................................................................................... 277 Wiring Diagram...................................................................................................................... 278 Connector List...................................................................................................................... 280 Diagnosis of The Faults Based on the Status of 4WD Indicator Lamp, 4WD Switch and T/F Change Lever.................................. 281 Shift On The Fly Vacuum Piping and Electrical Equipment................................................................................. 286 Vacuum Piping Diagram............................................................................................................... 286 Actuator Assembly................................................................................................................... 286 Vacuum Tank......................................................................................................................... 286 Inspection and Repair................................................................................................................... 287 Vacuum Piping....................................................................................................................... 287 Check Valve......................................................................................................................... 287 VSV Assembly........................................................................................................................ 288 Functional Detective Switch......................................................................................................... 288 Motor Actuator Assembly............................................................................................................. 288 Transfer Position Switch............................................................................................................ 289 4WD Control Unit........................................................................................................................ 290 4WD Control Unit Associated Parts................................................................................................... 290 Removal............................................................................................................................. 291 Installation........................................................................................................................ 291 4C DRIVE SHAFT SYSTEM..................................................................................................................... 292 Service Precaution...................................................................................................................... 292 General Description..................................................................................................................... 293 Diagnosis............................................................................................................................... 293 Front Hub and Disc (2WD Model).......................................................................................................... 294 Disassembled View................................................................................................................... 294 Disassembly......................................................................................................................... 294 Inspection and Repair............................................................................................................... 295 Reassembly.......................................................................................................................... 296 Front Hub and Disc (4WD Model).......................................................................................................... 299 Disassembled View................................................................................................................... 299 Disassembly......................................................................................................................... 299 Inspection and Repair............................................................................................................... 300 Reassembly.......................................................................................................................... 301 Front Drive Shaft Joint................................................................................................................. 304 Front Drive Shaft Joints Replacement................................................................................................ 304 Front Axle Drive Shaft.................................................................................................................. 305 Front Axle Drive Shaft and Associated Parts......................................................................................... 305 Disassembly......................................................................................................................... 306 Inspection And Repair............................................................................................................... 307 Bushing Replacement................................................................................................................. 307 Reassembly.......................................................................................................................... 307 Shift On The Fly System................................................................................................................. 310 Shift On The Fly System and Associated Parts........................................................................................ 310 Disassembly......................................................................................................................... 310 Inspection And Repair............................................................................................................... 312 Reassembly.......................................................................................................................... 315 Main Data and Specifications........................................................................................................ 317 Special Tools....................................................................................................................... 319 Propeller Shaft......................................................................................................................... 320 General Description..................................................................................................................... 320 Universal Joint......................................................................................................................... 321 Diagnosis of Propeller Shaft and Universal Joint........................................................................................ 322 Front Propeller Shaft................................................................................................................... 323 Front Propeller Shaft and Associated Parts.......................................................................................... 323 Removal............................................................................................................................. 323 Installation........................................................................................................................ 323 Disassembly......................................................................................................................... 324 Universal Joint Disassembly......................................................................................................... 325 Inspection and Repair............................................................................................................... 326 Universal Joint Reassembly.......................................................................................................... 327 Reassembly.......................................................................................................................... 328 Main Data and Specifications........................................................................................................ 329 Rear Propeller Shaft.................................................................................................................... 330 Inspection.............................................................................................................................. 334 Rear Propeller Shaft and Associated Parts........................................................................................... 330 Removal............................................................................................................................. 330 Installation........................................................................................................................ 330 Slip Joint Disassembly.............................................................................................................. 331 Universal Joint Disassembly......................................................................................................... 332 Universal Joint Reassembly.......................................................................................................... 335 Slip Joint Reassembly............................................................................................................... 336 Main Data and Specifications........................................................................................................ 337 4D TRANSFER CASE.......................................................................................................................... 338 Service Precaution...................................................................................................................... 338 General Description..................................................................................................................... 339 Transfer Rear Oil Seal.................................................................................................................. 341 Transfer Rear Oil Seal and Associated Parts......................................................................................... 341 Removal............................................................................................................................. 341 Installation........................................................................................................................ 341 Transfer Case Assembly (A/T)............................................................................................................ 343 Transfer Case Assembly (A/T) and Associated Parts................................................................................... 343 Removal............................................................................................................................. 344 Installation........................................................................................................................ 345 Transfer Rear Case Assembly (A/T)....................................................................................................... 348 Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 348 Removal............................................................................................................................. 348 Installation........................................................................................................................ 350 Transfer Rear Cover Assembly........................................................................................................ 353 Disassembly......................................................................................................................... 353 Inspection and Repair............................................................................................................... 354 Reassembly.......................................................................................................................... 354 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 356 Disassembled View................................................................................................................... 356 Disassembly......................................................................................................................... 357 Inspection and Repair............................................................................................................... 358 Reassembly.......................................................................................................................... 358 Transfer Case Assembly.................................................................................................................. 360 Disassembled View................................................................................................................... 360 Disassembly......................................................................................................................... 361 Inspection and Repair............................................................................................................... 364 Reassembly.......................................................................................................................... 367 Main Data and Specifications............................................................................................................ 374 Special Tools........................................................................................................................... 377 Sec.5 BRAKES.................................................................................................................................. 378 5A BRAKE CONTROL SYSTEM................................................................................................................... 378 Service Precaution...................................................................................................................... 379 General Description..................................................................................................................... 380 Functional Description.............................................................................................................. 381 System Components................................................................................................................... 387 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 387 ABS Warning Light................................................................................................................... 387 Wheel Speed Sensor.................................................................................................................. 387 G-Sensor............................................................................................................................ 387 Normal and Anti-lock Braking........................................................................................................ 387 Brake Pedal Travel.................................................................................................................. 387 Acronyms and Abbreviations.......................................................................................................... 387 General Diagnosis....................................................................................................................... 388 General Information................................................................................................................. 388 ABS Service Precautions............................................................................................................. 388 Computer System Service Precautions................................................................................................. 388 General Service Precautions......................................................................................................... 388 Note on Intermittents............................................................................................................... 388 Test Driving ABS Complaint Vehicles................................................................................................. 389 "ABS" Warning Light................................................................................................................. 389 Normal Operation.................................................................................................................... 389 Tech 2 Scan Tool.................................................................................................................... 390 DATA LIST........................................................................................................................... 393 ACTUATOR TEST....................................................................................................................... 394 Tech 2 Service Bleed................................................................................................................ 398 Basic Diagnostic Flow Chart......................................................................................................... 399 Basic Inspection Procedure.......................................................................................................... 400 EHCU Connector Pin-out Checks........................................................................................................... 401 Circuit Diagram..................................................................................................................... 402 Connector List...................................................................................................................... 405 Part Location....................................................................................................................... 406 Symptom Diagnosis....................................................................................................................... 407 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 407 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 408 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 408 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....................................................................... 408 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 409 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 410 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................ 411 Diagnostic Trouble Codes................................................................................................................ 412 Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 414 Diagnostic Trouble Codes (DTCs)..................................................................................................... 415 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 417 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....................................... 418 Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))................................... 418 Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)).................................................. 418 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))............................................. 419 Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)).............................................. 419 Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))................................................. 419 Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal .... 420 Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................ 420 Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications))..................................... 421 Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))........................... 421 Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................ 421 Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))........................... 422 Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))................................. 422 Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))......................... 422 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)).............................. 423 Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))..................................... 423 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))..................................... 424 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))................................... 425 Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...................................... 426 Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...................................... 427 Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).................................... 428 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)).................. 429 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....................................... 430 Unit Inspection Procedure............................................................................................................... 431 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 431 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 432 Chart C-1-3 Rear Sensor Output Inspection Procedure................................................................................. 432 Chart TC-1 Sensor Output Inspection Procedure....................................................................................... 433 Special Tools........................................................................................................................... 434 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 435 Service Precaution...................................................................................................................... 435 Electronic Hydraulic Control Unit....................................................................................................... 436 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 436 Removal............................................................................................................................. 436 Disassembled View................................................................................................................... 437 Disassembly......................................................................................................................... 437 Reassembly.......................................................................................................................... 437 Installation........................................................................................................................ 437 Front Wheel Speed Sensor................................................................................................................ 438 Front Wheel Speed Sensor and Associated Parts....................................................................................... 438 Removal............................................................................................................................. 438 Inspection and Repair............................................................................................................... 438 Installation........................................................................................................................ 438 Rear Wheel Speed Sensor................................................................................................................. 439 Removal............................................................................................................................. 439 Inspection and Repair............................................................................................................... 439 Installation........................................................................................................................ 439 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 440 Service Precaution...................................................................................................................... 441 General Description..................................................................................................................... 441 Diagnosis............................................................................................................................... 445 General Diagnosis....................................................................................................................... 446 Hydraulic Brakes........................................................................................................................ 449 Filling Master Cylinder Reservoir................................................................................................... 449 Deterioration of Brake Fluid........................................................................................................ 449 Leakage of Brake Fluid.............................................................................................................. 449 Bleeding Brake Hydraulic System..................................................................................................... 449 Flushing Brake Hydraulic System..................................................................................................... 450 Brake Pipes and Hoses............................................................................................................... 450 Brake Hose Inspection............................................................................................................... 450 Front Caliper Brake Hose................................................................................................................ 451 Front Caliper Brake Hose and Associated Parts....................................................................................... 451 Removal............................................................................................................................. 451 Installation........................................................................................................................ 451 Rear Axle Brake Hose.................................................................................................................... 452 Rear Axle Brake Hose and Associated Parts........................................................................................... 452 Removal............................................................................................................................. 452 Installation........................................................................................................................ 452 Brake Pipe.............................................................................................................................. 453 Removal............................................................................................................................. 453 Installation........................................................................................................................ 453 P & B (Proportioning and Bypass) Valve.................................................................................................. 454 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 454 Removal............................................................................................................................. 454 Installation........................................................................................................................ 454 Main Data and Specifications........................................................................................................ 455 Brake Pedal............................................................................................................................. 456 Checking Pedal Height............................................................................................................... 456 Checking Pedal Travel............................................................................................................... 456 Brake Pedal and Associated Parts.................................................................................................... 457 Removal............................................................................................................................. 457 Installation........................................................................................................................ 457 Stoplight Switch........................................................................................................................ 458 Parts Location...................................................................................................................... 458 Removal............................................................................................................................. 458 Installation........................................................................................................................ 458 Main Data and Specifications........................................................................................................ 459 Fluid Reservoir Tank.................................................................................................................... 460 Fluid Reservoir Tank and Associated Parts........................................................................................... 460 Removal............................................................................................................................. 460 Installation........................................................................................................................ 460 Master Cylinder Assembly................................................................................................................ 461 Master Cylinder Assembly and Associated Parts....................................................................................... 461 Removal............................................................................................................................. 461 Inspection and Repair............................................................................................................... 461 Installation........................................................................................................................ 462 Main Data and Specifications........................................................................................................ 463 Special Tools....................................................................................................................... 463 Vacuum Booster Assembly................................................................................................................. 464 Vacuum Booster Assembly and Associated Parts........................................................................................ 464 Removal............................................................................................................................. 464 Inspection and Repair............................................................................................................... 464 Installation........................................................................................................................ 465 Exterior Components..................................................................................................................... 467 Exterior Components and Associated Parts............................................................................................ 467 Removal............................................................................................................................. 467 Inspection and Repair............................................................................................................... 468 Installation........................................................................................................................ 468 Vacuum Booster Overhaul................................................................................................................. 468 Vacuum Booster...................................................................................................................... 468 Main Data and Specifications........................................................................................................ 469 Special Tools....................................................................................................................... 470 Front Disc Brake Pads................................................................................................................... 471 Front Disc Brake Pads Inspection.................................................................................................... 471 Front Disc Brake Pads and Associated Parts.......................................................................................... 471 Removal............................................................................................................................. 472 Installation........................................................................................................................ 472 Front Disc Brake Rotor.................................................................................................................. 474 Inspection.......................................................................................................................... 474 Replacing Brake Rotors.............................................................................................................. 474 Refinishing Brake Rotors............................................................................................................ 474 Front Disc Brake Caliper Assembly....................................................................................................... 475 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 475 Removal............................................................................................................................. 476 Installation........................................................................................................................ 476 Front Disc Brake Caliper................................................................................................................ 478 Front Disc Brake Caliper Disassembled View.......................................................................................... 478 Disassembly......................................................................................................................... 478 Inspection and Repair............................................................................................................... 479 Reassembly.......................................................................................................................... 479 Main Data and Specifications........................................................................................................ 481 Rear Disc Brake Pads (4ﾗ4 Model)........................................................................................................ 482 Brake Pads Inspection............................................................................................................... 482 Brake Pads and Associated Parts..................................................................................................... 482 Removal............................................................................................................................. 483 Installation........................................................................................................................ 483 Rear Disc Brake Rotor (4ﾗ4 Model)....................................................................................................... 485 Inspection.......................................................................................................................... 485 Replacing Brake Rotors.............................................................................................................. 485 Refinishing Brake Rotors............................................................................................................ 485 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 486 Rear Disc Brake Caliper Assembly (4ﾗ4 Model)............................................................................................ 487 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 487 Removal............................................................................................................................. 487 Installation........................................................................................................................ 488 Rear Disc Brake Caliper (4ﾗ4 Model)..................................................................................................... 489 Rear Disc Brake Caliper Disassembled View........................................................................................... 489 Disassembly......................................................................................................................... 490 Inspection and Repair............................................................................................................... 490 Reassembly.......................................................................................................................... 490 Main Data and Specifications (4ﾗ4 Model)............................................................................................ 492 Brake Lining............................................................................................................................ 493 Brake Lining and Associated Parts................................................................................................... 493 Removal............................................................................................................................. 493 Brake Lining Inspection............................................................................................................. 494 Installation........................................................................................................................ 494 Drum Brake Adjustment (4ﾗ2 Model)................................................................................................... 495 Servicing The Brake Drum............................................................................................................ 495 Wheel Cylinder Assembly (4ﾗ2 Model)..................................................................................................... 496 Wheel Cylinder Assembly and Associated Parts........................................................................................ 496 Removal............................................................................................................................. 496 Installation........................................................................................................................ 496 Disassembled View................................................................................................................... 497 Disassembly......................................................................................................................... 497 Inspection and Repair............................................................................................................... 497 Reassembly.......................................................................................................................... 497 Main Data and Specifications........................................................................................................ 499 5D1 PARKING BRAKE SYSTEM (4x4 Model)....................................................................................................... 500 Service Precaution...................................................................................................................... 500 General Description..................................................................................................................... 500 Operation............................................................................................................................... 501 Parking Brake Lever and Front Cable..................................................................................................... 502 Parking Brake Lever Assembly and Associated Parts................................................................................... 502 Removal............................................................................................................................. 502 Installation........................................................................................................................ 502 Parking Brake Rear Cable................................................................................................................ 503 Parking Brake Rear Cable and Associated Parts....................................................................................... 503 Removal............................................................................................................................. 504 Installation........................................................................................................................ 504 Inspection and Repair............................................................................................................... 505 Parking Brake Adjustment............................................................................................................ 505 Main Data and Specifications............................................................................................................ 506 5D2 PARKING BRAKE SYSTEM (4x2 Model)....................................................................................................... 507 Service Precaution...................................................................................................................... 507 General Description..................................................................................................................... 507 Parking Brake Lever..................................................................................................................... 508 Parking Brake Lever Assembly and Associated Parts................................................................................... 508 Removal............................................................................................................................. 508 Installation........................................................................................................................ 508 Parking Brake Rear Cable................................................................................................................ 509 Parking Brake Rear Cable and Associated Parts....................................................................................... 509 Removal............................................................................................................................. 510 Installation........................................................................................................................ 510 Parking Brake Adjustment................................................................................................................ 510 Main Data and Specifications............................................................................................................ 511 Sec.6 ENGINE.................................................................................................................................. 512 X22SE 2.2L ENGINE........................................................................................................................... 512 6A ENGINE MECHANICAL (X22SE 2.2L)..................................................................................................... 512 Service Precaution.................................................................................................................. 513 General Description................................................................................................................. 513 Engine Diagnosis.................................................................................................................... 514 Cylinder Head Cover................................................................................................................. 527 Removal......................................................................................................................... 527 Installation.................................................................................................................... 528 Exhaust Manifold.................................................................................................................... 529 Removal......................................................................................................................... 529 Installation.................................................................................................................... 529 Crankshaft Pulley................................................................................................................... 530 Removal......................................................................................................................... 530 Installation.................................................................................................................... 530 Intake Manifold..................................................................................................................... 531 Removal......................................................................................................................... 531 Installation.................................................................................................................... 532 Cylinder Head Assembly.............................................................................................................. 533 Removal......................................................................................................................... 533 Installation.................................................................................................................... 535 Timing Belt......................................................................................................................... 539 Removal......................................................................................................................... 539 Installation.................................................................................................................... 540 Camshaft............................................................................................................................ 543 Removal......................................................................................................................... 543 Installation.................................................................................................................... 544 Engine Assembly..................................................................................................................... 546 Removal......................................................................................................................... 547 Installation.................................................................................................................... 548 Cylinder Head....................................................................................................................... 550 Cylinder Head and Associated Parts.............................................................................................. 550 Disassembly..................................................................................................................... 550 Inspection and Repair........................................................................................................... 551 Reassembly...................................................................................................................... 552 Valve Spring, Valve, Valve Guide.................................................................................................... 553 Valve Spring, Valve, Valve Guide and Associated Parts........................................................................... 553 Disassembly..................................................................................................................... 553 Inspection and Repair........................................................................................................... 554 Valve Seat Insert Replacement................................................................................................... 555 Reassembly...................................................................................................................... 555 Camshaft............................................................................................................................ 556 Camshaft and Associated Parts................................................................................................... 556 Disassembly..................................................................................................................... 556 Reassembly...................................................................................................................... 557 Crankshaft.......................................................................................................................... 558 Crankshaft and Associated Parts................................................................................................. 558 Disassembly..................................................................................................................... 558 Inspection and Repair........................................................................................................... 559 Inspection and Repair........................................................................................................... 560 Reassembly...................................................................................................................... 561 Piston and Connecting Rod........................................................................................................... 564 Piston, Connecting Rod and Associate Parts...................................................................................... 564 Disassembly..................................................................................................................... 564 Inspection and Repair........................................................................................................... 565 Reassembly...................................................................................................................... 567 Cylinder Block...................................................................................................................... 568 Cylinder Block and Associated Parts............................................................................................. 568 Disassembly..................................................................................................................... 569 Inspection and Repair........................................................................................................... 569 Reassembly...................................................................................................................... 570 Cylinder Head Cover................................................................................................................. 571 Cylinder Head Cover and Associated parts........................................................................................ 571 Removal......................................................................................................................... 572 Installation.................................................................................................................... 572 Balance Unit Assembly............................................................................................................... 574 Balance Unit Assembly Associated Parts.......................................................................................... 574 Disassembly..................................................................................................................... 575 Adjustment...................................................................................................................... 575 Reassembly...................................................................................................................... 577 Main Data and Specifications........................................................................................................ 579 6B ENGINE COOLING (X22SE 2.2L)........................................................................................................ 585 Service Precaution.................................................................................................................. 585 General Description................................................................................................................. 586 Diagnosis........................................................................................................................... 588 Draining and Refilling Cooling System............................................................................................... 588 Water Pump.......................................................................................................................... 589 Water Pump and Associated Parts................................................................................................. 589 Removal......................................................................................................................... 589 Inspection...................................................................................................................... 589 Installation.................................................................................................................... 589 Thermostat.......................................................................................................................... 590 Removal......................................................................................................................... 590 Inspection...................................................................................................................... 590 Installation.................................................................................................................... 590 Radiator............................................................................................................................ 591 Radiator and Associated Parts................................................................................................... 591 Removal......................................................................................................................... 591 Inspection...................................................................................................................... 592 Installation.................................................................................................................... 592 Main Data and Specifications........................................................................................................ 593 Special Tool........................................................................................................................ 593 6C ENGINE FUEL (X22SE 2.2L)........................................................................................................... 594 Service Precaution.................................................................................................................. 594 General Description................................................................................................................. 595 Fuel Metering....................................................................................................................... 596 Fuel Filter......................................................................................................................... 597 Fuel Filter and Associated Parts................................................................................................ 597 Removal......................................................................................................................... 597 Inspection...................................................................................................................... 597 Installation.................................................................................................................... 597 Inspection...................................................................................................................... 597 In-Tank Fuel Filter............................................................................................................. 597 Fuel Pump Flow Test............................................................................................................. 598 Fuel Pump........................................................................................................................... 599 Fuel Pump and Associated Parts.................................................................................................. 599 Removal......................................................................................................................... 599 Installation.................................................................................................................... 599 Fuel Tube / Quick-Connector Fittings................................................................................................ 600 Precautions..................................................................................................................... 600 Cautions During Work............................................................................................................ 600 Removal......................................................................................................................... 600 Reuse of Quick-Connector........................................................................................................ 602 Assembling Advice............................................................................................................... 602 Fuel Pump Relay..................................................................................................................... 603 General Description............................................................................................................. 603 Fuel Tank........................................................................................................................... 603 Fuel Tank and Associated Parts.................................................................................................. 603 Removal......................................................................................................................... 604 Installation.................................................................................................................... 604 Fuel Gage Unit...................................................................................................................... 604 Removal and Installation........................................................................................................ 604 Fuel Filler Cap..................................................................................................................... 605 General Description............................................................................................................. 605 Inspection...................................................................................................................... 605 Main Data and Specifications........................................................................................................ 606 Special Tool........................................................................................................................ 606 6D1 ENGINE ELECTRICAL (X22SE 2.2L)..................................................................................................... 607 Service Precaution.................................................................................................................. 607 Battery............................................................................................................................. 608 General Description............................................................................................................. 608 Diagnosis....................................................................................................................... 608 Battery Charging................................................................................................................ 609 Jump Starting................................................................................................................... 609 Battery Removal................................................................................................................. 610 Battery Installation............................................................................................................ 610 Main Data and Specifications........................................................................................................ 611 6D2 IGNITION SYSTEM (X22SE 2.2L)....................................................................................................... 612 Service Precaution.................................................................................................................. 612 General Description................................................................................................................. 612 Diagnosis........................................................................................................................... 612 Ignition Module..................................................................................................................... 613 Removal......................................................................................................................... 613 Installation.................................................................................................................... 613 Spark Plug.......................................................................................................................... 613 Removal......................................................................................................................... 613 Inspection and Repair........................................................................................................... 613 Installation.................................................................................................................... 614 Crankshaft Angle Sensor............................................................................................................. 614 Removal......................................................................................................................... 614 Installation.................................................................................................................... 614 Main Data and Specifications........................................................................................................ 615 6D3 STARTING AND CHARGING SYSTEM (X22SE 2.2L).......................................................................................... 616 Service Precaution.................................................................................................................. 616 Starting System..................................................................................................................... 617 General Description................................................................................................................. 617 Diagnosis........................................................................................................................... 617 Starter............................................................................................................................. 618 Removal......................................................................................................................... 618 Installation.................................................................................................................... 618 Disassembled View............................................................................................................... 619 Inspection and Repair........................................................................................................... 620 Characteristic Test............................................................................................................. 621 Charging System..................................................................................................................... 622 General Description................................................................................................................. 622 General On-Vehicle Inspection....................................................................................................... 622 Generator........................................................................................................................... 623 Removal......................................................................................................................... 623 Inspection...................................................................................................................... 623 Installation.................................................................................................................... 624 Disassembly..................................................................................................................... 624 Inspection and Repair........................................................................................................... 626 Reassembly...................................................................................................................... 628 Main Data and Specifications........................................................................................................ 629 6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 630 SPECIFICATIONS...................................................................................................................... 635 TIGHTENING SPECIFICATIONS....................................................................................................... 635 DIAGRAMS AND SCHEMATICS............................................................................................................. 636 PCM WIRING DIAGRAM (1 of 10).................................................................................................... 636 PCM WIRING DIAGRAM (2 of 10).................................................................................................... 637 PCM WIRING DIAGRAM (3 of 10).................................................................................................... 638 PCM WIRING DIAGRAM (4 of 10).................................................................................................... 639 PCM WIRING DIAGRAM (5 of 10).................................................................................................... 640 PCM WIRING DIAGRAM (6 of 10).................................................................................................... 641 PCM WIRING DIAGRAM (7 of 10).................................................................................................... 642 PCM WIRING DIAGRAM (8 of 10).................................................................................................... 643 PCM WIRING DIAGRAM (9 of 10).................................................................................................... 644 PCM WIRING DIAGRAM (10 of 10)................................................................................................... 645 PCM PINOUTS......................................................................................................................... 646 PCM Pinout Table, 32鳳in Red Connector-Row "A"................................................................................... 646 PCM Pinout Table, 32鳳in Red Connector-Row "B"................................................................................... 647 PCM Pinout Table, 32鳳in White Connector-Row "C"................................................................................. 648 PCM Pinout Table, 32鳳in White Connector-Row "D"................................................................................. 649 PCM Pinout Table, 32鳳in White Connector-Row "E"................................................................................. 650 PCM Pinout Table, 32鳳in White Connector-Row "F"................................................................................. 651 COMPONENT LOCATOR............................................................................................................... 652 Engine Component Locator Table.................................................................................................. 654 Undercarriage Component Locator Table........................................................................................... 654 Fuse And Relay Panel (Underhood Electrical Center).............................................................................. 654 DIAGNOSIS Strategy-Based Diagnostics................................................................................................ 656 DTC Stored...................................................................................................................... 656 No DTC.......................................................................................................................... 656 No Matching Symptom............................................................................................................. 656 Intermittents................................................................................................................... 656 No Trouble Found................................................................................................................ 656 Verifying Vehicle Repair........................................................................................................ 656 GENERAL SERVICE INFORMATION......................................................................................................... 657 OBD II Serviceability Issues.................................................................................................... 657 Emissions Control Information Label............................................................................................. 657 Maintenance Schedule............................................................................................................ 658 Visual/Physical Engine Compartment Inspection................................................................................... 658 Basic Knowledge Of Tools Required............................................................................................... 658 SERIAL DATA COMMUNICATIONS.......................................................................................................... 658 Class II Serial Data Communications............................................................................................. 658 ON-BOARD DIAGNOSTIC (OBD II)........................................................................................................ 658 On-board Diagnostic Tests....................................................................................................... 658 Comprehensive Component Monitor Diagnostic Operation............................................................................ 658 System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 659 Common OBD II Terms............................................................................................................. 659 The Diagnostic Executive........................................................................................................ 660 DTC Types....................................................................................................................... 661 Decimal/Binary/Hexadecimal Conversions.......................................................................................... 662 Verifying Vehicle Repair........................................................................................................ 662 Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....................................................................... 662 Tech 2.......................................................................................................................... 663 Tech 2 Features................................................................................................................. 664 Getting Started................................................................................................................. 664 Operating Procedure (Example)................................................................................................... 665 Menu............................................................................................................................ 666 DTC Modes....................................................................................................................... 666 DTC Information Mode............................................................................................................ 666 Miscellaneous Test.............................................................................................................. 667 Lamps Test...................................................................................................................... 667 Relays Test..................................................................................................................... 668 EVAP Test....................................................................................................................... 670 Idle Air Control System Test.................................................................................................... 671 Fuel System Test................................................................................................................ 673 EGR Control Test................................................................................................................ 674 Injector Balance Test........................................................................................................... 675 Plotting Snapshot Graph............................................................................................................. 676 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 677 Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 678 PRIMARY SYSTEM-BASED DIAGNOSTICS.................................................................................................... 679 Primary System-based Diagnostics................................................................................................ 679 Fuel Control Heated Oxygen Sensors.............................................................................................. 679 HO2S Heater..................................................................................................................... 679 Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation................................................................. 679 MISFIRE MONITOR DIAGNOSTIC OPERATION................................................................................................ 680 Misfire Counters................................................................................................................ 680 FUEL TRIM SYSTEM MONITOR............................................................................................................ 681 Fuel Trim Cell Diagnostic Weights............................................................................................... 681 ON-BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK........................................................................................... 682 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................ 685 ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................ 688 EVAP CANISTER PURGE SOLENOID........................................................................................................ 688 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER................................................................................... 688 IDLE AIR CONTROL (IAC) VALVE........................................................................................................ 688 FUEL SYSTEM PRESSURE TEST........................................................................................................... 688 FUEL METERING SYSTEM CHECK.......................................................................................................... 688 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE.......................................................... 689 POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS........................................................................................... 694 MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................ 694 EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS........................................................................................... 698 ENGINE Tech 2 DATA DEFINITIONS AND RANGES........................................................................................... 698 TYPICAL SCAN DATA VALUES............................................................................................................ 701 NO MALFUNCTION INDICATOR LAMP (MIL)................................................................................................. 705 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY.......................................................................................... 708 ENGINE CRANKS BUT WILL NOT RUN...................................................................................................... 710 FUEL SYSTEM ELECTRICAL TEST......................................................................................................... 716 FUEL SYSTEM DIAGNOSIS............................................................................................................... 719 IDLE AIR CONTROL (IAC) SYSTEM CHECK................................................................................................. 724 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................ 727 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....................................................................................... 729 EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK.................................................................... 731 Upshift Lamp System Check (Manual Transmission Only)................................................................................ 734 PCM DIAGNOSTIC TROUBLE CODES........................................................................................................ 737 DIAGNOSTIC TROUBLE CODE (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM.............................. 740 DIAGNOSTIC TROUBLE CODE (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT....................................... 743 DIAGNOSTIC TROUBLE CODE (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT............................................. 746 DIAGNOSTIC TROUBLE CODE (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT........................................... 749 DIAGNOSTIC TROUBLE CODE (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT.......................................... 752 DIAGNOSTIC TROUBLE CODE (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT....................................... 755 DIAGNOSTIC TROUBLE CODE (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT...................................... 758 DIAGNOSTIC TROUBLE CODE (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM................................. 761 DIAGNOSTIC TROUBLE CODE (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT.................................................. 764 DIAGNOSTIC TROUBLE CODE (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT................................................ 767 DIAGNOSTIC TROUBLE CODE (DTC) P0125 INSUFFICIENT COOLANT TEMPERATURE FOR CLOSED LOOP FUEL CONTROL................................... 770 DIAGNOSTIC TROUBLE CODE (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1)................................................. 773 DIAGNOSTIC TROUBLE CODE (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)................................................ 776 DIAGNOSTIC TROUBLE CODE (DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1)............................................... 779 DIAGNOSTIC TROUBLE CODE (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)........................................ 782 DIAGNOSTIC TROUBLE CODE (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1).......................................... 785 DIAGNOSTIC TROUBLE CODE (DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)................................................. 788 DIAGNOSTIC TROUBLE CODE (DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)................................................ 791 DIAGNOSTIC TROUBLE CODE (DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)........................................ 794 DIAGNOSTIC TROUBLE CODE (DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2).......................................... 797 DIAGNOSTIC TROUBLE CODE (DTC) P0171 SYSTEM TOO LEAN (BANK 1)........................................................................ 800 DIAGNOSTIC TROUBLE CODE (DTC) P0172 SYSTEM TOO RICH (BANK 1)........................................................................ 804 DIAGNOSTIC TROUBLE CODE (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 1......................................................... 808 DIAGNOSTIC TROUBLE CODE (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 2......................................................... 811 DIAGNOSTIC TROUBLE CODE (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 3......................................................... 814 DIAGNOSTIC TROUBLE CODE (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION-CYLINDER 4......................................................... 817 DIAGNOSTIC TROUBLE CODE (DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 820 DIAGNOSTIC TROUBLE CODE (DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 824 DIAGNOSTIC TROUBLE CODE (DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 828 DIAGNOSTIC TROUBLE CODE (DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 832 DIAGNOSTIC TROUBLE CODE (DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED....................................................... 836 DIAGNOSTIC TROUBLE CODE (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION........................................................... 840 DIAGNOSTIC TROUBLE CODE (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT............................................................. 843 DIAGNOSTIC TROUBLE CODE (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE...................................... 846 DIAGNOSTIC TROUBLE CODE (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT.............................................. 848 DIAGNOSTIC TROUBLE CODE (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE........................................ 851 DIAGNOSTIC TROUBLE CODE (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT................................................ 854 DIAGNOSTIC TROUBLE CODE (DTC) P0351 IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT MALFUNCTION......................................... 857 DIAGNOSTIC TROUBLE CODE (DTC) P0352 IGNITION COIL "B" PRIMARY/SECONDARY CIRCUIT MALFUNCTION......................................... 859 DIAGNOSTIC TROUBLE CODE (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED...................................... 861 DIAGNOSTIC TROUBLE CODE (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED......................................... 864 DIAGNOSTIC TROUBLE CODE (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE....................................... 866 DIAGNOSTIC TROUBLE CODE (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW.............................................. 870 DIAGNOSTIC TROUBLE CODE (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH............................................. 873 DIAGNOSTIC TROUBLE CODE (DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD...................................................... 877 DIAGNOSTIC TROUBLE CODE (DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION.......................................... 880 DIAGNOSTIC TROUBLE CODE (DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED.................................. 885 DIAGNOSTIC TROUBLE CODE (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION.............. 889 DIAGNOSTIC TROUBLE CODE (DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION..................... 892 DIAGNOSTIC TROUBLE CODE (DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION.............. 896 DIAGNOSTIC TROUBLE CODE (DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE..................................................... 899 DIAGNOSTIC TROUBLE CODE (DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT............................................................. 901 DIAGNOSTIC TROUBLE CODE (DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT............................................................ 903 DIAGNOSTIC TROUBLE CODE (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION....................................................... 905 DIAGNOSTIC TROUBLE CODE (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION....................................................... 908 DIAGNOSTIC TROUBLE CODE (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT.................................................... 911 DIAGNOSTIC TROUBLE CODE (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED..................................................... 913 DIAGNOSTIC TROUBLE CODE (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED.................................................... 916 DIAGNOSTIC TROUBLE CODE (DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT............................................... 919 DIAGNOSTIC TROUBLE CODE (DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT.............................................. 922 DIAGNOSTIC TROUBLE CODE (DTC) P0562 SYSTEM VOLTAGE LOW.............................................................................. 925 DIAGNOSTIC TROUBLE CODE (DTC) P0563 SYSTEM VOLTAGE HIGH............................................................................. 927 DIAGNOSTIC TROUBLE CODE (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR.................................................. 929 DIAGNOSTIC TROUBLE CODE (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....................... 931 DIAGNOSTIC TROUBLE CODE (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE........................ 933 DIAGNOSTIC TROUBLE CODE (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE........................... 935 DIAGNOSTIC TROUBLE CODE (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE............................ 938 DIAGNOSTIC TROUBLE CODE (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE........................ 940 DIAGNOSTIC TROUBLE CODE (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE....................... 942 DIAGNOSTIC TROUBLE CODE (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE................................. 945 DIAGNOSTIC TROUBLE CODE (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE.................................. 947 DIAGNOSTIC TROUBLE CODE (DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1).............................................. 949 DIAGNOSTIC TROUBLE CODE (DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1)............................................... 952 DIAGNOSTIC TROUBLE CODE (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION............................................................ 955 DIAGNOSTIC TROUBLE CODE (DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED................................... 958 DIAGNOSTIC TROUBLE CODE (DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT..................................................................... 961 DIAGNOSTIC TROUBLE CODE (DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT........................................................ 963 DIAGNOSTIC TROUBLE CODE (DTC) 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE..................................................... 966 DIAGNOSTIC TROUBLE CODE (DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON-PURGE........................................ 969 DIAGNOSTIC TROUBLE CODE (DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION................................................ 972 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................ 975 DIAGNOSTIC TROUBLE CODE (DTC) P1627 PCM A/D CONVERSION MALFUNCTION.................................................................. 977 DIAGNOSTIC TROUBLE CODE (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION.................................................... 979 DIAGNOSTIC TROUBLE CODE (DTC) P1640 ODM OUTPUT CIRCUIT FAULT........................................................................ 981 SYMPTOM DIAGNOSIS................................................................................................................... 984 DEFAULT MATRIX TABLE................................................................................................................ 1007 Camshaft Position (CMP) Sensor...................................................................................................... 1010 Crankshaft Position (CKP) Sensor.................................................................................................... 1011 EEPROM.............................................................................................................................. 1013 Engine Coolant Temperature (ECT) Sensor............................................................................................. 1013 Heated Oxygen Sensor (HO2S)......................................................................................................... 1014 Intake Air Temperature (IAT) Sensor................................................................................................. 1015 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 1016 Malfunction Indicator Lamp (MIL).................................................................................................... 1017 Powertrain Control Module (PCM)..................................................................................................... 1017 Throttle Position (TP) Sensor....................................................................................................... 1020 Vehicle Speed Sensor (VSS).......................................................................................................... 1021 Air Filter.......................................................................................................................... 1022 Idle Air Control (IAC) Valve........................................................................................................ 1023 Intake Air Duct..................................................................................................................... 1024 Knock Sensor........................................................................................................................ 1026 Oil Pressure Switch................................................................................................................. 1027 FUEL METERING SYSTEM Accelerator Cable Assembly..................................................................................... 1027 Cable Adjustment Section............................................................................................................ 1029 Fuel Filler Cap..................................................................................................................... 1030 Fuel Filter......................................................................................................................... 1030 Fuel Injectors...................................................................................................................... 1032 Fuel Pressure Regulator............................................................................................................. 1033 Fuel Pump Assembly.................................................................................................................. 1035 Fuel Pump Relay..................................................................................................................... 1037 Fuel Rail Assembly.................................................................................................................. 1037 Fuel Tank........................................................................................................................... 1039 Throttle body (TB).................................................................................................................. 1040 ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................ 1042 Ignition Coil....................................................................................................................... 1042 Spark Plugs......................................................................................................................... 1043 Spark Plug Cables................................................................................................................... 1044 EMISSIONS Catalytic Converter....................................................................................................... 1045 Air Conditioning Relay.............................................................................................................. 1045 Ignition Timing Adjustment.......................................................................................................... 1045 EVAP Canister Hoses................................................................................................................. 1045 EVAP Canister....................................................................................................................... 1045 EVAP Canister Vent Solenoid......................................................................................................... 1046 EVAP Canister Purge Valve Solenoid.................................................................................................. 1046 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................ 1047 Wiring and Connectors............................................................................................................... 1049 PCM Connectors And Terminals........................................................................................................ 1049 Connectors And Terminals............................................................................................................ 1049 Wire Harness Repair: Twisted Shielded Cable......................................................................................... 1049 Twisted Leads....................................................................................................................... 1050 Weather-Pack Connector.............................................................................................................. 1051 Com-Pack III........................................................................................................................ 1053 Metri-Pack.......................................................................................................................... 1053 GENERAL DESCRIPTION-PCM AND SENSORS................................................................................................. 1054 58X Reference PCM Input......................................................................................................... 1054 A/C Request Signal.............................................................................................................. 1054 Crankshaft Position (CKP) Sensor................................................................................................ 1054 Camshaft Position (CMP) Sensor And Signal....................................................................................... 1054 Engine Coolant Temperature (ECT) Sensor......................................................................................... 1054 Electrically Erasable Programmable Read Only Memory (EEPROM).................................................................... 1055 Fuel Control Heated Oxygen Sensor (Pre Catalyst)................................................................................ 1055 Catalyst Monitor Heated Oxygen Sensor (Post Catalyst)........................................................................... 1055 Intake Air Temperature (IAT) Sensor............................................................................................. 1056 Linear Exhaust Gas Recirculation (EGR) Control.................................................................................. 1056 Manifold Absolute Pressure (MAP) Sensor......................................................................................... 1056 Powertrain Control Module (PCM)................................................................................................. 1057 PCM Function.................................................................................................................... 1057 PCM Components.................................................................................................................. 1057 PCM Voltage Description......................................................................................................... 1057 PCM Inputs/Outputs.............................................................................................................. 1057 PCM Service Precautions......................................................................................................... 1058 Reprogramming the PCM........................................................................................................... 1058 Tooth Error Correction (TEC) Service Bay Guidelines............................................................................. 1058 Throttle Position (TP) Sensor................................................................................................... 1059 Transmission Range Switch....................................................................................................... 1059 Vehicle Speed Sensor (VSS)...................................................................................................... 1059 Use of Circuit Testing Tools.................................................................................................... 1060 Aftermarket Electrical And Vacuum Equipment..................................................................................... 1060 Electrostatic Discharge Damage.................................................................................................. 1060 Upshift Lamp.................................................................................................................... 1060 GENERAL DESCRIPTION-AIR INDUCTION................................................................................................... 1060 Air Induction System............................................................................................................ 1060 GENERAL DESCRIPTION-FUEL METERING................................................................................................... 1061 Acceleration Mode............................................................................................................... 1061 Accelerator Controls............................................................................................................ 1061 Battery Voltage Correction Mode................................................................................................. 1061 CMP Signal...................................................................................................................... 1061 Clear Flood Mode................................................................................................................ 1061 Deceleration Fuel Cutoff (DFCO) Mode............................................................................................ 1061 Engine Speed/Vehicle Speed/ Fuel Disable Mode................................................................................... 1061 Fuel Cutoff Mode................................................................................................................ 1061 Fuel Injector................................................................................................................... 1061 Fuel Metering System Components................................................................................................. 1062 Basic System Operation.......................................................................................................... 1062 Fuel Metering System Purpose.................................................................................................... 1062 Fuel Pressure Regulator......................................................................................................... 1062 Fuel Pump Electrical Circuit.................................................................................................... 1062 Fuel Rail....................................................................................................................... 1062 Idle Air Control (IAC) Valve.................................................................................................... 1063 Run Mode........................................................................................................................ 1063 Starting Mode................................................................................................................... 1063 Throttle Body Unit.............................................................................................................. 1063 GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM...................................................................................... 1064 Camshaft Position (CMP) Sensor.................................................................................................. 1064 Crankshaft Position (CKP) Sensor................................................................................................ 1064 Electronic Ignition............................................................................................................. 1064 Ignition Coils.................................................................................................................. 1064 Ignition Control................................................................................................................ 1064 Ignition Control Module (ICM)................................................................................................... 1065 Ignition Control PCM Output..................................................................................................... 1065 Powertrain Control Module (PCM)................................................................................................. 1065 Spark Plug...................................................................................................................... 1066 A/C CLUTCH DIAGNOSIS................................................................................................................ 1067 A/C Clutch Circuit Operation.................................................................................................... 1067 A/C Clutch Circuit Purpose...................................................................................................... 1067 A/C Request Signal.............................................................................................................. 1067 GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP) SYSTEM.............................................................................. 1068 EVAP Emission Control System Purpose............................................................................................ 1068 EVAP Emission Control System Operation.......................................................................................... 1068 Enhanced Evaporative Emission Control System.................................................................................... 1068 System Fault Detection.......................................................................................................... 1069 GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION (EGR) SYSTEM.......................................................................... 1069 EGR Purpose..................................................................................................................... 1069 Linear EGR Valve................................................................................................................ 1069 Linear EGR Control.............................................................................................................. 1069 Linear EGR Valve Operation And Results Of Incorrect Operation................................................................... 1070 EGR Pintle Position Sensor...................................................................................................... 1070 GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM..................................................................... 1070 Crankcase Ventilation System Purpose............................................................................................ 1070 SPECIAL TOOLS....................................................................................................................... 1071 6F ENGINE EXHAUST (X22SE 2.2L)........................................................................................................ 1073 Service Precaution.................................................................................................................. 1073 General Description................................................................................................................. 1074 Front Exhaust Pipe.................................................................................................................. 1075 Front Exhaust Pipe and Associated Parts......................................................................................... 1075 Removal......................................................................................................................... 1075 Installation.................................................................................................................... 1075 Exhaust Silencer.................................................................................................................... 1076 Exhaust Silencer and Associated Parts........................................................................................... 1076 Removal......................................................................................................................... 1076 Installation.................................................................................................................... 1076 Rear Exhaust pipe................................................................................................................... 1077 Rear Exhaust pipe and Associated Parts.......................................................................................... 1077 Removal......................................................................................................................... 1077 Installation.................................................................................................................... 1077 Main Data and Specifications........................................................................................................ 1078 6G ENGINE LUBRICATION (X22SE 2.2L).................................................................................................... 1079 Service Precaution.................................................................................................................. 1079 General Description................................................................................................................. 1080 Oil Pump............................................................................................................................ 1081 Oil Pump and Associated Parts................................................................................................... 1081 Disassembly..................................................................................................................... 1082 Inspection and Repair........................................................................................................... 1082 Reassembly...................................................................................................................... 1082 6H ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)........................................................................................... 1083 Service Precaution.................................................................................................................. 1083 Accelerator Pedal Control Cable..................................................................................................... 1084 Removal......................................................................................................................... 1084 Inspection...................................................................................................................... 1084 Installation.................................................................................................................... 1084 Accelerator Pedal................................................................................................................... 1085 Accelerator Pedal and Associated Parts.......................................................................................... 1085 Removal......................................................................................................................... 1085 Installation.................................................................................................................... 1085 6J INDUCTION (X22SE 2.2L).............................................................................................................. 1086 Service Precaution.................................................................................................................. 1086 Air Cleaner Filter.................................................................................................................. 1087 Removal......................................................................................................................... 1087 Inspection...................................................................................................................... 1087 Installation.................................................................................................................... 1087 6VD1 3.2L ENGINE............................................................................................................................ 1088 6A ENGINE MECHANICAL (6VD1 3.2L)...................................................................................................... 1088 Service Precaution.................................................................................................................. 1089 General Description................................................................................................................. 1090 Engine Diagnosis.................................................................................................................... 1091 Cylinder Head Cover LH.............................................................................................................. 1106 Removal......................................................................................................................... 1106 Installation.................................................................................................................... 1107 Cylinder Head Cover RH.............................................................................................................. 1108 Removal......................................................................................................................... 1108 Installation.................................................................................................................... 1108 Common Chamber...................................................................................................................... 1109 Removal......................................................................................................................... 1109 Installation.................................................................................................................... 1109 Exhaust Manifold LH................................................................................................................. 1111 Removal......................................................................................................................... 1111 Installation.................................................................................................................... 1111 Exhaust Manifold RH................................................................................................................. 1112 Removal......................................................................................................................... 1112 Installation.................................................................................................................... 1112 Crankshaft Pulley................................................................................................................... 1113 Removal......................................................................................................................... 1113 Installation.................................................................................................................... 1113 Timing Belt......................................................................................................................... 1114 Removal......................................................................................................................... 1114 Installation.................................................................................................................... 1115 Camshaft............................................................................................................................ 1119 Removal......................................................................................................................... 1119 Installation.................................................................................................................... 1120 Cylinder Head....................................................................................................................... 1123 Removal......................................................................................................................... 1123 Installation.................................................................................................................... 1123 Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................ 1125 Removal......................................................................................................................... 1125 Installation.................................................................................................................... 1125 Piston, Piston Ring and Connecting Rod.............................................................................................. 1126 Removal......................................................................................................................... 1126 Installation.................................................................................................................... 1127 Crankshaft and Main Bearings........................................................................................................ 1128 Removal......................................................................................................................... 1128 Installation.................................................................................................................... 1129 Rear Oil Seal....................................................................................................................... 1133 Removal......................................................................................................................... 1133 Installation.................................................................................................................... 1133 Engine Assembly..................................................................................................................... 1134 Removal......................................................................................................................... 1134 Installation.................................................................................................................... 1134 Cylinder Head....................................................................................................................... 1138 Cylinder Head and Associated Parts.............................................................................................. 1138 Disassembly..................................................................................................................... 1138 Clean........................................................................................................................... 1139 Inspection and Repair........................................................................................................... 1139 Reassembly...................................................................................................................... 1140 Valve Spring, Oil Controller, Valve, Valve Guide.................................................................................... 1142 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts........................................................... 1142 Disassembly..................................................................................................................... 1142 Inspection and Repair........................................................................................................... 1143 Reassembly...................................................................................................................... 1146 Camshaft............................................................................................................................ 1149 Camshaft and Associated Parts................................................................................................... 1149 Disassembly..................................................................................................................... 1149 Inspection and Repair........................................................................................................... 1150 Reassembly...................................................................................................................... 1152 Crankshaft.......................................................................................................................... 1155 Crankshaft and Associated Parts................................................................................................. 1155 Disassembly..................................................................................................................... 1155 Inspection and Repair........................................................................................................... 1156 Inspection and Repair........................................................................................................... 1158 Reassembly...................................................................................................................... 1159 Piston and Connecting Rod........................................................................................................... 1163 Piston, Connecting Rod and Associate Parts...................................................................................... 1163 Disassembly..................................................................................................................... 1163 Inspection and Repair........................................................................................................... 1164 Reassembly...................................................................................................................... 1168 Cylinder Block...................................................................................................................... 1170 Cylinder Block and Associated Parts............................................................................................. 1170 Disassembly..................................................................................................................... 1170 Inspection and Repair........................................................................................................... 1171 Reassembly...................................................................................................................... 1172 Main Data and Specification......................................................................................................... 1175 Special Tool........................................................................................................................ 1181 6B ENGINE COOLING (6VD1 3.2L)......................................................................................................... 1183 Service Precaution.................................................................................................................. 1183 General Description................................................................................................................. 1184 Diagnosis........................................................................................................................... 1186 Draining and Refilling Cooling System............................................................................................... 1187 Water Pump.......................................................................................................................... 1188 Water Pump and Associated Parts................................................................................................. 1188 Removal......................................................................................................................... 1188 Inspection...................................................................................................................... 1188 Installation.................................................................................................................... 1188 Thermostat.......................................................................................................................... 1189 Thermostat and Associated Parts................................................................................................. 1189 Removal......................................................................................................................... 1189 Inspection...................................................................................................................... 1189 Installation.................................................................................................................... 1189 Radiator............................................................................................................................ 1190 Radiator and Associated Parts................................................................................................... 1190 Removal......................................................................................................................... 1190 Inspection...................................................................................................................... 1191 Installation.................................................................................................................... 1192 Drive Belt and Cooling Fan.......................................................................................................... 1193 Drive Belt and Associated Parts................................................................................................. 1193 Inspection...................................................................................................................... 1193 Installation.................................................................................................................... 1193 Main Data and Specifications........................................................................................................ 1194 Special Tool........................................................................................................................ 1195 6C ENGINE FUEL........................................................................................................................ 1196 Service Precaution.................................................................................................................. 1196 General Description................................................................................................................. 1197 Fuel Metering....................................................................................................................... 1198 Fuel Filter......................................................................................................................... 1199 Removal......................................................................................................................... 1199 Inspection...................................................................................................................... 1199 Installation.................................................................................................................... 1199 Inspection...................................................................................................................... 1200 In-Tank Fuel Filter............................................................................................................. 1200 Fuel Pump Flow Test............................................................................................................. 1200 Fuel Pump........................................................................................................................... 1201 Fuel Pump and Associated Parts.................................................................................................. 1201 Removal......................................................................................................................... 1201 Installation.................................................................................................................... 1201 Fuel Tube / Quick ・Connector Fittings............................................................................................... 1202 Precautions..................................................................................................................... 1202 Cautions During Work............................................................................................................ 1202 Removal......................................................................................................................... 1202 Reuse of Quick-Connector........................................................................................................ 1204 Assembling Advice............................................................................................................... 1204 Fuel Pump Relay..................................................................................................................... 1205 General Description............................................................................................................. 1205 Fuel Tank........................................................................................................................... 1205 Fuel Tank and Associated Parts.................................................................................................. 1205 Removal......................................................................................................................... 1206 Installation.................................................................................................................... 1206 Fuel Gauge Unit..................................................................................................................... 1206 Removal and Installation........................................................................................................ 1206 Fuel Filler Cap..................................................................................................................... 1207 General Description............................................................................................................. 1207 Inspection...................................................................................................................... 1207 Main Data and Specifications........................................................................................................ 1208 6D1 ENGINE ELECTRICAL (6VD1 3.2L)...................................................................................................... 1209 Service Precaution.................................................................................................................. 1209 Battery............................................................................................................................. 1210 General Description................................................................................................................. 1210 Diagnosis........................................................................................................................... 1210 Battery Charging................................................................................................................ 1211 Jump Starting....................................................................................................................... 1211 Battery Removal..................................................................................................................... 1212 Battery Installation................................................................................................................ 1212 Main Data and Specifications........................................................................................................ 1213 6D2 IGNITION SYSTEM (6VD1 3.2L)........................................................................................................ 1214 Service Precaution.................................................................................................................. 1214 General Description................................................................................................................. 1215 Diagnosis........................................................................................................................... 1215 Ignition Coil....................................................................................................................... 1216 Removal......................................................................................................................... 1216 Inspection and Repair........................................................................................................... 1216 Installation.................................................................................................................... 1216 Spark Plug.......................................................................................................................... 1217 Removal......................................................................................................................... 1217 Inspection and Repair........................................................................................................... 1217 Installation.................................................................................................................... 1217 Crankshaft Angle Sensor............................................................................................................. 1218 Removal......................................................................................................................... 1218 Installation.................................................................................................................... 1218 Main Data and Specifications........................................................................................................ 1219 6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)........................................................................................... 1220 Service Precaution.................................................................................................................. 1220 Starting System..................................................................................................................... 1221 General Description................................................................................................................. 1221 Diagnosis........................................................................................................................... 1223 Starter............................................................................................................................. 1224 Removal......................................................................................................................... 1224 Installation.................................................................................................................... 1224 Disassembled View............................................................................................................... 1225 Disassembly..................................................................................................................... 1226 Inspection and Repair........................................................................................................... 1228 Reassembly...................................................................................................................... 1232 Main Data and Specifications.................................................................................................... 1234 Charging System..................................................................................................................... 1237 General Description................................................................................................................. 1237 General On-Vehicle Inspection....................................................................................................... 1237 Generator........................................................................................................................... 1238 Removal......................................................................................................................... 1238 Inspection...................................................................................................................... 1238 Installation.................................................................................................................... 1239 Disassembled View............................................................................................................... 1239 Disassembly..................................................................................................................... 1240 Inspection and Repair........................................................................................................... 1241 Reassembly...................................................................................................................... 1243 Bench Test...................................................................................................................... 1244 Main Data and Specifications.................................................................................................... 1245 6E2 3.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 1246 Specification....................................................................................................................... 1251 Tightening Specifications....................................................................................................... 1251 Diagrams and Schematics............................................................................................................. 1252 PCM Wiring Diagram (1 of 8)..................................................................................................... 1252 PCM Wiring Diagram (2 of 8)..................................................................................................... 1253 PCM Wiring Diagram (3 of 8)..................................................................................................... 1254 PCM Wiring Diagram (4 of 8)..................................................................................................... 1255 PCM Wiring Diagram (5 of 8)..................................................................................................... 1256 PCM Wiring Diagram (6 of 8)..................................................................................................... 1257 PCM Wiring Diagram (7 of 8)..................................................................................................... 1258 PCM Wiring Diagram (8 of 8)..................................................................................................... 1259 PCM Pinouts......................................................................................................................... 1260 PCM Pinout Table, 32-Way Red Connector-Row "A".................................................................................. 1260 PCM Pinout Table, 32-Way Red Connector-Row "B".................................................................................. 1261 PCM Pinout Table, 32-Way White Connector-Row "C"................................................................................ 1262 PCM Pinout Table, 32-Way White Connector-Row "D"................................................................................ 1263 PCM Pinout Table, 32-Way Blue Connector-Row "E"................................................................................. 1264 PCM Pinout Table, 32-Way Blue Connector-Row "F"................................................................................. 1265 Component Locators.................................................................................................................. 1266 Engine Component Locator........................................................................................................ 1266 Engine Component Locator Table.................................................................................................. 1267 Undercarriage Component Locator................................................................................................. 1268 Undercarriage Component Locator Table........................................................................................... 1268 Sensors and Miscellaneous Component Locators.................................................................................... 1269 Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 1272 Diagnosis........................................................................................................................... 1273 Strategy-Based Diagnostics...................................................................................................... 1273 DTC Stored...................................................................................................................... 1273 No DTC.......................................................................................................................... 1273 No Matching Symptom............................................................................................................. 1273 Intermittents................................................................................................................... 1273 No Trouble Found................................................................................................................ 1273 Verifying Vehicle Repair........................................................................................................ 1273 General Service Information......................................................................................................... 1274 OBD II Serviceability Issues.................................................................................................... 1274 Emissions Control Information Label............................................................................................. 1274 Maitenance Schedule............................................................................................................. 1275 Visual/Physical Engine Compartment Inspection................................................................................... 1275 Basic Knowledge of Tools Required............................................................................................... 1275 Seral Data Communications........................................................................................................... 1275 Class II Serial Data Communications............................................................................................. 1275 On-Board Diagnostic (OBD II)........................................................................................................ 1275 On-Board Diagnostic Tests....................................................................................................... 1275 Comprehensive Component Monitor Diagnostic Operation............................................................................ 1275 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 1276 Common OBD II Terms............................................................................................................. 1276 The Diagnostic Executive........................................................................................................ 1277 DTC Types....................................................................................................................... 1278 Decimal/Binary/Hexadecimal Conversions.......................................................................................... 1279 Verifying Vehicle Repair........................................................................................................ 1279 Reading Diagnostic Trouble Codes Using the TECH 2 Scan Tool..................................................................... 1279 Tech 2.......................................................................................................................... 1280 Tech 2 Features................................................................................................................. 1281 Getting Started................................................................................................................. 1281 Operating Procedure (For Example)............................................................................................... 1282 Menu............................................................................................................................ 1283 DTC Modes....................................................................................................................... 1283 DTC Information Mode............................................................................................................ 1283 Miscellaneous Test.............................................................................................................. 1284 Lamps Test...................................................................................................................... 1284 Relays Test..................................................................................................................... 1285 EVAP Test....................................................................................................................... 1286 Idle Air Control System Test.................................................................................................... 1288 Fuel System Test................................................................................................................ 1289 EGR Control Test................................................................................................................ 1291 Variable Intake Manifold Solenoid Test.......................................................................................... 1291 Injector Balance Test........................................................................................................... 1292 Plotting Snapshot Graph............................................................................................................. 1293 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 1294 Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 1295 To upload Snapshots to a PC and Download Diagnostic Software from a CD ROM Disk................................................. 1296 Primary System-Based Diagnostics.................................................................................................... 1296 Primary System-Based Diagnostics................................................................................................ 1296 Fuel Control Heated Oxygen Sensors.............................................................................................. 1296 HO2S Heater..................................................................................................................... 1296 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation................................................................. 1296 Misfire Monitor Diagnostic Operation................................................................................................ 1297 Misfire Monitor Diagnostic Operation............................................................................................ 1297 Misfire Counters................................................................................................................ 1297 Fuel Trim System Monitor Diagnostic Operation....................................................................................... 1298 Fuel Trim System Monitor Diagnostic Operation................................................................................... 1298 Fuel Trim Cell Diagnostic Weights............................................................................................... 1298 On-Board Diagnostic (OBD II) System Check........................................................................................... 1299 A/C Clutch Control Circuit Diagnosis................................................................................................ 1302 Electronic Ignition System Diagnosis................................................................................................ 1308 EVAP Canister Purge Solenoid........................................................................................................ 1308 Visual Check of The Evaporative Emission Canister................................................................................... 1308 Fuel Metering System Check.......................................................................................................... 1308 Idle Air Control (IAC) Valve........................................................................................................ 1308 Fuel System Pressure Test........................................................................................................... 1308 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.......................................................... 1308 Knock Sensor Diagnosis.............................................................................................................. 1313 Powertrain Control Module (PCM) Diagnosis........................................................................................... 1313 Multiple PCM Information Sensor DTCS Set............................................................................................ 1313 Multiple PCM Information Sensor DTCs Set........................................................................................... 1314 Exhaust Gas Recirculation (EGR) Diagnosis........................................................................................... 1316 Engine Tech 2 Data Definitions and Ranges........................................................................................... 1316 Typical Scan Data Values............................................................................................................ 1319 No Malfunction Indicator Lamp (MIL)................................................................................................. 1326 Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................ 1329 Engine Cranks But Will Not Run...................................................................................................... 1332 Fuel System Electrical Test......................................................................................................... 1337 Fuel System Diagnosis............................................................................................................... 1340 Idle Air Control (IAC) System Check................................................................................................. 1345 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy).................................................... 1348 Exhaust Gas Recirculation (EGR) System Check........................................................................................ 1350 Manifold Absolute Pressure (MAP) Output Check....................................................................................... 1352 Evaporative (EVAP) Emissions Canister Purge Valve Check............................................................................. 1354 Up-Shift Lamp System Check.......................................................................................................... 1357 PCM Diagnostic Trouble Codes........................................................................................................ 1360 Diagnostic Trouble Code (DTC) P0101 MAF System Performance.......................................................................... 1364 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................ 1367 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency............................................................... 1370 Diagnostic Trouble Code (DTC) P0106 MAP System Performance.......................................................................... 1373 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage.................................................................. 1376 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit Hight Voltage................................................................ 1379 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage.................................................................. 1382 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage................................................................. 1385 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage.................................................................. 1388 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage................................................................. 1391 Diagnostic Trouble Code (DTC) P0121 TP System Performance........................................................................... 1394 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage................................................................... 1397 Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage.................................................................. 1400 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control.................................................. 1403 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................ 1406 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1....................................................... 1409 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.............................................................. 1412 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.............................................. 1416 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1............................................................. 1419 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................ 1422 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2....................................................... 1425 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................... 1428 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2............................................................. 1431 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................ 1434 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1....................................................... 1437 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.............................................................. 1440 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.............................................. 1444 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1............................................................. 1447 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................ 1450 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2....................................................... 1453 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.............................................. 1456 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2............................................................. 1459 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Too Lean Bank 1................................................................ 1462 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1.................................................................... 1466 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2.................................................................... 1470 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2.................................................................... 1474 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit...................................................................... 1478 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit...................................................................... 1481 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit...................................................................... 1484 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit...................................................................... 1487 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit...................................................................... 1490 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit...................................................................... 1493 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected......................................................................... 1496 Diagnostic Trouble Code (DTC) P0301 Cylinder 1 Misfire Detected..................................................................... 1500 Diagnostic Trouble Code (DTC) P0302 Cylinder 2 Misfire Detected..................................................................... 1502 Diagnostic Trouble Code (DTC) P0303 Cylinder 3 Misfire Detected..................................................................... 1504 Diagnostic Trouble Code (DTC) P0304 Cylinder 4 Misfire Detected..................................................................... 1506 Diagnostic Trouble Code (DTC) P0305 Cylinder 5 Misfire Detected..................................................................... 1508 Diagnostic Trouble Code (DTC) P0306 Cylinder 6 Misfire Detected..................................................................... 1510 Diagnostic Trouble Code (DTC) P0325 KS Module Circuit............................................................................... 1512 Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit............................................................................... 1514 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit.................................................................... 1517 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................ 1520 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performamce.................................................................. 1523 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.......................................................................... 1527 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit...................................................................... 1531 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit...................................................................... 1534 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit...................................................................... 1537 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit...................................................................... 1540 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit...................................................................... 1543 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit...................................................................... 1546 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient........................................................................... 1549 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.......................................................................... 1552 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck.................................................................................. 1554 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage................................................................................. 1556 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................ 1559 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................ 1562 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................ 1565 Diagnostic Trouble Code (DTC) P0440 EVAP System..................................................................................... 1568 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected................................................................. 1573 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked...................................................................... 1578 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage........................................................... 1581 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.......................................................... 1584 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage........................................................... 1587 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.......................................................... 1590 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input........................................................................... 1592 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM................................................................. 1595 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................ 1598 Diagnositc Troule Code (DTC) P0562 System Voltage Low............................................................................... 1601 Diagnostic Trouble Code (DTC) P0563 System Voltage High............................................................................. 1603 Diagnostic Trouble Code (DTC) P0601 PCM Memory...................................................................................... 1604 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage.................................................... 1605 Diagnostic Trouble Code (DTC) P1107 MAP Sensor Circuit Intermittent Low Voltage..................................................... 1607 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage.................................................... 1609 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage..................................................... 1612 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage..................................................... 1614 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage.................................................... 1616 Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage..................................................... 1619 Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage...................................................... 1621 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1..................................................... 1623 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1...................................................... 1627 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1..................................................... 1631 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.............................................. 1635 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean Dueing Acceleration............................................................ 1639 Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault................................................................. 1642 Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link.............................................................. 1643 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................ 1644 Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error........................................................ 1643 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................ 1644 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge............................................................... 1647 Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.............................................................................. 1650 Diagnostic Trouble Code (DTC) P1509 IAC System High RPM............................................................................. 1653 Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error........................ 1656 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................ 1657 Diagnostic Trouble Code (DTC) P1640 Output Driver Module (ODM) "A" Fault............................................................ 1658 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault.................................................................... 1660 Symptom Diagnosis................................................................................................................... 1663 Default Matrix Table................................................................................................................ 1691 On-Vehicle Service Camshaft Position (CMP) Sensor................................................................................... 1694 Crankshaft Position (CKP) Sensor.................................................................................................... 1695 Engine Coolant Temperature (ECT) Sensor............................................................................................. 1695 Heated Oxygen Sensor (HO2S)......................................................................................................... 1696 Intake Air Temperature (IAT) Sensor................................................................................................. 1698 Knock Sensor (KS)................................................................................................................... 1699 Mass Air Flow (MAF) Sensor.......................................................................................................... 1700 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 1701 Malfunction Indicator Lamp (MIL).................................................................................................... 1701 Powertrain Control Module (PCM)..................................................................................................... 1702 EEPROM.............................................................................................................................. 1703 Throttle Position (TP) Sensor....................................................................................................... 1704 Vehicle Speed Sensor (VSS).......................................................................................................... 1704 Air Cleaner/Air Filter.............................................................................................................. 1706 Idle Air Control (IAC) Valve........................................................................................................ 1707 Common Chamber...................................................................................................................... 1708 Accelerator Cable Assembly.......................................................................................................... 1708 Accelerator Pedal Replacement....................................................................................................... 1711 Fuel Fillter Cap.................................................................................................................... 1713 Fuel Filter......................................................................................................................... 1713 Fuel Gauge Unit..................................................................................................................... 1716 Fuel Injectors...................................................................................................................... 1716 Fuel Pressure Regulator............................................................................................................. 1717 Fuel Metering System................................................................................................................ 1719 Fuel Pump Assembly.................................................................................................................. 1719 Fuel Pump Relay..................................................................................................................... 1720 Fuel Rail Assembly.................................................................................................................. 1720 Fuel Tank........................................................................................................................... 1721 Throttle Body (TB).................................................................................................................. 1721 Electronic Ignition System.......................................................................................................... 1723 Catalytic Converter................................................................................................................. 1724 Air Conditioning Relay.............................................................................................................. 1724 EVAP Canister Hoses................................................................................................................. 1724 EVAP Canister....................................................................................................................... 1725 EVAP Canister Vent Solenoid......................................................................................................... 1726 Fuel Tank Pressure Sensor........................................................................................................... 1727 EVAP Canister Purge Solenoid........................................................................................................ 1728 Fuel Tank Vent Valve................................................................................................................ 1729 Linear Exhaust Gas Recircula-tion (EGR) Valve....................................................................................... 1729 Positive Crankcase Ventilation (PCV) Valve.......................................................................................... 1730 Wiring and Connectors............................................................................................................... 1730 PCM Connectors and Terminals........................................................................................................ 1731 Wire Harness Repair: Twisted Shielded Cable......................................................................................... 1731 Twisted Leads....................................................................................................................... 1732 Weather-Pack Connector.............................................................................................................. 1733 Com-Pack III........................................................................................................................ 1734 Metri-Pack.......................................................................................................................... 1734 General Description (PCM and Sensors)............................................................................................... 1736 58X Reference PCM Input......................................................................................................... 1736 A/C Request Signal.............................................................................................................. 1736 Crankshaft Position (CKP) Sensor................................................................................................ 1736 Camshaft Position (CMP) Sensor and Signal....................................................................................... 1736 Engine Coolant Temperature (ECT) Sensor......................................................................................... 1736 Electrically Erasable Programmable Read Only Memory (EEPROM).................................................................... 1737 Fuel Control Heated Oxygen Sensors.............................................................................................. 1737 Catalyst Monitor Heated Oxygen Sensors.......................................................................................... 1737 Intake Air Temperature (IAT) Sensor............................................................................................. 1738 Knock Sensor.................................................................................................................... 1738 Linear Exhaust Gas Recirculation (EGR) Control.................................................................................. 1739 Mass Air Flow (MAF) Sensor...................................................................................................... 1739 Manifold Absolute Pressure (MAP) Sensor......................................................................................... 1739 Powertrain Control Module (PCM)................................................................................................. 1740 PCM Function.................................................................................................................... 1740 PCM Components.................................................................................................................. 1740 PCM Voltage Description......................................................................................................... 1740 PCM Input/Outputs............................................................................................................... 1740 PCM Service Precautions......................................................................................................... 1741 Reprogramming The PCM........................................................................................................... 1741 Throttle Position (TP) Sensor................................................................................................... 1741 Transmission Fluid Temperature (TFT) Sensor..................................................................................... 1741 Transmission Range Switch....................................................................................................... 1741 Vehicle Speed Sensor (VSS)...................................................................................................... 1742 Use of Circuit Testing Tools.................................................................................................... 1742 Aftermarket Electrical and Vacuum Equipment..................................................................................... 1742 Electrostatic Discharge Damage.................................................................................................. 1742 Upshift Lamp.................................................................................................................... 1743 General Description (Air Induction)................................................................................................. 1743 Air Induction System............................................................................................................ 1743 General Description (Fuel Metering)................................................................................................. 1743 Acceleration Mode............................................................................................................... 1743 Accelerator Controls............................................................................................................ 1743 Battery Voltage Correction Mode................................................................................................. 1743 CMP Signal...................................................................................................................... 1743 Clear Flood Mode................................................................................................................ 1743 Deceleration Mode............................................................................................................... 1743 Engine Speed/Vehicle Speed/Fuel Disable Mode.................................................................................... 1743 Fuel Cutoff Mode................................................................................................................ 1743 Fuel Injector................................................................................................................... 1743 Fuel Metering System Components................................................................................................. 1744 Fuel Metering System Purpose.................................................................................................... 1744 Fuel Pressure Regulator......................................................................................................... 1744 Fuel Pump Electrical Circuit.................................................................................................... 1744 Fuel Rail....................................................................................................................... 1744 Idle Air Control (IAC) Valve.................................................................................................... 1745 Run Mode........................................................................................................................ 1745 Starting Mode................................................................................................................... 1745 Throttle Body Unit.............................................................................................................. 1746 General Description (Electronic Ignition System).................................................................................... 1746 Camshaft Position (CMP) Sensor.................................................................................................. 1746 Crankshaft Position (CKP) Sensor................................................................................................ 1746 Electronic Ignition............................................................................................................. 1746 Ignition Coils.................................................................................................................. 1747 Ignition Control................................................................................................................ 1747 Ignition Control PCM Output..................................................................................................... 1748 Knock Sensor (KS) PCM Input..................................................................................................... 1748 Powertrain Control Module (PCM)................................................................................................. 1748 Spark Plug...................................................................................................................... 1748 A/C Clutch Diagnosis................................................................................................................ 1750 A/C Clutch Circuit Operation.................................................................................................... 1750 A/C Clutch Circuit Purpose...................................................................................................... 1750 A/C Request Signal.............................................................................................................. 1750 General Description (Evaporative (EVAP) Emission System)............................................................................ 1751 EVAP Emission Control System Purpose............................................................................................ 1751 EVAP Emission Control System Operation.......................................................................................... 1751 Enhanced Evaporative Emission Control System.................................................................................... 1751 General Description (Exhaust Gas Recirculation (EGR) System)........................................................................ 1754 EGR Purpose..................................................................................................................... 1754 Linear EGR Valve................................................................................................................ 1755 Linear EGR Control.............................................................................................................. 1755 Linear EGR Valve Operation and Results of Incorrect Operation................................................................... 1755 EGR Pintle Position Sensor...................................................................................................... 1755 General Description (Positive Crankcase Ventilation (PCV) System)................................................................... 1755 Crankcase Ventilation System Purpose............................................................................................ 1755 Crankcase Ventilation System Operation.......................................................................................... 1756 Special Tools....................................................................................................................... 1757 6F ENGINE EXHAUST (6VD1 3.2L)......................................................................................................... 1759 Service Precaution.................................................................................................................. 1759 General Description................................................................................................................. 1760 Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................ 1761 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts................................................... 1761 Removal......................................................................................................................... 1761 Installation.................................................................................................................... 1761 Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................ 1762 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts................................................... 1762 Removal......................................................................................................................... 1762 Installation.................................................................................................................... 1762 Forked Exhaust Pipe................................................................................................................. 1763 Forked Exhaust Pipe and Associated Parts........................................................................................ 1763 Removal......................................................................................................................... 1763 Installation.................................................................................................................... 1763 Exhaust Silencer.................................................................................................................... 1764 Exhaust Silencer and Associated Parts........................................................................................... 1764 Removal......................................................................................................................... 1764 Installation.................................................................................................................... 1764 Rear Exhaust pipe................................................................................................................... 1765 Rear Exhaust pipe and Associated Parts.......................................................................................... 1765 Removal......................................................................................................................... 1765 Installation.................................................................................................................... 1765 Main Data and Specifications........................................................................................................ 1766 6G ENGINE LUBRICATION (6VD1 3.2L)..................................................................................................... 1767 Service Precaution.................................................................................................................. 1767 General Description................................................................................................................. 1768 Oil Pump............................................................................................................................ 1769 Oil Pump and Associated Parts................................................................................................... 1769 Disassembly..................................................................................................................... 1770 Inspection and Repair........................................................................................................... 1770 Reassembly...................................................................................................................... 1771 Oil Pan and Crankcase............................................................................................................... 1773 Removal......................................................................................................................... 1773 Installation.................................................................................................................... 1773 Oil Pump............................................................................................................................ 1775 Removal......................................................................................................................... 1775 Installation.................................................................................................................... 1775 Oil Pump Oil Seal................................................................................................................... 1777 Removal......................................................................................................................... 1777 Installation.................................................................................................................... 1777 Oil Filter.......................................................................................................................... 1778 Removal......................................................................................................................... 1778 Installation.................................................................................................................... 1778 Main Data and Specification......................................................................................................... 1779 6H ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)............................................................................................ 1780 Service Precaution.................................................................................................................. 1780 Accelerator Pedal Control Cable..................................................................................................... 1781 Removal......................................................................................................................... 1781 Inspection...................................................................................................................... 1781 Installation.................................................................................................................... 1781 Accelerator Pedal................................................................................................................... 1782 Accelerator Pedal and Associated Parts.......................................................................................... 1782 Removal......................................................................................................................... 1782 Installation.................................................................................................................... 1782 6J INDUCTION (6VD1 3.2L).............................................................................................................. 1783 Service Precaution.................................................................................................................. 1783 Air Cleaner Element................................................................................................................. 1784 Removal......................................................................................................................... 1784 Inspection...................................................................................................................... 1784 Installation.................................................................................................................... 1784 Sec.7 TRANSMISSION............................................................................................................................ 1785 7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 1785 Service Precaution...................................................................................................................... 1786 Construction............................................................................................................................ 1787 Range Reference Chart................................................................................................................... 1788 Normal Operation of 1999 4L30-E Transmission............................................................................................ 1789 Diagnosis............................................................................................................................... 1789 General Diagnosis Procedure............................................................................................................. 1792 Preliminary Inspection Chart............................................................................................................ 1793 Checking Transmission Fluid Level and Condition......................................................................................... 1794 Test Driving............................................................................................................................ 1795 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 1796 Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 1797 Stall Test.............................................................................................................................. 1806 Line Pressure Test...................................................................................................................... 1807 Shift Speed Chart....................................................................................................................... 1808 Lockup Speed Chart...................................................................................................................... 1809 Changing Transmission Fluid............................................................................................................. 1810 Selector Lever.......................................................................................................................... 1810 Inspection.......................................................................................................................... 1810 Removal............................................................................................................................. 1810 Installation........................................................................................................................ 1811 Select Cable............................................................................................................................ 1812 Removal............................................................................................................................. 1812 Installation........................................................................................................................ 1814 Shift Lock Cable........................................................................................................................ 1816 Removal............................................................................................................................. 1816 Installation........................................................................................................................ 1817 Mode Switch............................................................................................................................. 1818 Removal............................................................................................................................. 1818 Installation........................................................................................................................ 1818 Transmission............................................................................................................................ 1820 Transmission and Associated Parts................................................................................................... 1820 Removal............................................................................................................................. 1821 Installation........................................................................................................................ 1823 Solenoid (Main Case Valve Body)......................................................................................................... 1828 Removal............................................................................................................................. 1828 Installation........................................................................................................................ 1828 Solenoid (Adapter Case Valve Body)...................................................................................................... 1829 Removal............................................................................................................................. 1829 Installation........................................................................................................................ 1829 Valve Body Assembly (Main Case)......................................................................................................... 1830 Removal............................................................................................................................. 1830 Installation........................................................................................................................ 1830 Valve Body Assembly (Adapter Case)...................................................................................................... 1831 Removal............................................................................................................................. 1831 Installation........................................................................................................................ 1831 Powertrain Control Module (PCM)......................................................................................................... 1832 Removal............................................................................................................................. 1832 Installation........................................................................................................................ 1832 Speed Sensor (Extension Housing)........................................................................................................ 1833 Removal............................................................................................................................. 1833 Installation........................................................................................................................ 1833 Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 1833 Removal............................................................................................................................. 1833 Installation........................................................................................................................ 1833 Front Oil Seal (Converter Housing)...................................................................................................... 1834 Removal............................................................................................................................. 1834 Installation........................................................................................................................ 1834 Rear Oil Seal (Extension Housing)....................................................................................................... 1834 Removal............................................................................................................................. 1834 Installation........................................................................................................................ 1834 Transmission (4L30-E)................................................................................................................... 1835 Disassembly......................................................................................................................... 1835 Reassembly.......................................................................................................................... 1839 Converter Housing and Oil Pump Assembly................................................................................................. 1849 Disassembled View................................................................................................................... 1849 Disassembly......................................................................................................................... 1849 Inspection and Repair............................................................................................................... 1849 Reassembly.......................................................................................................................... 1849 Oil Pump................................................................................................................................ 1850 Disassembled View................................................................................................................... 1850 Disassembly......................................................................................................................... 1850 Inspection and Repair............................................................................................................... 1850 Reassembly.......................................................................................................................... 1850 Main Case Valve Body.................................................................................................................... 1851 Disassembled View................................................................................................................... 1851 Disassembly......................................................................................................................... 1852 Inspection and Repair............................................................................................................... 1852 Reassembly.......................................................................................................................... 1852 Adapter Case Valve Body................................................................................................................. 1853 Disassembled View................................................................................................................... 1853 Disassembly......................................................................................................................... 1853 Inspection and Repair............................................................................................................... 1853 Reassembly.......................................................................................................................... 1853 Third Clutch and Sprag Unit............................................................................................................. 1854 Disassembled View................................................................................................................... 1854 Disassembly......................................................................................................................... 1854 Inspection and Repair............................................................................................................... 1855 Reassembly.......................................................................................................................... 1855 Third Clutch............................................................................................................................ 1855 Disassembled View................................................................................................................... 1855 Disassemble......................................................................................................................... 1856 Inspection and Repair............................................................................................................... 1856 Reassembly.......................................................................................................................... 1856 Sprag Unit.............................................................................................................................. 1857 Disassembled View................................................................................................................... 1857 Disassembly......................................................................................................................... 1857 Inspection and Repair............................................................................................................... 1857 Reassembly.......................................................................................................................... 1857 Second Clutch........................................................................................................................... 1858 Disassembled View................................................................................................................... 1858 Disassembly......................................................................................................................... 1858 Inspection and Repair............................................................................................................... 1859 Reassembly.......................................................................................................................... 1859 3-4 Accumulator Piston.................................................................................................................. 1860 Disassembled View................................................................................................................... 1860 Disassembly......................................................................................................................... 1860 Inspection and Repair............................................................................................................... 1860 Reassembly.......................................................................................................................... 1861 Reverse Clutch Piston and Center Support................................................................................................ 1862 Disassembled View................................................................................................................... 1862 Disassembly......................................................................................................................... 1863 Inspection and Repair............................................................................................................... 1863 Reassembly.......................................................................................................................... 1863 Overrun Clutch and Turbine Shaft........................................................................................................ 1864 Disassembled View................................................................................................................... 1864 Disassembly......................................................................................................................... 1865 Inspection and Repair............................................................................................................... 1865 Reassembly.......................................................................................................................... 1865 Main Data and Specification............................................................................................................. 1867 Special Tools........................................................................................................................... 1871 4L30-E Parts List....................................................................................................................... 1874 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 1882 Service Precaution...................................................................................................................... 1883 General Description..................................................................................................................... 1883 Electronic Control Diagram.......................................................................................................... 1884 Powertrain Control Module (PCM)..................................................................................................... 1885 Control System Diagram.............................................................................................................. 1886 Shift Control....................................................................................................................... 1887 Band Apply Control.................................................................................................................. 1887 Torque Converter Clutch Control..................................................................................................... 1887 Line Pressure Control............................................................................................................... 1887 On-Board Diagnostic System.......................................................................................................... 1887 Fail-Safe Mechanism................................................................................................................. 1887 Torque Management Control........................................................................................................... 1887 ATF Warning Control................................................................................................................. 1887 Shift Mode Control.................................................................................................................. 1888 Gear Shift Control.................................................................................................................. 1889 Winter Drive Mode................................................................................................................... 1890 Functions of Input / Output Components.............................................................................................. 1891 Diagnosis............................................................................................................................... 1892 Electronic Diagnosis................................................................................................................ 1892 How To Diagnose The Problem......................................................................................................... 1892 Check Trans Indicator............................................................................................................... 1892 Diagnostic Check.................................................................................................................... 1892 "Check Trans" Check................................................................................................................. 1893 Tech-2 OBD II Connection............................................................................................................ 1894 F0: Transmission Data............................................................................................................... 1898 F1: PC Solenoid Data................................................................................................................ 1899 OBD II Diagnostic Management System................................................................................................. 1900 16-Terminal Data Link Connector (DLC)............................................................................................... 1901 Malfunction Indicator Lamp (MIL).................................................................................................... 1902 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 1902 Clear DTC........................................................................................................................... 1902 DTC Check........................................................................................................................... 1903 PCM Precaution...................................................................................................................... 1903 Information On PCM.................................................................................................................. 1903 Intermittent Conditions............................................................................................................. 1904 Transmission and PCM Identification................................................................................................. 1904 Isuzu Rodeo......................................................................................................................... 1905 Diagnostic Trouble Code (DTC) Identification........................................................................................ 1906 DTC P0218 Transmission Fluid Over Temperature........................................................................................... 1907 DTC P0560 System Voltage Malfunction.................................................................................................... 1909 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 1912 DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 1915 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 1918 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 1921 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 1924 DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 1927 DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 1930 DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 1933 DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 1936 DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 1938 DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 1941 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 1943 DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 1945 DTC P0753 Shift Solenoid A Electrical................................................................................................... 1947 DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 1950 DTC P0758 Shift Solenoid B Electrical................................................................................................... 1952 DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 1956 DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 1957 DTC P1835 Kickdown Switch Always On..................................................................................................... 1958 DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 1960 DTC P1860 TCC Solenoid Electrical....................................................................................................... 1964 DTC P1870 Transmission Component Slipping............................................................................................... 1967 7B MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2).............................................................................. 1969 Service Precaution...................................................................................................................... 1970 General Description..................................................................................................................... 1970 Diagnosis (MUA)......................................................................................................................... 1973 Diagnosis (TREMEC T5R).................................................................................................................. 1974 Rear Oil Seal (4X2)..................................................................................................................... 1975 Disassembled View................................................................................................................... 1975 Removal............................................................................................................................. 1975 Installation........................................................................................................................ 1975 Transmission (MUA)...................................................................................................................... 1976 Disassembled View................................................................................................................... 1976 Removal............................................................................................................................. 1977 Installation........................................................................................................................ 1981 Transmission (TREMEC T5R)............................................................................................................... 1986 Disassembled View................................................................................................................... 1986 Removal............................................................................................................................. 1987 Installation........................................................................................................................ 1989 Transmission Case....................................................................................................................... 1993 Major Component (MUA, 4X2).......................................................................................................... 1993 Disassembly......................................................................................................................... 1994 Reassembly.......................................................................................................................... 1995 Transmission Case and Transfer Case..................................................................................................... 1998 Major Component (MUA, 4X4).......................................................................................................... 1998 Disassembly......................................................................................................................... 1999 Reassembly.......................................................................................................................... 2002 Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin (MUA)....................................................... 2008 Disassembled View................................................................................................................... 2008 Disassembly......................................................................................................................... 2009 Inspection and Repair............................................................................................................... 2010 Reassembly.......................................................................................................................... 2011 Reverse Gear and 5th Gear (MUA)......................................................................................................... 2012 Disassembled View................................................................................................................... 2012 Disassembly......................................................................................................................... 2013 Inspection and Repair............................................................................................................... 2015 Reassembly.......................................................................................................................... 2015 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft (MUA)........................................................................... 2021 Disassmebled View................................................................................................................... 2021 Disassembly......................................................................................................................... 2022 Reassembly.......................................................................................................................... 2026 Transmission Case (TREMEC T5R).......................................................................................................... 2032 Disassembled View................................................................................................................... 2032 Disassembly......................................................................................................................... 2033 Inspection and Repair............................................................................................................... 2039 Reassembly.......................................................................................................................... 2044 Mainshaft (TREMEC T5R).................................................................................................................. 2050 Disassembled View................................................................................................................... 2050 Disassembly......................................................................................................................... 2050 Reassembly.......................................................................................................................... 2053 Input Shaft (TREMEC T5R)................................................................................................................ 2055 Disassembled View................................................................................................................... 2055 Disassembly......................................................................................................................... 2055 Reassembly.......................................................................................................................... 2056 Input Bearing Retainer (TREMEC T5R)..................................................................................................... 2057 Disassembled View................................................................................................................... 2057 Disassembly......................................................................................................................... 2057 Reassembly.......................................................................................................................... 2057 Counter Shaft (TREMEC T5R).............................................................................................................. 2058 Disassembled View................................................................................................................... 2058 Disassembly......................................................................................................................... 2058 Reassembly.......................................................................................................................... 2059 Extension Housing (TREMEC T5R).......................................................................................................... 2060 Disassembled View................................................................................................................... 2060 Disassembly......................................................................................................................... 2060 Reassembly.......................................................................................................................... 2061 Shift Cover (TREMEC T5R)................................................................................................................ 2062 Disassembled View................................................................................................................... 2062 Disassembly......................................................................................................................... 2062 Reassembly.......................................................................................................................... 2063 Pre-Installation Checks (TREMEC T5R)................................................................................................ 2066 Main Data and Specifications............................................................................................................ 2068 Special Tools (MUA)..................................................................................................................... 2074 Special Tools (TREMEC T5R).............................................................................................................. 2076 7C CLUTCH................................................................................................................................. 2078 Service Precaution...................................................................................................................... 2078 General Description..................................................................................................................... 2079 Diagnosis............................................................................................................................... 2085 Clutch Assembly (X22SE, TREMEC T5R / MUA)............................................................................................... 2086 Clutch Assembly (X22SE, TREMEC T5R) and Associated Parts............................................................................ 2086 Clutch Assembly (X22SE, MUA) and Associated Parts................................................................................... 2087 Removal............................................................................................................................. 2087 Inspection and Repair............................................................................................................... 2088 Installation........................................................................................................................ 2092 Clutch Assembly (6VD1, MUA)............................................................................................................. 2095 Clutch Assembly (6VD1, MUA) and Associated Parts.................................................................................... 2095 Removal............................................................................................................................. 2095 Inspection and Repair............................................................................................................... 2097 Installation........................................................................................................................ 2101 Clutch Control.......................................................................................................................... 2103 Parts Location View................................................................................................................. 2103 Removal............................................................................................................................. 2104 Inspection and Repair............................................................................................................... 2104 Installation........................................................................................................................ 2105 Master Cylinder......................................................................................................................... 2107 Slave Cylinder...................................................................................................................... 2108 Disassembled View................................................................................................................... 2108 Disassembly......................................................................................................................... 2108 Inspection and Repair............................................................................................................... 2108 Reassembly.......................................................................................................................... 2109 Main Data and Specifications............................................................................................................ 2110 Special Tools........................................................................................................................... 2113 Sec.8 BODY AND ACCESSORIES.................................................................................................................... 2114 8A LIGHTING SYSTEM........................................................................................................................ 2114 Service Precaution...................................................................................................................... 2114 Headlight Bulb.......................................................................................................................... 2115 Headlight Assembly...................................................................................................................... 2115 Headlight Adjustment................................................................................................................ 2116 Fog Light Bulb.......................................................................................................................... 2116 Fog Light Assembly...................................................................................................................... 2117 Fog Light Adjustment................................................................................................................ 2117 Side Marker Light Bulb.................................................................................................................. 2117 Front Combination Light Assembly........................................................................................................ 2118 Taillight Bulb.......................................................................................................................... 2118 License Plate Light Bulb (Bumper Type).................................................................................................. 2119 License Plate Light Bulb (Tailgate Type)................................................................................................ 2119 Stoplight Bulb.......................................................................................................................... 2120 High Mounted Stoplight Assembly......................................................................................................... 2120 High Mounted Stoplight Bulb............................................................................................................. 2121 Backup Light Bulb....................................................................................................................... 2121 Front Turn Signal Light Bulb............................................................................................................ 2122 Rear Turn Signal Light Bulb............................................................................................................. 2122 Dome Light Bulb......................................................................................................................... 2123 Courtesy Light Bulb..................................................................................................................... 2123 Spotlight Bulb.......................................................................................................................... 2124 Luggage Room Light Bulb................................................................................................................. 2124 HVAC Bezel Illumination Light Bulb...................................................................................................... 2125 Shift Lever Illumination Light Bulb (A/T)............................................................................................... 2125 Vanity Mirror Illumination Light Bulb................................................................................................... 2126 Starter Switch.......................................................................................................................... 2126 Lighting Switch (Combination Switch).................................................................................................... 2127 DimmerｷPassing Switch (Combination Switch).............................................................................................. 2127 Door Switch............................................................................................................................. 2128 Rear Defogger Switch.................................................................................................................... 2128 Key Remind Switch (Starter Switch)...................................................................................................... 2129 Hazard Warning Light Switch............................................................................................................. 2129 Stoplight Switch........................................................................................................................ 2129 Backup Light Switch (M/T)............................................................................................................... 2130 Turn Signal Light Switch (Combination Switch)........................................................................................... 2130 Illumination Controller................................................................................................................. 2130 Light and Bulb Specifications........................................................................................................... 2131 8B WIPER / WASHER SYSTEM.................................................................................................................. 2133 Service Precaution...................................................................................................................... 2133 Windshield Wiper/Washer System.......................................................................................................... 2134 General Description................................................................................................................. 2134 Windshield Wiper And Washer Switch...................................................................................................... 2134 Removal and Installation............................................................................................................ 2134 Windshield Wiper Motor.................................................................................................................. 2134 Removal............................................................................................................................. 2134 Installation........................................................................................................................ 2134 Windshield Washer Motor................................................................................................................. 2135 Removal............................................................................................................................. 2135 Installation........................................................................................................................ 2135 Windshield Washer Spray Pattern......................................................................................................... 2136 Windshield Wiper Linkage............................................................................................................ 2137 Windshield Wiper Linkage and Associated Parts....................................................................................... 2137 Removal............................................................................................................................. 2137 Installation........................................................................................................................ 2137 Windshield Wiper Arm/Blade.............................................................................................................. 2138 Removal............................................................................................................................. 2138 Installation........................................................................................................................ 2138 Windshield Wiper Blade Rubber........................................................................................................... 2139 Removal............................................................................................................................. 2139 Installation........................................................................................................................ 2139 Rear Wiper/Washer System................................................................................................................ 2140 General Description................................................................................................................. 2140 Rear Wiper and Washer Switch............................................................................................................ 2140 Removal............................................................................................................................. 2140 Installation........................................................................................................................ 2140 Rear Wiper Motor........................................................................................................................ 2141 Removal............................................................................................................................. 2141 Installation........................................................................................................................ 2141 Rear Washer Motor....................................................................................................................... 2142 Removal............................................................................................................................. 2142 Installation........................................................................................................................ 2142 Alarm and Relay Control Unit............................................................................................................ 2142 Removal............................................................................................................................. 2142 Installation........................................................................................................................ 2142 Rear Wiper Arm/Blade.................................................................................................................... 2143 Removal............................................................................................................................. 2143 Installation........................................................................................................................ 2143 Rear Washer Nozzle...................................................................................................................... 2143 Removal............................................................................................................................. 2143 Installation........................................................................................................................ 2143 Rear Washer Spray Pattern........................................................................................................... 2143 Rear Wiper Blade Rubber................................................................................................................. 2144 Removal............................................................................................................................. 2144 Installation........................................................................................................................ 2144 Main Data and Specifications............................................................................................................ 2145 8C ENTERTAINMENT.......................................................................................................................... 2146 Service Precaution...................................................................................................................... 2146 Cigarette Lighter....................................................................................................................... 2147 General Description................................................................................................................. 2147 Removal............................................................................................................................. 2147 Installation........................................................................................................................ 2147 Digital Clock........................................................................................................................... 2147 Removal............................................................................................................................. 2147 Installation........................................................................................................................ 2148 Rod Type Antenna........................................................................................................................ 2148 Removal............................................................................................................................. 2148 Installation........................................................................................................................ 2148 Accessory Socket........................................................................................................................ 2149 Front Accessory Socket.............................................................................................................. 2149 Rear Accessory Socket............................................................................................................... 2149 Radio................................................................................................................................... 2150 Removal............................................................................................................................. 2150 Installation........................................................................................................................ 2150 Speaker................................................................................................................................. 2151 Front Speaker....................................................................................................................... 2151 Tweeter Assembly.................................................................................................................... 2151 Rear Speaker........................................................................................................................ 2151 Horn.................................................................................................................................... 2152 Removal............................................................................................................................. 2152 Installation........................................................................................................................ 2152 8D WIRING SYSTEM.......................................................................................................................... 2153 Service Precaution...................................................................................................................... 2154 General Description..................................................................................................................... 2155 Main Data and Specifications............................................................................................................ 2177 Start and Charging...................................................................................................................... 2197 General Description................................................................................................................. 2197 Circuit Diagram..................................................................................................................... 2198 Parts Location...................................................................................................................... 2201 Powertrain Control Module (PCM)......................................................................................................... 2202 General Description................................................................................................................. 2202 Circuit Diagram..................................................................................................................... 2203 Parts Location...................................................................................................................... 2216 Circuit Diagram..................................................................................................................... 2219 Parts Location...................................................................................................................... 2229 Headlight and Fog Light................................................................................................................. 2231 General Description................................................................................................................. 2231 Circuit Diagram..................................................................................................................... 2232 Parts Location...................................................................................................................... 2234 Diagnosis........................................................................................................................... 2235 Front Side Marker Light, Parking Light, Tail Light and License Plate Light.............................................................. 2238 General Description................................................................................................................. 2238 Circuit Diagram..................................................................................................................... 2239 Parts Location...................................................................................................................... 2241 Diagnosis........................................................................................................................... 2242 Interior Illumination Light............................................................................................................. 2245 General Description................................................................................................................. 2245 Circuit Diagram..................................................................................................................... 2246 Parts Location...................................................................................................................... 2250 Turn Signal Light, Hazard Warning Light................................................................................................. 2251 General Description................................................................................................................. 2251 Circuit Diagram..................................................................................................................... 2252 Parts Location...................................................................................................................... 2255 Diagnosis........................................................................................................................... 2256 Stoplight............................................................................................................................... 2258 General Description................................................................................................................. 2258 Circuit Diagram..................................................................................................................... 2259 Parts Location...................................................................................................................... 2260 Diagnosis........................................................................................................................... 2261 Backup Light............................................................................................................................ 2263 General Description................................................................................................................. 2263 Circuit Diagram..................................................................................................................... 2264 Parts Location...................................................................................................................... 2265 Diagnosis........................................................................................................................... 2266 Horn.................................................................................................................................... 2267 General Description................................................................................................................. 2267 Circuit Diagram..................................................................................................................... 2268 Parts Location...................................................................................................................... 2269 Diagnosis........................................................................................................................... 2270 Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 2271 General Description................................................................................................................. 2271 Circuit Diagram..................................................................................................................... 2272 Parts Location...................................................................................................................... 2277 Power Door Lock......................................................................................................................... 2278 General Description................................................................................................................. 2278 Circuit Diagram..................................................................................................................... 2279 Parts Location...................................................................................................................... 2283 Diagnosis........................................................................................................................... 2284 Power Window............................................................................................................................ 2286 General Description................................................................................................................. 2286 Circuit Diagram..................................................................................................................... 2287 Parts Location...................................................................................................................... 2288 Diagnosis........................................................................................................................... 2289 Cruise Control.......................................................................................................................... 2293 General Description................................................................................................................. 2293 Circuit Diagram..................................................................................................................... 2294 Parts Location...................................................................................................................... 2296 Diagnosis........................................................................................................................... 2297 Diagnosis........................................................................................................................... 2299 Anti-Lock Brake System (ABS)............................................................................................................ 2301 General Description................................................................................................................. 2301 Circuit Diagram..................................................................................................................... 2302 Parts Location...................................................................................................................... 2305 A/T Shift Lock.......................................................................................................................... 2306 General Description................................................................................................................. 2306 Circuit Diagram..................................................................................................................... 2307 Parts Location...................................................................................................................... 2308 Windshield Wiper and Washer............................................................................................................. 2309 General Description................................................................................................................. 2309 Circuit Diagram..................................................................................................................... 2310 Parts Location...................................................................................................................... 2312 Diagnosis........................................................................................................................... 2313 Rear Wiper/Washer....................................................................................................................... 2319 General Description................................................................................................................. 2319 Circuit Diagram..................................................................................................................... 2320 Parts Location...................................................................................................................... 2323 Diagnosis........................................................................................................................... 2324 Rear Defogger/Mirror Defogger........................................................................................................... 2329 General Description................................................................................................................. 2329 Circuit Diagram..................................................................................................................... 2330 Parts Location...................................................................................................................... 2332 Diagnosis........................................................................................................................... 2333 Parts Location...................................................................................................................... 2332 Diagnosis........................................................................................................................... 2333 Audio................................................................................................................................... 2336 General Description................................................................................................................. 2336 Circuit Diagram..................................................................................................................... 2337 Parts Location...................................................................................................................... 2338 Cigarette Lighter, Digital Clock and Accessory Socket................................................................................... 2339 General Description................................................................................................................. 2339 Circuit Diagram..................................................................................................................... 2340 Parts Location...................................................................................................................... 2341 Diagnosis........................................................................................................................... 2342 Power Door Mirror....................................................................................................................... 2343 General Description................................................................................................................. 2343 Circuit Diagram..................................................................................................................... 2344 Parts Location...................................................................................................................... 2346 Diagnosis........................................................................................................................... 2347 Keyless Entry and Anti-Theft System..................................................................................................... 2348 General Description................................................................................................................. 2348 Circuit Diagram..................................................................................................................... 2349 Parts Location...................................................................................................................... 2354 Diagnosis........................................................................................................................... 2355 Meter and Warning/Indicator Light....................................................................................................... 2365 General Description................................................................................................................. 2365 Circuit Diagram..................................................................................................................... 2366 Parts Location...................................................................................................................... 2373 Diagnosis........................................................................................................................... 2374 A/T Shift Indicator..................................................................................................................... 2380 General Description................................................................................................................. 2380 Circuit Diagram..................................................................................................................... 2381 Parts Location...................................................................................................................... 2383 Heater and Air Conditioning............................................................................................................. 2384 General Description................................................................................................................. 2384 Circuit Diagram..................................................................................................................... 2385 Parts Location...................................................................................................................... 2388 Sun Roof................................................................................................................................ 2389 General Description................................................................................................................. 2389 Circuit Diagram..................................................................................................................... 2390 Parts Location...................................................................................................................... 2391 Diagnosis........................................................................................................................... 2392 Supplemental Restraint System (SRS) -Air Bag............................................................................................ 2393 General Description................................................................................................................. 2393 Circuit Diagram..................................................................................................................... 2394 Parts Location...................................................................................................................... 2395 Shift on the Fly System................................................................................................................. 2396 General Description................................................................................................................. 2396 Circuit Diagram..................................................................................................................... 2397 Parts Location...................................................................................................................... 2399 Harness Connector Faces................................................................................................................. 2400 8E METER AND GAUGE........................................................................................................................ 2416 Service Precaution...................................................................................................................... 2416 General Description..................................................................................................................... 2416 Meter Assembly.......................................................................................................................... 2417 General Description................................................................................................................. 2417 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 2417 Table for Meter/Gauge Connector Terminal Connections................................................................................ 2421 Removal............................................................................................................................. 2425 Installation........................................................................................................................ 2425 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 2425 Removal............................................................................................................................. 2425 Installation........................................................................................................................ 2425 Vehicle Speed Sensor.................................................................................................................... 2426 Removal............................................................................................................................. 2426 Installation........................................................................................................................ 2426 Fuel Tank Unit.......................................................................................................................... 2426 Removal............................................................................................................................. 2426 Installation........................................................................................................................ 2426 Main Data and Specifications............................................................................................................ 2427 8F BODY STRUCTURE......................................................................................................................... 2428 Service Precaution...................................................................................................................... 2429 Frame................................................................................................................................... 2430 General Description................................................................................................................. 2430 Frame Dimensions................................................................................................................ 2430 General Description (Bumper)............................................................................................................ 2431 Front Bumper............................................................................................................................ 2431 Parts Location...................................................................................................................... 2431 Removal............................................................................................................................. 2432 Installation........................................................................................................................ 2432 Rear Bumper............................................................................................................................. 2433 Parts Location...................................................................................................................... 2433 Removal............................................................................................................................. 2433 Installation........................................................................................................................ 2433 General Description (Sheet Metal)....................................................................................................... 2435 Engine Hood and Fender.................................................................................................................. 2435 Parts Location...................................................................................................................... 2435 Removal............................................................................................................................. 2436 Installation........................................................................................................................ 2437 Body Dimension.......................................................................................................................... 2439 General Description (Body).............................................................................................................. 2452 Instrument Panel Assembly............................................................................................................... 2452 Parts Location...................................................................................................................... 2452 Removal............................................................................................................................. 2453 Installation........................................................................................................................ 2454 Front Door Assembly..................................................................................................................... 2455 Parts Location...................................................................................................................... 2455 Removal............................................................................................................................. 2455 Installation........................................................................................................................ 2456 Rear Door Assembly...................................................................................................................... 2457 Parts Location...................................................................................................................... 2457 Removal............................................................................................................................. 2457 Installation........................................................................................................................ 2458 Front Window Regulator, Glass and Glass Run............................................................................................. 2459 Parts Location...................................................................................................................... 2459 Removal............................................................................................................................. 2460 Installation........................................................................................................................ 2462 Rear Window Regulator, Glass and Glass Run.............................................................................................. 2463 Parts Location...................................................................................................................... 2463 Removal............................................................................................................................. 2464 Installation........................................................................................................................ 2466 Rear Tailgate (Lower Side).............................................................................................................. 2467 Parts Location...................................................................................................................... 2467 Removal............................................................................................................................. 2468 Installation........................................................................................................................ 2468 Rear Hatchgate (Upper Side)............................................................................................................. 2469 Parts Location...................................................................................................................... 2469 Removal............................................................................................................................. 2470 Installation........................................................................................................................ 2470 Adjustment.......................................................................................................................... 2472 Spare Tire Carrier...................................................................................................................... 2473 Parts Location...................................................................................................................... 2473 Removal............................................................................................................................. 2473 Installation........................................................................................................................ 2473 Headlining.............................................................................................................................. 2474 Parts Location...................................................................................................................... 2474 Removal............................................................................................................................. 2475 Installation........................................................................................................................ 2475 Windshield.............................................................................................................................. 2476 Parts Location...................................................................................................................... 2476 Removal............................................................................................................................. 2477 Installation........................................................................................................................ 2477 Rear Quarter Glass...................................................................................................................... 2480 Parts Location...................................................................................................................... 2480 Removal............................................................................................................................. 2481 Installation........................................................................................................................ 2481 Main Data and Specifications............................................................................................................ 2481 Special Tools........................................................................................................................... 2484 8G SEATS.................................................................................................................................. 2485 Service Precaution...................................................................................................................... 2485 Front Seat Assembly..................................................................................................................... 2486 Front Seat Assembly and Associated Parts............................................................................................ 2486 Removal............................................................................................................................. 2486 Installation........................................................................................................................ 2486 Rear Seat Assembly...................................................................................................................... 2487 Rear Seat Assembly and Associated Parts............................................................................................. 2487 Removal............................................................................................................................. 2487 Installation........................................................................................................................ 2487 Main Data and Specifications............................................................................................................ 2488 8H SECURITY AND LOCKS..................................................................................................................... 2490 Service Precaution...................................................................................................................... 2490 Front Door Lock Assembly................................................................................................................ 2491 Front Door Lock Assembly and Associated Parts....................................................................................... 2491 Removal............................................................................................................................. 2492 Installation........................................................................................................................ 2493 Front Outside Handle.................................................................................................................... 2494 Front Outside Handle and Associated Parts........................................................................................... 2494 Removal............................................................................................................................. 2494 Installation........................................................................................................................ 2494 Rear Door Lock Assembly................................................................................................................. 2495 Rear Door Lock Assembly and Associated Parts........................................................................................ 2495 Removal............................................................................................................................. 2496 Installation........................................................................................................................ 2496 Rear Outside Handle..................................................................................................................... 2497 Rear Outside Handle and Associated Parts............................................................................................ 2497 Removal............................................................................................................................. 2497 Installation........................................................................................................................ 2497 Tailgate Lock and Hatchgate Lock........................................................................................................ 2498 Tailgate Lock, Hatchgate Lock and Associated Parts.................................................................................. 2498 Removal............................................................................................................................. 2499 Installation........................................................................................................................ 2499 Key..................................................................................................................................... 2500 Key Coding.......................................................................................................................... 2500 Key Styles.......................................................................................................................... 2500 Power Door Lock System.................................................................................................................. 2501 General Description................................................................................................................. 2501 Door Lock Key Switch................................................................................................................ 2501 Front Door Lock Actuator............................................................................................................ 2501 Rear Door Lock Actuator............................................................................................................. 2501 Tailgate Lock Actuator.............................................................................................................. 2501 Anti-Theft System....................................................................................................................... 2501 General Description................................................................................................................. 2501 Anti-Theft & Keyless Entry Controller............................................................................................... 2501 Anti-Theft Indicator................................................................................................................ 2502 Anti-Theft Horn..................................................................................................................... 2502 Engine Hood Switch.................................................................................................................. 2503 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 2503 8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 2504 Service Precaution...................................................................................................................... 2504 Sun Roof Glass.......................................................................................................................... 2505 Sun Roof Glass and Associated Parts................................................................................................. 2505 Removal............................................................................................................................. 2505 Installation........................................................................................................................ 2506 Sun Roof Deflector...................................................................................................................... 2506 Removal............................................................................................................................. 2506 Installation........................................................................................................................ 2506 Sunshade................................................................................................................................ 2507 Disassembled View................................................................................................................... 2507 Removal............................................................................................................................. 2507 Installation........................................................................................................................ 2508 Sun Roof Frame Complete Assembly........................................................................................................ 2509 Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 2509 Removal............................................................................................................................. 2509 Installation........................................................................................................................ 2510 Sun Roof Switch......................................................................................................................... 2510 Removal............................................................................................................................. 2510 Installation........................................................................................................................ 2510 Sun Roof Control Unit................................................................................................................... 2511 Removal............................................................................................................................. 2511 Installation........................................................................................................................ 2511 Safety Stop Switch...................................................................................................................... 2511 Removal............................................................................................................................. 2511 Installation........................................................................................................................ 2511 Limit Switch............................................................................................................................ 2512 Removal............................................................................................................................. 2512 Installation........................................................................................................................ 2512 Sun Roof Motor.......................................................................................................................... 2512 Removal............................................................................................................................. 2512 Installation........................................................................................................................ 2512 Main Data and Specifications............................................................................................................ 2513 8J EXTERIOR / INTERIOR TRIM............................................................................................................... 2514 Service Precaution...................................................................................................................... 2514 Consoles................................................................................................................................ 2515 Consoles and Associated Parts....................................................................................................... 2515 Removal............................................................................................................................. 2515 Installation........................................................................................................................ 2515 Front Door Trim Panel................................................................................................................... 2516 Front Door Trim Panel and Associated Parts.......................................................................................... 2516 Removal............................................................................................................................. 2516 Installation........................................................................................................................ 2518 Rear Door Trim Panel.................................................................................................................... 2519 Rear Door Trim Panel and Associated Parts........................................................................................... 2519 Removal............................................................................................................................. 2519 Installation........................................................................................................................ 2520 Interior Trim Panels.................................................................................................................... 2521 Interior Trim Panels and Associated Parts........................................................................................... 2521 Removal............................................................................................................................. 2521 Installation........................................................................................................................ 2522 Power Door Mirror System................................................................................................................ 2522 General Description................................................................................................................. 2522 Door Mirror Switch.................................................................................................................. 2522 Power Window System..................................................................................................................... 2523 General Description................................................................................................................. 2523 Power Window Switch Driver Seat Side................................................................................................ 2523 Power Window Motor.................................................................................................................. 2524 Sec.9 RESTRAINTS.............................................................................................................................. 2525 9A SEAT BELT SYSTEM....................................................................................................................... 2525 Service Precaution...................................................................................................................... 2525 Front Seat Belt......................................................................................................................... 2526 Front Seat Belt and Associated Parts................................................................................................ 2526 Removal............................................................................................................................. 2526 Installation........................................................................................................................ 2526 Rear Seat Belt.......................................................................................................................... 2527 Rear Seat Belt and Associated Parts................................................................................................. 2527 Removal............................................................................................................................. 2527 Installation........................................................................................................................ 2528 Front Seat Buckle Assembly.............................................................................................................. 2529 Removal............................................................................................................................. 2529 Installation........................................................................................................................ 2529 Main Data and Specifications............................................................................................................ 2530 9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 2531 Service Precaution...................................................................................................................... 2532 General Description..................................................................................................................... 2532 Restraint Devices................................................................................................................... 2532 System Description.................................................................................................................. 2533 SRS Component and Wiring Location View.................................................................................................. 2534 Component Description................................................................................................................... 2534 SDM (Sensing and Diagnostic Module)................................................................................................. 2534 "Air Bag" Warning Lamp.............................................................................................................. 2535 SRS Coil Assembly................................................................................................................... 2535 Air Bag Assemblies.................................................................................................................. 2535 Steering Column..................................................................................................................... 2536 Knee Bolster........................................................................................................................ 2536 Definition.............................................................................................................................. 2536 Diagnosis............................................................................................................................... 2537 Diagnostic Trouble Codes............................................................................................................ 2537 Scan Tool Diagnostics............................................................................................................... 2537 Use of Special Tools................................................................................................................ 2538 SRS Connector Body Face Views........................................................................................................... 2538 Repairs and Inspections Required After an Accident.................................................................................. 2538 Accident With Deployment-Component Replacement and Inspections...................................................................... 2539 Accident With or Without Deployment-Component Inspection............................................................................ 2539 SDM Replacement Guidelines.......................................................................................................... 2539 Wiring Damage....................................................................................................................... 2539 SRS Connector (Plastic Body And Terminal Metal Pin) Damage.......................................................................... 2539 SRS Wire Pigtail Damage............................................................................................................. 2539 On-Vehicle Service...................................................................................................................... 2539 Service Precautions................................................................................................................. 2539 Disabling The SRS................................................................................................................... 2539 Enabling The SRS.................................................................................................................... 2539 Handling / Installation / Diagnosis................................................................................................. 2540 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 2540 Live (Undeployed) Air Bag Assembly.................................................................................................. 2540 Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................ 2541 Deployed Air Bag Assembly........................................................................................................... 2541 Air Bag Assembly Scrapping Procedure................................................................................................ 2541 Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................ 2541 Deployment Outside Vehicle (Passenger Air Bag Assembly)............................................................................. 2543 Deployment Inside Vehicle (Vehicle Scrapping Procedure)............................................................................. 2545 Deployed Air Bag Assembly Handling.................................................................................................. 2548 Special Tools........................................................................................................................... 2548 J-41433 SRS Driver/Passenger Load Tool.............................................................................................. 2548 J-39200 DVM......................................................................................................................... 2549 Scan Tool........................................................................................................................... 2549 J-35616-A Connector Test Adapter Kit................................................................................................ 2549 J-42986 SRS Deployment Tool......................................................................................................... 2549 J-42987 SRS Adapter For Load Tool................................................................................................... 2550 J-41497 SRS Deployment Fixture...................................................................................................... 2550 Tech 2 Scan Tool.................................................................................................................... 2551 Service Precaution...................................................................................................................... 2554 Disabling The SRS................................................................................................................... 2554 Enabling The SRS.................................................................................................................... 2554 Handling / Installation / Diagnosis................................................................................................. 2554 Inspections Required After An Accident.............................................................................................. 2554 Sensing and Diagnostic Module (SDM)..................................................................................................... 2555 Service Precautions................................................................................................................. 2555 Removal............................................................................................................................. 2555 Installation........................................................................................................................ 2556 Driver Air Bag Assembly................................................................................................................. 2556 Service Precautions................................................................................................................. 2556 Removal............................................................................................................................. 2556 Installation........................................................................................................................ 2557 Steering Wheel.......................................................................................................................... 2557 Service Precautions................................................................................................................. 2557 Removal............................................................................................................................. 2557 Installation........................................................................................................................ 2558 SRS Coil Assembly....................................................................................................................... 2559 Service Precaution.................................................................................................................. 2559 Removal............................................................................................................................. 2559 Installation........................................................................................................................ 2559 Steering Column......................................................................................................................... 2561 Service Precaution.................................................................................................................. 2561 Removal............................................................................................................................. 2561 Installation........................................................................................................................ 2562 Passenger Air Bag Assembly.............................................................................................................. 2563 Service Precaution.................................................................................................................. 2563 Removal............................................................................................................................. 2563 Installation........................................................................................................................ 2563 9J1 SRS CONTROL SYSTEM..................................................................................................................... 2564 Service Precaution...................................................................................................................... 2564 Diagnostic Information.................................................................................................................. 2565 Diagnostic Procedures............................................................................................................... 2565 Diagnostic Codes.................................................................................................................... 2565 How To Read Trouble Codes........................................................................................................... 2565 How To Clear Trouble Codes.......................................................................................................... 2565 Scan Tool Diagnostics............................................................................................................... 2565 Basic Knowledge Required............................................................................................................ 2565 Basic Electrical Circuits........................................................................................................... 2565 "Flash Code" Diagnostics............................................................................................................ 2565 System Schematic........................................................................................................................ 2566 SRS Diagnostic System Check............................................................................................................. 2567 SRS Diagnostic System Check............................................................................................................. 2568 Chart A SDM Integrity Check............................................................................................................. 2569 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 2571 Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady............................................................................... 2573 DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 2576 DTC 16 Passenger Deployment Loop Resistance Low......................................................................................... 2579 DTC 17 Passenger Deployment Loop Open................................................................................................... 2582 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 2584 DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 2586 DTC 21 Driver Deployment Loop Resistance High........................................................................................... 2588 DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 2591 DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 2594 DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 2596 DTC 26 Driver Deployment Loop Open...................................................................................................... 2599 DTC 51 Deployment Event Commanded....................................................................................................... 2602 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 2604 DTC 61 Warning Lamp Circuit Failure..................................................................................................... 2606 DTC 71 Internal SDM Fault............................................................................................................... 2608 Sec.10 CONTROL SYSTEM.......................................................................................................................... 2610 10A CRUISE CONTROL SYSTEM.................................................................................................................. 2610 Service Precaution...................................................................................................................... 2610 General Description..................................................................................................................... 2610 Diagnosis............................................................................................................................... 2611 Brake Switch............................................................................................................................ 2611 Removal and Installation............................................................................................................ 2611 Adjustment.......................................................................................................................... 2611 Clutch Switch........................................................................................................................... 2612 Removal and Installation............................................................................................................ 2612 Adjustment.......................................................................................................................... 2612 Cruise Control Unit..................................................................................................................... 2612 Removal............................................................................................................................. 2612 Installation........................................................................................................................ 2612 Cruise Actuator......................................................................................................................... 2613 Actuator Cable Diagram.............................................................................................................. 2613 Removal............................................................................................................................. 2613 Installation........................................................................................................................ 2613 Adjustment.......................................................................................................................... 2613 Mode Switch............................................................................................................................. 2614 Removal and Installation............................................................................................................ 2614 Cruise Control Main Switch.............................................................................................................. 2614 Removal............................................................................................................................. 2614 Installation........................................................................................................................ 2614 Cruise Control Switch (Combination Switch).............................................................................................. 2615 Removal and Installation............................................................................................................ 2615 (UA) AMIGO.......................................................................................................................................... 2616 Sec.0 GENERAL INFORMATION..................................................................................................................... 2617 0A GENERAL INFORMATION.................................................................................................................... 2617 General Repair Instruction.............................................................................................................. 2617 Illustration Arrows..................................................................................................................... 2618 Identification.......................................................................................................................... 2619 Theft Prevention Standard............................................................................................................... 2621 Lifting Instructions.................................................................................................................... 2626 Standard Bolts Torque Specifications.................................................................................................... 2628 Abbreviations Charts.................................................................................................................... 2629 Service Parts Identification Plate...................................................................................................... 2630 0B MAINTENANCE AND LUBRICATION............................................................................................................ 2631 Maintenance Schedule List............................................................................................................... 2631 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 2635 Recommended Fluids and Lubricants................................................................................................... 2638 Lubricant Viscosity Chart............................................................................................................... 2639 Recommended Liquid Gasket........................................................................................................... 2641 Recommended Thread Locking Agents................................................................................................... 2642 Maintenance Service Data................................................................................................................ 2643 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 2644 1A HVAC SYSTEMS........................................................................................................................... 2644 Sec.2 STEERING................................................................................................................................ 2645 2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 2645 Sec.3 SUSPENSION.............................................................................................................................. 2646 3C FRONT SUSPENSION....................................................................................................................... 2646 3D REAR SUSPENSION........................................................................................................................ 2646 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 2646 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 2648 4A1 DIFFERENTIAL (FRONT)................................................................................................................... 2648 Main Data And Specifications............................................................................................................ 2649 4A2 DIFFERENTIAL (REAR).................................................................................................................... 2650 Main Data And Specifications............................................................................................................ 2651 4B DRIVELINE CONTROL SYSTEM............................................................................................................... 2647 4C DRIVE SHAFT SYSTEM..................................................................................................................... 2652 Service Precaution...................................................................................................................... 2653 Front Propeller Shaft................................................................................................................... 2654 General Description................................................................................................................. 2654 Diagnosis of Propeller Shaft and Universal Joint.................................................................................... 2656 Front Propeller Shaft and Associated Parts.......................................................................................... 2657 Removal............................................................................................................................. 2657 Installation........................................................................................................................ 2657 Slip Joint Disassembly.............................................................................................................. 2658 Universal Joint Disassembly(Single Cardan Type)..................................................................................... 2659 Universal Joint Disassembly (Double Cardan Type).................................................................................... 2661 Inspection and Repair............................................................................................................... 2662 Universal Joint Reassembly(Single Cardan Type)...................................................................................... 2664 Universal Joint Reassembly (Double Cardan Type)..................................................................................... 2665 Slip Joint Reassembly............................................................................................................... 2667 Main Data And Specifications........................................................................................................ 2668 Rear Propeller Shaft.................................................................................................................... 2669 General Description................................................................................................................. 2669 Diagnosis of Propeller Shaft and Universal Joint.................................................................................... 2671 Rear Propeller Shaft and Associated Parts........................................................................................... 2672 Removal............................................................................................................................. 2672 Installation........................................................................................................................ 2672 Slip Joint Disassembly (6VD1 Model and X22SE 4×4 Model Only)........................................................................ 2673 Universal Joint Disassembly......................................................................................................... 2674 Inspection.......................................................................................................................... 2676 Universal Joint Reassembly.......................................................................................................... 2677 Slip Joint Reassembly (6VD1 Model and X22SE 4×4 Model Only)......................................................................... 2678 Main Data and Specifications........................................................................................................ 2679 4D TRANSFER CASE.......................................................................................................................... 2647 Sec.5 BRAKE CONTROL SYSTEM.................................................................................................................... 2680 5A BRAKE CONTROL SYSTEM................................................................................................................... 2680 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 2680 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 2680 5D1 PARKING BRAKE SYSTEM (4x4 Model)....................................................................................................... 2680 5D2 PARKING BRAKE SYSTEM (4x2 Model)....................................................................................................... 2680 Sec.6 ENGINE.................................................................................................................................... 2681 X22SE 2.2L ENGINE........................................................................................................................... 2681 6A ENGINE MECHANICAL (X22SE 2.2L)..................................................................................................... 2681 6B ENGINE COOLING (X22SE 2.2L)........................................................................................................ 2681 6C ENGINE FUEL (X22SE 2.2L)........................................................................................................... 2682 Service Precaution.................................................................................................................. 2682 General Description................................................................................................................. 2683 Fuel Metering....................................................................................................................... 2684 Fuel Filter......................................................................................................................... 2685 Fuel Filter and Associated Parts................................................................................................ 2685 Removal......................................................................................................................... 2685 Inspection...................................................................................................................... 2685 Installation.................................................................................................................... 2685 Inspection...................................................................................................................... 2685 In-Tank Fuel Filter............................................................................................................. 2685 Fuel Pump Flow Test............................................................................................................. 2686 Fuel Pump Relay..................................................................................................................... 2687 General Description............................................................................................................. 2687 Fuel Tank........................................................................................................................... 2687 Fuel Tank and Associated Parts.................................................................................................. 2687 Removal......................................................................................................................... 2688 Installation.................................................................................................................... 2688 Fuel Gauge Unit..................................................................................................................... 2688 Removal and Installation........................................................................................................ 2688 Fuel Tube / Quick-Connector Fittings................................................................................................ 2689 Precautions..................................................................................................................... 2689 Cautions During Work............................................................................................................ 2689 Removal......................................................................................................................... 2689 Reuse of Quick-Connector........................................................................................................ 2691 Assembling Advice............................................................................................................... 2691 Fuel Filler Cap..................................................................................................................... 2692 General Description............................................................................................................. 2692 Inspection...................................................................................................................... 2692 Fuel Pump........................................................................................................................... 2693 Fuel Pump and Associated Parts.................................................................................................. 2693 Removal......................................................................................................................... 2693 Installation.................................................................................................................... 2694 Main Data and Specifications........................................................................................................ 2694 Special Tool........................................................................................................................ 2694 6D1 ENGINE ELECTRICAL (X22SE 2.2L)..................................................................................................... 2681 6D2 IGNITION SYSTEM (X22SE 2.2L)....................................................................................................... 2681 6D3 STARTING AND CHARGING SYSTEM (X22SE 2.2L).......................................................................................... 2681 6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 2681 6F ENGINE EXHAUST (X22SE 2.2L)........................................................................................................ 2695 Service Precaution.................................................................................................................. 2695 General Description................................................................................................................. 2696 Front Exhaust Pipe.................................................................................................................. 2697 Front Exhaust Pipe and Associated Parts......................................................................................... 2697 Removal......................................................................................................................... 2697 Installation.................................................................................................................... 2697 Exhaust Silencer.................................................................................................................... 2698 Exhaust Silencer and Associated Parts........................................................................................... 2698 Removal......................................................................................................................... 2698 Installation.................................................................................................................... 2698 Rear Exhaust pipe................................................................................................................... 2699 Rear Exhaust pipe and Associated Parts.......................................................................................... 2699 Removal......................................................................................................................... 2699 Installation.................................................................................................................... 2699 Main Data and Specifications........................................................................................................ 2700 6G ENGINE LUBRICATION (X22SE 2.2L).................................................................................................... 2681 6H ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)........................................................................................... 2681 6J INDUCTION (X22SE 2.2L).............................................................................................................. 2681 6VD1 3.2L ENGINE............................................................................................................................ 2701 6A ENGINE MECHANICAL (6VD1 3.2L)...................................................................................................... 2701 6B ENGINE COOLING (6VD1 3.2L)......................................................................................................... 2701 6C ENGINE FUEL (6VD1 3.2L)............................................................................................................ 2702 Service Precaution.................................................................................................................. 2702 General Description................................................................................................................. 2703 Fuel Metering....................................................................................................................... 2704 Fuel Filter......................................................................................................................... 2705 Removal......................................................................................................................... 2705 Inspection...................................................................................................................... 2705 Installation.................................................................................................................... 2705 Inspection...................................................................................................................... 2706 In-Tank Fuel Filter............................................................................................................. 2706 Fuel Pump Flow Test............................................................................................................. 2706 Fuel Pump Relay..................................................................................................................... 2706 General Description............................................................................................................. 2706 Fuel Tank........................................................................................................................... 2707 Fuel Tank and Associated Parts.................................................................................................. 2707 Removal......................................................................................................................... 2707 Installation.................................................................................................................... 2708 Fuel Tube / Quick-Connector Fittings................................................................................................ 2708 Precautions..................................................................................................................... 2708 Cautions During Work............................................................................................................ 2708 Removal......................................................................................................................... 2708 Reuse of Quick-Connector........................................................................................................ 2710 Assembling Advice............................................................................................................... 2710 Fuel Gauge Unit..................................................................................................................... 2711 Removal and Installation........................................................................................................ 2711 Fuel Pump........................................................................................................................... 2711 Fuel Pump and Associated Parts.................................................................................................. 2711 Removal......................................................................................................................... 2712 Installation.................................................................................................................... 2712 Fuel Filler Cap..................................................................................................................... 2712 General Description............................................................................................................. 2712 Inspection...................................................................................................................... 2712 Main Data and Specifications........................................................................................................ 2713 Special Tool........................................................................................................................ 2713 6D1 ENGINE ELECTRICAL (6VD1 3.2L)...................................................................................................... 2701 6D2 IGNITION SYSTEM (6VD1 3.2L)........................................................................................................ 2701 6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)........................................................................................... 2714 Service Precaution.................................................................................................................. 2714 Starting System..................................................................................................................... 2715 General Description............................................................................................................. 2715 Diagnosis....................................................................................................................... 2717 Starter............................................................................................................................. 2718 Removal......................................................................................................................... 2718 Installation.................................................................................................................... 2718 Disassembled View............................................................................................................... 2719 Disassembly..................................................................................................................... 2720 Inspection and Repair........................................................................................................... 2722 Reassembly...................................................................................................................... 2726 Main Data and Specifications.................................................................................................... 2728 Charging System..................................................................................................................... 2731 General Description............................................................................................................. 2731 General On-Vehicle Inspection................................................................................................... 2731 Generator........................................................................................................................... 2732 Removal......................................................................................................................... 2732 Inspection...................................................................................................................... 2732 Installation.................................................................................................................... 2733 Disassembled View............................................................................................................... 2733 Disassembly..................................................................................................................... 2734 Inspection and Repair........................................................................................................... 2735 Reassembly...................................................................................................................... 2737 Bench Test...................................................................................................................... 2738 Main Data and Specifications.................................................................................................... 2739 6E1 3.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 2701 6F ENGINE EXHAUST (6VD1 3.2L)......................................................................................................... 2740 Service Precaution.................................................................................................................. 2740 General Description................................................................................................................. 2741 Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................ 2742 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts................................................... 2742 Removal......................................................................................................................... 2742 Installation.................................................................................................................... 2742 Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................ 2743 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts................................................... 2743 Removal......................................................................................................................... 2743 Installation.................................................................................................................... 2743 Forked Exhaust Pipe................................................................................................................. 2744 Forked Exhaust Pipe and Associated Parts........................................................................................ 2744 Removal......................................................................................................................... 2744 Installation.................................................................................................................... 2744 Exhaust Silencer.................................................................................................................... 2745 Exhaust Silencer and Associated Parts........................................................................................... 2745 Removal......................................................................................................................... 2745 Installation.................................................................................................................... 2745 Rear Exhaust pipe................................................................................................................... 2746 Rear Exhaust pipe and Associated Parts.......................................................................................... 2746 Removal......................................................................................................................... 2746 Installation.................................................................................................................... 2746 Main Data and Specifications........................................................................................................ 2747 6G ENGINE LUBRICATION (6VD1 3.2L)..................................................................................................... 2701 6H ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)............................................................................................ 2701 6J INDUCTION (6VD1 3.2L).............................................................................................................. 2701 Sec.7 AUTOMATIC TRANSMISSION.................................................................................................................. 2748 7B MANUAL TRANSMISSION MUA 5C (4X2, 4X4) AND TREMEC T5R(4X2).............................................................................. 2748 7C CLUTCH................................................................................................................................. 2748 Sec.8 BODY AND ACCESSORIES.................................................................................................................... 2750 8A LIGHTING SYSTEM........................................................................................................................ 2750 Service Precaution...................................................................................................................... 2750 Headlight Bulb.......................................................................................................................... 2751 Headlight Assembly...................................................................................................................... 2751 Headlight Adjustment................................................................................................................ 2752 Fog Light Bulb.......................................................................................................................... 2752 Fog Light Assembly...................................................................................................................... 2753 Fog Light Adjustment................................................................................................................ 2753 Side Marker Light Bulb.................................................................................................................. 2753 Front Combination Light Assembly........................................................................................................ 2754 Taillight Bulb.......................................................................................................................... 2754 License Plate Light Bulb................................................................................................................ 2755 Stoplight Bulb.......................................................................................................................... 2755 High Mounted Stoplight Assembly (Soft Top Model)........................................................................................ 2756 High Mounted Stoplight Bulb (Soft Top Model)............................................................................................ 2756 High Mounted Stoplight Assembly (Resin Top Model)....................................................................................... 2757 High Mounted Stoplight Bulb (Resin Top Model)........................................................................................... 2757 Backup Light Bulb....................................................................................................................... 2758 Front Turn Signal Light Bulb............................................................................................................ 2758 Rear Turn Signal Light Bulb............................................................................................................. 2759 Dome Light Bulb......................................................................................................................... 2759 Courtesy Light Bulb..................................................................................................................... 2760 Spotlight Bulb.......................................................................................................................... 2760 Luggage Room Light Bulb (Resin Top Model)............................................................................................... 2761 HVAC Bezel Illumination Light Bulb...................................................................................................... 2761 Shift Lever Illumination Light Bulb (A/T)............................................................................................... 2762 Starter Switch.......................................................................................................................... 2762 Lighting Switch (Combination Switch).................................................................................................... 2763 Dimmer-Passing Switch (Combination Switch).............................................................................................. 2763 Door Switch............................................................................................................................. 2763 Key Remind Switch (Starter Switch)...................................................................................................... 2764 Hazard Warning Light Switch............................................................................................................. 2764 Stoplight Switch........................................................................................................................ 2764 Backup Light Switch (M/T)............................................................................................................... 2765 Turn Signal Light Switch (Combination Switch)........................................................................................... 2765 Illumination Controller................................................................................................................. 2765 Light and Bulb Specifications........................................................................................................... 2766 8B WIPER / WASHER SYSTEM.................................................................................................................. 2768 Service Precaution...................................................................................................................... 2768 Windshield Wiper/Washer System.......................................................................................................... 2769 General Description................................................................................................................. 2769 Windshield Wiper And Washer Switch...................................................................................................... 2769 Removal and Installation............................................................................................................ 2769 Windshield Wiper Motor.................................................................................................................. 2769 Removal............................................................................................................................. 2769 Installation........................................................................................................................ 2769 Windshield Washer Motor................................................................................................................. 2770 Removal............................................................................................................................. 2770 Installation........................................................................................................................ 2770 Windshield Washer Spray Pattern......................................................................................................... 2771 Windshield Wiper Linkage................................................................................................................ 2772 Windshield Wiper Linkage and Associated Parts....................................................................................... 2772 Removal............................................................................................................................. 2772 Installation........................................................................................................................ 2772 Windshield Wiper Arm/Blade.............................................................................................................. 2773 Removal............................................................................................................................. 2773 Installation........................................................................................................................ 2773 Windshield Wiper Blade Rubber........................................................................................................... 2774 Removal............................................................................................................................. 2774 Installation........................................................................................................................ 2774 Rear Wiper/Washer System (Resin Top Model).............................................................................................. 2775 General Description................................................................................................................. 2775 Rear Wiper and Washer Switch (Resin Top Model).......................................................................................... 2775 Removal............................................................................................................................. 2775 Installation........................................................................................................................ 2775 Rear Wiper Motor (Resin Top Model)...................................................................................................... 2776 Removal............................................................................................................................. 2776 Installation........................................................................................................................ 2776 Rear Washer Motor (Resin Top Model)..................................................................................................... 2776 Removal............................................................................................................................. 2776 Installation........................................................................................................................ 2776 Alarm and Relay Control Unit............................................................................................................ 2777 Removal............................................................................................................................. 2777 Installation........................................................................................................................ 2777 Rear Wiper Arm/Blade (Resin Top Model).................................................................................................. 2777 Removal............................................................................................................................. 2777 Installation........................................................................................................................ 2777 Rear Washer Nozzle (Resin Top Model).................................................................................................... 2778 Removal............................................................................................................................. 2778 Installation........................................................................................................................ 2778 Rear Washer Spray Pattern........................................................................................................... 2778 Rear Wiper Blade Rubber (Resin Top Model)............................................................................................... 2778 Removal............................................................................................................................. 2778 Installation........................................................................................................................ 2779 Main Data and Specifications............................................................................................................ 2779 8C ENTERTAINMENT.......................................................................................................................... 2780 Service Precaution...................................................................................................................... 2780 Cigarette Lighter....................................................................................................................... 2781 General Description................................................................................................................. 2781 Removal............................................................................................................................. 2781 Installation........................................................................................................................ 2781 Digital Clock........................................................................................................................... 2781 Removal............................................................................................................................. 2781 Installation........................................................................................................................ 2782 Rod Type Antenna........................................................................................................................ 2782 Removal............................................................................................................................. 2782 Installation........................................................................................................................ 2782 Accessory Socket........................................................................................................................ 2783 Front Accessory Socket.............................................................................................................. 2783 Rear Accessory Socket............................................................................................................... 2783 Radio................................................................................................................................... 2784 Removal............................................................................................................................. 2784 Installation........................................................................................................................ 2784 Speaker................................................................................................................................. 2785 Front Speaker....................................................................................................................... 2785 Tweeter Assembly.................................................................................................................... 2785 Rear Speaker........................................................................................................................ 2785 Horn.................................................................................................................................... 2786 Removal............................................................................................................................. 2786 Installation........................................................................................................................ 2786 8D WIRING SYSTEM.......................................................................................................................... 2787 Service Precaution...................................................................................................................... 2789 Main Data and Specifications............................................................................................................ 2790 Relay Location.......................................................................................................................... 2798 Diode Location.......................................................................................................................... 2800 Grounding Point......................................................................................................................... 2802 Cable Harness Routing................................................................................................................... 2806 Stoplight............................................................................................................................... 2809 General Description................................................................................................................. 2809 Circuit Diagram..................................................................................................................... 2810 Parts Location...................................................................................................................... 2811 Diagnosis........................................................................................................................... 2812 Horn.................................................................................................................................... 2814 General Description................................................................................................................. 2814 Circuit Diagram..................................................................................................................... 2815 Parts Location...................................................................................................................... 2816 Diagnosis........................................................................................................................... 2817 Dome Light, Luggage Room Light, Courtesy Light, Map Light, Seat Belt Switch and Warning Buzzer.......................................... 2819 General Description................................................................................................................. 2819 Circuit Diagram..................................................................................................................... 2820 Parts Location...................................................................................................................... 2824 Diagnosis........................................................................................................................... 2825 Power Door Lock......................................................................................................................... 2826 General Description................................................................................................................. 2826 Circuit Diagram..................................................................................................................... 2827 Parts Location...................................................................................................................... 2831 Diagnosis........................................................................................................................... 2832 Rear Wiper/Washer....................................................................................................................... 2834 General Description................................................................................................................. 2834 Circuit Diagram..................................................................................................................... 2835 Parts Location...................................................................................................................... 2838 Diagnosis........................................................................................................................... 2839 Rear Defogger/Mirror Defogger........................................................................................................... 2845 General Description................................................................................................................. 2845 Circuit Diagram..................................................................................................................... 2846 Parts Location...................................................................................................................... 2849 Diagnosis........................................................................................................................... 2850 Audio................................................................................................................................... 2852 General Description................................................................................................................. 2852 Circuit Diagram..................................................................................................................... 2853 Parts Location...................................................................................................................... 2854 Cigarette Lighter, and Digital Clock Accessory Socket................................................................................... 2855 General Description................................................................................................................. 2855 Circuit Diagram..................................................................................................................... 2856 Parts Location...................................................................................................................... 2857 Diagnosis........................................................................................................................... 2858 Keyless Entry and Anti-Theft System..................................................................................................... 2859 General Description................................................................................................................. 2859 Circuit Diagram..................................................................................................................... 2860 Parts Location...................................................................................................................... 2865 Diagnosis........................................................................................................................... 2866 ID Code Registration.................................................................................................................... 2871 Answer Back (Anti-theft Horn Operation) Change Mode..................................................................................... 2874 8E METER AND GAUGE........................................................................................................................ 2749 8F BODY STRUCTURE......................................................................................................................... 2875 Service Precaution...................................................................................................................... 2876 Frame................................................................................................................................... 2877 General Description................................................................................................................. 2877 Frame Dimensions.................................................................................................................... 2877 Body Dimension.......................................................................................................................... 2878 Rear Tailgate (Lower Side).............................................................................................................. 2887 Parts Location...................................................................................................................... 2887 Removal............................................................................................................................. 2888 Installation........................................................................................................................ 2888 Rear Hatchgate (Upper Side)............................................................................................................. 2889 Parts Location (Resin Top Model).................................................................................................... 2889 Removal............................................................................................................................. 2890 Installation........................................................................................................................ 2890 Headlining.............................................................................................................................. 2891 Parts Location...................................................................................................................... 2891 Removal............................................................................................................................. 2892 Installation........................................................................................................................ 2892 Side Window Glass....................................................................................................................... 2893 Parts Location...................................................................................................................... 2893 Removal............................................................................................................................. 2893 Installation........................................................................................................................ 2893 Rear Quarter Glass...................................................................................................................... 2894 Parts Location (Resin Top Model).................................................................................................... 2894 Removal............................................................................................................................. 2894 Installation........................................................................................................................ 2894 8G SEATS.................................................................................................................................. 2896 Service Precaution...................................................................................................................... 2896 Rear Seat Assembly...................................................................................................................... 2897 Rear Seat Assembly and Associated Parts............................................................................................. 2897 Removal............................................................................................................................. 2897 Installation........................................................................................................................ 2898 Main Data and Specifications............................................................................................................ 2899 8H SECURITY AND LOCKS..................................................................................................................... 2900 Service Precaution...................................................................................................................... 2901 Tailgate Lock........................................................................................................................... 2902 Tailgate Lock and Associated Parts.................................................................................................. 2902 Removal............................................................................................................................. 2903 Installation........................................................................................................................ 2903 Main Data and Specifications............................................................................................................ 2903 8I SUN ROOF/CONVERTIBLE TOP............................................................................................................... 2904 Service Precaution...................................................................................................................... 2904 Sun Roof Glass.......................................................................................................................... 2905 Sun Roof Glass and Associated Parts................................................................................................. 2905 Removal............................................................................................................................. 2905 Installation........................................................................................................................ 2906 Sun Roof Deflector...................................................................................................................... 2907 Parts Location...................................................................................................................... 2907 Removal............................................................................................................................. 2907 Installation........................................................................................................................ 2907 Soft Top Assembly....................................................................................................................... 2908 Soft Top Assembly and Associated Parts.............................................................................................. 2908 Removal............................................................................................................................. 2909 Installation........................................................................................................................ 2909 Resin Top Assembly...................................................................................................................... 2910 Resin Top Assembly and Associated Parts............................................................................................. 2910 Removal............................................................................................................................. 2910 Installation........................................................................................................................ 2911 Seat Belt Cross Bar Assembly............................................................................................................ 2912 Seat Belt Cross Bar Assembly and Associated......................................................................................... 2912 Removal............................................................................................................................. 2912 Installation........................................................................................................................ 2913 Main Data and Specifications............................................................................................................ 2914 8J EXTERIOR / INTERIOR TRIM............................................................................................................... 2915 Service Precaution...................................................................................................................... 2915 Interior Trim Panels.................................................................................................................... 2916 Interior Trim Panels and Associated Parts........................................................................................... 2916 Removal............................................................................................................................. 2916 Installation........................................................................................................................ 2917 Sec.9 RESTRAINTS.............................................................................................................................. 2919 9A SEAT BELT SYSTEM....................................................................................................................... 2919 Service Precaution...................................................................................................................... 2919 Front Seat Belt......................................................................................................................... 2920 Front Seat Belt and Associated Parts................................................................................................ 2920 Removal............................................................................................................................. 2920 Installation........................................................................................................................ 2921 Rear Seat Belt.......................................................................................................................... 2922 Rear Seat Belt and Associated Parts................................................................................................. 2922 Removal............................................................................................................................. 2922 Installation........................................................................................................................ 2923 Rear Center Seat Belt / Buckle Assembly................................................................................................. 2924 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 2924 Removal............................................................................................................................. 2924 Installation........................................................................................................................ 2924 Main Data and Specifications............................................................................................................ 2925 9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 2918 9J1 SRS CONTROL SYSTEM..................................................................................................................... 2918 Sec.10 CRUISE CONTROL SYSTEM................................................................................................................... 2926 10A CRUISE CONTROL SYSTEM.................................................................................................................. 2926 (VX) VEHICROSS...................................................................................................................................... 5231 Sec.0 GENERAL INFORMATION..................................................................................................................... 5232 0A GENERAL INFORMATION.................................................................................................................... 5232 General Repair Instruction.............................................................................................................. 5232 Illustration Arrows..................................................................................................................... 5233 Identification.......................................................................................................................... 5234 Theft Prevention Standard............................................................................................................... 5236 Lifting Instructions.................................................................................................................... 5240 Standard Bolts Torque Specifications.................................................................................................... 5243 Abbreviations Charts.................................................................................................................... 5244 Service Parts Identification Plate...................................................................................................... 5245 0B MAINTENANCE AND LUBRICATION............................................................................................................ 5246 Maintenance Schedule List............................................................................................................... 5246 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 5249 Recommended Fluids and Lubricants................................................................................................... 5252 Lubricant Viscosity Chart............................................................................................................... 5253 Recommended Liquid Gasket........................................................................................................... 5254 Recommended Thread Locking Agents................................................................................................... 5255 Maintenance Service Data................................................................................................................ 5256 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................ 5257 1A HEATING, VENTILATION AND AIR CONDITIONING (HVAC)....................................................................................... 5257 Service Precaution...................................................................................................................... 5258 Heating and Ventilation System.......................................................................................................... 5258 General Description................................................................................................................. 5258 Wiring Diagram...................................................................................................................... 5262 Diagnosis........................................................................................................................... 5263 Individual Inspection............................................................................................................... 5267 Heater.................................................................................................................................. 5269 Heater Unit and Associated Parts.................................................................................................... 5269 Removal............................................................................................................................. 5269 Installation........................................................................................................................ 5270 Heater Core and / or Mode Door.......................................................................................................... 5270 Disassembled View................................................................................................................... 5270 Removal............................................................................................................................. 5271 Inspection.......................................................................................................................... 5271 Installation........................................................................................................................ 5271 Heater Mode Control Link Unit........................................................................................................... 5272 Disassembled View................................................................................................................... 5272 Removal............................................................................................................................. 5272 Installation........................................................................................................................ 5273 Heater Temperature Control Link Unit.................................................................................................... 5273 Disassembled View................................................................................................................... 5273 Removal............................................................................................................................. 5273 Installation........................................................................................................................ 5273 Blower Assembly......................................................................................................................... 5274 Blower Assembly and Associated Parts................................................................................................ 5274 Removal............................................................................................................................. 5274 Installation........................................................................................................................ 5275 Blower Link Unit and / or Mode door..................................................................................................... 5275 Disassembled View................................................................................................................... 5275 Removal............................................................................................................................. 5275 Installation........................................................................................................................ 5276 Blower Motor............................................................................................................................ 5277 Blower Motor and Associated Parts................................................................................................... 5277 Removal............................................................................................................................. 5277 Installation........................................................................................................................ 5277 Defroster Nozzle and Ventilation Duct................................................................................................... 5278 Defroster Nozzle, Ventilation Duct and Associated Parts............................................................................. 5278 Removal............................................................................................................................. 5278 Installation........................................................................................................................ 5279 Control Lever Assembly and / or Control Cable........................................................................................... 5279 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 5279 Removal............................................................................................................................. 5280 Installation........................................................................................................................ 5281 Heater Bezel Illumination Bulb.......................................................................................................... 5282 Heater Bezel Illumination Bulb and Associated Parts................................................................................. 5282 Removal............................................................................................................................. 5282 Installation........................................................................................................................ 5282 Resistor................................................................................................................................ 5283 Resistor and Associated Parts....................................................................................................... 5283 Removal............................................................................................................................. 5283 Installation........................................................................................................................ 5283 Air Conditioning System................................................................................................................. 5284 General Description................................................................................................................. 5284 Air Conditioning Refrigerant Cycle Construction..................................................................................... 5285 Wiring Diagram...................................................................................................................... 5292 Connector List...................................................................................................................... 5296 Diagnosis........................................................................................................................... 5298 Checking The Refrigerant System With Manifold Gauge................................................................................. 5299 Magnetic Clutch Diagnosis........................................................................................................... 5303 Individual Inspection............................................................................................................... 5308 General Repair Procedure............................................................................................................ 5309 Leak Check.......................................................................................................................... 5312 Compressor Assembly..................................................................................................................... 5317 Compressor Assembly and Associated Parts............................................................................................ 5317 Removal............................................................................................................................. 5317 Installation........................................................................................................................ 5318 New Compressor Installation......................................................................................................... 5318 Condenser Assembly...................................................................................................................... 5319 Condenser Assembly and Associated Parts............................................................................................. 5319 Removal............................................................................................................................. 5319 Installation........................................................................................................................ 5319 Condenser Fan Motor..................................................................................................................... 5320 Condenser Fan Motor and Associated Parts............................................................................................ 5320 Removal............................................................................................................................. 5321 Installation........................................................................................................................ 5321 Receiver / Drier........................................................................................................................ 5321 Receiver / Drier and Associated Parts............................................................................................... 5321 Removal............................................................................................................................. 5321 Installation........................................................................................................................ 5321 Pressure Switch......................................................................................................................... 5322 Pressure Switch and Associated Parts................................................................................................ 5322 Removal............................................................................................................................. 5322 Installation........................................................................................................................ 5322 Evaporator Assembly..................................................................................................................... 5323 Evaporator Assembly and Associated Parts............................................................................................ 5323 Removal............................................................................................................................. 5323 Installation........................................................................................................................ 5324 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 5324 Disassembled View................................................................................................................... 5324 Removal............................................................................................................................. 5325 Installation........................................................................................................................ 5325 Refrigerant Line........................................................................................................................ 5326 Refrigerant Line and Associated Parts............................................................................................... 5326 Removal............................................................................................................................. 5327 Installation........................................................................................................................ 5327 Main Data And Specifications........................................................................................................ 5328 Compressor.............................................................................................................................. 5331 Service Precaution.................................................................................................................. 5331 General Description................................................................................................................. 5331 Diagnosis........................................................................................................................... 5332 Magnetic Clutch Assembly (DKV-14D Type)................................................................................................. 5333 Parts Location View................................................................................................................. 5333 Removal............................................................................................................................. 5333 Inspection and Repair............................................................................................................... 5335 Installation........................................................................................................................ 5335 Compressor Oil.......................................................................................................................... 5337 Oil Specification................................................................................................................... 5337 Handling of Oil..................................................................................................................... 5337 Compressor Oil Check................................................................................................................ 5337 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 5337 Checking and Adjusting for Compressor Replacement................................................................................... 5338 Contamination of Compressor Oil..................................................................................................... 5338 Oil Return Operation................................................................................................................ 5338 Replacement of Component Parts...................................................................................................... 5338 Main Data and Specifications............................................................................................................ 5339 Special Tools........................................................................................................................... 5341 Sec.2 STEERING................................................................................................................................ 5342 2A POWER ASSISTED SYSTEM.................................................................................................................. 5342 Service Precaution...................................................................................................................... 5343 General Description..................................................................................................................... 5343 Diagnosis............................................................................................................................... 5346 Power Steering System Test.............................................................................................................. 5352 Maintenance............................................................................................................................. 5352 Fluid Level............................................................................................................................. 5353 Bleeding The Power Steering System...................................................................................................... 5353 Bleeding Procedure...................................................................................................................... 5353 Flushing The Power Steering System...................................................................................................... 5353 Steering Wheel Free Play Adjustment..................................................................................................... 5353 Front End Alignment Inspection and Adjustment........................................................................................... 5354 Main Data and Specifications............................................................................................................ 5359 Special Tools........................................................................................................................... 5360 Power Steering Gear..................................................................................................................... 5361 Power Steering Gear and Associated Parts............................................................................................ 5361 Removal............................................................................................................................. 5361 Installation........................................................................................................................ 5362 Steering Gear Disassembled View..................................................................................................... 5363 Disassembly......................................................................................................................... 5363 Inspection and Repair............................................................................................................... 5365 Reassembly.......................................................................................................................... 5366 Main Data and Specifications........................................................................................................ 5368 Special Tools....................................................................................................................... 5369 Power Steering Pump..................................................................................................................... 5370 Power Steering Pump and Associated Parts............................................................................................ 5370 Removal............................................................................................................................. 5370 Installation........................................................................................................................ 5371 Power Steering Pump Disassembled View............................................................................................... 5372 Disassembly......................................................................................................................... 5372 Inspection and Repair............................................................................................................... 5373 Reassembly.......................................................................................................................... 5374 Main Data and Specifications........................................................................................................ 5375 Center Track Rod Assembly............................................................................................................... 5376 Center Track Rod Assembly and Associated Parts...................................................................................... 5376 Removal............................................................................................................................. 5376 Inspection and Repair............................................................................................................... 5377 Installation........................................................................................................................ 5377 Outer Track Rod Assembly................................................................................................................ 5378 Outer Track Rod Assembly and Associated Parts....................................................................................... 5378 Removal............................................................................................................................. 5378 Inspection and Repair............................................................................................................... 5380 Installation........................................................................................................................ 5380 Relay Lever............................................................................................................................. 5381 Relay Lever and Associated Parts.................................................................................................... 5381 Removal............................................................................................................................. 5381 Installation........................................................................................................................ 5382 Steering Linkage and Associated Parts................................................................................................... 5383 Main Data and Specifications........................................................................................................ 5383 Special Tools....................................................................................................................... 5384 Supplemental Restraint System Steering Wheel & Column................................................................................... 5385 Service Precaution.................................................................................................................. 5385 SRS Connectors (3 pin).............................................................................................................. 5385 SRS Connectors (2 pin).............................................................................................................. 5385 Inflator Module......................................................................................................................... 5387 Inflator Module and Associated Parts................................................................................................ 5387 Removal............................................................................................................................. 5387 Inspection and Repair............................................................................................................... 5388 Installation........................................................................................................................ 5388 Steering Wheel.......................................................................................................................... 5389 Steering Wheel and Associated Parts................................................................................................. 5389 Removal............................................................................................................................. 5389 Installation........................................................................................................................ 5391 Combination Switch...................................................................................................................... 5392 Combination Switch and Associated Parts............................................................................................. 5392 Removal............................................................................................................................. 5392 Installation........................................................................................................................ 5394 Lock Cylinder........................................................................................................................... 5396 Lock Cylinder and Associated Parts.................................................................................................. 5396 Removal............................................................................................................................. 5396 Installation........................................................................................................................ 5398 System Inspection................................................................................................................... 5399 Steering Column......................................................................................................................... 5400 Steering Column and Associated Parts................................................................................................ 5400 Removal............................................................................................................................. 5400 Inspection.......................................................................................................................... 5402 Installation........................................................................................................................ 5404 System Inspection................................................................................................................... 5405 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 5406 Main Data and Specifications........................................................................................................ 5406 Special Tools....................................................................................................................... 5407 Sec.3 SUSPENSION.............................................................................................................................. 5408 3C FRONT SUSPENSION....................................................................................................................... 5408 Service Precaution...................................................................................................................... 5408 General Description..................................................................................................................... 5409 General Diagnosis....................................................................................................................... 5410 Shock Absorber.......................................................................................................................... 5413 Shock Absorber and Associated Parts................................................................................................. 5413 Removal............................................................................................................................. 5413 Inspection and Repair............................................................................................................... 5414 Installation........................................................................................................................ 5414 Stabilizer Bar.......................................................................................................................... 5415 Stabilizer Bar and Associated Parts................................................................................................. 5415 Removal............................................................................................................................. 5415 Inspection and Repair............................................................................................................... 5415 Installation........................................................................................................................ 5415 Torsion Bar............................................................................................................................. 5416 Torsion Bar and Associated Parts.................................................................................................... 5416 Removal............................................................................................................................. 5416 Inspection and Repair............................................................................................................... 5417 Installation........................................................................................................................ 5417 Special Tools........................................................................................................................... 5434 3D REAR SUSPENSION........................................................................................................................ 5435 Service Precaution...................................................................................................................... 5435 General Description..................................................................................................................... 5436 Coil Spring............................................................................................................................. 5437 Coil Spring and Associated Parts.................................................................................................... 5437 Removal............................................................................................................................. 5437 Inspection and Repair............................................................................................................... 5438 Installation........................................................................................................................ 5438 Shock Absorber.......................................................................................................................... 5439 Shock Absorber and Associated Parts................................................................................................. 5439 Removal............................................................................................................................. 5439 Inspection and Repair............................................................................................................... 5439 Installation........................................................................................................................ 5440 Trailing Link........................................................................................................................... 5441 Trailing Link and Associated Parts.................................................................................................. 5441 Removal............................................................................................................................. 5441 Inspection and Repair............................................................................................................... 5441 Installation........................................................................................................................ 5442 Center Link............................................................................................................................. 5443 Center Link and Associated Parts.................................................................................................... 5443 Removal............................................................................................................................. 5443 Inspection and Repair............................................................................................................... 5443 Installation........................................................................................................................ 5444 Lateral Rod............................................................................................................................. 5445 Lateral Rod and Associated Parts.................................................................................................... 5445 Removal............................................................................................................................. 5445 Inspection and Repair............................................................................................................... 5445 Installation........................................................................................................................ 5446 Stabilizer Bar.......................................................................................................................... 5447 Stabilizer Bar and Associated Parts................................................................................................. 5447 Removal............................................................................................................................. 5447 Inspection and Repair............................................................................................................... 5447 Installation........................................................................................................................ 5448 Main Data and Specifications............................................................................................................ 5449 Special Tools........................................................................................................................... 5451 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 5452 Service Precaution...................................................................................................................... 5452 General Description..................................................................................................................... 5453 Diagnosis............................................................................................................................... 5454 Wheel................................................................................................................................... 5460 Wheel and Associated Parts.......................................................................................................... 5460 Removal............................................................................................................................. 5460 Installation........................................................................................................................ 5460 Tire.................................................................................................................................... 5461 Tire Replacement.................................................................................................................... 5461 Temporary Spare Tire................................................................................................................ 5461 General Balance Procedure........................................................................................................... 5461 Balancing Wheel and Tire............................................................................................................ 5462 Main Data and Specifications............................................................................................................ 5463 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 5464 4A1 DIFFERENTIAL (FRONT)................................................................................................................... 5464 Service Precaution...................................................................................................................... 5464 Front Drive Axle........................................................................................................................ 5465 Diagnosis........................................................................................................................... 5465 Pinion Shaft Oil Seal................................................................................................................... 5466 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 5466 Removal............................................................................................................................. 5466 Inspection and Repair............................................................................................................... 5467 Installation........................................................................................................................ 5467 Front Drive Axle Assembly............................................................................................................... 5468 Front Drive Axle Assembly and Associated Parts...................................................................................... 5468 Removal............................................................................................................................. 5468 Installation........................................................................................................................ 5469 Differential Assembly................................................................................................................... 5471 Disassembled View................................................................................................................... 5471 Disassembly......................................................................................................................... 5472 Reassembly.......................................................................................................................... 5474 Differential Cage Assembly.............................................................................................................. 5483 Disassembled View................................................................................................................... 5483 Disassembly......................................................................................................................... 5483 Inspection and Repair............................................................................................................... 5484 Reassembly.......................................................................................................................... 5485 Main Data and Specifications............................................................................................................ 5487 Special Tools........................................................................................................................... 5489 4A2 DIFFERENTIAL (REAR).................................................................................................................... 5491 Service Precaution...................................................................................................................... 5491 General Description..................................................................................................................... 5492 Diagnosis............................................................................................................................... 5493 Axle Housing............................................................................................................................ 5494 Axle Housing and Associated Parts................................................................................................... 5494 Removal............................................................................................................................. 5494 Oil Seal Replacement................................................................................................................ 5495 Installation........................................................................................................................ 5495 Pinion Oil Seal......................................................................................................................... 5496 Pinion Oil Seal and Associated Parts................................................................................................ 5496 Removal............................................................................................................................. 5496 Inspection and Repair............................................................................................................... 5497 Installation........................................................................................................................ 5497 Differential Assembly................................................................................................................... 5498 Differential Assembly and Associated Parts.......................................................................................... 5498 Removal............................................................................................................................. 5498 Installation........................................................................................................................ 5499 Disassembled View................................................................................................................... 5500 Disassembly......................................................................................................................... 5501 Reassembly.......................................................................................................................... 5503 Limited Slip Differential............................................................................................................... 5511 Disassembled View................................................................................................................... 5511 Disassembly......................................................................................................................... 5512 Inspection and Repair............................................................................................................... 5512 Reassembly.......................................................................................................................... 5514 Main Data and Specifications............................................................................................................ 5517 Special Tools........................................................................................................................... 5518 4B2 DRIVELINE CONTROL SYSTEM (TOD)......................................................................................................... 5520 Service Precaution...................................................................................................................... 5520 General Description..................................................................................................................... 5521 System Components....................................................................................................................... 5523 Parts Location...................................................................................................................... 5523 Functions of Indicator Lamp............................................................................................................. 5527 Diagnosis............................................................................................................................... 5531 Basic Diagnostic Flow Chart............................................................................................................. 5534 Parts Location.......................................................................................................................... 5535 Circuit Diagram......................................................................................................................... 5536 Connector List.......................................................................................................................... 5539 Checking Failed Pin..................................................................................................................... 5540 Checking Failed TOD Control Unit Pin.................................................................................................... 5543 Tech 2 Scan Tool.................................................................................................................... 5544 Diagnostic Trouble Codes................................................................................................................ 5547 Diagnosis from Trouble Codes............................................................................................................ 5548 Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 5565 Diagnosis from Symptom.................................................................................................................. 5584 4C DRIVE SHAFT SYSTEM..................................................................................................................... 5592 Service Precaution...................................................................................................................... 5592 General Description..................................................................................................................... 5592 Diagnosis............................................................................................................................... 5593 Front Hub and Disc...................................................................................................................... 5594 Disassembled View................................................................................................................... 5594 Disassembly......................................................................................................................... 5594 Inspection and Repair............................................................................................................... 5595 Reassembly.......................................................................................................................... 5596 Main Data and Specifications........................................................................................................ 5599 Special Tools....................................................................................................................... 5600 Front Drive Shaft Joint................................................................................................................. 5601 Front Drive Shaft Joints Replacement................................................................................................ 5601 Front Axle Drive Shaft.................................................................................................................. 5602 Front Axle Drive Shaft and Associated Parts......................................................................................... 5602 Disassembly......................................................................................................................... 5603 Inspection and Repair............................................................................................................... 5604 Bushing Replacement................................................................................................................. 5604 Reassembly.......................................................................................................................... 5605 Front Propeller Shaft................................................................................................................... 5607 General Description................................................................................................................. 5607 Front Propeller Shaft and Associated Parts.......................................................................................... 5607 Removal............................................................................................................................. 5608 Installation........................................................................................................................ 5608 Inspection and Repair............................................................................................................... 5609 Main Data and Specifications........................................................................................................ 5611 Rear Propeller Shaft.................................................................................................................... 5612 General Description................................................................................................................. 5612 Rear Propeller Shaft and Associated Parts........................................................................................... 5612 Removal............................................................................................................................. 5613 Installation........................................................................................................................ 5613 Disassembly......................................................................................................................... 5614 Universal Joint Disassembly......................................................................................................... 5615 Inspection and Repair............................................................................................................... 5616 Universal Joint Reassembly.......................................................................................................... 5617 Reassembly.......................................................................................................................... 5618 Main Data and Specifications........................................................................................................ 5619 4D2 TRANSFER CASE (TOD).................................................................................................................... 5620 Service Precaution...................................................................................................................... 5620 Transfer Case Assembly.................................................................................................................. 5621 Removal............................................................................................................................. 5622 Installation........................................................................................................................ 5622 Transfer Rear Oil Seal.................................................................................................................. 5624 Transfer Rear Oil Seal and Associated Parts......................................................................................... 5624 Removal............................................................................................................................. 5624 Installation........................................................................................................................ 5624 TOD ECU................................................................................................................................. 5626 Removal............................................................................................................................. 5626 Installation........................................................................................................................ 5626 Unit Repair............................................................................................................................. 5627 Inspection.......................................................................................................................... 5627 Transfer Case........................................................................................................................... 5628 Disassembled View................................................................................................................... 5628 Disassembly......................................................................................................................... 5628 Reassembly.......................................................................................................................... 5629 Transfer Cover Assembly................................................................................................................. 5631 Disassembled View................................................................................................................... 5631 Disassembly......................................................................................................................... 5631 Reassembly.......................................................................................................................... 5633 Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 5635 Disassembled View................................................................................................................... 5635 Disassembly......................................................................................................................... 5635 Sprocket and Mechanical Lock............................................................................................................ 5637 Disassembled View................................................................................................................... 5637 Disassembly......................................................................................................................... 5637 Output Shafts and Shift Control Shaft................................................................................................... 5639 Disassembled View................................................................................................................... 5639 Disassembly......................................................................................................................... 5640 Transfer Case........................................................................................................................... 5642 Disassembled View................................................................................................................... 5642 Disassembly......................................................................................................................... 5643 Inspection and Repair............................................................................................................... 5645 Transfer Case........................................................................................................................... 5649 Disassembled View................................................................................................................... 5649 Reassembly.......................................................................................................................... 5649 Output Shafts and Shift Control Shaft................................................................................................... 5653 Disassembled View................................................................................................................... 5653 Reassembly.......................................................................................................................... 5653 Sprocket and Mechanical Lock............................................................................................................ 5656 Disassembled View................................................................................................................... 5656 Reassembly.......................................................................................................................... 5656 Clutch Pack and Clutch Cam.............................................................................................................. 5658 Disassembled View................................................................................................................... 5658 Reassembly.......................................................................................................................... 5658 Main Data and Specifications............................................................................................................ 5660 Special Tools........................................................................................................................... 5662 Sec.5 BRAKES.................................................................................................................................. 5663 5A BRAKE CONTROL SYSTEM................................................................................................................... 5663 Service Precaution...................................................................................................................... 5664 General Description..................................................................................................................... 5665 System Components................................................................................................................... 5666 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 5666 ABS Warning Light................................................................................................................... 5666 Wheel Speed Sensor.................................................................................................................. 5666 G-Sensor............................................................................................................................ 5666 Normal and Anti-lock Braking........................................................................................................ 5666 Brake Pedal Travel.................................................................................................................. 5666 Acronyms and Abbreviations.......................................................................................................... 5666 General Diagnosis....................................................................................................................... 5667 General Information................................................................................................................. 5667 ABS Service Precautions............................................................................................................. 5667 General Service Precautions......................................................................................................... 5667 Note on Intermittents............................................................................................................... 5667 Test Driving ABS Complaint Vehicles................................................................................................. 5668 "ABS" Warning Light................................................................................................................. 5668 Normal Operation.................................................................................................................... 5668 Basic Diagnostic Flow Chart......................................................................................................... 5668 Basic Inspection Procedure.......................................................................................................... 5669 Tech 2 Scan Tool.................................................................................................................... 5670 Getting Started..................................................................................................................... 5671 Operating Procedure................................................................................................................. 5671 Data List............................................................................................................................... 5673 EHCU Connector Pin-out Checks........................................................................................................... 5674 Circuit Diagram..................................................................................................................... 5675 Connector List...................................................................................................................... 5677 Part Location....................................................................................................................... 5679 Symptom Diagnosis....................................................................................................................... 5680 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 5681 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 5682 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 5682 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 5683 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 5684 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 5685 Diagnostic Trouble Codes................................................................................................................ 5686 Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 5687 Diagnostic Trouble Codes (DTCs)..................................................................................................... 5688 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 5691 Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 5691 Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 5692 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 5692 Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 5693 Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 5694 Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 5694 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 5695 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 5695 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 5695 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 5696 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 5696 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 5696 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 5697 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 5697 Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 5697 Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 5698 Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 5698 Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 5699 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 5700 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 5701 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 5702 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 5703 Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 5704 Sensor Signal Abnormality Criteria using TECH 2..................................................................................... 5704 Unit Inspection Procedure............................................................................................................... 5705 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 5705 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 5706 Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 5706 Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 5707 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 5707 Chart C-2 Transmission Input Inspection Procedure................................................................................... 5708 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 5708 Special Tools........................................................................................................................... 5709 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 5710 Service Precaution...................................................................................................................... 5710 Electronic Hydraulic Control Unit....................................................................................................... 5711 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 5711 Removal............................................................................................................................. 5711 Installation........................................................................................................................ 5711 G-Sensor................................................................................................................................ 5712 Removal............................................................................................................................. 5712 Inspection and Repair............................................................................................................... 5712 Installation........................................................................................................................ 5712 Front Wheel Speed Sensor................................................................................................................ 5713 Front Wheel Speed Sensor and Associated Parts....................................................................................... 5713 Removal............................................................................................................................. 5713 Inspection and Repair............................................................................................................... 5714 Installation........................................................................................................................ 5714 Rear Wheel Speed Sensor................................................................................................................. 5715 Rear Wheel Speed Sensor and Associated Parts........................................................................................ 5715 Removal............................................................................................................................. 5715 Inspection and Repair............................................................................................................... 5715 Installation........................................................................................................................ 5715 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 5716 Service Precaution...................................................................................................................... 5717 General Description..................................................................................................................... 5717 Diagnosis............................................................................................................................... 5720 General Diagnosis....................................................................................................................... 5721 Hydraulic Brakes........................................................................................................................ 5724 Filling Master Cylinder Reservoir................................................................................................... 5724 Deterioration of Brake Fluid........................................................................................................ 5724 Leakage of Brake Fluid.............................................................................................................. 5724 Bleeding Brake Hydraulic System..................................................................................................... 5724 Flushing Brake Hydraulic System..................................................................................................... 5725 Brake Pipes and Hoses............................................................................................................... 5725 Brake Hose Inspection............................................................................................................... 5725 Front / Rear Caliper Brake Hose......................................................................................................... 5726 Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 5726 Removal............................................................................................................................. 5726 Installation........................................................................................................................ 5726 Rear Axle Brake Hose.................................................................................................................... 5727 Rear Axle Brake Hose and Associated Parts........................................................................................... 5727 Removal............................................................................................................................. 5727 Installation........................................................................................................................ 5727 Brake Pipe.............................................................................................................................. 5728 Removal............................................................................................................................. 5728 Installation........................................................................................................................ 5728 P & B (Proportioning and Bypass) Valve.................................................................................................. 5729 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 5729 Removal............................................................................................................................. 5729 Installation........................................................................................................................ 5729 Main Data and Specifications........................................................................................................ 5730 Brake Pedal............................................................................................................................. 5731 Checking Pedal Height............................................................................................................... 5731 Checking Pedal Travel............................................................................................................... 5731 Brake Pedal and Associated Parts.................................................................................................... 5732 Removal............................................................................................................................. 5732 Installation........................................................................................................................ 5732 Stoplight Switch........................................................................................................................ 5733 Removal............................................................................................................................. 5733 Installation........................................................................................................................ 5733 Main Data and Specifications........................................................................................................ 5734 Fluid Reservoir Tank.................................................................................................................... 5735 Fluid Reservoir Tank and Associated Parts........................................................................................... 5735 Removal............................................................................................................................. 5735 Installation........................................................................................................................ 5735 Master Cylinder Assembly................................................................................................................ 5736 Master Cylinder Assembly and Associated Parts....................................................................................... 5736 Removal............................................................................................................................. 5736 Inspection and Repair............................................................................................................... 5736 Installation........................................................................................................................ 5737 Main Data and Specifications........................................................................................................ 5738 Special Tools....................................................................................................................... 5739 Vacuum Booster Assembly................................................................................................................. 5740 Vacuum Booster Assembly and Associated Parts........................................................................................ 5740 Removal............................................................................................................................. 5740 Inspection and Repair............................................................................................................... 5740 Installation........................................................................................................................ 5741 Exterior Components..................................................................................................................... 5743 Exterior Components and Associated Parts............................................................................................ 5743 Removal............................................................................................................................. 5743 Inspection and Repair............................................................................................................... 5744 Installation........................................................................................................................ 5744 Vacuum Booster Overhaul................................................................................................................. 5744 Vacuum Booster...................................................................................................................... 5744 Main Data and Specifications........................................................................................................ 5745 Special Tools....................................................................................................................... 5746 Front Disc Brake Pads................................................................................................................... 5747 Front Disc Brake Pads Inspection.................................................................................................... 5747 Front Disc Brake Pads and Associated Parts.......................................................................................... 5747 Removal............................................................................................................................. 5748 Installation........................................................................................................................ 5748 Front Disc Brake Rotor.................................................................................................................. 5750 Inspection.......................................................................................................................... 5750 Replacing Brake Rotors.............................................................................................................. 5750 Front Disc Brake Caliper Assembly....................................................................................................... 5752 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 5752 Removal............................................................................................................................. 5752 Installation........................................................................................................................ 5753 Front Disc Brake Caliper................................................................................................................ 5755 Front Disc Brake Caliper Disassembled View.......................................................................................... 5755 Disassembly......................................................................................................................... 5755 Inspection and Repair............................................................................................................... 5756 Reassembly.......................................................................................................................... 5756 Main Data and Specifications........................................................................................................ 5758 Rear Disc Brake Pads.................................................................................................................... 5759 Brake Pads Inspection............................................................................................................... 5759 Brake Pads and Associated Parts..................................................................................................... 5759 Removal............................................................................................................................. 5760 Installation........................................................................................................................ 5760 Rear Disc Brake Rotor................................................................................................................... 5762 Inspection.......................................................................................................................... 5762 Replacing Brake Rotors.............................................................................................................. 5762 Refinishing Brake Rotors............................................................................................................ 5762 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 5763 Rear Disc Brake Caliper Assembly........................................................................................................ 5764 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 5764 Removal............................................................................................................................. 5764 Installation........................................................................................................................ 5765 Rear Disc Brake Caliper................................................................................................................. 5767 Rear Disc Brake Caliper Disassembled View........................................................................................... 5767 Disassembly......................................................................................................................... 5767 Inspection and Repair............................................................................................................... 5768 Reassembly.......................................................................................................................... 5768 Main Data and Specifications........................................................................................................ 5770 5D PARKING BRAKE SYSTEM................................................................................................................... 5771 Service Precaution...................................................................................................................... 5771 General Description..................................................................................................................... 5771 Operation............................................................................................................................... 5772 Parking Brake Lever and Front Cable..................................................................................................... 5773 Parking Brake Lever, Front Cable and Associated Parts............................................................................... 5773 Removal............................................................................................................................. 5773 Installation........................................................................................................................ 5774 Parking Brake Rear Cable................................................................................................................ 5775 Parking Brake Rear Cable and Associated Parts....................................................................................... 5775 Removal............................................................................................................................. 5775 Installation........................................................................................................................ 5776 Inspection and Repair............................................................................................................... 5777 Parking Brake Adjustment............................................................................................................ 5777 Main Data and Specifications............................................................................................................ 5778 Sec.6 ENGINE.................................................................................................................................. 5779 6A ENGINE MECHANICAL...................................................................................................................... 5779 Service Precaution...................................................................................................................... 5780 General Description..................................................................................................................... 5781 Engine Diagnosis........................................................................................................................ 5782 Cylinder Head Cover LH.................................................................................................................. 5796 Removal............................................................................................................................. 5796 Installation........................................................................................................................ 5797 Cylinder Head Cover RH.................................................................................................................. 5799 Removal............................................................................................................................. 5799 Installation........................................................................................................................ 5800 Common Chamber.......................................................................................................................... 5802 Removal............................................................................................................................. 5802 Installation........................................................................................................................ 5802 Exhaust Manifold LH..................................................................................................................... 5804 Removal............................................................................................................................. 5804 Installation........................................................................................................................ 5804 Exhaust Manifold RH..................................................................................................................... 5806 Removal............................................................................................................................. 5806 Installation........................................................................................................................ 5807 Crankshaft Pulley....................................................................................................................... 5808 Removal............................................................................................................................. 5808 Installation........................................................................................................................ 5808 Timing Belt............................................................................................................................. 5809 Removal............................................................................................................................. 5809 Installation........................................................................................................................ 5810 Camshaft................................................................................................................................ 5813 Removal............................................................................................................................. 5813 Installation........................................................................................................................ 5813 Cylinder Head........................................................................................................................... 5816 Removal............................................................................................................................. 5816 Installation........................................................................................................................ 5816 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 5818 Removal............................................................................................................................. 5818 Installation........................................................................................................................ 5818 Piston, Piston Ring and Connecting Rod.................................................................................................. 5819 Removal............................................................................................................................. 5819 Installation........................................................................................................................ 5820 Crankshaft and Main Bearings............................................................................................................ 5821 Removal............................................................................................................................. 5821 Installation........................................................................................................................ 5822 Rear Oil Seal........................................................................................................................... 5826 Removal............................................................................................................................. 5826 Installation........................................................................................................................ 5826 Engine Assembly......................................................................................................................... 5827 Removal............................................................................................................................. 5827 Installation........................................................................................................................ 5827 Cylinder Head........................................................................................................................... 5830 Cylinder Head and Associated Parts.................................................................................................. 5830 Disassembly......................................................................................................................... 5830 Clean............................................................................................................................... 5831 Inspection and Repair............................................................................................................... 5831 Reassembly.......................................................................................................................... 5831 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 5834 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 5834 Disassembly......................................................................................................................... 5834 Inspection and Repair............................................................................................................... 5835 Reassembly.......................................................................................................................... 5838 Valve Clearance Adjustments......................................................................................................... 5839 Camshaft................................................................................................................................ 5841 Camshaft and Associated Parts....................................................................................................... 5841 Disassembly......................................................................................................................... 5841 Inspection and Repair............................................................................................................... 5842 Reassembly.......................................................................................................................... 5844 Crankshaft.............................................................................................................................. 5847 Crankshaft and Associated Parts..................................................................................................... 5847 Disassembly......................................................................................................................... 5847 Inspection and Repair............................................................................................................... 5848 Inspection and Repair............................................................................................................... 5849 Reassembly.......................................................................................................................... 5851 Piston and Connecting Rod............................................................................................................... 5855 Piston, Connecting Rod and Associate Parts.......................................................................................... 5855 Disassembly......................................................................................................................... 5855 Inspection and Repair............................................................................................................... 5856 Reassembly.......................................................................................................................... 5860 Cylinder Block.......................................................................................................................... 5863 Cylinder Block and Associated Parts................................................................................................. 5863 Disassembly......................................................................................................................... 5863 Inspection and Repair............................................................................................................... 5864 Reassembly.......................................................................................................................... 5865 Main Data and Specification............................................................................................................. 5868 Special Tool............................................................................................................................ 5874 6B ENGINE COOLING......................................................................................................................... 5876 Service Precaution...................................................................................................................... 5876 General Description..................................................................................................................... 5877 Diagnosis............................................................................................................................... 5880 Draining and Refilling Cooling System................................................................................................... 5881 Engine coolant change................................................................................................................... 5881 Water Pump.............................................................................................................................. 5882 Water Pump and Associated Parts..................................................................................................... 5882 Removal............................................................................................................................. 5882 Inspection.......................................................................................................................... 5882 Installation........................................................................................................................ 5882 Thermostat.............................................................................................................................. 5883 Thermostat and Associated Parts..................................................................................................... 5883 Removal............................................................................................................................. 5883 Inspection.......................................................................................................................... 5883 Installation........................................................................................................................ 5883 Radiator................................................................................................................................ 5884 Radiator and Associated Parts....................................................................................................... 5884 Removal............................................................................................................................. 5884 Inspection.......................................................................................................................... 5885 Installation........................................................................................................................ 5886 Drive Belt and Cooling Fan.............................................................................................................. 5887 Drive Belt and Associated Parts..................................................................................................... 5887 Inspection.......................................................................................................................... 5887 Installation........................................................................................................................ 5887 Main Data and Specifications............................................................................................................ 5888 Special Tool............................................................................................................................ 5889 6C ENGINE FUEL............................................................................................................................ 5890 Service Precaution...................................................................................................................... 5890 General Description..................................................................................................................... 5891 Fuel Metering........................................................................................................................... 5892 Fuel Filter............................................................................................................................. 5893 Fuel Filter and Associated Parts.................................................................................................... 5893 Removal............................................................................................................................. 5893 Inspection.......................................................................................................................... 5893 Installation........................................................................................................................ 5893 Inspection.......................................................................................................................... 5894 In-Tank Fuel Filter................................................................................................................. 5894 Fuel Pump Flow Test................................................................................................................. 5894 Fuel Pump............................................................................................................................... 5895 Fuel Pump and Associated Parts...................................................................................................... 5895 Removal............................................................................................................................. 5895 Installation........................................................................................................................ 5895 Fuel Pump Relay......................................................................................................................... 5896 General Description................................................................................................................. 5896 Fuel Tank............................................................................................................................... 5896 Fuel Tank and Associated Parts...................................................................................................... 5896 Removal............................................................................................................................. 5897 Installation........................................................................................................................ 5897 Fuel Tube / Quick-Connect Fittings...................................................................................................... 5897 Precautions......................................................................................................................... 5897 Cautions During Work................................................................................................................ 5897 Removal............................................................................................................................. 5897 Reuse of Quick-Connector............................................................................................................ 5899 Assembling Advice................................................................................................................... 5899 Fuel Gauge Unit......................................................................................................................... 5900 Fuel Gauge Unit and Associated Parts................................................................................................ 5900 Removal............................................................................................................................. 5900 Installation........................................................................................................................ 5900 Fuel Filler Cap......................................................................................................................... 5901 General Description................................................................................................................. 5901 Inspection.......................................................................................................................... 5901 Main Data and Specifications............................................................................................................ 5901 6D1 ENGINE ELECTRICAL...................................................................................................................... 5902 Battery................................................................................................................................. 5902 General Description..................................................................................................................... 5902 Diagnosis............................................................................................................................... 5902 Battery Charging.................................................................................................................... 5903 Jump Starting....................................................................................................................... 5903 Battery Removal..................................................................................................................... 5904 Battery Installation................................................................................................................ 5904 Main Data and Specifications............................................................................................................ 5905 6D2 IGNITION SYSTEM........................................................................................................................ 5906 Service Precaution...................................................................................................................... 5906 General Description..................................................................................................................... 5907 Diagnosis............................................................................................................................... 5910 Ignition Coil........................................................................................................................... 5910 Removal............................................................................................................................. 5910 Inspection and Repair............................................................................................................... 5910 Installation........................................................................................................................ 5910 Spark Plug.............................................................................................................................. 5911 Removal............................................................................................................................. 5911 Inspection and Repair............................................................................................................... 5911 Installation........................................................................................................................ 5911 Crankshaft Position Sensor.............................................................................................................. 5912 Removal............................................................................................................................. 5912 Installation........................................................................................................................ 5912 Main Data and Specifications............................................................................................................ 5913 6D3 STARTING AND CHARGING SYSTEM........................................................................................................... 5914 Service Precaution...................................................................................................................... 5914 Starting System......................................................................................................................... 5915 General Description..................................................................................................................... 5915 Diagnosis............................................................................................................................... 5917 Starter................................................................................................................................. 5918 Removal............................................................................................................................. 5918 Installation........................................................................................................................ 5918 Disassembled View................................................................................................................... 5919 Disassembly......................................................................................................................... 5920 Inspection and Repair............................................................................................................... 5922 Reassembly.......................................................................................................................... 5926 Main Data and Specifications........................................................................................................ 5928 Charging System......................................................................................................................... 5931 General Description..................................................................................................................... 5931 General On-Vehicle Inspection........................................................................................................... 5931 Generator............................................................................................................................... 5932 Removal............................................................................................................................. 5932 Inspection.......................................................................................................................... 5932 Installation........................................................................................................................ 5932 Disassembled View................................................................................................................... 5933 Disassembly......................................................................................................................... 5934 Inspection and Repair............................................................................................................... 5936 Reassembly.......................................................................................................................... 5938 Bench Test.......................................................................................................................... 5938 Main Data and Specifications............................................................................................................ 5939 6E 3.5L ENGINE DRIVEABILITY AND EMISSIONS................................................................................................. 5940 Specifications.......................................................................................................................... 5944 Tightening Specifications........................................................................................................... 5944 Diagrams and Schematics................................................................................................................. 5945 PCM Wiring Diagram (1 of 8)......................................................................................................... 5945 PCM Wiring Diagram (2 of 8)......................................................................................................... 5946 PCM Wiring Diagram (3 of 8)......................................................................................................... 5947 PCM Wiring Diagram (4 of 8)......................................................................................................... 5948 PCM Wiring Diagram (5 of 8)......................................................................................................... 5949 PCM Wiring Diagram (6 of 8)......................................................................................................... 5950 PCM Wiring Diagram (7 of 8)......................................................................................................... 5951 PCM Wiring Diagram (8 of 8)......................................................................................................... 5952 PCM Pinouts............................................................................................................................. 5953 PCM Pinout Table, 32-Way Red Connector-Row "A"...................................................................................... 5953 PCM Pinout Table, 32-Way Red Connector-Row "B"...................................................................................... 5955 PCM Pinout Table, 32-Way White Connector-Row "C".................................................................................... 5956 PCM Pinout Table, 32-Way White Connector-Row "D".................................................................................... 5957 PCM Pinout Table, 32-Way Blue Connector-Row "E"..................................................................................... 5959 PCM Pinout Table, 32-Way Blue Connector-Row "F"..................................................................................... 5960 Component Locators...................................................................................................................... 5961 Engine Component Locator............................................................................................................ 5961 Engine Component Locator Table...................................................................................................... 5961 Undercarriage Component Locator..................................................................................................... 5962 Undercarriage Component Locator Table............................................................................................... 5962 Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 5963 Sensors and Miscellaneous Component Locators........................................................................................ 5964 Diagnosis............................................................................................................................... 5966 Strategy-Based Diagnostics.......................................................................................................... 5966 DTC Stored.......................................................................................................................... 5966 No DTC.............................................................................................................................. 5966 No Matching Symptom................................................................................................................. 5966 Intermittents....................................................................................................................... 5966 No Trouble Found.................................................................................................................... 5966 Verifying Vehicle Repair............................................................................................................ 5966 General Service Information............................................................................................................. 5966 OBD II Serviceablity Issues......................................................................................................... 5966 Emissions Control Information Label................................................................................................. 5967 Maintenance Schedule................................................................................................................ 5967 Visual / Physical Engine Compartment Inspection..................................................................................... 5967 Basic Knowledge of Tools Required................................................................................................... 5968 Serial Data Communications.............................................................................................................. 5968 Class II Serial Data Communications................................................................................................. 5968 On-Board Diagnostic (OBD) II............................................................................................................ 5968 On-Board Diagnostic Tests........................................................................................................... 5968 Comprehensive Component Monitor Diagnostic Operation................................................................................ 5968 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 5969 Common OBD II Terms................................................................................................................. 5969 The Diagnostic Executive............................................................................................................ 5969 DTC Types........................................................................................................................... 5970 Decimal/Binary/Hexadecimal Conversions.............................................................................................. 5972 Verifying Vehicle Repair............................................................................................................ 5972 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 5972 Tech 2.............................................................................................................................. 5973 Tech 2 Features..................................................................................................................... 5973 Getting Started..................................................................................................................... 5974 Operating Procedure (For Example)................................................................................................... 5974 DTC Modes........................................................................................................................... 5975 DTC Information Mode................................................................................................................ 5976 Miscellaneous Test.................................................................................................................. 5976 Lamps Test.......................................................................................................................... 5977 Relays Test......................................................................................................................... 5978 EVAP Test........................................................................................................................... 5979 Idle Air Control (IAC) System Test.................................................................................................. 5980 Fuel System Test.................................................................................................................... 5982 EGR Control Test.................................................................................................................... 5983 Variable Intake Manifold Solenoid Test.............................................................................................. 5984 Injector Balance Test............................................................................................................... 5985 Plotting Snapshot Graph................................................................................................................. 5986 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 5987 Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 5988 Primary System-Based Diagnostic......................................................................................................... 5989 Fuel Control Heated Oxygen Sensor................................................................................................... 5989 HO2S Heater......................................................................................................................... 5989 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 5989 Misfire Monitor Diagnostic Operation.................................................................................................... 5990 Misfire Counters.................................................................................................................... 5990 Fuel Trim System Monitor Diagnostic Operation........................................................................................... 5991 Fuel Trim Cell Diagnostic Weights................................................................................................... 5991 On-Board Diagnostic (OBD II) System Check............................................................................................... 5992 A/C Clutch Control Circuit Diagnosis.................................................................................................... 5995 Electronic Ignition System Diagnosis.................................................................................................... 6001 Visual Check of The Evaporative Emission Canister....................................................................................... 6001 Fuel Metering System Check.............................................................................................................. 6001 Idle Air Control (IAC) Valve............................................................................................................ 6001 Fuel System Pressure Test............................................................................................................... 6001 Fuel Injector Coil Test Procedure Fuel Injector Balance Test Procedure.................................................................. 6001 Knock Sensor Diagnosis.................................................................................................................. 6006 Powertrain Control Module (PCM) Diagnosis............................................................................................... 6006 Multiple PCM Information Sensor DTCS Set................................................................................................ 6006 Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 6009 Engine Tech 2 Data Definitions and Ranges............................................................................................... 6009 Typical Scan Data Values................................................................................................................ 6012 No Malfunction Indicator Lamp (MIL)..................................................................................................... 6018 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 6021 Engine Cranks But Will Not Run.......................................................................................................... 6023 Fuel System Electrical Test............................................................................................................. 6029 Fuel System Diagnosis................................................................................................................... 6032 Idle Air Control (IAC) System Check..................................................................................................... 6037 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................ 6040 Exhaust Gas Recirculation (EGR) System Check............................................................................................ 6042 Manifold Absolute Pressure (MAP) Output Check........................................................................................... 6044 Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 6046 PCM Diagnostic Trouble Codes............................................................................................................ 6049 Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 6053 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 6056 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 6059 Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 6062 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 6065 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 6068 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 6071 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 6074 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 6077 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 6080 Diagnostic Trouble Code (DTC) P0121 TP System Performance............................................................................... 6083 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage....................................................................... 6086 Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage...................................................................... 6089 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 6092 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 6095 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 6098 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 6101 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.................................................. 6105 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 6108 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 6111 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 6114 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 6117 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 6120 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 6123 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 6126 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 6129 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 6133 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1................................................................. 6136 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 6139 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 6142 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 6145 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 6148 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 6151 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 6155 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 6159 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 6163 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 6167 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 6170 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 6173 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 6176 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 6179 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 6182 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 6185 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 6189 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 6191 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 6193 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 6195 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 6197 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 6199 Diagnostic Trouble Code (DTC) P0325 KS Module Circuit................................................................................... 6201 Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit................................................................................... 6203 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 6206 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 6209 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 6212 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 6216 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 6220 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 6223 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 6226 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 6229 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 6232 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 6235 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 6238 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Position Error........................................................................... 6241 Diagnostic Trouble Code (DTC) P0404 EGR Pintle Open/Stuck............................................................................... 6243 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 6245 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 6248 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1.................................................................... 6251 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2.................................................................... 6254 Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 6256 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 6260 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 6263 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage............................................................... 6266 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage.............................................................. 6269 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................ 6272 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit蓬igh Voktage............................................................... 6274 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 6276 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 6279 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 6282 Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 6285 Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 6287 Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 6289 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 6290 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 6292 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 6294 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 6297 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 6299 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 6301 Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage......................................................... 6304 Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage.......................................................... 6306 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 6308 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 6312 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 6316 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 6320 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 6324 Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault..................................................................... 6327 Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................ 6329 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 6330 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 6333 Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM.................................................................................. 6336 Diagnostic Trouble Code (DTC) P1509 IAC System High RPM................................................................................. 6339 Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................ 6342 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 6343 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 6344 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 6347 Symptom Diagnosis....................................................................................................................... 6350 Default Matrix Table.................................................................................................................... 6377 On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 6380 Crankshaft Position (CKP) Sensor........................................................................................................ 6380 Engine Coolant Temperature (ECT) Sensor................................................................................................. 6381 Heated Oxygen Sensor (HO2S)............................................................................................................. 6382 Intake Air Temperature (IAT) Sensor..................................................................................................... 6384 Knock Sensor (KS)....................................................................................................................... 6385 Mass Air Flow (MAF) Sensor.............................................................................................................. 6386 Manifold Absolute Pressure (MAP) Sensor................................................................................................. 6387 Malfunction Indicator Lamp (MIL)........................................................................................................ 6388 Powertrain Control Module (PCM)......................................................................................................... 6388 EEPROM.................................................................................................................................. 6389 Throttle Position (TP) Sensor........................................................................................................... 6389 Vehicle Speed Sensor (VSS).............................................................................................................. 6390 Air Cleaner/Air Filter.................................................................................................................. 6391 Idle Air Control (IAC) Valve............................................................................................................ 6392 Common Chamber.......................................................................................................................... 6393 Accelerator Cable Assembly.............................................................................................................. 6393 Accelerator Pedal Replacement........................................................................................................... 6396 Fuel Filter Cap......................................................................................................................... 6398 Fuel Filter............................................................................................................................. 6398 Fuel Gauge Unit......................................................................................................................... 6400 Fuel Injectors.......................................................................................................................... 6401 Fuel Pressure Regulator................................................................................................................. 6403 Fuel Metering System.................................................................................................................... 6405 Fuel Pump Assembly...................................................................................................................... 6405 Fuel Pump Relay......................................................................................................................... 6406 Fuel Rail Assembly...................................................................................................................... 6406 Fuel Tank............................................................................................................................... 6407 Throttle Body (TB)...................................................................................................................... 6409 Electronic Ignition System.............................................................................................................. 6411 Catalytic Converter..................................................................................................................... 6412 Air Conditioning Relay.................................................................................................................. 6412 EVAP Canister Hoses..................................................................................................................... 6413 EVAP Canister........................................................................................................................... 6413 EVAP Canister Vent Solenoid............................................................................................................. 6414 Fuel Tank Pressure Sensor............................................................................................................... 6415 EVAP Canister Purge Solenoid............................................................................................................ 6415 Fuel Tank Vent Valve.................................................................................................................... 6416 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................ 6416 Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 6417 Wiring and Connectors................................................................................................................... 6418 PCM Connectors and Terminals............................................................................................................ 6418 Wire Harness Repair: Twisted Shielded Cable............................................................................................. 6418 Twisted Leads........................................................................................................................... 6419 Weather-Pack Connector.................................................................................................................. 6421 Com-Pack III............................................................................................................................ 6422 Metri-Pack.............................................................................................................................. 6422 General Description (PCM and Sensors)................................................................................................... 6423 Catalyst Monitor Heated Oxygen Sensors.................................................................................................. 6424 58X Reference PCM Input............................................................................................................. 6423 A/C Request Signal.................................................................................................................. 6423 Crankshaft Position (CKP) Sensor.................................................................................................... 6423 Camshaft Position (CMP) Sensor and Signal........................................................................................... 6423 Engine Coolant Temperature (ECT) Sensor............................................................................................. 6423 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 6424 Fuel Control Heated Oxygen Sensors.................................................................................................. 6424 Intake Air Temperature (IAT) Sensor................................................................................................. 6425 Knock Sensor........................................................................................................................ 6425 Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 6426 Mass Air Flow (MAF) Sensor.......................................................................................................... 6426 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 6426 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 6426 Powertrain Control Module (PCM)..................................................................................................... 6427 PCM Function........................................................................................................................ 6427 PCM Components...................................................................................................................... 6427 PCM Voltage Description............................................................................................................. 6427 PCM Input/Outputs................................................................................................................... 6427 PCM Service Precautions............................................................................................................. 6428 Reprogramming The PCM............................................................................................................... 6428 Throttle Position (TP) Sensor....................................................................................................... 6428 Transmission Fluid Temperature (TFT) Sensor......................................................................................... 6428 Transmission Range Switch........................................................................................................... 6428 Vehicle Speed Sensor (VSS).......................................................................................................... 6429 Use of Circuit Testing Tools........................................................................................................ 6429 Aftermarket Electrical and Vacuum Equipment......................................................................................... 6429 Electrostatic Discharge Damage...................................................................................................... 6429 General Description (Air Induction)..................................................................................................... 6430 Air Induction System................................................................................................................ 6430 General Description (Fuel Metering)..................................................................................................... 6430 Acceleration Mode................................................................................................................... 6430 Accelerator Controls................................................................................................................ 6430 Battery Voltage Correction Mode..................................................................................................... 6430 CMP Signal.......................................................................................................................... 6430 Clear Flood Mode.................................................................................................................... 6430 Deceleration Mode................................................................................................................... 6430 Engine Speed/Fuel Disable Mode...................................................................................................... 6430 Fuel Cutoff Mode.................................................................................................................... 6430 Fuel Injector....................................................................................................................... 6430 Fuel Metering System Components..................................................................................................... 6431 Fuel Metering System Purpose........................................................................................................ 6431 Fuel Pressure Regulator............................................................................................................. 6431 Fuel Pump Electrical Circuit........................................................................................................ 6431 Fuel Rail........................................................................................................................... 6431 Idle Air Control (IAC) Valve........................................................................................................ 6432 Run Mode............................................................................................................................ 6432 Starting Mode....................................................................................................................... 6432 Throttle Body Unit.................................................................................................................. 6433 General Description (Electronic Ignition System)........................................................................................ 6433 Camshaft Position (CMP) Sensor...................................................................................................... 6433 Crankshaft Position (CKP) Sensor.................................................................................................... 6433 Electronic Ignition................................................................................................................. 6434 Ignition Coils...................................................................................................................... 6434 Ignition Control.................................................................................................................... 6434 Knock Sensor (KS) PCM Input......................................................................................................... 6435 Powertrain Control Module (PCM)..................................................................................................... 6435 Spark Plug.......................................................................................................................... 6435 A/C Clutch Diagnosis.................................................................................................................... 6437 A/C Clutch Circuit Operation........................................................................................................ 6437 A/C Clutch Circuit Purpose.......................................................................................................... 6437 A/C Request Signal.................................................................................................................. 6437 General Description (Evaporative (EVAP) Emission System)................................................................................ 6438 EVAP Emission Control System Purpose................................................................................................ 6438 EVAP Emission Control System Operation.............................................................................................. 6438 Enhanced Evaporative Emission Control System........................................................................................ 6439 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 6442 EGR Purpose......................................................................................................................... 6442 Linear EGR Valve.................................................................................................................... 6442 Linear EGR Control.................................................................................................................. 6442 Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 6442 EGR Pintle Position Sensor.......................................................................................................... 6442 General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 6443 Crankcase Ventilation System Purpose................................................................................................ 6443 Crankcase Ventilation System Operation.............................................................................................. 6443 Special Tools........................................................................................................................... 6444 6F ENGINE EXHAUST......................................................................................................................... 6446 General Description..................................................................................................................... 6447 Three Way Catalytic Converter LH........................................................................................................ 6448 Removal............................................................................................................................. 6448 Installation........................................................................................................................ 6448 Three Way Catalytic Converter RH........................................................................................................ 6449 Removal............................................................................................................................. 6449 Installation........................................................................................................................ 6449 Exhaust Silencer........................................................................................................................ 6450 Exhaust Silencer and Associated Parts............................................................................................... 6450 Removal............................................................................................................................. 6450 Installation........................................................................................................................ 6450 Rear Exhaust pipe....................................................................................................................... 6451 Rear Exhaust pipe and Associated Parts.............................................................................................. 6451 Removal............................................................................................................................. 6451 Installation........................................................................................................................ 6451 Main Data and Specifications............................................................................................................ 6452 6G ENGINE LUBRICATION..................................................................................................................... 6453 Service Precaution...................................................................................................................... 6453 General Description..................................................................................................................... 6454 Oil Pump................................................................................................................................ 6455 Oil Pump and Associated Parts....................................................................................................... 6455 Oil Pump and Associated Parts....................................................................................................... 6455 Inspection and Repair............................................................................................................... 6456 Reassembly.......................................................................................................................... 6457 Oil Pan and Crankcase................................................................................................................... 6459 Removal............................................................................................................................. 6459 Installation........................................................................................................................ 6459 Oil Pump................................................................................................................................ 6461 Removal............................................................................................................................. 6461 Installation........................................................................................................................ 6461 Oil Pump Oil Seal....................................................................................................................... 6463 Removal............................................................................................................................. 6463 Installation........................................................................................................................ 6463 Oil Filter.............................................................................................................................. 6464 Removal............................................................................................................................. 6464 Installation........................................................................................................................ 6464 Main Data and Specification............................................................................................................. 6465 Special Tool............................................................................................................................ 6466 6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 6467 Service Precaution...................................................................................................................... 6467 Accelerator Pedal Control Cable......................................................................................................... 6468 Removal............................................................................................................................. 6468 Inspection.......................................................................................................................... 6468 Installation........................................................................................................................ 6468 Accelerator Pedal....................................................................................................................... 6469 Accelerator Pedal and Associated Parts.............................................................................................. 6469 Removal............................................................................................................................. 6469 Installation........................................................................................................................ 6469 6J INDUCTION.............................................................................................................................. 6470 Service Precaution...................................................................................................................... 6470 Air Cleaner Element..................................................................................................................... 6471 Removal............................................................................................................................. 6471 Inspection.......................................................................................................................... 6471 Installation........................................................................................................................ 6471 Sec.7 TRANSMISSION............................................................................................................................ 6472 7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................ 6472 Service Precaution...................................................................................................................... 6474 Construction............................................................................................................................ 6474 Range Reference Chart................................................................................................................... 6475 Normal Operation Of 1999 4L30-E Transmission............................................................................................ 6476 Diagnosis............................................................................................................................... 6476 Driver Information...................................................................................................................... 6476 General Diagnosis Procedure............................................................................................................. 6479 Preliminary Inspection Chart............................................................................................................ 6480 Checking Transmission Fluid Level and Condition......................................................................................... 6481 Test Driving............................................................................................................................ 6482 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 6483 Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 6484 Stall Test.............................................................................................................................. 6494 Line Pressure Test...................................................................................................................... 6494 Shift Speed Chart....................................................................................................................... 6495 Lockup Speed Chart...................................................................................................................... 6497 Changing Transmission Fluid............................................................................................................. 6498 Selector Lever.......................................................................................................................... 6498 Inspection.......................................................................................................................... 6498 Removal............................................................................................................................. 6499 Installation........................................................................................................................ 6499 Mode Switch............................................................................................................................. 6500 Removal............................................................................................................................. 6500 Installation........................................................................................................................ 6500 Transmission (With Transfer Case)....................................................................................................... 6502 Transmission And Associated Parts................................................................................................... 6502 Removal............................................................................................................................. 6502 Installation........................................................................................................................ 6506 Solenoid (Main Case Valve Body)......................................................................................................... 6510 Removal............................................................................................................................. 6510 Installation........................................................................................................................ 6510 Solenoid (Adapter Case Valve Body)...................................................................................................... 6511 Removal............................................................................................................................. 6511 Installation........................................................................................................................ 6511 Valve Body Assembly (Main Case)......................................................................................................... 6512 Removal............................................................................................................................. 6512 Installation........................................................................................................................ 6512 Valve Body Assembly (Adapter Case)...................................................................................................... 6514 Removal............................................................................................................................. 6514 Installation........................................................................................................................ 6514 Powertrain Control Module (PCM)......................................................................................................... 6514 Removal............................................................................................................................. 6514 Installation........................................................................................................................ 6514 Speed Sensor (Extension Housing)........................................................................................................ 6515 Removal............................................................................................................................. 6515 Installation........................................................................................................................ 6515 Transmission Oil Temperature Sensor (Adapter Case)...................................................................................... 6515 Removal............................................................................................................................. 6515 Installation........................................................................................................................ 6515 Front Oil Seal (Converter Housing)...................................................................................................... 6516 Removal............................................................................................................................. 6516 Installation........................................................................................................................ 6516 Rear Oil Seal (Extension Housing)....................................................................................................... 6516 Removal............................................................................................................................. 6516 Installation........................................................................................................................ 6517 Transmission (4L30-E)................................................................................................................... 6517 Disassembly......................................................................................................................... 6517 Reassembly.......................................................................................................................... 6521 Converter Housing And Oil Pump Assembly................................................................................................. 6532 Disassembled View................................................................................................................... 6532 Disassembly......................................................................................................................... 6532 Inspection And Repair............................................................................................................... 6532 Reassembly.......................................................................................................................... 6532 Oil Pump................................................................................................................................ 6533 Disassembled View................................................................................................................... 6533 Disassembly......................................................................................................................... 6533 Inspection And Repair............................................................................................................... 6533 Reassembly.......................................................................................................................... 6533 Main Case Valve Body.................................................................................................................... 6534 Disassembled View................................................................................................................... 6534 Disassembly......................................................................................................................... 6534 Inspection And Repair............................................................................................................... 6535 Reassembly.......................................................................................................................... 6535 Adapter Case Valve Body................................................................................................................. 6536 Disassembled View................................................................................................................... 6536 Disassembly......................................................................................................................... 6536 Inspection And Repair............................................................................................................... 6536 Reassembly.......................................................................................................................... 6536 Third Clutch And Sprag Unit............................................................................................................. 6538 Disassembled View................................................................................................................... 6538 Disassembly......................................................................................................................... 6538 Inspection And Repair............................................................................................................... 6539 Reassembly.......................................................................................................................... 6539 Third Clutch............................................................................................................................ 6540 Disassembled View................................................................................................................... 6540 Disassemble......................................................................................................................... 6540 Inspection And Repair............................................................................................................... 6540 Reassembly.......................................................................................................................... 6540 Sprag Unit.............................................................................................................................. 6542 Disassembled View................................................................................................................... 6542 Disassembly......................................................................................................................... 6542 Inspection And Repair............................................................................................................... 6542 Reassembly.......................................................................................................................... 6542 Second Clutch........................................................................................................................... 6543 Disassembled View................................................................................................................... 6543 Disassembly......................................................................................................................... 6543 Inspection And Repair............................................................................................................... 6544 Reassembly.......................................................................................................................... 6544 3-4 Accumulator Piston.................................................................................................................. 6545 Disassembled View................................................................................................................... 6545 Disassembly......................................................................................................................... 6545 Inspection And Repair............................................................................................................... 6545 Reassembly.......................................................................................................................... 6546 Reverse Clutch Piston And Center Support................................................................................................ 6547 Disassembled View................................................................................................................... 6547 Disassembly......................................................................................................................... 6547 Inspection And Repair............................................................................................................... 6548 Reassembly.......................................................................................................................... 6548 Overrun Clutch And Turbine Shaft........................................................................................................ 6549 Disassembled View................................................................................................................... 6549 Disassembly......................................................................................................................... 6549 Inspection And Repair............................................................................................................... 6550 Reassembly.......................................................................................................................... 6550 Main Data And Specification............................................................................................................. 6552 Special Tools........................................................................................................................... 6556 4L30-E Parts List....................................................................................................................... 6559 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 6567 Service Precaution...................................................................................................................... 6568 General Description..................................................................................................................... 6568 Electronic Control Diagram.......................................................................................................... 6569 Powertrain Control Module (PCM)..................................................................................................... 6570 Control System Diagram.............................................................................................................. 6571 Shift Control....................................................................................................................... 6572 Band Apply Control.................................................................................................................. 6572 Torque Converter Clutch Control..................................................................................................... 6572 Line Pressure Control............................................................................................................... 6572 On-Board Diagnostic System.......................................................................................................... 6572 Fail Safe Mechanism................................................................................................................. 6572 Torque Management Control........................................................................................................... 6572 ATF Warning Control................................................................................................................. 6572 ABS Control......................................................................................................................... 6572 Shift Mode Control.................................................................................................................. 6573 Gear Shift Control.................................................................................................................. 6574 Winter Drive Mode................................................................................................................... 6575 Backup Mode......................................................................................................................... 6575 Functions of Input / Output Components.............................................................................................. 6576 Diagnosis............................................................................................................................... 6577 Electronic Diagnosis................................................................................................................ 6577 How To Diagnose The Problem......................................................................................................... 6577 Check Trans Indicator............................................................................................................... 6577 Diagnostic Check.................................................................................................................... 6577 "Check Trans" Check................................................................................................................. 6578 Tech 2 OBD II Connection............................................................................................................ 6579 F0: Transmission Data............................................................................................................... 6583 F1: PC Solenoid Data................................................................................................................ 6584 OBD II Diagnostic Management System................................................................................................. 6585 16-Terminal Data Link Connector (DLC)............................................................................................... 6586 Malfunction Indicator Lamp (MIL).................................................................................................... 6587 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 6587 Clear DTC........................................................................................................................... 6587 DTC Check........................................................................................................................... 6588 PCM Precaution...................................................................................................................... 6588 Information On PCM.................................................................................................................. 6588 Intermittent Conditions............................................................................................................. 6588 Transmission And PCM Identification................................................................................................. 6589 Diagnostic Trouble Code (DTC) Identification........................................................................................ 6590 DTC P0218 Transmission Fluid Over Temperature........................................................................................... 6591 DTC P0560 System Voltage Malfunction.................................................................................................... 6593 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 6596 DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 6599 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance......................................................... 6602 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 6605 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 6608 DTC P0719 TCC Brake Switch Circuit High (Stuck On)...................................................................................... 6611 DTC P0722 Transmission Output Speed Sensor (OSS) Low Input.............................................................................. 6614 DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent........................................................................... 6617 DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)...................................................................................... 6620 DTC P0730 Transmission Incorrect Gear Ratio............................................................................................. 6622 DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................ 6625 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 6627 DTC P0751 Shift Solenoid A Performance Without Input Speed.............................................................................. 6629 DTC P0753 Shift Solenoid A Electrical................................................................................................... 6631 DTC P0756 Shift Solenoid B Performance Without Input Speed.............................................................................. 6634 DTC P0758 Shift Solenoid B Electrical................................................................................................... 6636 DTC P1790 ROM Transmission Side Bad Check Sum........................................................................................... 6640 DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................ 6641 DTC P1835 Kickdown Switch Always On..................................................................................................... 6642 DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 6644 DTC P1860 TCC Solenoid Electrical....................................................................................................... 6648 DTC P1870 Transmission Component Slipping............................................................................................... 6651 Circuit Diagram......................................................................................................................... 6653 Parts Location.......................................................................................................................... 6655 Harness Connector Faces................................................................................................................. 6656 Sec.8 BODY AND ACCESSORIES.................................................................................................................... 6821 8A LIGHTING SYSTEM........................................................................................................................ 6658 Service Precaution...................................................................................................................... 6659 Headlight Bulb.......................................................................................................................... 6659 Removal............................................................................................................................. 6659 Installation........................................................................................................................ 6659 Headlight............................................................................................................................... 6660 Removal............................................................................................................................. 6660 Installation........................................................................................................................ 6660 Headlight Adjustment................................................................................................................ 6660 Fender Marker Light Bulb................................................................................................................ 6662 Removal............................................................................................................................. 6662 Installation........................................................................................................................ 6662 Front Side Marker Light Bulb............................................................................................................ 6662 Removal............................................................................................................................. 6662 Installation........................................................................................................................ 6662 Rear Side Marker Light Bulb............................................................................................................. 6663 Removal............................................................................................................................. 6663 Installation........................................................................................................................ 6663 Parking Light Bulb...................................................................................................................... 6663 Removal............................................................................................................................. 6663 Installation........................................................................................................................ 6663 Taillight Bulb.......................................................................................................................... 6664 Removal............................................................................................................................. 6664 Installation........................................................................................................................ 6664 License Plate Light Bulb................................................................................................................ 6664 Removal............................................................................................................................. 6664 Installation........................................................................................................................ 6664 Stoplight Bulb.......................................................................................................................... 6665 Removal and Installation............................................................................................................ 6665 High Mounted Stop Light................................................................................................................. 6665 Removal............................................................................................................................. 6665 Installation........................................................................................................................ 6665 Front Turn Signal Light Bulb............................................................................................................ 6666 Removal............................................................................................................................. 6666 Installation........................................................................................................................ 6666 Rear Turn Signal Light Bulb............................................................................................................. 6666 Removal............................................................................................................................. 6666 Installation........................................................................................................................ 6666 Backup Light Bulb....................................................................................................................... 6667 Removal............................................................................................................................. 6667 Installation........................................................................................................................ 6667 Dome Light Bulb......................................................................................................................... 6667 Removal............................................................................................................................. 6667 Installation........................................................................................................................ 6667 Map Light Switch/Bulb................................................................................................................... 6668 Removal............................................................................................................................. 6668 Installation........................................................................................................................ 6668 Cigarette Lighter Illumination Bulb..................................................................................................... 6668 Removal............................................................................................................................. 6668 Installation........................................................................................................................ 6668 Ashtray Illumination Bulb............................................................................................................... 6669 Removal............................................................................................................................. 6669 Installation........................................................................................................................ 6669 HVAC Bezel Illumination Light Bulb...................................................................................................... 6669 Removal and Installation............................................................................................................ 6669 Shift Lever Illumination Light Bulb (A/T)............................................................................................... 6670 Removal............................................................................................................................. 6670 Installation........................................................................................................................ 6670 Starter Switch.......................................................................................................................... 6670 Removal............................................................................................................................. 6670 Installation........................................................................................................................ 6670 Lighting Switch (Combination Switch).................................................................................................... 6671 Removal............................................................................................................................. 6671 Installation........................................................................................................................ 6671 Stoplight Switch........................................................................................................................ 6672 Removal............................................................................................................................. 6672 Installation........................................................................................................................ 6672 Turn Signal Switch(Combination Switch).................................................................................................. 6673 Removal and Installation............................................................................................................ 6673 Hazard Warning Switch................................................................................................................... 6673 Removal............................................................................................................................. 6673 Installation........................................................................................................................ 6673 Key Remind Switch(Starter Switch)....................................................................................................... 6673 Removal and Installation............................................................................................................ 6673 Door Switch............................................................................................................................. 6674 Removal............................................................................................................................. 6674 Installation........................................................................................................................ 6674 Rear Defogger Switch.................................................................................................................... 6674 Removal............................................................................................................................. 6674 Installation........................................................................................................................ 6674 Illumination Controller................................................................................................................. 6675 Removal............................................................................................................................. 6675 Installation........................................................................................................................ 6675 Main Data and Specifications............................................................................................................ 6676 8B WIPER / WASHER SYSTEM.................................................................................................................. 6679 Service Precaution...................................................................................................................... 6679 Windshield Wiper/Washer System.......................................................................................................... 6680 General Description................................................................................................................. 6680 Windshield Wiper And Washer Switch...................................................................................................... 6680 Removal and Installation............................................................................................................ 6680 Windshield Wiper Motor.................................................................................................................. 6680 Removal............................................................................................................................. 6680 Installation........................................................................................................................ 6680 Windshield Washer Motor................................................................................................................. 6681 Removal............................................................................................................................. 6681 Installation........................................................................................................................ 6681 Washer Nozzle Angle Adjustment...................................................................................................... 6681 Windshield Wiper Linkage................................................................................................................ 6682 Windshield Wiper Linkage and Associated Parts....................................................................................... 6682 Removal............................................................................................................................. 6682 Installation........................................................................................................................ 6682 Windshield Wiper Arm/Blade.............................................................................................................. 6683 Removal............................................................................................................................. 6683 Installation........................................................................................................................ 6683 Windshield Wiper Blade Rubber........................................................................................................... 6684 Removal............................................................................................................................. 6684 Installation........................................................................................................................ 6684 Alarm & Relay Control Unit.............................................................................................................. 6685 Removal............................................................................................................................. 6685 Installation........................................................................................................................ 6685 Intermittent Relay...................................................................................................................... 6685 Removal............................................................................................................................. 6685 Installation........................................................................................................................ 6685 Main Data and Specifications............................................................................................................ 6686 8C ENTERTAINMENT.......................................................................................................................... 6687 Service Precaution...................................................................................................................... 6687 Cigarette Lighter....................................................................................................................... 6688 General Description................................................................................................................. 6688 Removal............................................................................................................................. 6688 Installation........................................................................................................................ 6688 Antenna................................................................................................................................. 6689 Removal............................................................................................................................. 6689 Installation........................................................................................................................ 6689 Radio................................................................................................................................... 6690 Removal............................................................................................................................. 6690 Installation........................................................................................................................ 6690 Front Speaker........................................................................................................................... 6690 Removal............................................................................................................................. 6690 Installation........................................................................................................................ 6690 Tweeter Assembly........................................................................................................................ 6691 Removal............................................................................................................................. 6691 Installation........................................................................................................................ 6691 Rear Speaker............................................................................................................................ 6691 Removal............................................................................................................................. 6691 Installation........................................................................................................................ 6691 Horn (Low note)......................................................................................................................... 6692 Removal............................................................................................................................. 6692 Installation........................................................................................................................ 6692 Horn (High note)........................................................................................................................ 6692 Removal............................................................................................................................. 6692 Installation........................................................................................................................ 6692 8D WIRING SYSTEM.......................................................................................................................... 6693 Fuse, Relay and Diode................................................................................................................... 6694 Relay and Fuse Box / Relay Box Location............................................................................................. 6694 Fuse Layout......................................................................................................................... 6695 Relay Layout........................................................................................................................ 6696 Diode Layout........................................................................................................................ 6697 Circuit Diagram......................................................................................................................... 6698 Harness and Connector Location.......................................................................................................... 6719 8E METER AND GAUGE........................................................................................................................ 6738 Service Precaution...................................................................................................................... 6738 Meter Assembly.......................................................................................................................... 6739 General Description................................................................................................................. 6739 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 6739 Table for Meter/Gauge Connector Terminal Connections................................................................................ 6741 Removal............................................................................................................................. 6743 Installation........................................................................................................................ 6743 Speedometer............................................................................................................................. 6744 Removal............................................................................................................................. 6744 Installation........................................................................................................................ 6744 Tachometer.............................................................................................................................. 6745 Removal............................................................................................................................. 6745 Installation........................................................................................................................ 6745 Coolant Temperature gauge and Fuel Gauge................................................................................................ 6746 Removal............................................................................................................................. 6746 Installation........................................................................................................................ 6746 TOD Indicator Assembly.................................................................................................................. 6747 Removal............................................................................................................................. 6747 Installation........................................................................................................................ 6747 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb....................................................................... 6748 Removal............................................................................................................................. 6748 Installation........................................................................................................................ 6748 A/T Indicator Light Bulb................................................................................................................ 6748 Removal............................................................................................................................. 6748 Installation........................................................................................................................ 6748 Vehicle Speed Sensor.................................................................................................................... 6749 Removal............................................................................................................................. 6749 Installation........................................................................................................................ 6749 Thermo Unit............................................................................................................................. 6749 Removal............................................................................................................................. 6749 Installation........................................................................................................................ 6749 Fuel Tank Unit.......................................................................................................................... 6750 Removal............................................................................................................................. 6750 Installation........................................................................................................................ 6750 Main Data and Specifications............................................................................................................ 6751 8F BODY STRUCTURE......................................................................................................................... 6752 Service Precaution...................................................................................................................... 6753 Frame................................................................................................................................... 6753 General Description................................................................................................................. 6753 Frame Dimensions.................................................................................................................... 6754 Front Bumper............................................................................................................................ 6755 Parts Location...................................................................................................................... 6755 Removal............................................................................................................................. 6756 Installation........................................................................................................................ 6756 Rear Bumper............................................................................................................................. 6757 Parts Location...................................................................................................................... 6757 Removal............................................................................................................................. 6757 Installation........................................................................................................................ 6757 Engine Hood............................................................................................................................. 6758 Parts Location...................................................................................................................... 6758 Removal............................................................................................................................. 6758 Installation........................................................................................................................ 6759 Engine Hood Cover....................................................................................................................... 6760 Parts Location...................................................................................................................... 6760 Removal............................................................................................................................. 6760 Installation........................................................................................................................ 6760 Engine Hood Lock........................................................................................................................ 6761 Parts Location...................................................................................................................... 6761 Removal............................................................................................................................. 6761 Installation........................................................................................................................ 6762 Radiator Grille......................................................................................................................... 6762 Parts Location...................................................................................................................... 6762 Removal............................................................................................................................. 6762 Installation........................................................................................................................ 6762 Front Fender Panel...................................................................................................................... 6763 Parts Location...................................................................................................................... 6763 Removal............................................................................................................................. 6763 Installation........................................................................................................................ 6764 Body Mounting........................................................................................................................... 6765 Parts Location...................................................................................................................... 6765 Tightening Torque................................................................................................................... 6765 Body Dimension...................................................................................................................... 6766 Instrument Panel Assembly and Cross Beam Assembly....................................................................................... 6776 Parts Location...................................................................................................................... 6776 Removal............................................................................................................................. 6777 Installation........................................................................................................................ 6780 Front Door Assembly..................................................................................................................... 6782 Parts Location...................................................................................................................... 6782 Removal............................................................................................................................. 6782 Installation........................................................................................................................ 6783 Door Strikers........................................................................................................................... 6784 Adjustment.......................................................................................................................... 6784 Front Window Regulator, Glass and Glass Run............................................................................................. 6785 Parts Location...................................................................................................................... 6785 Removal............................................................................................................................. 6786 Installation........................................................................................................................ 6788 Tailgate Assembly....................................................................................................................... 6789 Parts Location...................................................................................................................... 6789 Removal............................................................................................................................. 6789 Installation........................................................................................................................ 6790 Tailgate Dove-Tail...................................................................................................................... 6791 Parts Location...................................................................................................................... 6791 Removal............................................................................................................................. 6791 Installation........................................................................................................................ 6791 Spare Tire Carrier...................................................................................................................... 6792 Parts Location...................................................................................................................... 6792 Removal............................................................................................................................. 6792 Installation........................................................................................................................ 6792 Windshield.............................................................................................................................. 6793 Parts Location...................................................................................................................... 6793 Removal............................................................................................................................. 6793 Installation........................................................................................................................ 6794 Rear Quarter............................................................................................................................ 6798 Parts Location...................................................................................................................... 6798 Removal............................................................................................................................. 6798 Installation........................................................................................................................ 6799 Center Glass............................................................................................................................ 6800 Parts Location...................................................................................................................... 6800 Removal............................................................................................................................. 6800 Installation........................................................................................................................ 6801 Tailgate Glass.......................................................................................................................... 6802 Parts Location...................................................................................................................... 6802 Removal............................................................................................................................. 6802 Installation........................................................................................................................ 6802 Main Data and Specifications............................................................................................................ 6804 8G SEATS.................................................................................................................................. 6805 Service Precaution...................................................................................................................... 6805 Front Seat Assembly..................................................................................................................... 6806 Disassembled View................................................................................................................... 6806 Removal............................................................................................................................. 6806 Installation........................................................................................................................ 6807 Disassembly......................................................................................................................... 6807 Reassembly.......................................................................................................................... 6807 Rear Seat Assembly...................................................................................................................... 6808 Disassembled View................................................................................................................... 6808 Removal............................................................................................................................. 6808 Installation........................................................................................................................ 6808 Disassembly......................................................................................................................... 6809 Reassembly.......................................................................................................................... 6809 Main Data and Specifications............................................................................................................ 6810 8H SECURITY AND LOCKS..................................................................................................................... 6811 Service Precaution...................................................................................................................... 6811 Front Door Lock Assembly................................................................................................................ 6812 Front Door Lock Assembly and Associated Parts....................................................................................... 6812 Removal............................................................................................................................. 6812 Installation........................................................................................................................ 6813 Front Outside Handle and Door Lock Cylinder............................................................................................. 6814 Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 6814 Removal............................................................................................................................. 6814 Installation........................................................................................................................ 6815 Tailgate Lock and Lock Cylinder......................................................................................................... 6816 Tailgate Lock, Lock Cylinder and Associated Parts................................................................................... 6816 Removal............................................................................................................................. 6816 Installation........................................................................................................................ 6817 Key..................................................................................................................................... 6818 Key Coding.......................................................................................................................... 6818 Key Styles.......................................................................................................................... 6818 Power Door Lock System.................................................................................................................. 6819 General Description................................................................................................................. 6819 Front Door Lock Actuator Removal.................................................................................................... 6819 Front Door Lock Actuator Installation............................................................................................... 6819 Main Data and Specifications............................................................................................................ 6820 8J EXTERIOR / INTERIOR TRIM............................................................................................................... 6821 Service Precaution...................................................................................................................... 6821 Consoles................................................................................................................................ 6822 Consoles and Associated Parts....................................................................................................... 6822 Removal............................................................................................................................. 6822 Installation........................................................................................................................ 6822 Front Door Trim Assembly................................................................................................................ 6823 Front Door Trim Assembly and Associated Parts....................................................................................... 6823 Removal............................................................................................................................. 6823 Installation........................................................................................................................ 6824 Door Mirror............................................................................................................................. 6824 Door Mirror and Associated Parts.................................................................................................... 6824 Removal............................................................................................................................. 6824 Installation........................................................................................................................ 6824 Interior Trim Cover and Assist Grip..................................................................................................... 6825 Interior Trim Cover, Assist Grip and Associated Parts............................................................................... 6825 Removal............................................................................................................................. 6825 Installation........................................................................................................................ 6826 Headlining.............................................................................................................................. 6827 Parts Location...................................................................................................................... 6827 Removal............................................................................................................................. 6827 Installation........................................................................................................................ 6828 Tailgate Trim Cover..................................................................................................................... 6828 Tailgate Trim Cover and Associated Parts............................................................................................ 6828 Removal............................................................................................................................. 6828 Installation........................................................................................................................ 6828 Body Side Protectors.................................................................................................................... 6829 Body Side Protectors and Associated Parts........................................................................................... 6829 Removal............................................................................................................................. 6830 Installation........................................................................................................................ 6830 Tailgate Protector...................................................................................................................... 6831 Parts Location...................................................................................................................... 6831 Removal............................................................................................................................. 6831 Installation........................................................................................................................ 6831 Fuel Filler Lid......................................................................................................................... 6832 Parts Location...................................................................................................................... 6832 Removal............................................................................................................................. 6832 Installation........................................................................................................................ 6832 Roof Rail Assembly...................................................................................................................... 6833 Parts Location...................................................................................................................... 6833 Removal............................................................................................................................. 6833 Installation........................................................................................................................ 6833 Rear Roof Spoiler....................................................................................................................... 6834 Parts Location...................................................................................................................... 6834 Removal............................................................................................................................. 6834 Installation........................................................................................................................ 6834 Power Door Mirror System................................................................................................................ 6835 General Description................................................................................................................. 6835 Door Mirror Control Switch and Door Mirror Defogger Switch Removal.................................................................. 6835 Installation........................................................................................................................ 6835 Power Door Mirror....................................................................................................................... 6835 General Description................................................................................................................. 6835 Removal and Installation............................................................................................................ 6835 Power Window System..................................................................................................................... 6836 General Description................................................................................................................. 6836 Power Window Switch Removal and Installation........................................................................................ 6836 Power Window Motor Removal and Installation......................................................................................... 6837 Main Data and Specifications............................................................................................................ 6838 Sec.9 RESTRAINTS.............................................................................................................................. 6839 9A SEAT BELT SYSTEM....................................................................................................................... 6839 Service Precaution...................................................................................................................... 6839 Front Seat Belt......................................................................................................................... 6840 Front Seat Belt and Associated Parts................................................................................................ 6840 Removal............................................................................................................................. 6840 Inspection.......................................................................................................................... 6840 Installation........................................................................................................................ 6841 Rear Seat Belt.......................................................................................................................... 6842 Rear Seat Belt and Associated Parts................................................................................................. 6842 Removal............................................................................................................................. 6842 Inspection.......................................................................................................................... 6843 Installation........................................................................................................................ 6843 Front Seat Belt Buckle Assembly......................................................................................................... 6844 Front Seat Belt Buckle Assembly and Associated Parts................................................................................ 6844 Removal............................................................................................................................. 6844 Installation........................................................................................................................ 6844 Rear Seat Belt Buckle Assembly.......................................................................................................... 6845 Removal............................................................................................................................. 6845 Installation........................................................................................................................ 6845 Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 6846 General Description................................................................................................................. 6846 Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 6846 Installation........................................................................................................................ 6846 Main Data and Specifications............................................................................................................ 6847 9J SUPPLEMENTAL RESTRAINT SYSTEM.......................................................................................................... 6848 Service Precaution...................................................................................................................... 6848 General Description..................................................................................................................... 6849 SRS Component and Wiring Location View.............................................................................................. 6851 Component Description................................................................................................................... 6851 Definition.............................................................................................................................. 6854 Diagnosis............................................................................................................................... 6855 SRS Connector Body Face Views........................................................................................................... 6856 Repairs and Inspections Required After an Accident...................................................................................... 6856 On-Vehicle Service...................................................................................................................... 6857 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 6858 Special Tools........................................................................................................................... 6874 Service Precaution...................................................................................................................... 6879 Sensing and Diagnostic Module (SDM)..................................................................................................... 6881 Service Precautions................................................................................................................. 6881 Removal............................................................................................................................. 6881 Installation........................................................................................................................ 6881 Driver Air Bag Assembly................................................................................................................. 6883 Service Precautions................................................................................................................. 6883 Removal............................................................................................................................. 6883 Installation........................................................................................................................ 6883 Steering Wheel.......................................................................................................................... 6884 Service Precautions................................................................................................................. 6884 Removal............................................................................................................................. 6884 Installation........................................................................................................................ 6885 SRS Coil Assembly....................................................................................................................... 6886 Service Precaution.................................................................................................................. 6886 Removal............................................................................................................................. 6886 Installation........................................................................................................................ 6887 Steering Column......................................................................................................................... 6889 Service Precaution.................................................................................................................. 6889 Removal............................................................................................................................. 6889 Installation........................................................................................................................ 6891 Passenger Air Bag Assembly.............................................................................................................. 6893 Service Precaution.................................................................................................................. 6893 Removal............................................................................................................................. 6893 Installation........................................................................................................................ 6893 Main Data and Specifications............................................................................................................ 6894 SRS Air Bag System Inspection Standards For Repair...................................................................................... 6895 9J1 SRS CONTROL SYSTEM..................................................................................................................... 6896 Service Precaution...................................................................................................................... 6896 Diagnostic Information.................................................................................................................. 6897 Parts For Electrical Circuit............................................................................................................ 6899 System Schematic........................................................................................................................ 6900 SRS Diagnostic System Check............................................................................................................. 6900 Chart A SDM Integrity Check............................................................................................................. 6903 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 6905 Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady............................................................................... 6907 DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 6910 DTC 16 Passenger Deployment Loop Resistance Low......................................................................................... 6913 DTC 17 Passenger Deployment Loop Open................................................................................................... 6916 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 6918 DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 6920 DTC 21 Driver Deployment Loop Resistance High........................................................................................... 6922 DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 6925 DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 6928 DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 6930 DTC 26 Driver Deployment Loop Open...................................................................................................... 6933 DTC 51 Deployment Event Commanded....................................................................................................... 6936 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 6938 DTC 61 Warning Lamp Circuit Failure..................................................................................................... 6940 DTC 71 Internal SDM Fault............................................................................................................... 6942 Sec.10 CONTROL SYSTEM.......................................................................................................................... 6944 10A CRUISE CONTROL SYSTEM.................................................................................................................. 6944 Service Precaution...................................................................................................................... 6944 General Description..................................................................................................................... 6945 Diagnosis............................................................................................................................... 6945 Brake Switch............................................................................................................................ 6946 Removal and Installation............................................................................................................ 6946 Adjustment.......................................................................................................................... 6946 Cruise Control Unit..................................................................................................................... 6946 Removal............................................................................................................................. 6946 Installation........................................................................................................................ 6946 Cruise Actuator......................................................................................................................... 6947 Actuator Cable Diagram.............................................................................................................. 6947 Removal............................................................................................................................. 6947 Installation........................................................................................................................ 6948 Adjustment.......................................................................................................................... 6948 Mode Switch............................................................................................................................. 6949 Removal and Installation............................................................................................................ 6949 Cruise Control Main Switch.............................................................................................................. 6949 Removal............................................................................................................................. 6949 Installation........................................................................................................................ 6949 Cruise Control Switch (Combination Switch).............................................................................................. 6949 Removal and Installation............................................................................................................ 6949 2000 MODEL.............................................................................................................................................. 2 (UX) TROOPER........................................................................................................................................ 6950 Sec.0 GENERAL INFORMATION..................................................................................................................... 6951 0A GENERAL INFORMATION..................................................................................................................... 6951 General Repair Instruction.............................................................................................................. 6951 Illustration Arrows..................................................................................................................... 6952 Identification.......................................................................................................................... 6953 Theft Prevention Standard............................................................................................................... 6955 Lifting Instructions.................................................................................................................... 6960 Standard Bolts Torque Specifications.................................................................................................... 6963 Abbreviations Charts.................................................................................................................... 6964 Service Parts Identification Plate...................................................................................................... 6965 0B MAINTENANCE AND LUBRICATION............................................................................................................. 6966 Maintenance Schedule List............................................................................................................... 6966 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 6970 Recommended Fluids and Lubricants................................................................................................... 6973 Lubricant Viscosity Chart............................................................................................................... 6974 Recommended Liquid Gasket........................................................................................................... 6976 Recommended Thread Locking Agents................................................................................................... 6977 Maintenance Service Data................................................................................................................ 6978 Sec.1 HEATING, VENTILATION AND AIR............................................................................................................ 6979 1A HVAC SYSTEMS............................................................................................................................ 6979 Service Precaution...................................................................................................................... 6981 Heating and Ventilation System.......................................................................................................... 6981 General Description..................................................................................................................... 6981 Wiring Diagram.......................................................................................................................... 6986 Diagnosis............................................................................................................................... 6987 Individual Inspection................................................................................................................... 6990 Heater Unit............................................................................................................................. 6992 Heater Unit and Associated Parts.................................................................................................... 6992 Removal............................................................................................................................. 6992 Installation........................................................................................................................ 6993 Heater Core and / or Mode Door.......................................................................................................... 6994 Disassembled View................................................................................................................... 6994 Removal............................................................................................................................. 6994 Inspection.......................................................................................................................... 6995 Installation........................................................................................................................ 6995 Heater Mode Control Link Unit........................................................................................................... 6996 Disassembled View................................................................................................................... 6996 Removal............................................................................................................................. 6996 Installation........................................................................................................................ 6997 Heater Temperature Control Link Unit.................................................................................................... 6997 Disassembled View................................................................................................................... 6997 Removal............................................................................................................................. 6997 Installation........................................................................................................................ 6997 Blower Assembly......................................................................................................................... 6998 Blower Assembly and Associated Parts................................................................................................ 6998 Removal............................................................................................................................. 6998 Installation........................................................................................................................ 6999 Blower Link Unit and / or Mode door..................................................................................................... 6999 Disassembled View................................................................................................................... 6999 Removal............................................................................................................................. 6999 Installation........................................................................................................................ 7000 Blower Motor............................................................................................................................ 7001 Blower Motor and Associated Parts................................................................................................... 7001 Removal............................................................................................................................. 7001 Installation........................................................................................................................ 7001 Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 7002 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 7002 Removal............................................................................................................................. 7002 Installation........................................................................................................................ 7003 Center and / or Drive Side Vent......................................................................................................... 7003 Center Vent, Drive Side Vent and Associated Parts................................................................................... 7003 Removal............................................................................................................................. 7003 Installation........................................................................................................................ 7003 Control Lever Assembly and / or Control Cable........................................................................................... 7004 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 7004 Removal............................................................................................................................. 7004 Installation........................................................................................................................ 7005 Control Panel Illumination Bulb......................................................................................................... 7006 Control Panel Illumination Bulb and Associated Parts................................................................................ 7006 Removal............................................................................................................................. 7006 Installation........................................................................................................................ 7006 Resistor................................................................................................................................ 7007 Resistor and Associated Parts....................................................................................................... 7007 Removal............................................................................................................................. 7007 Installation........................................................................................................................ 7007 Air Conditioning System................................................................................................................. 7008 General Description..................................................................................................................... 7008 Diagnosis............................................................................................................................... 7017 Individual Inspection................................................................................................................... 7025 General Repair Procedure............................................................................................................ 7026 Compressor Assembly..................................................................................................................... 7033 Compressor Assembly and Associated Parts............................................................................................ 7033 Removal............................................................................................................................. 7033 Installation........................................................................................................................ 7034 Condenser Assembly...................................................................................................................... 7035 Condenser Assembly and Associated Parts............................................................................................. 7035 Removal............................................................................................................................. 7035 Installation........................................................................................................................ 7035 Receiver / Drier........................................................................................................................ 7036 Receiver / Drier and Associated Parts............................................................................................... 7036 Removal............................................................................................................................. 7036 Installation........................................................................................................................ 7036 Pressure Switch......................................................................................................................... 7037 Pressure Switch and Associated Parts................................................................................................ 7037 Removal............................................................................................................................. 7037 Installation........................................................................................................................ 7037 Evaporator Assembly..................................................................................................................... 7038 Evaporator Assembly and Associated Parts............................................................................................ 7038 Removal............................................................................................................................. 7038 Installation........................................................................................................................ 7039 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 7039 Disassembled View................................................................................................................... 7039 Removal............................................................................................................................. 7039 Installation........................................................................................................................ 7040 Air Conditioning Switch and Illumination Bulb........................................................................................... 7041 Air Conditioning Switch, Illumination Bulb and Associated Parts..................................................................... 7041 Removal............................................................................................................................. 7041 Installation........................................................................................................................ 7041 Refrigerant Line........................................................................................................................ 7042 Refrigerant Line and Associated Parts............................................................................................... 7042 Removal............................................................................................................................. 7042 Installation........................................................................................................................ 7043 Main Data And Specifications............................................................................................................ 7044 Compressor.............................................................................................................................. 7046 Service Precaution.................................................................................................................. 7046 General Description..................................................................................................................... 7046 Metric Thread Size Information...................................................................................................... 7048 Compressor Clutch Plate and Hub Assembly................................................................................................ 7048 Removal............................................................................................................................. 7048 Installation........................................................................................................................ 7048 Compressor Clutch Rotor and/or Bearing.................................................................................................. 7049 Removal............................................................................................................................. 7049 Installation........................................................................................................................ 7049 Compressor Clutch Coil.................................................................................................................. 7050 Removal............................................................................................................................. 7050 Installation........................................................................................................................ 7051 Compressor Shaft Seal................................................................................................................... 7052 Service Precaution...................................................................................................................... 7052 Seal Leak Detection................................................................................................................. 7052 Removal............................................................................................................................. 7052 Cleaning............................................................................................................................ 7053 Installation........................................................................................................................ 7053 Compressor Pressure Relief Valve........................................................................................................ 7054 Removal............................................................................................................................. 7054 Installation........................................................................................................................ 7054 Compressor Oil.......................................................................................................................... 7054 Compressor Oil Check................................................................................................................ 7054 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 7054 Checking and Adjusting for Compressor Replacement................................................................................... 7054 Contamination of Compressor Oil..................................................................................................... 7055 Oil Return Operation................................................................................................................ 7055 Replacement of Component Parts...................................................................................................... 7055 Compressor Leak Testing (External and Internal)..................................................................................... 7055 Special Tools........................................................................................................................... 7057 Automatic Air Conditioning System....................................................................................................... 7059 General Description..................................................................................................................... 7059 Full Automatic Air Conditioner Parts Configuration.................................................................................. 7059 Refrigerant Line and Associated Parts............................................................................................... 7060 Circuit Diagram......................................................................................................................... 7061 Functions and Features.................................................................................................................. 7066 Automatic Air Conditioner Block Diagram................................................................................................. 7067 Control Panel Layout.................................................................................................................... 7068 Air Control Functions................................................................................................................... 7069 Operation and Functions of Control Panel Switches....................................................................................... 7070 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....................................... 7072 Overview of Automatic Control of Automatic Air Conditioner.............................................................................. 7076 Troubleshooting......................................................................................................................... 7080 Troubleshooting, Its Overview and Procedures........................................................................................ 7080 Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................ 7081 Performance and Movement checklist for Automatic Air Conditioner Related Parts...................................................... 7083 Troubleshooting With Self-Diagnosis Function........................................................................................ 7085 Inspection By Failed Location........................................................................................................... 7089 Inspection of the Sensors........................................................................................................... 7089 Inspection of the Intake Actuator System............................................................................................ 7093 Inspection of the Mix Actuator System............................................................................................... 7096 Inspection of the Mode Actuator System.............................................................................................. 7099 Inspection of the Fan Motor System.................................................................................................. 7102 Inspection of the Magnetic Clutch System............................................................................................ 7107 Individual Inspection............................................................................................................... 7110 On-Vehicle Service...................................................................................................................... 7113 Power Transistor.................................................................................................................... 7113 Removal......................................................................................................................... 7113 Installation.................................................................................................................... 7113 Automatic Heater/Air Conditioner Control Unit....................................................................................... 7113 Removal......................................................................................................................... 7113 Installation.................................................................................................................... 7113 In Car Sensor....................................................................................................................... 7114 Removal......................................................................................................................... 7114 Installation.................................................................................................................... 7114 Ambient Sensor...................................................................................................................... 7114 Removal......................................................................................................................... 7114 Installation.................................................................................................................... 7114 Sun Sensor.......................................................................................................................... 7115 Removal......................................................................................................................... 7115 Installation.................................................................................................................... 7115 Electronic Thermostat............................................................................................................... 7115 Removal......................................................................................................................... 7115 Installation.................................................................................................................... 7115 Mode Actuator....................................................................................................................... 7116 Removal......................................................................................................................... 7116 Installation.................................................................................................................... 7116 Mix Actuator........................................................................................................................ 7116 Removal......................................................................................................................... 7116 Installation.................................................................................................................... 7116 Intake Actuator..................................................................................................................... 7117 Removal......................................................................................................................... 7117 Installation.................................................................................................................... 7117 Sec.2 STEERING................................................................................................................................ 7118 2A POWER ASSISTED SYSTEM................................................................................................................... 7118 Service Precaution...................................................................................................................... 7119 General Description..................................................................................................................... 7119 Diagnosis............................................................................................................................... 7122 Power Steering System Test.............................................................................................................. 7128 Maintenance............................................................................................................................. 7129 Fluid Level............................................................................................................................. 7129 Bleeding The Power Steering System...................................................................................................... 7129 Bleeding Procedure...................................................................................................................... 7129 Flushing The Power Steering System...................................................................................................... 7129 Steering Wheel Free Play Adjustment..................................................................................................... 7130 Front End Alignment Inspection and Adjustment........................................................................................... 7130 Main Data and Specifications............................................................................................................ 7135 Special Tools........................................................................................................................... 7136 Power Steering Gear..................................................................................................................... 7137 Power Steering Gear and Associated Parts............................................................................................ 7137 Removal............................................................................................................................. 7137 Installation........................................................................................................................ 7138 Steering Gear Disassembled View..................................................................................................... 7139 Disassembly......................................................................................................................... 7140 Inspection and Repair............................................................................................................... 7141 Reassembly.......................................................................................................................... 7142 Main Data and Specifications........................................................................................................ 7144 Power Steering Pump..................................................................................................................... 7145 Power Steering Pump and Associated Parts............................................................................................ 7145 Removal............................................................................................................................. 7145 Installation........................................................................................................................ 7146 Power Steering Pump Disassembled View............................................................................................... 7147 Disassembly......................................................................................................................... 7147 Inspection and Repair............................................................................................................... 7148 Reassembly.......................................................................................................................... 7149 Main Data and Specifications........................................................................................................ 7150 Center Track Rod Assembly............................................................................................................... 7151 Center Track Rod Assembly and Associated Parts...................................................................................... 7151 Removal............................................................................................................................. 7152 Inspection and Repair............................................................................................................... 7152 Installation........................................................................................................................ 7152 Outer Track Rod Assembly................................................................................................................ 7153 Outer Track Rod Assembly and Associated Parts....................................................................................... 7153 Removal............................................................................................................................. 7154 Inspection and Repair............................................................................................................... 7154 Installation........................................................................................................................ 7155 Relay Lever............................................................................................................................. 7156 Relay Lever and Associated Parts.................................................................................................... 7156 Removal............................................................................................................................. 7156 Installation........................................................................................................................ 7157 Steering Linkage and Associated Parts................................................................................................... 7158 Main Data and Specifications........................................................................................................ 7158 Special Tools....................................................................................................................... 7159 Supplemental Restraint System Steering Wheel & Column................................................................................... 7160 Service Precaution.................................................................................................................. 7160 SRS Connectors...................................................................................................................... 7160 Inflator Module......................................................................................................................... 7162 Inflator Module and Associated Parts................................................................................................ 7162 Removal............................................................................................................................. 7162 Inspection and Repair............................................................................................................... 7163 Installation........................................................................................................................ 7163 Steering Wheel.......................................................................................................................... 7164 Steering Wheel and Associated Parts................................................................................................. 7164 Removal............................................................................................................................. 7164 Installation........................................................................................................................ 7166 Combination Switch...................................................................................................................... 7167 Combination Switch and Associated Parts............................................................................................. 7167 Removal............................................................................................................................. 7167 Installation........................................................................................................................ 7169 Lock Cylinder........................................................................................................................... 7171 Lock Cylinder and Associated Parts.................................................................................................. 7171 Removal............................................................................................................................. 7171 Installation........................................................................................................................ 7173 System Inspection................................................................................................................... 7174 Steering Column......................................................................................................................... 7175 Steering Column and Associated Parts................................................................................................ 7175 Removal............................................................................................................................. 7175 Inspection.......................................................................................................................... 7177 Installation........................................................................................................................ 7179 System Inspection................................................................................................................... 7180 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 7181 Main Data and Specifications........................................................................................................ 7181 Special Tools....................................................................................................................... 7182 Sec.3 SUSPENSION.............................................................................................................................. 7183 3C FRONT SUSPENSION....................................................................................................................... 7183 Service Precaution...................................................................................................................... 7183 General Description..................................................................................................................... 7184 General Diagnosis....................................................................................................................... 7185 Shock Absorber.......................................................................................................................... 7188 Shock Absorber and Associated Parts................................................................................................. 7188 Removal............................................................................................................................. 7188 Inspection and Repair............................................................................................................... 7188 Installation........................................................................................................................ 7188 Stabilizer Bar.......................................................................................................................... 7189 Stabilizer Bar and Associated Parts................................................................................................. 7189 Removal............................................................................................................................. 7189 Inspection and Repair............................................................................................................... 7189 Installation........................................................................................................................ 7189 Torsion Bar............................................................................................................................. 7190 Torsion Bar and Associated Parts.................................................................................................... 7190 Removal............................................................................................................................. 7190 Inspection and Repair............................................................................................................... 7191 Installation........................................................................................................................ 7191 Knuckle................................................................................................................................. 7193 Knuckle and Associated Parts........................................................................................................ 7193 Removal............................................................................................................................. 7193 Inspection and Repair............................................................................................................... 7194 Installation........................................................................................................................ 7194 Upper Control Arm....................................................................................................................... 7196 Upper Control Arm and Associated Parts.............................................................................................. 7196 Removal............................................................................................................................. 7196 Inspection and Repair............................................................................................................... 7197 Installation........................................................................................................................ 7198 Lower Control Arm....................................................................................................................... 7200 Lower Control Arm and Associated Parts.............................................................................................. 7200 Removal............................................................................................................................. 7200 Inspection and Repair............................................................................................................... 7202 Installation........................................................................................................................ 7202 Upper Ball Joint........................................................................................................................ 7204 Upper Ball Joint and Associated Parts............................................................................................... 7204 Removal............................................................................................................................. 7204 Inspection and Repair............................................................................................................... 7205 Installation........................................................................................................................ 7205 Lower Ball Joint........................................................................................................................ 7206 Lower Ball Joint and Associated Parts............................................................................................... 7206 Removal............................................................................................................................. 7206 Inspection and Repair............................................................................................................... 7207 Installation........................................................................................................................ 7207 Main Data and Specifications............................................................................................................ 7208 Special Tools........................................................................................................................... 7209 3D REAR SUSPENSION........................................................................................................................ 7210 Service Precaution...................................................................................................................... 7210 General Description..................................................................................................................... 7211 Coil Spring............................................................................................................................. 7212 Coil Spring and Associated Parts.................................................................................................... 7212 Removal............................................................................................................................. 7212 Inspection and Repair............................................................................................................... 7213 Installation........................................................................................................................ 7213 Shock Absorber.......................................................................................................................... 7214 Shock Absorber and Associated Parts................................................................................................. 7214 Removal............................................................................................................................. 7214 Inspection and Repair............................................................................................................... 7214 Installation........................................................................................................................ 7214 Trailing Link........................................................................................................................... 7215 Trailing Link and Associated Parts.................................................................................................. 7215 Removal............................................................................................................................. 7215 Inspection and Repair............................................................................................................... 7215 Installation........................................................................................................................ 7216 Center Link............................................................................................................................. 7217 Center Link and Associated Parts.................................................................................................... 7217 Removal............................................................................................................................. 7217 Inspection and Repair............................................................................................................... 7217 Installation........................................................................................................................ 7218 Lateral Rod............................................................................................................................. 7219 Lateral Rod and Associated Parts.................................................................................................... 7219 Removal............................................................................................................................. 7219 Inspection and Repair............................................................................................................... 7219 Installation........................................................................................................................ 7220 Stabilizer Bar.......................................................................................................................... 7221 Stabilizer Bar and Associated Parts................................................................................................. 7221 Removal............................................................................................................................. 7221 Inspection and Repair............................................................................................................... 7221 Installation........................................................................................................................ 7222 Main Data and Specifications............................................................................................................ 7223 Special Tools........................................................................................................................... 7225 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 7226 Service Precaution...................................................................................................................... 7226 General Description..................................................................................................................... 7227 Diagnosis............................................................................................................................... 7228 Wheel................................................................................................................................... 7234 Wheel and Associated Parts.......................................................................................................... 7234 Removal............................................................................................................................. 7234 Installation........................................................................................................................ 7234 Tire.................................................................................................................................... 7235 Tire Replacement.................................................................................................................... 7235 General Balance Procedure............................................................................................................... 7235 Balancing Wheel and Tire................................................................................................................ 7236 Main Data and Specifications............................................................................................................ 7237 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 7238 4A1 DIFFERENTIAL (FRONT).................................................................................................................. 7238 Service Precaution...................................................................................................................... 7238 Front Drive Axle........................................................................................................................ 7239 Diagnosis............................................................................................................................... 7239 Pinion Shaft Oil Seal................................................................................................................... 7240 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 7240 Removal............................................................................................................................. 7240 Inspection and Repair............................................................................................................... 7241 Installation........................................................................................................................ 7241 Front Drive Axle Assembly............................................................................................................... 7242 Front Drive Axle Assembly and Associated Parts...................................................................................... 7242 Removal............................................................................................................................. 7242 Installation........................................................................................................................ 7244 Differential Assembly................................................................................................................... 7246 Disassembled View................................................................................................................... 7246 Disassembly......................................................................................................................... 7246 Reassembly.......................................................................................................................... 7249 Differential Cage Assembly.............................................................................................................. 7258 Disassembled View................................................................................................................... 7258 Disassembly......................................................................................................................... 7258 Inspection and Repair............................................................................................................... 7259 Reassembly.......................................................................................................................... 7260 Main Data and Specifications............................................................................................................ 7262 Special Tools........................................................................................................................... 7264 4A2 DIFFERENTIAL (REAR)................................................................................................................... 7266 Service Precaution...................................................................................................................... 7266 General Description..................................................................................................................... 7268 Diagnosis............................................................................................................................... 7269 Axle Housing............................................................................................................................ 7270 Axle Housing and Associated Parts................................................................................................... 7270 Removal............................................................................................................................. 7270 Oil Seal Replacement................................................................................................................ 7271 Installation........................................................................................................................ 7271 Axle Shaft.............................................................................................................................. 7272 Axle Shaft and Associated Parts..................................................................................................... 7272 Removal............................................................................................................................. 7272 Inspection and Repair............................................................................................................... 7273 Oil Seal Replacement................................................................................................................ 7274 Installation........................................................................................................................ 7274 Pinion Oil Seal......................................................................................................................... 7275 Pinion Oil Seal and Associated Parts................................................................................................ 7275 Removal............................................................................................................................. 7275 Inspection and Repair............................................................................................................... 7276 Installation........................................................................................................................ 7276 Differential Assembly................................................................................................................... 7277 Differential Assembly and Associated Parts.......................................................................................... 7277 Removal............................................................................................................................. 7277 Installation........................................................................................................................ 7278 Disassembled View................................................................................................................... 7279 Disassembly......................................................................................................................... 7280 Reassembly.......................................................................................................................... 7282 Differential Cage Assembly.............................................................................................................. 7289 Disassembled View................................................................................................................... 7289 Disassembly......................................................................................................................... 7290 Inspection and Repair............................................................................................................... 7290 Reassembly.......................................................................................................................... 7291 Limited Slip Differential............................................................................................................... 7293 Disassembled View................................................................................................................... 7293 Disassembly......................................................................................................................... 7294 Inspection and Repair............................................................................................................... 7294 Reassembly.......................................................................................................................... 7296 Main Data and Specifications............................................................................................................ 7300 Special Tools........................................................................................................................... 7301 4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)........................................................................................... 7304 Service Precaution...................................................................................................................... 7304 Shift On The Fly System................................................................................................................. 7305 Outline of Shift on The Fly System...................................................................................................... 7305 Functions of Indicator Lamp............................................................................................................. 7309 Diagnosis............................................................................................................................... 7310 Front Axle Diagnosis.................................................................................................................... 7320 Shift On The Fly Vacuum Piping And Electric Equipment................................................................................... 7322 Vacuum piping diagram................................................................................................................... 7322 Inspection And Repair................................................................................................................... 7323 4WD Control Unit........................................................................................................................ 7326 4WD Control Unit Associated Parts................................................................................................... 7326 Removal............................................................................................................................. 7327 Installation........................................................................................................................ 7327 4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................................ 7328 Service Precaution...................................................................................................................... 7328 General Description..................................................................................................................... 7329 System Components....................................................................................................................... 7331 Parts Location...................................................................................................................... 7331 Functions of Indicator Lamp............................................................................................................. 7335 Diagnosis............................................................................................................................... 7338 Basic Diagnostic Flow Chart............................................................................................................. 7342 Parts Location.......................................................................................................................... 7343 Circuit Diagram......................................................................................................................... 7344 Connector List.......................................................................................................................... 7347 Checking Failed Pin..................................................................................................................... 7349 Checking Failed TOD Control Unit Pin.................................................................................................... 7352 Tech 2 Scan Tool.................................................................................................................... 7353 Diagnostic Trouble Codes................................................................................................................ 7356 Diagnosis from Trouble Codes............................................................................................................ 7357 Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 7381 Diagnosis from Symptom.................................................................................................................. 7410 4C DRIVE SHAFT SYSTEM .................................................................................................................. 7420 Service Precaution...................................................................................................................... 7421 General Description..................................................................................................................... 7421 Diagnosis............................................................................................................................... 7422 Front Hub and Disc (2WD Model).......................................................................................................... 7423 Disassembled View................................................................................................................... 7423 Disassembly......................................................................................................................... 7423 Inspection and Repair............................................................................................................... 7425 Reassembly.......................................................................................................................... 7425 Main Data and Specifications........................................................................................................ 7428 Special Tools....................................................................................................................... 7429 Front Hub and Disc (4WD Model).......................................................................................................... 7430 Disassembled View................................................................................................................... 7430 Disassembly......................................................................................................................... 7430 Inspection and Repair............................................................................................................... 7431 Reassembly.......................................................................................................................... 7431 Main Data and Specifications........................................................................................................ 7435 Special Tools....................................................................................................................... 7436 Front Drive Shaft Joint................................................................................................................. 7437 Front Drive Shaft Joints Replace-ment............................................................................................... 7437 Front Axle Drive Shaft.................................................................................................................. 7438 Front Axle Drive Shaft and Associated Parts......................................................................................... 7438 Disassembly......................................................................................................................... 7439 Inspection and Repair............................................................................................................... 7440 Bushing Replacement................................................................................................................. 7440 Reassembly.......................................................................................................................... 7441 Shift On The Fly System................................................................................................................. 7443 Shift On The Fly System and Associated Parts........................................................................................ 7443 Disassembly......................................................................................................................... 7443 Inspection and Repair............................................................................................................... 7445 Main Data and Specifications........................................................................................................ 7450 Special Tools....................................................................................................................... 7451 Front Propeller Shaft................................................................................................................... 7452 General Description................................................................................................................. 7452 Front Propeller Shaft and Associated Parts.......................................................................................... 7453 Removal............................................................................................................................. 7453 Installation........................................................................................................................ 7454 Disassembly (Except TOD 4×4)........................................................................................................ 7455 Universal Joint Disassembly......................................................................................................... 7456 Inspection and Repair............................................................................................................... 7457 Universal Joint Reassembly.......................................................................................................... 7460 Reassembly (Except TOD 4ﾗ4)......................................................................................................... 7461 Main Data and Specifications........................................................................................................ 7462 Rear Propeller Shaft.................................................................................................................... 7463 General Description................................................................................................................. 7463 Rear Propeller Shaft and Associated Parts........................................................................................... 7463 Removal............................................................................................................................. 7463 Installation........................................................................................................................ 7464 Disassembly......................................................................................................................... 7465 Universal Joint Disassembly......................................................................................................... 7466 Inspection and Repair............................................................................................................... 7467 Universal Joint Reassembly.......................................................................................................... 7468 Reassembly.......................................................................................................................... 7469 Main Data and Specifications........................................................................................................ 7470 4D1 TRANSFER CASE (STANDARD TYPE)......................................................................................................... 7471 Service Precaution...................................................................................................................... 7471 General Description..................................................................................................................... 7472 Transfer Rear Oil Seal.................................................................................................................. 7474 Removal............................................................................................................................. 7474 Installation........................................................................................................................ 7474 Transfer Case Assembly.................................................................................................................. 7475 Removal............................................................................................................................. 7475 Installation........................................................................................................................ 7475 Transfer Rear Case Assembly............................................................................................................. 7477 Removal............................................................................................................................. 7477 Installation........................................................................................................................ 7478 Disassembly......................................................................................................................... 7481 Inspection and Repair............................................................................................................... 7482 Reassembly.......................................................................................................................... 7482 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 7484 Disassembled View................................................................................................................... 7484 Disassembly......................................................................................................................... 7484 Inspection and Repair............................................................................................................... 7486 Reassembly.......................................................................................................................... 7486 Transfer Case Assembly.................................................................................................................. 7488 Disassembled View................................................................................................................... 7488 Disassembly......................................................................................................................... 7489 Inspection and Repair............................................................................................................... 7491 Reassembly.......................................................................................................................... 7495 Main Data and Specifications............................................................................................................ 7501 Special Tools........................................................................................................................... 7504 4D2 TRANSFER CASE (TOD)................................................................................................................... 7506 Service Precaution...................................................................................................................... 7506 Transfer Case Assembly.................................................................................................................. 7507 Removal............................................................................................................................. 7507 Installation........................................................................................................................ 7508 Transfer Rear Oil Seal.................................................................................................................. 7510 Transfer Rear Oil Seal and Associated Parts......................................................................................... 7510 Removal............................................................................................................................. 7510 Installation........................................................................................................................ 7510 TOD ECU................................................................................................................................. 7512 Removal............................................................................................................................. 7512 Installation........................................................................................................................ 7512 Unit Repair............................................................................................................................. 7513 Inspection.......................................................................................................................... 7513 Transfer Case........................................................................................................................... 7514 Disassembled View................................................................................................................... 7514 Disassembly......................................................................................................................... 7514 Reassembly.......................................................................................................................... 7515 Transfer Cover Assembly................................................................................................................. 7517 Disassembled View................................................................................................................... 7517 Disassembly......................................................................................................................... 7517 Reassembly.......................................................................................................................... 7519 Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 7521 Disassembled View................................................................................................................... 7521 Disassembly......................................................................................................................... 7521 Sprocket and Mechanical Lock............................................................................................................ 7523 Disassembled View................................................................................................................... 7523 Disassembly......................................................................................................................... 7523 Output Shafts and Shift Control Shaft................................................................................................... 7525 Disassembled View................................................................................................................... 7525 Disassembly......................................................................................................................... 7526 Transfer Case........................................................................................................................... 7528 Disassembled View................................................................................................................... 7528 Disassembly......................................................................................................................... 7529 Inspection and Repair............................................................................................................... 7531 Transfer Case........................................................................................................................... 7535 Disassembled View................................................................................................................... 7535 Reassembly.......................................................................................................................... 7535 Output Shafts and Shift Control Shaft................................................................................................... 7538 Disassembled View................................................................................................................... 7538 Reassembly.......................................................................................................................... 7538 Sprocket and Mechanical Lock............................................................................................................ 7541 Disassembled View................................................................................................................... 7541 Reassembly.......................................................................................................................... 7541 Clutch Pack and Clutch Cam.............................................................................................................. 7543 Disassembled View................................................................................................................... 7543 Reassembly.......................................................................................................................... 7543 Main Data and Specifications............................................................................................................ 7545 Special Tools........................................................................................................................... 7547 Sec.5 BRAKES.................................................................................................................................. 7600 5A BRAKE CONTROL SYSTEM................................................................................................................... 7548 Service Precaution...................................................................................................................... 7549 General Description..................................................................................................................... 7550 System Components................................................................................................................... 7550 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 7550 ABS Warning Light................................................................................................................... 7551 Wheel Speed Sensor.................................................................................................................. 7551 G-Sensor............................................................................................................................ 7551 Normal and Anti-lock Braking........................................................................................................ 7551 Brake Pedal Travel.................................................................................................................. 7551 Acronyms and Abbreviations.......................................................................................................... 7551 General Diagnosis....................................................................................................................... 7552 General Information................................................................................................................. 7552 ABS Service Precautions............................................................................................................. 7552 Computer System Service Precautions................................................................................................. 7552 General Service Precautions......................................................................................................... 7552 Note on Intermittents............................................................................................................... 7552 Test Driving ABS Complaint Vehicles................................................................................................. 7552 "ABS" Warning Light................................................................................................................. 7553 Normal Operation.................................................................................................................... 7553 Basic Diagnostic Flow Chart......................................................................................................... 7553 Basic Inspection Procedure.......................................................................................................... 7554 Tech 2 Scan Tool.................................................................................................................... 7555 Getting Started..................................................................................................................... 7556 Operating Procedure................................................................................................................. 7556 Data List............................................................................................................................... 7558 EHCU Connector Pin-out Checks........................................................................................................... 7559 Circuit Diagram..................................................................................................................... 7560 Connector List...................................................................................................................... 7563 Part Location....................................................................................................................... 7565 Symptom Diagnosis....................................................................................................................... 7566 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 7566 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 7567 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 7567 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 7568 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 7568 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 7569 Diagnostic Trouble Codes................................................................................................................ 7570 Diagnosis By "ABS" Warning Light Illumination Pattern............................................................................... 7571 Diagnostic Trouble Codes (DTCs)..................................................................................................... 7571 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 7574 Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 7574 Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 7575 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 7575 Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 7575 Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 7576 Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 7577 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 7577 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 7578 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 7578 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 7578 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 7579 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 7579 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 7579 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 7580 Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 7580 Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 7581 Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 7581 Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 7582 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 7583 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 7584 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 7585 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 7586 Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 7587 Sensor Signal Abnormality Criteria using TECH 2..................................................................................... 7587 Unit Inspection Procedure............................................................................................................... 7588 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 7588 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 7589 Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 7589 Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 7590 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 7590 Chart C-2 Transmission Input Inspection Procedure................................................................................... 7591 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 7592 Special Tools........................................................................................................................... 7593 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 7594 Service Precaution...................................................................................................................... 7594 Electronic Hydraulic Control Unit....................................................................................................... 7595 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 7595 Removal............................................................................................................................. 7595 Installation........................................................................................................................ 7595 G-Sensor................................................................................................................................ 7596 Removal............................................................................................................................. 7596 Inspection and Repair............................................................................................................... 7596 Installation........................................................................................................................ 7596 Front Wheel Speed Sensor................................................................................................................ 7597 Front Wheel Speed Sensor and Associated Parts....................................................................................... 7597 Removal............................................................................................................................. 7597 Inspection and Repair............................................................................................................... 7598 Installation........................................................................................................................ 7598 Rear Wheel Speed Sensor................................................................................................................. 7599 Rear Wheel Speed Sensor and Associated Parts........................................................................................ 7599 Removal............................................................................................................................. 7599 Inspection and Repair............................................................................................................... 7599 Installation........................................................................................................................ 7599 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 7600 Service Precaution...................................................................................................................... 7601 General Description..................................................................................................................... 7601 Diagnosis............................................................................................................................... 7604 General Diagnosis....................................................................................................................... 7605 Hydraulic Brakes........................................................................................................................ 7608 Filling Master Cylinder Reservoir................................................................................................... 7608 Deterioration of Brake Fluid........................................................................................................ 7608 Leakage of Brake Fluid.............................................................................................................. 7608 Bleeding Brake Hydraulic System..................................................................................................... 7608 Flushing Brake Hydraulic System..................................................................................................... 7609 Brake Pipes and Hoses............................................................................................................... 7609 Brake Hose Inspection............................................................................................................... 7609 Front / Rear Caliper Brake Hose......................................................................................................... 7610 Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 7610 Removal............................................................................................................................. 7610 Installation........................................................................................................................ 7610 Rear Axle Brake Hose.................................................................................................................... 7611 Rear Axle Brake Hose and Associated Parts........................................................................................... 7611 Removal............................................................................................................................. 7611 Installation........................................................................................................................ 7611 Brake Pipe.............................................................................................................................. 7612 Removal............................................................................................................................. 7612 Installation........................................................................................................................ 7612 P & B (Proportioning and Bypass) Valve.................................................................................................. 7613 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 7613 Removal............................................................................................................................. 7613 Installation........................................................................................................................ 7613 Main Data and Specifications........................................................................................................ 7614 Brake Pedal............................................................................................................................. 7615 Checking Pedal Height............................................................................................................... 7615 Checking Pedal Travel............................................................................................................... 7615 Brake Pedal and Associated Parts.................................................................................................... 7616 Removal............................................................................................................................. 7616 Installation........................................................................................................................ 7616 Stoplight Switch........................................................................................................................ 7617 Removal............................................................................................................................. 7617 Installation........................................................................................................................ 7617 Main Data and Specifications........................................................................................................ 7618 Fluid Reservoir Tank.................................................................................................................... 7619 Fluid Reservoir Tank and Associated Parts........................................................................................... 7619 Removal............................................................................................................................. 7619 Installation........................................................................................................................ 7619 Master Cylinder Assembly................................................................................................................ 7620 Master Cylinder Assembly and Associated Parts....................................................................................... 7620 Removal............................................................................................................................. 7620 Inspection and Repair............................................................................................................... 7620 Installation........................................................................................................................ 7621 Main Data and Specifications........................................................................................................ 7622 Special Tools....................................................................................................................... 7623 Vacuum Booster Assembly................................................................................................................. 7624 Vacuum Booster Assembly and Associated Parts........................................................................................ 7624 Removal............................................................................................................................. 7624 Inspection and Repair............................................................................................................... 7624 Installation........................................................................................................................ 7625 Exterior Components..................................................................................................................... 7627 Exterior Components and Associated Parts............................................................................................ 7627 Removal............................................................................................................................. 7627 Inspection and Repair............................................................................................................... 7628 Installation........................................................................................................................ 7628 Vacuum Booster Overhaul................................................................................................................. 7628 Vacuum Booster...................................................................................................................... 7628 Main Data and Specifications........................................................................................................ 7629 Special Tools....................................................................................................................... 7630 Front Disc Brake Pads................................................................................................................... 7631 Front Disc Brake Pads Inspection.................................................................................................... 7631 Front Disc Brake Pads and Associated Parts.......................................................................................... 7631 Removal............................................................................................................................. 7632 Installation........................................................................................................................ 7632 Front Disc Brake Rotor.................................................................................................................. 7634 Inspection.......................................................................................................................... 7634 Replacing Brake Rotors.............................................................................................................. 7634 Refinishing Brake Rotors............................................................................................................ 7634 Front Disc Brake Caliper Assembly....................................................................................................... 7636 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 7636 Removal............................................................................................................................. 7636 Installation........................................................................................................................ 7637 Front Disc Brake Caliper................................................................................................................ 7639 Front Disc Brake Caliper Disassembled View.......................................................................................... 7639 Disassembly......................................................................................................................... 7639 Inspection and Repair............................................................................................................... 7640 Reassembly.......................................................................................................................... 7640 Main Data and Specifications........................................................................................................ 7642 Rear Disc Brake Pads.................................................................................................................... 7643 Brake Pads Inspection............................................................................................................... 7643 Brake Pads and Associated Parts..................................................................................................... 7643 Removal............................................................................................................................. 7644 Installation........................................................................................................................ 7644 Rear Disc Brake Rotor................................................................................................................... 7646 Inspection.......................................................................................................................... 7646 Replacing Brake Rotors.............................................................................................................. 7646 Refinishing Brake Rotors............................................................................................................ 7646 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 7647 Rear Disc Brake Caliper Assembly........................................................................................................ 7648 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 7648 Removal............................................................................................................................. 7648 Installation........................................................................................................................ 7649 Rear Disc Brake Caliper................................................................................................................. 7651 Rear Disc Brake Caliper Disassembled View........................................................................................... 7651 Disassembly......................................................................................................................... 7651 Inspection and Repair............................................................................................................... 7652 Reassembly.......................................................................................................................... 7652 Main Data and Specifications........................................................................................................ 7654 5D PARKING BRAKE SYSTEM................................................................................................................... 7655 Service Precaution...................................................................................................................... 7655 General Description..................................................................................................................... 7655 Operation............................................................................................................................... 7656 Parking Brake Lever and Front Cable..................................................................................................... 7657 Parking Brake Lever, Front Cable and Associated Parts............................................................................... 7657 Removal............................................................................................................................. 7657 Installation........................................................................................................................ 7658 Parking Brake Rear Cable................................................................................................................ 7659 Parking Brake Rear Cable and Associated Parts....................................................................................... 7659 Removal............................................................................................................................. 7659 Installation........................................................................................................................ 7660 Inspection and Repair............................................................................................................... 7661 Parking Brake Adjustment................................................................................................................ 7661 Main Data and Specifications............................................................................................................ 7662 Sec.6 ENGINE.................................................................................................................................. 7663 6A ENGINE MECHANICAL..................................................................................................................... 7663 Service Precaution...................................................................................................................... 7664 General Description..................................................................................................................... 7665 Engine Diagnosis........................................................................................................................ 7666 Cylinder Head Cover LH.................................................................................................................. 7681 Removal............................................................................................................................. 7681 Installation........................................................................................................................ 7682 Cylinder Head Cover RH.................................................................................................................. 7683 Removal............................................................................................................................. 7683 Installation........................................................................................................................ 7683 Common Chamber.......................................................................................................................... 7684 Removal............................................................................................................................. 7684 Installation........................................................................................................................ 7684 Exhaust Manifold LH..................................................................................................................... 7686 Removal............................................................................................................................. 7686 Installation........................................................................................................................ 7686 Exhaust Manifold RH..................................................................................................................... 7687 Removal............................................................................................................................. 7687 Installation........................................................................................................................ 7687 Crankshaft Pulley....................................................................................................................... 7688 Removal............................................................................................................................. 7688 Installation........................................................................................................................ 7688 Timing Belt............................................................................................................................. 7689 Removal............................................................................................................................. 7689 Installation........................................................................................................................ 7690 Camshaft................................................................................................................................ 7694 Removal............................................................................................................................. 7694 Installation........................................................................................................................ 7694 Cylinder Head........................................................................................................................... 7697 Removal............................................................................................................................. 7697 Installation........................................................................................................................ 7697 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 7699 Removal............................................................................................................................. 7699 Installation........................................................................................................................ 7699 Piston, Piston Ring and Connecting Rod.................................................................................................. 7700 Removal............................................................................................................................. 7700 Installation........................................................................................................................ 7701 Crankshaft and Main Bearings............................................................................................................ 7702 Removal............................................................................................................................. 7702 Installation........................................................................................................................ 7703 Rear Oil Seal........................................................................................................................... 7707 Removal............................................................................................................................. 7707 Installation........................................................................................................................ 7707 Engine Assembly......................................................................................................................... 7708 Removal............................................................................................................................. 7708 Installation........................................................................................................................ 7709 Cylinder Head........................................................................................................................... 7711 Cylinder Head and Associated Parts.................................................................................................. 7711 Disassembly......................................................................................................................... 7712 Clean............................................................................................................................... 7712 Inspection and Repair............................................................................................................... 7712 Reassembly.......................................................................................................................... 7713 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 7715 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 7715 Disassembly......................................................................................................................... 7715 Inspection and Repair............................................................................................................... 7716 Reassembly.......................................................................................................................... 7719 Valve Clearance Adjustments......................................................................................................... 7720 Camshaft................................................................................................................................ 7722 Camshaft and Associated Parts....................................................................................................... 7722 Disassembly......................................................................................................................... 7722 Inspection and Repair............................................................................................................... 7723 Reassembly.......................................................................................................................... 7725 Crankshaft.............................................................................................................................. 7728 Crankshaft and Associated Parts..................................................................................................... 7728 Disassembly......................................................................................................................... 7729 Inspection and Repair............................................................................................................... 7729 Inspection and Repair............................................................................................................... 7730 Reassembly.......................................................................................................................... 7732 Piston and Connecting Rod............................................................................................................... 7736 Piston, Connecting Rod and Associate Parts.......................................................................................... 7736 Disassembly......................................................................................................................... 7736 Inspection and Repair............................................................................................................... 7737 Reassembly.......................................................................................................................... 7741 Cylinder Block.......................................................................................................................... 7743 Cylinder Block and Associated Parts................................................................................................. 7743 Disassembly......................................................................................................................... 7743 Inspection and Repair............................................................................................................... 7744 Reassembly.......................................................................................................................... 7745 Main Data and Specification............................................................................................................. 7748 Special Tool............................................................................................................................ 7754 6B ENGINE COOLING........................................................................................................................ 7756 Service Precaution...................................................................................................................... 7756 General Description..................................................................................................................... 7757 Diagnosis............................................................................................................................... 7760 Draining and Refilling Cooling System................................................................................................... 7761 Water Pump.............................................................................................................................. 7762 Water Pump and Associated Parts..................................................................................................... 7762 Removal............................................................................................................................. 7762 Inspection.......................................................................................................................... 7762 Thermostat.............................................................................................................................. 7763 Thermostat and Associated Parts..................................................................................................... 7763 Removal............................................................................................................................. 7763 Inspection.......................................................................................................................... 7763 Installation........................................................................................................................ 7763 Radiator................................................................................................................................ 7764 Radiator and Associated Parts....................................................................................................... 7764 Removal............................................................................................................................. 7764 Inspection.......................................................................................................................... 7765 Installation........................................................................................................................ 7766 Drive Belt and Cooling Fan.............................................................................................................. 7767 Drive Belt and Associated Parts..................................................................................................... 7767 Inspection.......................................................................................................................... 7767 Installation........................................................................................................................ 7767 Main Data and Specifications............................................................................................................ 7768 Special Tool............................................................................................................................ 7769 6C ENGINE FUEL........................................................................................................................... 7770 Service Precaution...................................................................................................................... 7770 General Description..................................................................................................................... 7771 Fuel Metering........................................................................................................................... 7772 Fuel Filter............................................................................................................................. 7773 Fuel Filter and Associated Parts.................................................................................................... 7773 Removal............................................................................................................................. 7773 Inspection.......................................................................................................................... 7773 Installation........................................................................................................................ 7773 Inspection.......................................................................................................................... 7774 In-Tank Fuel Filter................................................................................................................. 7774 Fuel Pump Flow Test................................................................................................................. 7774 Fuel Pump............................................................................................................................... 7775 Fuel Pump and Associated Parts...................................................................................................... 7775 Removal............................................................................................................................. 7775 Installation........................................................................................................................ 7775 Fuel Pump Relay......................................................................................................................... 7776 General Description................................................................................................................. 7776 Fuel Tank............................................................................................................................... 7776 Fuel Tank and Associated Parts...................................................................................................... 7776 Removal............................................................................................................................. 7776 Installation........................................................................................................................ 7777 Fuel Tube / Quick-Connect Fittings...................................................................................................... 7777 Precautions......................................................................................................................... 7777 Cautions During Work................................................................................................................ 7777 Removal............................................................................................................................. 7777 Reuse of Quick Connector................................................................................................................ 7779 Assembling Advice....................................................................................................................... 7779 Fuel Gauge Unit......................................................................................................................... 7780 Fuel Gauge Unit and Associated Parts................................................................................................ 7780 Removal............................................................................................................................. 7780 Installation........................................................................................................................ 7780 Fuel Filler Cap......................................................................................................................... 7781 General Description................................................................................................................. 7781 Inspection.......................................................................................................................... 7781 Main Data and Specifications............................................................................................................ 7781 6D1 ENGINE ELECTRICAL..................................................................................................................... 7782 Battery................................................................................................................................. 7782 General Description................................................................................................................. 7782 Diagnosis........................................................................................................................... 7782 Battery Charging.................................................................................................................... 7783 Jump Starting....................................................................................................................... 7783 Battery Removal..................................................................................................................... 7784 Battery Installation................................................................................................................ 7784 Main Data and Specifications........................................................................................................ 7785 6D2 IGNITION SYSTEM....................................................................................................................... 7786 Service Precaution...................................................................................................................... 7786 General Description..................................................................................................................... 7787 Diagnosis............................................................................................................................... 7787 Ignition Coil........................................................................................................................... 7788 Removal............................................................................................................................. 7788 Inspection and Repair............................................................................................................... 7788 Installation........................................................................................................................ 7788 Spark Plug.............................................................................................................................. 7790 Removal............................................................................................................................. 7790 Inspection and Repair............................................................................................................... 7790 Installation........................................................................................................................ 7790 Crankshaft Position Sensor.............................................................................................................. 7791 Removal............................................................................................................................. 7791 Installation........................................................................................................................ 7791 Main Data and Specifications............................................................................................................ 7792 6D3 STARTING AND CHARGING SYSTEM.......................................................................................................... 7793 Service Precaution...................................................................................................................... 7793 Starting System......................................................................................................................... 7794 General Description..................................................................................................................... 7794 Diagnosis............................................................................................................................... 7796 Starter................................................................................................................................. 7797 Removal............................................................................................................................. 7797 Installation........................................................................................................................ 7797 Disassembled View................................................................................................................... 7798 Disassembly......................................................................................................................... 7799 Inspection and Repair............................................................................................................... 7801 Reassembly.......................................................................................................................... 7805 Main Data and Specifications........................................................................................................ 7807 Charging System......................................................................................................................... 7810 General Description..................................................................................................................... 7810 General On-Vehicle Inspection........................................................................................................... 7810 Generator............................................................................................................................... 7811 Removal............................................................................................................................. 7811 Inspection.......................................................................................................................... 7811 Installation........................................................................................................................ 7811 Disassembled View................................................................................................................... 7812 Disassembly......................................................................................................................... 7813 Inspection and Repair............................................................................................................... 7815 Reassembly.......................................................................................................................... 7817 Bench Test.......................................................................................................................... 7817 Main Data and Specifications........................................................................................................ 7818 6E TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................ 7819 Specifications.......................................................................................................................... 7824 Tightening Specifications........................................................................................................... 7824 Diagrams and Schematics................................................................................................................. 7825 PCM Wiring Diagram (1 of 7)......................................................................................................... 7825 PCM Wiring Diagram (2 of 7)......................................................................................................... 7826 PCM Wiring Diagram (3 of 7)......................................................................................................... 7827 PCM Wiring Diagram (4 of 7)......................................................................................................... 7828 PCM Wiring Diagram (5 of 7)......................................................................................................... 7829 PCM Wiring Diagram (6 of 7)......................................................................................................... 7830 PCM Wiring Diagram (7 of 7)......................................................................................................... 7831 PCM Pinouts............................................................................................................................. 7832 PCM Pinout Table, 80-Way Blue Connector-Row "F1 ~ 20"............................................................................... 7832 PCM Pinout Table, 80-Way Blue Connector-Row "F20 ~ 40".............................................................................. 7834 PCM Pinout Table, 80-Way Blue Connector-Row "F41 ~ 60".............................................................................. 7836 PCM Pinout Table, 80-Way Blue Connector-Row "F61 ~ 80".............................................................................. 7838 PCM Pinout Table, 80-Way Red Connector-Row "S1 ~ 20"................................................................................ 7840 PCM Pinout Table, 80-Way Red Connector-Row "S21 ~ 40"............................................................................... 7842 PCM Pinout Table, 80-Way Red Connector-Row "S41 ~ 60"............................................................................... 7844 PCM Pinout Table, 80-Way Red Connector-Row "F61 ~ 80"............................................................................... 7846 Component Locators...................................................................................................................... 7848 Engine Component Locator............................................................................................................ 7848 Engine Component Locator Table...................................................................................................... 7849 Undercarriage Component Locator..................................................................................................... 7850 Undercarriage Component Locator Table............................................................................................... 7850 Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 7851 Sensors and Miscellaneous Component Locators........................................................................................ 7852 Diagnosis............................................................................................................................... 7855 Strategy-Based Diagnostics.......................................................................................................... 7855 DTC Stored.......................................................................................................................... 7855 No DTC.............................................................................................................................. 7855 No Matching Symptom................................................................................................................. 7855 Intermittents....................................................................................................................... 7855 No Trouble Found.................................................................................................................... 7855 Verifying Vehicle Repair............................................................................................................ 7855 General Service Information............................................................................................................. 7856 OBD II Serviceablity Issues......................................................................................................... 7856 Emissions Control Information Label................................................................................................. 7856 Visual / Physical Engine Compartment Inspection..................................................................................... 7856 Basic Knowledge of Tools Required................................................................................................... 7857 Serial Data Communications.............................................................................................................. 7857 Class II Serial Data Communications................................................................................................. 7857 On-Board Diagnostic (OBD II)............................................................................................................ 7857 On-Board Diagnostic Tests........................................................................................................... 7857 Comprehensive Component Monitor Diagnostic Operation................................................................................ 7857 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 7858 Common OBD II Terms................................................................................................................. 7858 The Diagnostic Executive............................................................................................................ 7858 DTC Types........................................................................................................................... 7859 Decimal/Binary/Hexadecimal Conversions.............................................................................................. 7861 Verifying Vehicle Repair............................................................................................................ 7861 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 7861 Tech 2.............................................................................................................................. 7862 Tech 2 Features..................................................................................................................... 7863 Getting Started..................................................................................................................... 7863 Operating Procedure (For Example)................................................................................................... 7864 DTC Modes........................................................................................................................... 7865 DTC Information Mode................................................................................................................ 7865 Miscellaneous Test.................................................................................................................. 7866 Lamps Test.......................................................................................................................... 7866 Relays Test......................................................................................................................... 7868 EVAP Test........................................................................................................................... 7869 Fuel System Test.................................................................................................................... 7870 Instruments Test.................................................................................................................... 7872 EGR Control Test.................................................................................................................... 7874 Variable Intake Manifold Solenoid Test.............................................................................................. 7874 Injector Balance Test............................................................................................................... 7876 Plotting Snapshot Graph................................................................................................................. 7876 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 7877 Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 7878 Primary System-Based Diagnostic......................................................................................................... 7879 Fuel Control Heated Oxygen Sensor................................................................................................... 7879 HO2S Heater......................................................................................................................... 7879 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 7879 Evaporative Emission (EVAP) Purge System Vacuum Switch.............................................................................. 7880 Misfire Monitor Diagnostic Operation.................................................................................................... 7880 Misfire Counters.................................................................................................................... 7880 Fuel Trim System Monitor Diagnostic Operation........................................................................................... 7881 Fuel Trim Cell Diagnostic Weights................................................................................................... 7881 On-Board Diagnostic (OBD II) System Check............................................................................................... 7882 A/C Clutch Control Circuit Diagnosis.................................................................................................... 7885 Electronic Ignition System Diagnosis.................................................................................................... 7890 EVAP Canister Purge Solenoid and EVAP Vacuum Switch..................................................................................... 7890 Visual Check of The Evaporative Emission Canister....................................................................................... 7890 Fuel Metering System Check.............................................................................................................. 7890 Fuel System Pressure Test............................................................................................................... 7890 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.............................................................. 7890 Powertrain Control Module (PCM) Diagnosis............................................................................................... 7895 Multiple PCM Information Sensor DTCs Set................................................................................................ 7895 Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 7899 Engine Tech 2 Data Definitions and Ranges............................................................................................... 7899 Typical Scan Data Values................................................................................................................ 7901 No Malfunction Indicator Lamp (MIL)..................................................................................................... 7907 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 7910 No Reduced Power Lamp (RPL)............................................................................................................. 7912 Reduced Power Lamp (RPL) "ON" Steady.................................................................................................... 7915 Engine Cranks But Will Not Run.......................................................................................................... 7917 Fuel System Electrical Test............................................................................................................. 7924 Electric Throttle Control (ETC) System Check............................................................................................ 7928 Fuel System Diagnosis................................................................................................................... 7932 Exhaust Gas Recirculation (EGR) System Check............................................................................................ 7937 Manifold Absolute Pressure (MAP) Output Check........................................................................................... 7939 Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 7941 Upshift Lamp System Check (Manual Transmission Only).................................................................................... 7944 PCM Diagnostic Trouble Codes............................................................................................................ 7947 Diagnostic Trouble Code (DTC) P0101 MAF System Performance.............................................................................. 7951 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency.................................................................... 7954 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency................................................................... 7957 Diagnostic Trouble Code (DTC) P0106 MAP System Performance.............................................................................. 7960 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage...................................................................... 7963 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage..................................................................... 7966 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage...................................................................... 7969 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage..................................................................... 7972 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage...................................................................... 7975 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage..................................................................... 7978 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control...................................................... 7981 Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation............................................ 7984 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................ 7987 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1........................................................... 7990 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1.................................................................. 7993 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1.................................................. 7997 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1................................................................. 8000 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................ 8003 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2........................................................... 8006 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2................................................... 8009 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2................................................................. 8012 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................ 8015 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1........................................................... 8018 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1.................................................................. 8021 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1.................................................. 8025 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1................................................................. 8028 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................ 8031 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2........................................................... 8034 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2.................................................. 8037 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2................................................................. 8040 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................ 8043 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................ 8047 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................ 8051 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................ 8055 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit.......................................................................... 8059 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit.......................................................................... 8062 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit.......................................................................... 8065 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit.......................................................................... 8068 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit.......................................................................... 8071 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit.......................................................................... 8074 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected............................................................................. 8077 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected........................................................................... 8081 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected........................................................................... 8083 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected........................................................................... 8085 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected........................................................................... 8087 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected........................................................................... 8089 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected........................................................................... 8091 Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault........................................ 8093 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................ 8096 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency.................................................................... 8099 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance...................................................................... 8102 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low.............................................................................. 8106 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit.......................................................................... 8110 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit.......................................................................... 8113 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit.......................................................................... 8116 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit.......................................................................... 8119 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit.......................................................................... 8122 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit.......................................................................... 8125 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient............................................................................... 8128 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error.............................................................................. 8131 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck...................................................................................... 8133 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage..................................................................................... 8135 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage.................................................................................... 8138 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1.................................................................... 8141 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2.................................................................... 8144 Diagnostic Trouble Code (DTC) P0440 EVAP System......................................................................................... 8147 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected..................................................................... 8150 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked.......................................................................... 8153 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage....................................... 8156 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage...................................... 8159 Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak................................................................................ 8162 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage............................................................... 8165 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voktage.............................................................. 8168 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input............................................................................... 8170 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM..................................................................... 8173 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM.................................................................... 8176 Diagnostic Trouble Code (DTC) P0562 System Voltage Low.................................................................................. 8179 Diagnostic Trouble Code (DTC) P0563 System Voltage High................................................................................. 8181 Diagnostic Trouble Code (DTC) P0601 PCM Memory.......................................................................................... 8183 Diagnostic Trouble Code (DTC) P0602 PCM Programming Error............................................................................... 8185 Diagnostic Trouble Code (DTC) P0604 PCM RAM Error....................................................................................... 8187 Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance............................................................................ 8189 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................ 8191 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................ 8193 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................ 8195 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage......................................................... 8198 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage......................................................... 8200 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................ 8202 Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault.................................................. 8205 Diagnostic Trouble Code (DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode.............................................. 8208 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1......................................................... 8211 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1.......................................................... 8215 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1......................................................... 8219 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1.................................................. 8223 Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)................................................. 8227 Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)................................................. 8229 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................ 8231 Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault...................................................... 8234 Diagnosis Truble Code(DTC) P1221 TPS1-TPS2 correlation(Circuit Performance)............................................................. 8237 Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error........................................................................... 8240 Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error........................................................................... 8243 Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error........................................................................... 8246 Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault................................................................................. 8249 Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault................................................................................. 8251 Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault................................................................................. 8253 Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode................................................................................ 8255 Diagnostic Trouble Code (DTC) P1295 Power Management Mode............................................................................... 8258 Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode..................................................................... 8262 Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis........................................................................ 8266 Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC line 1 Circuit Fault......................................................... 8270 Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC line 2 Circuit Fault......................................................... 8273 Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault........................................... 8276 Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)................................ 8279 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed.................................................................................... 8282 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge................................................................... 8285 Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error......................................................................... 8288 Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error.............................................................. 8292 Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error.............................................................. 8295 Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance................................................................. 8298 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................ 8301 Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault................................................................. 8302 Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault................................................................. 8304 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM)................................................................. 8306 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................ 8309 Symptom Diagnosis....................................................................................................................... 8312 Default Matrix Table.................................................................................................................... 8341 On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................ 8344 Crankshaft Position (CKP) Sensor........................................................................................................ 8345 Engine Coolant Temperature (ECT) Sensor................................................................................................. 8345 Heated Oxygen Sensor (HO2S)............................................................................................................. 8346 Intake Air Temperature (IAT) Sensor..................................................................................................... 8349 ION Sensing Module...................................................................................................................... 8349 Mass Air Flow (MAF) Sensor.............................................................................................................. 8350 Manifold Absolute Pressure (MAP) Sensor................................................................................................. 8351 Malfunction Indicator Lamp (MIL)........................................................................................................ 8352 Reduced Power Lamp...................................................................................................................... 8352 Powertrain Control Module (PCM)......................................................................................................... 8352 EEPROM.................................................................................................................................. 8353 Throttle Position (TP) Sensor........................................................................................................... 8354 Vehicle Speed Sensor (VSS).............................................................................................................. 8354 Air Cleaner/Air Filter.................................................................................................................. 8356 Common Chamber.......................................................................................................................... 8356 Accelerator Pedal Replacement........................................................................................................... 8357 Fuel Filler Cap......................................................................................................................... 8358 Fuel Filter............................................................................................................................. 8358 Fuel Gauge Unit......................................................................................................................... 8360 Fuel Injectors.......................................................................................................................... 8361 Fuel Metering System.................................................................................................................... 8362 Fuel Pump Assembly...................................................................................................................... 8363 Fuel Pump Relay......................................................................................................................... 8363 Fuel Rail Assembly...................................................................................................................... 8364 Fuel Tank............................................................................................................................... 8365 Throttle Body (TB)...................................................................................................................... 8367 Electronic Ignition System.............................................................................................................. 8369 Catalytic Converter..................................................................................................................... 8370 Air Conditioning Thermo Relay........................................................................................................... 8370 EVAP Canister Hoses..................................................................................................................... 8370 EVAP Canister........................................................................................................................... 8371 EVAP Canister Vent Solenoid............................................................................................................. 8372 Fuel Tank Pressure Sensor............................................................................................................... 8373 EVAP Canister Purge Solenoid............................................................................................................ 8373 Fuel Tank Vent Valve.................................................................................................................... 8374 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................ 8374 Positive Crankcase Ventilation (PCV) Valve.............................................................................................. 8375 Wiring and Connectors................................................................................................................... 8376 PCM Connectors and Terminals............................................................................................................ 8376 Wire Harness Repair: Twisted Shielded Cable............................................................................................. 8376 Twisted Leads........................................................................................................................... 8377 Weather-Pack Connector.................................................................................................................. 8379 Com-Pack III............................................................................................................................ 8380 Metri-Pack.............................................................................................................................. 8380 General Description (PCM and Sensors)................................................................................................... 8381 58X Reference PCM Input............................................................................................................. 8381 A/C Request Signal.................................................................................................................. 8381 Crankshaft Position (CKP) Sensor.................................................................................................... 8381 Camshaft Position (CMP) Sensor and Signal........................................................................................... 8381 Engine Coolant Temperature (ECT) Sensor............................................................................................. 8381 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................ 8382 Fuel Control Heated Oxygen Sensors.................................................................................................. 8382 Catalyst Monitor Heated Oxygen Sensors.............................................................................................. 8382 Intake Air Temperature (IAT) Sensor................................................................................................. 8383 Linear Exhaust Gas Recirculation (EGR) Control...................................................................................... 8383 Mass Air Flow (MAF) Sensor.......................................................................................................... 8383 Manifold Absolute Pressure (MAP) Sensor............................................................................................. 8383 Powertrain Control Module (PCM)..................................................................................................... 8384 PCM Function........................................................................................................................ 8384 PCM Components...................................................................................................................... 8384 PCM Voltage Description............................................................................................................. 8384 PCM Input/Outputs................................................................................................................... 8385 PCM Service Precautions............................................................................................................. 8385 Reprogramming The PCM............................................................................................................... 8385 Throttle Position (TP) Sensor....................................................................................................... 8385 Transmission Fluid Temperature (TFT) Sensor......................................................................................... 8385 Transmission Range Switch........................................................................................................... 8385 Vehicle Speed Sensor (VSS).......................................................................................................... 8386 Use of Circuit Testing Tools........................................................................................................ 8386 Aftermarket Electrical and Vacuum Equipment......................................................................................... 8386 Electrostatic Discharge Damage...................................................................................................... 8386 Upshift Lamp........................................................................................................................ 8386 General Description (Air Induction)..................................................................................................... 8386 Air Induction System................................................................................................................ 8386 General Description (Fuel Metering)..................................................................................................... 8387 Acceleration Mode................................................................................................................... 8387 Battery Voltage Correction Mode..................................................................................................... 8387 CMP Signal.......................................................................................................................... 8387 Clear Flood Mode.................................................................................................................... 8387 Deceleration Mode................................................................................................................... 8387 Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................ 8387 Fuel Cutoff Mode.................................................................................................................... 8387 Fuel Injector....................................................................................................................... 8387 Fuel Metering System Components..................................................................................................... 8387 Basic System Operation.............................................................................................................. 8388 Fuel Metering System Purpose........................................................................................................ 8388 Fuel Pressure Regulator............................................................................................................. 8388 Fuel Pump Electrical Circuit........................................................................................................ 8388 Fuel Rail........................................................................................................................... 8388 Run Mode............................................................................................................................ 8389 Starting Mode....................................................................................................................... 8389 Throttle Body Unit.................................................................................................................. 8389 General Description (Electronic Ignition System)........................................................................................ 8389 Camshaft Position (CMP) Sensor...................................................................................................... 8389 Crankshaft Position (CKP) Sensor.................................................................................................... 8389 Electronic Ignition................................................................................................................. 8390 Ignition Coils...................................................................................................................... 8390 Ignition Control.................................................................................................................... 8390 Ignition Control PCM Output......................................................................................................... 8391 Powertrain Control Module (PCM)..................................................................................................... 8391 Spark Plug.......................................................................................................................... 8392 A/C Clutch Diagnosis.................................................................................................................... 8393 A/C Clutch Circuit Operation........................................................................................................ 8393 A/C Clutch Circuit Purpose.......................................................................................................... 8393 A/C Request Signal.................................................................................................................. 8393 General Description (Evaporative (EVAP) Emission System)................................................................................ 8394 EVAP Emission Control System Purpose................................................................................................ 8394 EVAP Emission Control System Operation.............................................................................................. 8394 Enhanced Evaporative Emission Control System........................................................................................ 8394 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................ 8397 EGR Purpose......................................................................................................................... 8397 Linear EGR Valve.................................................................................................................... 8398 Linear EGR Control.................................................................................................................. 8398 Linear EGR Valve Operation and Results of Incorrect Operation....................................................................... 8398 EGR Pintle Position Sensor.......................................................................................................... 8398 General Description (Positive Crankcase Ventilation (PCV) System)....................................................................... 8398 Crankcase Ventilation System Purpose................................................................................................ 8398 Crankcase Ventilation System Operation.............................................................................................. 8398 Special Tools........................................................................................................................... 8400 6F ENGINE EXHAUST........................................................................................................................ 8402 General Description..................................................................................................................... 8403 Front Exhaust Pipe...................................................................................................................... 8404 Front Exhaust Pipe and Associated Parts............................................................................................. 8404 Removal............................................................................................................................. 8404 Installation........................................................................................................................ 8404 Three Way Catalytic Converter LH........................................................................................................ 8405 Removal............................................................................................................................. 8405 Installation........................................................................................................................ 8405 Three Way Catalytic Converter RH........................................................................................................ 8406 Removal............................................................................................................................. 8406 Installation........................................................................................................................ 8406 Exhaust Silencer........................................................................................................................ 8407 Exhaust Silencer and Associated Parts............................................................................................... 8407 Removal............................................................................................................................. 8407 Installation........................................................................................................................ 8407 Rear Exhaust pipe....................................................................................................................... 8408 Rear Exhaust pipe and Associated Parts.............................................................................................. 8408 Removal............................................................................................................................. 8408 Installation........................................................................................................................ 8408 Main Data and Specifications............................................................................................................ 8409 6G ENGINE LUBRICATION.................................................................................................................... 8410 Service Precaution...................................................................................................................... 8410 General Description..................................................................................................................... 8411 Oil Pump................................................................................................................................ 8412 Oil Pump and Associated Parts....................................................................................................... 8412 Disassembly......................................................................................................................... 8412 Inspection and Repair............................................................................................................... 8413 Reassembly.......................................................................................................................... 8414 Oil Pan and Crankcase................................................................................................................... 8416 Removal............................................................................................................................. 8416 Installation........................................................................................................................ 8416 Oil Pump................................................................................................................................ 8419 Removal............................................................................................................................. 8419 Installation........................................................................................................................ 8419 Oil Pump Oil Seal....................................................................................................................... 8421 Removal............................................................................................................................. 8421 Installation........................................................................................................................ 8421 Oil Filter.............................................................................................................................. 8422 Removal............................................................................................................................. 8422 Installation........................................................................................................................ 8422 Main Data and Specification............................................................................................................. 8423 6H ENGINE SPEED CONTROL SYSTEM............................................................................................................ 8424 Service Precaution...................................................................................................................... 8424 Accelerator Pedal....................................................................................................................... 8425 Accelerator Pedal and Associated Parts.............................................................................................. 8425 Removal............................................................................................................................. 8425 Installation........................................................................................................................ 8425 6J INDUCTION............................................................................................................................ 8426 Service Precaution...................................................................................................................... 8426 Air Cleaner Element..................................................................................................................... 8427 Removal............................................................................................................................. 8427 Inspection.......................................................................................................................... 8427 Installation........................................................................................................................ 8427 Sec.7 TRANSMISSION............................................................................................................................ 8684 7A AUTOMATIC TRANSMISSION (4L30-E)....................................................................................................... 8428 Service Precaution...................................................................................................................... 8430 Construction............................................................................................................................ 8430 Range Reference Chart................................................................................................................... 8431 Normal Operation Of 2000 4L30-E Transmission ........................................................................................... 8432 Diagnosis............................................................................................................................... 8432 Driver Information...................................................................................................................... 8432 General Diagnosis Procedure............................................................................................................. 8435 Preliminary Inspection Chart............................................................................................................ 8436 Checking Transmission Fluid Level and Condition......................................................................................... 8437 Test Driving............................................................................................................................ 8438 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................ 8439 Mechanical / Hydraulic Diagnosis Symptoms Index......................................................................................... 8440 Stall Test.............................................................................................................................. 8450 Line Pressure Test...................................................................................................................... 8450 Shift Speed Chart....................................................................................................................... 8451 Lockup Speed Chart...................................................................................................................... 8453 Changing Transmission Fluid............................................................................................................. 8454 Selector Lever.......................................................................................................................... 8454 Inspection.......................................................................................................................... 8454 Removal............................................................................................................................. 8454 Installation........................................................................................................................ 8455 Mode Switch............................................................................................................................. 8456 Removal............................................................................................................................. 8456 Installation........................................................................................................................ 8456 Transmission (With Transfer Case / Extension Assembly).................................................................................. 8458 Transmission And Associated Parts................................................................................................... 8458 Removal............................................................................................................................. 8459 Installation........................................................................................................................ 8460 Solenoid (Main Case Valve Body)......................................................................................................... 8465 Removal............................................................................................................................. 8465 Installation........................................................................................................................ 8465 Solenoid (Adapter Case Valve Body)...................................................................................................... 8466 Removal............................................................................................................................. 8466 Installation........................................................................................................................ 8466 Valve Body Assembly (Main Case)......................................................................................................... 8467 Removal............................................................................................................................. 8467 Installation........................................................................................................................ 8467 Valve Body Assembly (Adapter Case)...................................................................................................... 8468 Removal............................................................................................................................. 8468 Installation........................................................................................................................ 8468 Powertrain Control Module (PCM)......................................................................................................... 8468 Removal............................................................................................................................. 8468 Installation........................................................................................................................ 8468 Speed Sensor (Extension Housing)........................................................................................................ 8469 Removal............................................................................................................................. 8469 Installation........................................................................................................................ 8469 Transmission Oil Temperature Sensor (Main Case)......................................................................................... 8469 Removal............................................................................................................................. 8469 Installation........................................................................................................................ 8469 Front Oil Seal (Converter Housing)...................................................................................................... 8470 Removal............................................................................................................................. 8470 Installation........................................................................................................................ 8470 Rear Oil Seal (Extension Housing)....................................................................................................... 8470 Removal............................................................................................................................. 8470 Installation........................................................................................................................ 8471 Transmission (4L30-E)................................................................................................................... 8471 Disassembly......................................................................................................................... 8471 Reassembly.......................................................................................................................... 8475 Converter Housing And Oil Pump Assembly................................................................................................. 8485 Disassembled View................................................................................................................... 8485 Disassembly......................................................................................................................... 8485 Inspection And Repair............................................................................................................... 8485 Reassembly.......................................................................................................................... 8485 Oil Pump................................................................................................................................ 8486 Disassembled View................................................................................................................... 8486 Disassembly......................................................................................................................... 8486 Inspection And Repair............................................................................................................... 8487 Reassembly.......................................................................................................................... 8487 Main Case Valve Body.................................................................................................................... 8488 Disassembled View................................................................................................................... 8488 Disassembly......................................................................................................................... 8488 Inspection And Repair............................................................................................................... 8489 Reassembly.......................................................................................................................... 8489 Adapter Case Valve Body................................................................................................................. 8490 Disassembled View................................................................................................................... 8490 Disassembly......................................................................................................................... 8490 Inspection And Repair............................................................................................................... 8490 Reassembly.......................................................................................................................... 8490 Third Clutch And Sprag Unit............................................................................................................. 8492 Disassembled View................................................................................................................... 8492 Disassembly......................................................................................................................... 8492 Inspection And Repair............................................................................................................... 8492 Reassembly.......................................................................................................................... 8493 Third Clutch............................................................................................................................ 8494 Disassembled View................................................................................................................... 8494 Disassemble......................................................................................................................... 8494 Inspection And Repair............................................................................................................... 8494 Reassembly.......................................................................................................................... 8494 Sprag Unit.............................................................................................................................. 8496 Disassembled View................................................................................................................... 8496 Disassembly......................................................................................................................... 8496 Inspection And Repair............................................................................................................... 8496 Reassembly.......................................................................................................................... 8496 Second Clutch........................................................................................................................... 8497 Disassembled View................................................................................................................... 8497 Disassembly......................................................................................................................... 8497 Inspection And Repair............................................................................................................... 8498 Reassembly.......................................................................................................................... 8498 3-4 Accumulator Piston.................................................................................................................. 8499 Disassembled View................................................................................................................... 8499 Disassembly......................................................................................................................... 8499 Inspection And Repair............................................................................................................... 8500 Reassembly.......................................................................................................................... 8500 Reverse Clutch Piston And Center Support................................................................................................ 8501 Disassembled View................................................................................................................... 8501 Disassembly......................................................................................................................... 8501 Inspection And Repair............................................................................................................... 8502 Reassembly.......................................................................................................................... 8502 Overrun Clutch And Turbine Shaft........................................................................................................ 8503 Disassembled View................................................................................................................... 8503 Disassembly......................................................................................................................... 8504 Inspection And Repair............................................................................................................... 8504 Reassembly.......................................................................................................................... 8504 Main Data And Specification............................................................................................................. 8506 Special Tools........................................................................................................................... 8510 4L30-L Parts List....................................................................................................................... 8513 Extension Housing Assembly Oil Seal..................................................................................................... 8521 Extension Housing Assembly Rear Oil Seal and Associated Parts....................................................................... 8521 Removal............................................................................................................................. 8521 Installation........................................................................................................................ 8521 Extension Housing Assembly.............................................................................................................. 8523 Extension Housing Assembly and Associated Parts..................................................................................... 8523 Removal............................................................................................................................. 8524 Installation........................................................................................................................ 8524 Extension Housing Assembly.............................................................................................................. 8526 Extension Housing Assembly and Associated Parts..................................................................................... 8526 Removal............................................................................................................................. 8527 Installation........................................................................................................................ 8527 Extension Housing Assembly.......................................................................................................... 8529 Disassembly......................................................................................................................... 8530 Reassembly.......................................................................................................................... 8530 Inspection and Repair............................................................................................................... 8531 Main Data and Specifications............................................................................................................ 8532 Special Tools........................................................................................................................... 8533 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)................................................................................................... 8534 Service Precaution...................................................................................................................... 8535 General Description..................................................................................................................... 8535 Electronic Control Diagram.......................................................................................................... 8536 Powertrain Control Module (PCM)..................................................................................................... 8537 Control System Diagram.............................................................................................................. 8538 Shift Control....................................................................................................................... 8539 Band Apply Control.................................................................................................................. 8539 Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC).................................................. 8539 Line Pressure Control............................................................................................................... 8539 On-Board Diagnostic System.......................................................................................................... 8539 Fail Safe Mechanism................................................................................................................. 8539 Torque Management Control........................................................................................................... 8539 ATF Warning Control................................................................................................................. 8539 ABS Control......................................................................................................................... 8539 Reverse Lock Out Control............................................................................................................ 8539 Downhill Control.................................................................................................................... 8539 Uphill Control...................................................................................................................... 8539 Shift Mode Control.................................................................................................................. 8540 Gear Shift Control.................................................................................................................. 8541 Winter Drive Mode................................................................................................................... 8542 Backup Mode......................................................................................................................... 8542 Functions of Input / Output Components.............................................................................................. 8543 Diagnosis............................................................................................................................... 8544 Electronic Diagnosis................................................................................................................ 8544 Check Trans Indicator............................................................................................................... 8544 Diagnostic Check.................................................................................................................... 8544 "Check Trans" Check................................................................................................................. 8545 Tech 2 OBD II Connection............................................................................................................ 8546 Transmission Data................................................................................................................... 8551 OBD II Diagnostic Management System................................................................................................. 8552 16 - Terminal Data Link Connector (DLC)............................................................................................. 8553 Malfunction Indicator Lamp (MIL).................................................................................................... 8554 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................ 8554 Clear DTC........................................................................................................................... 8554 DTC Check........................................................................................................................... 8555 PCM Precaution...................................................................................................................... 8555 Information On PCM.................................................................................................................. 8555 Intermittent Conditions............................................................................................................. 8555 Transmission And PCM Identification................................................................................................. 8556 Isuzu Trooper....................................................................................................................... 8556 Diagnostic Trouble Code (DTC) Identification........................................................................................ 8557 DTC P0218 Transmission Fluid Over Temperature........................................................................................... 8558 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position...................................................................... 8560 DTC P0706 Transmission Range Switch (Mode Switch) Performance........................................................................... 8563 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance....................................................................... 8566 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input................................................................. 8569 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................ 8572 DTC P0719 Brake Switch Circuit Low (Stuck On)........................................................................................... 8575 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input.................................................................... 8578 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent................................................................. 8581 DTC P0724 Brake Switch Circuit High (Stuck Off)......................................................................................... 8584 DTC P0730 Gear Error Without Input Speed................................................................................................ 8586 DTC P0742 Torque Converter Clutch (TCC) System Stuck On................................................................................. 8589 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical.............................................................. 8591 DTC P0751 Shift Solenoid A Performance (Stuck OFF)...................................................................................... 8593 DTC P0752 Shift Solenoid A Performance (Stuck ON)....................................................................................... 8595 DTC P0753 Shift Solenoid A Electrical................................................................................................... 8597 DTC P0756 Shift Solenoid B Performance (Stuck OFF)...................................................................................... 8600 DTC P0757 Shift Solenoid B Performance (Stuck ON)....................................................................................... 8602 DTC P0758 Shift Solenoid B Electrical................................................................................................... 8604 DTC P1850 Brake Band Apply Solenoid Malfunction......................................................................................... 8608 DTC P1860 TCC PWM Solenoid Electrical................................................................................................... 8612 DTC P1870 Transmission Component Slipping (TCC Stuck OFF)............................................................................... 8615 Connector List.......................................................................................................................... 8617 7B MANUAL TRANSMISSION................................................................................................................... 8619 Service Precaution...................................................................................................................... 8619 General Description..................................................................................................................... 8620 Diagnosis............................................................................................................................... 8621 Manual Transmission Assembly............................................................................................................ 8622 Removal............................................................................................................................. 8622 Installation........................................................................................................................ 8626 Disassembled View................................................................................................................... 8631 Disassembly......................................................................................................................... 8634 Inspection.......................................................................................................................... 8652 Reassembly.......................................................................................................................... 8654 Main Data and Specifications............................................................................................................ 8680 Special Tools........................................................................................................................... 8682 7C CLUTCH................................................................................................................................ 8684 Service Precaution...................................................................................................................... 8684 General Description..................................................................................................................... 8685 Diagnosis............................................................................................................................... 8689 Clutch Assembly......................................................................................................................... 8690 Clutch Assembly and Associated Parts................................................................................................ 8690 Removal............................................................................................................................. 8690 Inspection and Repair............................................................................................................... 8691 Installation........................................................................................................................ 8695 Clutch Control.......................................................................................................................... 8698 Clutch Control Parts................................................................................................................ 8698 Removal............................................................................................................................. 8698 Inspection and Repair............................................................................................................... 8698 Installation........................................................................................................................ 8699 Adjustment.......................................................................................................................... 8699 Master Cylinder......................................................................................................................... 8702 Inspection and Repair............................................................................................................... 8702 Slave Cylinder.......................................................................................................................... 8703 Disassembled View................................................................................................................... 8703 Disassembly......................................................................................................................... 8703 Inspection and Repair............................................................................................................... 8703 Reassembly.......................................................................................................................... 8704 Main Data and Specifications............................................................................................................ 8705 Special Tools........................................................................................................................... 8707 Sec.8 BODY AND ACCESSORIES.................................................................................................................... 8708 8A LIGHTING SYSTEM........................................................................................................................ 8708 Service Precaution...................................................................................................................... 8709 Headlight Bulb.......................................................................................................................... 8709 Removal............................................................................................................................. 8709 Installation........................................................................................................................ 8709 Headlight............................................................................................................................... 8710 Headlight and Associated Parts...................................................................................................... 8710 Removal............................................................................................................................. 8710 Installation........................................................................................................................ 8710 Headlight Adjustment................................................................................................................ 8710 Fog Light Bulb.......................................................................................................................... 8711 Removal............................................................................................................................. 8711 Installation........................................................................................................................ 8711 Fog Light Assembly...................................................................................................................... 8712 Removal............................................................................................................................. 8712 Installation........................................................................................................................ 8712 Fog Light Adjustment................................................................................................................ 8712 Front Side Marker Light Bulb............................................................................................................ 8712 Removal............................................................................................................................. 8712 Installation........................................................................................................................ 8712 Parking Light Bulb...................................................................................................................... 8713 Removal and Installation............................................................................................................ 8713 Taillight Bulb.......................................................................................................................... 8713 Removal............................................................................................................................. 8713 Installation........................................................................................................................ 8713 License Plate Light Bulb................................................................................................................ 8714 Removal............................................................................................................................. 8714 Installation........................................................................................................................ 8714 Stoplight Bulb.......................................................................................................................... 8714 Removal and Installation............................................................................................................ 8714 High Mount Stoplight.................................................................................................................... 8714 Removal............................................................................................................................. 8714 Installation........................................................................................................................ 8715 Front Turn Signal Light Bulb............................................................................................................ 8715 Removal............................................................................................................................. 8715 Installation........................................................................................................................ 8715 Rear Turn Signal Light Bulb............................................................................................................. 8716 Removal............................................................................................................................. 8716 Installation........................................................................................................................ 8716 Cornering Light Bulb.................................................................................................................... 8716 Removal............................................................................................................................. 8716 Installation........................................................................................................................ 8716 Backup Light Bulb....................................................................................................................... 8717 Removal............................................................................................................................. 8717 Installation........................................................................................................................ 8717 Dome Light Bulb......................................................................................................................... 8717 Removal............................................................................................................................. 8717 Installation........................................................................................................................ 8717 Luggage Room Light Bulb................................................................................................................. 8718 Removal............................................................................................................................. 8718 Installation........................................................................................................................ 8718 Courtesy Light Bulb..................................................................................................................... 8718 Removal............................................................................................................................. 8718 Installation........................................................................................................................ 8718 Map Light Switch/Bulb................................................................................................................... 8719 Removal............................................................................................................................. 8719 Installation........................................................................................................................ 8719 Cigarette Lighter Illumination Bulb..................................................................................................... 8719 Removal............................................................................................................................. 8719 Installation........................................................................................................................ 8719 Ashtray Illumination Bulb............................................................................................................... 8720 Removal............................................................................................................................. 8720 Installation........................................................................................................................ 8720 Glove Box Illumination Bulb............................................................................................................. 8720 Removal............................................................................................................................. 8720 Installation........................................................................................................................ 8720 Vanity Mirror Illumination Bulb......................................................................................................... 8721 Removal............................................................................................................................. 8721 Installation........................................................................................................................ 8721 Starter Switch.......................................................................................................................... 8721 Removal............................................................................................................................. 8721 Installation........................................................................................................................ 8722 Lighting Switch (Combination Switch).................................................................................................... 8722 Removal............................................................................................................................. 8722 Installation........................................................................................................................ 8723 Fog Light Switch........................................................................................................................ 8723 Removal............................................................................................................................. 8723 Installation........................................................................................................................ 8724 Stoplight Switch (W/O Cruise Control)................................................................................................... 8724 Removal............................................................................................................................. 8724 Installation........................................................................................................................ 8724 Brake Switch (W/Cruise Control)......................................................................................................... 8725 Removal............................................................................................................................. 8725 Installation........................................................................................................................ 8725 Turn Signal Switch/Cornering Light Switch (Combination Switch).......................................................................... 8725 Removal and Installation............................................................................................................ 8725 Hazard Warning Switch................................................................................................................... 8725 Removal............................................................................................................................. 8725 Installation........................................................................................................................ 8726 Tailgate Switch......................................................................................................................... 8726 Removal............................................................................................................................. 8726 Installation........................................................................................................................ 8726 Door Switch............................................................................................................................. 8727 Removal............................................................................................................................. 8727 Installation........................................................................................................................ 8727 Rear Defogger Switch.................................................................................................................... 8727 Removal............................................................................................................................. 8727 Installation........................................................................................................................ 8728 Seat Heater Switch...................................................................................................................... 8728 Removal............................................................................................................................. 8728 Installation........................................................................................................................ 8728 Key Remind Switch (Starter Switch)...................................................................................................... 8728 Removal and Installation............................................................................................................ 8728 Illumination Controller................................................................................................................. 8729 Removal............................................................................................................................. 8729 Installation........................................................................................................................ 8729 Main Data and Specifications............................................................................................................ 8730 8B WIPER / WASHER SYSTEM.................................................................................................................. 8732 Service Precaution...................................................................................................................... 8732 Windshield Wiper/Washer System.......................................................................................................... 8733 General Description................................................................................................................. 8733 Windshield Wiper And Washer Switch...................................................................................................... 8733 Removal and Installation............................................................................................................ 8733 Windshield Wiper Motor.................................................................................................................. 8733 Removal............................................................................................................................. 8733 Installation........................................................................................................................ 8733 Windshield Washer Motor................................................................................................................. 8734 Removal............................................................................................................................. 8734 Installation........................................................................................................................ 8734 Windshield Wiper Linkage................................................................................................................ 8735 Windshield Wiper Linkage and Associated Parts....................................................................................... 8735 Removal............................................................................................................................. 8735 Installation........................................................................................................................ 8735 Windshield Wiper Arm/Blade.............................................................................................................. 8736 Removal............................................................................................................................. 8736 Installation........................................................................................................................ 8736 Windshield Wiper Blade Rubber........................................................................................................... 8737 Removal............................................................................................................................. 8737 Installation........................................................................................................................ 8737 Rear Wiper/Washer System................................................................................................................ 8738 General Description................................................................................................................. 8738 Rear Wiper and Washer Switch............................................................................................................ 8738 Removal............................................................................................................................. 8738 Installation........................................................................................................................ 8738 Rear Wiper Motor........................................................................................................................ 8739 Removal............................................................................................................................. 8739 Installation........................................................................................................................ 8739 Alarm & Relay Control Unit.............................................................................................................. 8740 Removal............................................................................................................................. 8740 Installation........................................................................................................................ 8740 Rear Washer Motor....................................................................................................................... 8740 Removal............................................................................................................................. 8740 Installation........................................................................................................................ 8740 Rear Wiper Arm/Blade.................................................................................................................... 8741 Removal............................................................................................................................. 8741 Installation........................................................................................................................ 8741 Rear Washer Nozzle...................................................................................................................... 8741 Removal............................................................................................................................. 8741 Installation........................................................................................................................ 8741 Rear Washer Nozzle Angle Adjustment................................................................................................. 8741 Rear Wiper Blade Rubber................................................................................................................. 8742 Removal and Installation............................................................................................................ 8742 Main Data and Specifications............................................................................................................ 8742 8C ENTERTAINMENT.......................................................................................................................... 8743 Service Precaution...................................................................................................................... 8743 Cigarette Lighter....................................................................................................................... 8744 General Description................................................................................................................. 8744 Removal............................................................................................................................. 8744 Installation........................................................................................................................ 8744 Digital Clock........................................................................................................................... 8744 Removal............................................................................................................................. 8744 Installation........................................................................................................................ 8745 Rod Type Antenna........................................................................................................................ 8745 Removal............................................................................................................................. 8745 Installation........................................................................................................................ 8745 Diversity Glass Antenna................................................................................................................. 8746 Glass Antenna System Parts Location................................................................................................. 8746 Glass Antenna Pattern............................................................................................................... 8747 Glass Antenna Amplifier Removal..................................................................................................... 8747 Glass Antenna Amplifier Installation................................................................................................ 8747 Radio................................................................................................................................... 8748 Removal............................................................................................................................. 8748 Installation........................................................................................................................ 8748 Front Speaker........................................................................................................................... 8749 Removal............................................................................................................................. 8749 Installation........................................................................................................................ 8749 Tweeter Assembly........................................................................................................................ 8749 Removal............................................................................................................................. 8749 Installation........................................................................................................................ 8749 Rear Speaker............................................................................................................................ 8750 Removal............................................................................................................................. 8750 Installation........................................................................................................................ 8750 8D WIRING SYSTEM.......................................................................................................................... 8751 Fuse, Relay and Diode................................................................................................................... 8752 Relay and Fuse Box / Fuse Box Location.............................................................................................. 8752 Relay & Fuse Box.................................................................................................................... 8753 Fuse Box............................................................................................................................ 8754 Circuit Diagram......................................................................................................................... 8755 8E METER AND GAUGE........................................................................................................................ 8788 Service Precaution...................................................................................................................... 8788 General Description..................................................................................................................... 8788 Meter Assembly.......................................................................................................................... 8789 General Description................................................................................................................. 8789 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights.................................................. 8789 Table for Meter/Gauge Connector Terminal Connections................................................................................ 8793 Removal............................................................................................................................. 8797 Installation........................................................................................................................ 8797 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb............................................. 8797 Removal............................................................................................................................. 8797 Installation........................................................................................................................ 8797 Vehicle Speed Sensor.................................................................................................................... 8798 Removal............................................................................................................................. 8798 Installation........................................................................................................................ 8798 Fuel Tank Unit.......................................................................................................................... 8798 Removal............................................................................................................................. 8798 Installation........................................................................................................................ 8798 Multi Meter............................................................................................................................. 8799 Removal............................................................................................................................. 8799 Installation........................................................................................................................ 8799 Ambient Sensor.......................................................................................................................... 8799 Removal............................................................................................................................. 8799 Installation........................................................................................................................ 8799 Main Data and Specifications............................................................................................................ 8800 8F BODY STRUCTURE......................................................................................................................... 8801 Service Precaution...................................................................................................................... 8803 Frame................................................................................................................................... 8803 General Description................................................................................................................. 8803 Frame Dimensions.................................................................................................................... 8804 General Description..................................................................................................................... 8805 Front Bumper............................................................................................................................ 8805 Parts Location...................................................................................................................... 8805 Removal............................................................................................................................. 8806 Installation........................................................................................................................ 8806 Front Bumper Slider Bracket............................................................................................................. 8806 Removal............................................................................................................................. 8806 Installation........................................................................................................................ 8806 Rear Bumper............................................................................................................................. 8807 Parts Location...................................................................................................................... 8807 Removal............................................................................................................................. 8807 Installation........................................................................................................................ 8808 Rear Bumper Slider...................................................................................................................... 8809 Removal............................................................................................................................. 8809 Installation........................................................................................................................ 8809 General Description..................................................................................................................... 8810 Cowl Cover.............................................................................................................................. 8810 Parts Location...................................................................................................................... 8810 Removal............................................................................................................................. 8810 Installation........................................................................................................................ 8811 Engine Hood............................................................................................................................. 8811 Removal............................................................................................................................. 8811 Installation........................................................................................................................ 8811 Engine Hood Hinge....................................................................................................................... 8812 Parts Location...................................................................................................................... 8812 Removal............................................................................................................................. 8812 Installation........................................................................................................................ 8812 Engine Hood Lock........................................................................................................................ 8813 Parts Location...................................................................................................................... 8813 Removal............................................................................................................................. 8813 Installation........................................................................................................................ 8814 Radiator Grille And Front End Lower Panel............................................................................................... 8814 Parts Location...................................................................................................................... 8814 Removal............................................................................................................................. 8814 Installation........................................................................................................................ 8815 Front Fender Panel...................................................................................................................... 8816 Parts Location...................................................................................................................... 8816 Removal............................................................................................................................. 8816 Installation........................................................................................................................ 8817 Body Mounting........................................................................................................................... 8818 Parts Location...................................................................................................................... 8818 Removal (No.1 - No. 2).............................................................................................................. 8818 Removal (No. 3 - No. 6)............................................................................................................. 8819 Installation........................................................................................................................ 8820 General Description..................................................................................................................... 8821 Body Dimension.......................................................................................................................... 8822 Instrument Panel Assembly............................................................................................................... 8840 Parts Location...................................................................................................................... 8840 Removal............................................................................................................................. 8840 Installation........................................................................................................................ 8845 Cross Beam Assembly..................................................................................................................... 8846 Parts Location...................................................................................................................... 8846 Removal............................................................................................................................. 8846 Installation........................................................................................................................ 8847 Front Door Assembly..................................................................................................................... 8848 Parts Location...................................................................................................................... 8848 Removal............................................................................................................................. 8848 Installation........................................................................................................................ 8848 Rear Door Assembly...................................................................................................................... 8849 Parts Location...................................................................................................................... 8849 Removal............................................................................................................................. 8849 Installation........................................................................................................................ 8850 Door Strikers........................................................................................................................... 8850 Adjustment.......................................................................................................................... 8850 Door Check Arm Assembly (Front & Rear).................................................................................................. 8851 Parts Location...................................................................................................................... 8851 Removal............................................................................................................................. 8851 Installation........................................................................................................................ 8852 Front Window Regulator, Glass And Glass Run............................................................................................. 8852 Parts Location...................................................................................................................... 8852 Removal............................................................................................................................. 8852 Installation........................................................................................................................ 8854 Rear Window Regulator And Glass......................................................................................................... 8855 Parts Location...................................................................................................................... 8855 Removal............................................................................................................................. 8855 Installation........................................................................................................................ 8856 Rear Door Fixed Glass And Glass Run..................................................................................................... 8857 Parts Location...................................................................................................................... 8857 Removal............................................................................................................................. 8857 Installation........................................................................................................................ 8858 Front Door Sash Moulding................................................................................................................ 8859 Parts Location...................................................................................................................... 8859 Removal............................................................................................................................. 8859 Installation........................................................................................................................ 8859 Rear Door Moulding...................................................................................................................... 8860 Parts Location...................................................................................................................... 8860 Removal............................................................................................................................. 8860 Installation........................................................................................................................ 8860 Front Door Waist Seal................................................................................................................... 8861 Parts Location...................................................................................................................... 8861 Removal............................................................................................................................. 8861 Installation........................................................................................................................ 8861 Rear Door Waist Seal.................................................................................................................... 8862 Parts Location...................................................................................................................... 8862 Removal and Installation............................................................................................................ 8862 Front Door Weatherstrip................................................................................................................. 8863 Parts Location...................................................................................................................... 8863 Removal............................................................................................................................. 8863 Installation........................................................................................................................ 8864 Rear Door Weatherstrip.................................................................................................................. 8865 Parts Location...................................................................................................................... 8865 Removal and Installation............................................................................................................ 8865 Front Door Seal Finisher................................................................................................................ 8866 Parts Location...................................................................................................................... 8866 Removal............................................................................................................................. 8866 Installation........................................................................................................................ 8866 Rear Door Seal Finisher................................................................................................................. 8867 Parts Location...................................................................................................................... 8867 Removal............................................................................................................................. 8867 Installation........................................................................................................................ 8867 Tailgate Assembly (LH).................................................................................................................. 8868 Parts Location...................................................................................................................... 8868 Removal............................................................................................................................. 8868 Installation........................................................................................................................ 8869 Tailgate Assembly (RH).................................................................................................................. 8870 Parts Location...................................................................................................................... 8870 Removal............................................................................................................................. 8870 Installation........................................................................................................................ 8871 Tailgate Strikers....................................................................................................................... 8872 Adjustment.......................................................................................................................... 8872 Tailgate Stopper Assembly............................................................................................................... 8872 Parts Location...................................................................................................................... 8872 Removal............................................................................................................................. 8872 Installation........................................................................................................................ 8872 Tailgate Dove-Tail...................................................................................................................... 8873 Parts Location...................................................................................................................... 8873 Removal............................................................................................................................. 8873 Installation........................................................................................................................ 8873 Tailgate Dove-Tail Striker.............................................................................................................. 8874 Adjustment.......................................................................................................................... 8874 Tailgate Frame Cover (LH)............................................................................................................... 8875 Parts Location...................................................................................................................... 8875 Removal............................................................................................................................. 8875 Installation........................................................................................................................ 8875 Tailgate Frame Cover (RH)............................................................................................................... 8876 Removal............................................................................................................................. 8876 Installation........................................................................................................................ 8876 Tailgate Sash Trim Cover................................................................................................................ 8877 Parts Location...................................................................................................................... 8877 Removal............................................................................................................................. 8877 Installation........................................................................................................................ 8877 Tailgate Outer Weatherstrip............................................................................................................. 8878 Parts Location...................................................................................................................... 8878 Removal............................................................................................................................. 8878 Installation........................................................................................................................ 8878 Tailgate Center Weatherstrip............................................................................................................ 8879 Parts Location...................................................................................................................... 8879 Removal............................................................................................................................. 8879 Installation........................................................................................................................ 8879 Tailgate Main Weatherstrip.............................................................................................................. 8880 Parts Location...................................................................................................................... 8880 Removal............................................................................................................................. 8880 Installation........................................................................................................................ 8880 Spare Tire Carrier...................................................................................................................... 8881 Parts Location...................................................................................................................... 8881 Removal............................................................................................................................. 8881 Installation........................................................................................................................ 8881 Headlining.............................................................................................................................. 8882 Parts Location...................................................................................................................... 8882 Removal............................................................................................................................. 8882 Installation........................................................................................................................ 8883 Rear Air Deflector...................................................................................................................... 8884 Parts Location...................................................................................................................... 8884 Removal............................................................................................................................. 8884 Installation........................................................................................................................ 8884 Roof Moulding........................................................................................................................... 8886 Parts Location...................................................................................................................... 8886 Removal............................................................................................................................. 8886 Installation........................................................................................................................ 8886 Windshield.............................................................................................................................. 8888 Parts Location...................................................................................................................... 8888 Removal............................................................................................................................. 8888 Installation........................................................................................................................ 8889 Rear Quarter Side Glass................................................................................................................. 8893 Parts Location...................................................................................................................... 8893 Removal............................................................................................................................. 8893 Installation........................................................................................................................ 8893 Tailgate Glass.......................................................................................................................... 8895 Parts Location...................................................................................................................... 8895 Removal............................................................................................................................. 8895 Installation........................................................................................................................ 8896 Main Data and Specifications............................................................................................................ 8897 Special Tools........................................................................................................................... 8907 8G SEATS.................................................................................................................................. 8908 Service Precaution...................................................................................................................... 8908 Front Seat Assembly..................................................................................................................... 8909 Front Seat Assembly and Associated Parts............................................................................................ 8909 Removal............................................................................................................................. 8909 Installation........................................................................................................................ 8909 Disassembled View................................................................................................................... 8910 Disassembly......................................................................................................................... 8911 Reassembly.......................................................................................................................... 8912 Power Seat Assembly..................................................................................................................... 8913 General Description................................................................................................................. 8913 Disassembled View................................................................................................................... 8913 Disassembly......................................................................................................................... 8914 Reassembly.......................................................................................................................... 8916 Power Seat Switch....................................................................................................................... 8916 Removal............................................................................................................................. 8916 Installation........................................................................................................................ 8916 Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor....................................................................... 8917 Parts Location...................................................................................................................... 8917 Removal and Installation............................................................................................................ 8917 Seat Heater System...................................................................................................................... 8918 General Description................................................................................................................. 8918 Seat Heater Switch Removal and Installation......................................................................................... 8918 Heat Unit Parts Location............................................................................................................ 8918 Heat Unit Removal and Installation.................................................................................................. 8918 Rear Seat Assembly...................................................................................................................... 8919 Rear Seat Assembly and Associated Parts............................................................................................. 8919 Removal............................................................................................................................. 8919 Installation........................................................................................................................ 8919 Disassembled View (Split Type)...................................................................................................... 8920 Disassembly (Split Type)............................................................................................................ 8921 Reassembly (Split Type)............................................................................................................. 8922 Disassembled View (Bench Type)...................................................................................................... 8923 Disassembly (Bench Type)............................................................................................................ 8924 Reassembly (Bench Type)............................................................................................................. 8925 Rear Seat Foot Rest..................................................................................................................... 8925 Rear Seat Foot Rest and Associated Parts............................................................................................ 8925 Removal............................................................................................................................. 8926 Installation........................................................................................................................ 8926 Main Data and Specifications............................................................................................................ 8926 8H SECURITY AND LOCKS..................................................................................................................... 8928 Service Precaution...................................................................................................................... 8929 Front Door Lock Assembly................................................................................................................ 8929 Front Door Lock Assembly and Associated Parts....................................................................................... 8929 Removal............................................................................................................................. 8929 Installation........................................................................................................................ 8930 Front Outside Handle and Door Lock Cylinder............................................................................................. 8931 Front Outside Handle, Door Lock Cylinder and Associated Parts....................................................................... 8931 Removal............................................................................................................................. 8931 Installation........................................................................................................................ 8933 Rear Door Lock Assembly................................................................................................................. 8934 Rear Door Lock Assembly and Associated Parts........................................................................................ 8934 Removal............................................................................................................................. 8934 Installation........................................................................................................................ 8935 Rear Outside Handle..................................................................................................................... 8936 Rear Outside Handle and Associated Parts............................................................................................ 8936 Removal............................................................................................................................. 8936 Installation........................................................................................................................ 8937 Rear Door Inside Lock Knob Link......................................................................................................... 8937 Removal............................................................................................................................. 8937 Installation........................................................................................................................ 8937 Door Inside Lock Knob................................................................................................................... 8938 Removal............................................................................................................................. 8938 Installation........................................................................................................................ 8938 Door Inside Handle...................................................................................................................... 8938 Removal and Installation............................................................................................................ 8938 Tailgate Lock Assembly (LH)............................................................................................................. 8939 Tailgate Lock Assembly (LH) and Associated Parts.................................................................................... 8939 Removal............................................................................................................................. 8939 Installation........................................................................................................................ 8940 Tailgate Lock Assembly (RH)............................................................................................................. 8941 Tailgate Lock Assembly (RH) and Associated Parts.................................................................................... 8941 Removal............................................................................................................................. 8941 Installation........................................................................................................................ 8942 Tailgate Inside Lock Knob............................................................................................................... 8943 Removal............................................................................................................................. 8943 Installation........................................................................................................................ 8943 Tailgate Outside Handle and/or Tailgate Lock Cylinder................................................................................... 8944 Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts.......................................................... 8944 Removal............................................................................................................................. 8944 Installation........................................................................................................................ 8945 Key..................................................................................................................................... 8946 Key Coding.......................................................................................................................... 8946 Key Styles.......................................................................................................................... 8946 Power Door Lock System.................................................................................................................. 8947 General Description................................................................................................................. 8947 Front Door Lock Actuator Removal.................................................................................................... 8947 Front Door Lock Actuator Installation............................................................................................... 8947 Rear Door Lock Actuator Removal..................................................................................................... 8947 Rear Door Lock Actuator Installation................................................................................................ 8948 Tailgate Lock Actuator Removal...................................................................................................... 8948 Tailgate Lock Actuator Installation................................................................................................. 8948 Anti-theft System....................................................................................................................... 8949 General Description................................................................................................................. 8949 Anti-theft & Keyless Entry Control Unit Removal..................................................................................... 8949 Anti-theft & Keyless Entry Control Unit Installation................................................................................ 8949 Anti-theft Indicator Removal........................................................................................................ 8949 Anti-theft Indicator Installation................................................................................................... 8950 Anti-theft Horn Removal............................................................................................................. 8950 Anti-Theft Horn Installation........................................................................................................ 8950 Engine Hood Switch Removal.......................................................................................................... 8950 Engine Hood Switch Installation..................................................................................................... 8950 Keyless Entry System.................................................................................................................... 8951 ID Code Registration................................................................................................................ 8951 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement..................................................................... 8953 Main Data and Specifications............................................................................................................ 8954 8I SUN ROOF/CONVERTIBLE TOP.............................................................................................................. 8955 Service Precaution...................................................................................................................... 8955 Sun Roof Glass.......................................................................................................................... 8956 Sun Roof Glass and Associated Parts................................................................................................. 8956 Removal............................................................................................................................. 8956 Installation........................................................................................................................ 8957 Sun Roof Deflector...................................................................................................................... 8958 Removal............................................................................................................................. 8958 Installation........................................................................................................................ 8958 Sunshade................................................................................................................................ 8958 Disassembled View................................................................................................................... 8958 Removal............................................................................................................................. 8959 Installation........................................................................................................................ 8959 Sun Roof Frame Complete Assembly........................................................................................................ 8960 Sun Roof Frame Complete Assembly and Associated Parts............................................................................... 8960 Removal............................................................................................................................. 8960 Installation........................................................................................................................ 8961 Disassembled View................................................................................................................... 8961 Disassembly......................................................................................................................... 8961 Reassembly.......................................................................................................................... 8962 Sun Roof Drain Hose (Front Side)........................................................................................................ 8963 Sun Roof Drain Hose (Front Side) and Associated Parts............................................................................... 8963 Removal............................................................................................................................. 8963 Installation........................................................................................................................ 8963 Sun Roof Drain Hose (Rear Side)......................................................................................................... 8964 Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................ 8964 Removal............................................................................................................................. 8964 Installation........................................................................................................................ 8964 Sun Roof Switch......................................................................................................................... 8965 General Description................................................................................................................. 8965 Removal............................................................................................................................. 8965 Installation........................................................................................................................ 8965 Sun Roof Motor.......................................................................................................................... 8966 Removal............................................................................................................................. 8966 Installation........................................................................................................................ 8966 Main Data and Specifications............................................................................................................ 8967 8J EXTERIOR / INTERIOR TRIM............................................................................................................... 8968 Service Precaution...................................................................................................................... 8969 Dash Side Trim Panel.................................................................................................................... 8970 Removal............................................................................................................................. 8970 Installation........................................................................................................................ 8970 Assist Grip............................................................................................................................. 8970 Parts Location...................................................................................................................... 8970 Removal and Installation............................................................................................................ 8970 Consoles................................................................................................................................ 8971 Consoles and Associated Parts....................................................................................................... 8971 Removal............................................................................................................................. 8971 Installation........................................................................................................................ 8972 Front Door Trim Panel................................................................................................................... 8973 Front Door Trim Panel and Associated Parts.......................................................................................... 8973 Removal............................................................................................................................. 8973 Installation........................................................................................................................ 8976 Rear Door Trim Panel.................................................................................................................... 8977 Rear Door Trim Panel and Associated Parts........................................................................................... 8977 Removal............................................................................................................................. 8977 Installation........................................................................................................................ 8978 Door Wood Panel Assembly................................................................................................................ 8980 Door Wood Panel Assembly and Associated Parts....................................................................................... 8980 Removal............................................................................................................................. 8980 Installation........................................................................................................................ 8980 Door Mirror............................................................................................................................. 8981 Door Mirror and Associated Parts.................................................................................................... 8981 Removal............................................................................................................................. 8981 Installation........................................................................................................................ 8981 Luggage Side and Quarter Upper Trim Cover............................................................................................... 8982 Luggage Side, Quarter Upper Trim Cover and Associated Parts......................................................................... 8982 Removal............................................................................................................................. 8982 Installation........................................................................................................................ 8984 Center Pillar and Roof Side Trim Cover.................................................................................................. 8984 Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................ 8984 Removal............................................................................................................................. 8985 Installation........................................................................................................................ 8986 Front Pillar Trim Cover................................................................................................................. 8986 Front Pillar Trim Cover and Associated Parts........................................................................................ 8986 Removal............................................................................................................................. 8986 Installation........................................................................................................................ 8987 Center Pillar Assist Grip............................................................................................................... 8987 Parts Location...................................................................................................................... 8987 Removal and Installation............................................................................................................ 8987 Assist Grip............................................................................................................................. 8988 Parts Location...................................................................................................................... 8988 Removal and Installation............................................................................................................ 8988 Fuel Filler Lid Opener Cable............................................................................................................ 8989 Fuel Filler Lid Opener Cable and Associated Parts................................................................................... 8989 Removal............................................................................................................................. 8989 Installation........................................................................................................................ 8990 Fuel Filler Door........................................................................................................................ 8990 Parts Location...................................................................................................................... 8990 Removal............................................................................................................................. 8990 Installation........................................................................................................................ 8990 Rocker Protector (Without Wheel Opening Extension)...................................................................................... 8991 Rocker Protector (Without Wheel Opening Extension) and Associated Parts............................................................. 8991 Removal............................................................................................................................. 8991 Installation........................................................................................................................ 8991 Wheel Opening Extension and Rocker Protector Assembly................................................................................... 8992 Wheel Opening Extension, Rocker Protector Assembly and Associated Parts............................................................. 8992 Removal............................................................................................................................. 8992 Installation........................................................................................................................ 8993 Mud Flaps (With Wheel Opening Extension)................................................................................................ 8994 Mud Flaps (With Wheel Opening Extension) and Associated Parts....................................................................... 8994 Removal............................................................................................................................. 8994 Installation........................................................................................................................ 8994 Ventilation Assembly.................................................................................................................... 8995 Ventilation Assembly and Associated Parts........................................................................................... 8995 Removal............................................................................................................................. 8995 Installation........................................................................................................................ 8995 Tailgate Trim Panel (LH)................................................................................................................ 8996 Tailgate Trim Panel (LH) and Associated Parts....................................................................................... 8996 Removal............................................................................................................................. 8996 Installation........................................................................................................................ 8996 Tailgate Trim Panel (RH)................................................................................................................ 8997 Parts Location...................................................................................................................... 8997 Removal............................................................................................................................. 8997 Installation........................................................................................................................ 8997 Luggage Floor Box....................................................................................................................... 8998 Luggage Floor Box and Associated Parts.............................................................................................. 8998 Remove.............................................................................................................................. 8998 Installation........................................................................................................................ 8998 Rope Hook Set........................................................................................................................... 8998 Rope Hook Set and Associated Parts.................................................................................................. 8998 Removal............................................................................................................................. 8998 Installation........................................................................................................................ 8998 Power Door Mirror System................................................................................................................ 8999 General Description................................................................................................................. 8999 Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................ 8999 Installation........................................................................................................................ 8999 Power Door Mirror....................................................................................................................... 8999 General Description................................................................................................................. 8999 Removal and Installation............................................................................................................ 8999 Power Window System..................................................................................................................... 9000 General Description................................................................................................................. 9000 Power Window Switch Removal and Installation........................................................................................ 9000 Power Window Motor Removal and Installation......................................................................................... 9001 Main Data and Specifications............................................................................................................ 9002 Sec.9 RESTRAINTS.............................................................................................................................. 9053 9A SEAT BELT SYSTEM...................................................................................................................... 9003 Service Precaution...................................................................................................................... 9003 Seat Belt............................................................................................................................... 9004 Front Seat Belt and Associated Parts................................................................................................ 9004 Removal............................................................................................................................. 9004 Inspection.......................................................................................................................... 9004 Installation........................................................................................................................ 9005 Rear Seat Belt and Associated Parts................................................................................................. 9005 Removal............................................................................................................................. 9006 Inspection.......................................................................................................................... 9006 Installation........................................................................................................................ 9006 Front Seat Buckle Assembly.............................................................................................................. 9006 Removal............................................................................................................................. 9006 Installation........................................................................................................................ 9006 Rear Center Seat Belt / Buckle Assembly................................................................................................. 9007 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................ 9007 Removal............................................................................................................................. 9007 Installation........................................................................................................................ 9007 Rear Seat Lock Assembly................................................................................................................. 9008 Removal............................................................................................................................. 9008 Installation........................................................................................................................ 9008 Rear Seat Lock Assembly (Bench Type).................................................................................................... 9008 Removal............................................................................................................................. 9008 Installation........................................................................................................................ 9008 Rear Seat Strikers...................................................................................................................... 9009 Removal............................................................................................................................. 9009 Installation........................................................................................................................ 9009 Child Seat Tether Anchor Bracket (Child Restraint)...................................................................................... 9009 General Description................................................................................................................. 9009 Child Seat Tether Anchor Bracket and Associated Parts............................................................................... 9009 Installation........................................................................................................................ 9009 Main Data and Specifications............................................................................................................ 9010 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)................................................................................................... 9011 Service Precaution...................................................................................................................... 9011 General Description..................................................................................................................... 9012 SRS Component And Wiring Location View.................................................................................................. 9014 Component Description................................................................................................................... 9014 Definitions............................................................................................................................. 9017 Diagnosis............................................................................................................................... 9018 SRS Connector Body Face Views........................................................................................................... 9019 Repairs And Inspections Required After An Accident...................................................................................... 9019 On-Vehicle Service...................................................................................................................... 9020 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................ 9021 Special Tools........................................................................................................................... 9030 Service Precautions for SRS Component Service........................................................................................... 9034 SRS Connectors.......................................................................................................................... 9035 Sensing And Diagnostic Module (SDM)..................................................................................................... 9037 Service Precautions................................................................................................................. 9037 Removal............................................................................................................................. 9037 Installation........................................................................................................................ 9037 Driver Air Bag Assembly................................................................................................................. 9039 Service Precautions................................................................................................................. 9039 Removal............................................................................................................................. 9039 Installation........................................................................................................................ 9040 Steering Wheel.......................................................................................................................... 9041 Service Precautions................................................................................................................. 9041 Removal............................................................................................................................. 9041 Installation........................................................................................................................ 9042 SRS Coil Assembly....................................................................................................................... 9044 Service Precautions................................................................................................................. 9044 Removal............................................................................................................................. 9044 Installation........................................................................................................................ 9045 Steering Column......................................................................................................................... 9047 Service Precautions................................................................................................................. 9047 Removal............................................................................................................................. 9047 Installation........................................................................................................................ 9049 Passenger Air Bag Assembly.............................................................................................................. 9051 Service Precautions................................................................................................................. 9051 Removal............................................................................................................................. 9051 Installation........................................................................................................................ 9052 Main Data and Specifications............................................................................................................ 9052 9J1 RESTRAINT CONTROL SYSTEM............................................................................................................... 9053 Service Precaution...................................................................................................................... 9053 Diagnostic Information.................................................................................................................. 9054 System Schematic........................................................................................................................ 9056 SRS Diagnostic System Check............................................................................................................. 9056 Chart A SDM Integrity Check............................................................................................................. 9058 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................ 9060 Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady (1/2).......................................................................... 9062 DTC 15 Passenger Deployment Loop Resistance High........................................................................................ 9065 DTC 16 Passenger Deployment loop Resistance Low......................................................................................... 9067 DTC 17 Passenger Deployment Loop Open................................................................................................... 9069 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................ 9071 DTC 19 Passenger Deployment Loop Short To Voltage....................................................................................... 9073 DTC 21 Driver Deployment Loop Resistance High........................................................................................... 9075 DTC 22 Driver Deployment Loop Resistance Low............................................................................................ 9078 DTC 24 Driver Deployment Loop Short To Ground........................................................................................... 9080 DTC 25 Driver Deployment Loop Short To Voltage.......................................................................................... 9082 DTC 26 Driver Deployment Loop Open...................................................................................................... 9084 DTC 51 Deployment Event Commanded....................................................................................................... 9086 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range.................................................. 9088 DTC 61 Warning Lamp Circuit Failure..................................................................................................... 9090 DTC 71 Internal SDM Fault............................................................................................................... 9092 Sec.10 CONTROL SYSTEM.......................................................................................................................... 9094 10A CRUISE CONTROL SYSTEM................................................................................................................. 9094 Service Precaution...................................................................................................................... 9094 General Description..................................................................................................................... 9094 Brake Switch............................................................................................................................ 9095 Removal............................................................................................................................. 9095 Installation........................................................................................................................ 9095 Adjustment.......................................................................................................................... 9096 Clutch Switch........................................................................................................................... 9096 Removal and Installation............................................................................................................ 9096 Adjustment.......................................................................................................................... 9096 Starter Switch.......................................................................................................................... 9097 Removal............................................................................................................................. 9097 Installation........................................................................................................................ 9097 Cruise Control Main Switch.............................................................................................................. 9098 Removal............................................................................................................................. 9098 Installation........................................................................................................................ 9098 Cruise Control Switch (Combination Switch).............................................................................................. 9098 Removal and Installation............................................................................................................ 9098 Powertrain Control Module (PCM)......................................................................................................... 9098 Removal and Installation............................................................................................................ 9098 Mode Switch............................................................................................................................. 9098 Removal and Installation............................................................................................................ 9098 Diagnosis............................................................................................................................... 9099 (UE) RODEO.......................................................................................................................................... 9100 Sec.0 GENERAL INFORMATION..................................................................................................................... 9116 0A GENERAL INFORMATION..................................................................................................................... 9101 General Repair Instruction.............................................................................................................. 9101 Illustration Arrows..................................................................................................................... 9102 Identification.......................................................................................................................... 9103 Theft Prevention Standard............................................................................................................... 9106 Lifting Instructions.................................................................................................................... 9111 Standard Bolts Torque Specifications.................................................................................................... 9113 Abbreviations Charts.................................................................................................................... 9114 Service Parts Identification Plate...................................................................................................... 9115 0B MAINTENANCE AND LUBRICATION............................................................................................................. 9116 Maintenance Schedule List............................................................................................................... 9116 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 9120 Recommended Fluids and Lubricants................................................................................................... 9123 Lubricant Viscosity Chart............................................................................................................... 9124 Recommended Liquid Gasket........................................................................................................... 9126 Recommended Thread Locking Agents................................................................................................... 9126 Maintenance Service Data................................................................................................................ 9127 Sec.1 HVAC SYSTEMS............................................................................................................................ 9128 1A HVAC SYSTEMS........................................................................................................................... 9128 Service Precaution...................................................................................................................... 9129 Heating and Ventilation System.......................................................................................................... 9129 General Description................................................................................................................. 9129 Wiring Diagram...................................................................................................................... 9133 Diagnosis........................................................................................................................... 9134 Individual Inspection............................................................................................................... 9138 Heater Unit............................................................................................................................. 9140 Heater Unit and Associated Parts.................................................................................................... 9140 Removal............................................................................................................................. 9140 Installation........................................................................................................................ 9141 Heater Core and / or Mode Door.......................................................................................................... 9141 Disassembled View................................................................................................................... 9141 Removal............................................................................................................................. 9141 Inspection.......................................................................................................................... 9142 Installation........................................................................................................................ 9142 Heater Mode Control Link Unit........................................................................................................... 9143 Disassembled View................................................................................................................... 9143 Removal............................................................................................................................. 9143 Installation........................................................................................................................ 9144 Heater Temperature Control Link Unit.................................................................................................... 9144 Disassembled View................................................................................................................... 9144 Removal............................................................................................................................. 9144 Installation........................................................................................................................ 9145 Blower Assembly......................................................................................................................... 9145 Blower Assembly and Associated Parts................................................................................................ 9145 Removal............................................................................................................................. 9145 Installation........................................................................................................................ 9146 Blower Link Unit and / or Mode door..................................................................................................... 9146 Disassembled View................................................................................................................... 9146 Removal............................................................................................................................. 9146 Installation........................................................................................................................ 9147 Blower Motor............................................................................................................................ 9148 Blower Motor and Associated Parts................................................................................................... 9148 Removal............................................................................................................................. 9148 Installation........................................................................................................................ 9148 Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 9149 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 9149 Removal............................................................................................................................. 9149 Installation........................................................................................................................ 9150 Control Lever Assembly and / or Control Cable........................................................................................... 9150 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 9150 Removal............................................................................................................................. 9151 Installation........................................................................................................................ 9152 Control Panel Illumination Bulb......................................................................................................... 9153 Control Panel Illumination Bulb and Associated Parts................................................................................ 9153 Removal............................................................................................................................. 9153 Installation........................................................................................................................ 9153 Resistor................................................................................................................................ 9153 Resistor and Associated Parts....................................................................................................... 9153 Removal............................................................................................................................. 9153 Installation........................................................................................................................ 9153 Air Conditioning System................................................................................................................. 9154 General Description................................................................................................................. 9154 Wiring Diagram...................................................................................................................... 9161 Diagnosis........................................................................................................................... 9164 Air Source Select Lever Diagnosis................................................................................................... 9174 Individual Inspection............................................................................................................... 9177 General Repair Procedure............................................................................................................ 9178 Leak Check.......................................................................................................................... 9180 Compressor Assembly..................................................................................................................... 9185 Compressor Assembly and Associated Parts............................................................................................ 9185 Removal............................................................................................................................. 9185 Installation........................................................................................................................ 9186 New Compressor Installation......................................................................................................... 9186 Condenser Assembly...................................................................................................................... 9187 Condenser Assembly and Associated Parts............................................................................................. 9187 Removal............................................................................................................................. 9187 Installation........................................................................................................................ 9187 Condenser Fan Motor..................................................................................................................... 9188 Condenser Fan Motor and Associated Parts............................................................................................ 9188 Removal............................................................................................................................. 9188 Installation........................................................................................................................ 9188 Receiver / Drier........................................................................................................................ 9189 Receiver / Drier and Associated Parts............................................................................................... 9189 Removal............................................................................................................................. 9189 Installation........................................................................................................................ 9189 Pressure Switch......................................................................................................................... 9190 Pressure Switch and Associated Parts................................................................................................ 9190 Removal............................................................................................................................. 9190 Installation........................................................................................................................ 9190 Evaporator Assembly..................................................................................................................... 9191 Evaporator Assembly and Associated Parts............................................................................................ 9191 Removal............................................................................................................................. 9191 Installation........................................................................................................................ 9192 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 9192 Disassembled View................................................................................................................... 9192 Removal............................................................................................................................. 9193 Installation........................................................................................................................ 9193 Refrigerant Line........................................................................................................................ 9194 Refrigerant Line and Associated Parts............................................................................................... 9194 Removal............................................................................................................................. 9195 Installation........................................................................................................................ 9195 Main Data And Specifications............................................................................................................ 9195 Compressor.............................................................................................................................. 9198 Service Precaution.................................................................................................................. 9198 General Description................................................................................................................. 9198 Diagnosis........................................................................................................................... 9199 Magnetic Clutch Assembly (DKV-14G Type)................................................................................................. 9200 Parts Location View................................................................................................................. 9200 Removal............................................................................................................................. 9200 Inspection and Repair............................................................................................................... 9202 Installation........................................................................................................................ 9202 Compressor Oil.......................................................................................................................... 9204 Oil Specification................................................................................................................... 9204 Handling of Oil..................................................................................................................... 9204 Compressor Oil Check................................................................................................................ 9204 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 9204 Checking and Adjusting for Compressor Replacement................................................................................... 9205 Contamination of Compressor Oil..................................................................................................... 9205 Oil Return Operation................................................................................................................ 9205 Replacement of Component Parts...................................................................................................... 9205 Main Data and Specifications............................................................................................................ 9206 Special Tools........................................................................................................................... 9208 Sec.2 STEERING................................................................................................................................ 9209 2A POWER-ASSISTED STEERING SYSTEM......................................................................................................... 9209 Service Precaution...................................................................................................................... 9210 Diagnosis............................................................................................................................... 9210 General Description..................................................................................................................... 9216 Power Steering System Test.............................................................................................................. 9218 Maintenance............................................................................................................................. 9219 Fluid Level............................................................................................................................. 9219 Bleeding The Power Steering System...................................................................................................... 9219 Bleeding Procedure...................................................................................................................... 9219 Flushing The Power Steering System...................................................................................................... 9219 Steering Wheel Free Play Inspection..................................................................................................... 9220 Front End Alignment Inspection and Adjustment........................................................................................... 9220 Main Data and Specifications............................................................................................................ 9224 Special Tools........................................................................................................................... 9225 Power Steering Unit..................................................................................................................... 9226 Power Steering Unit and Associated Parts............................................................................................ 9226 Removal............................................................................................................................. 9226 Installation (4 × 2 Model).......................................................................................................... 9227 Installation (4 × 4 Model).......................................................................................................... 9227 Power Steering Unit Disassembled View............................................................................................... 9228 Disassembly......................................................................................................................... 9228 Inspection and Repair............................................................................................................... 9228 Reassembly.......................................................................................................................... 9228 Main Data and Specifications........................................................................................................ 9229 Special Tools....................................................................................................................... 9229 Power Steering Pump..................................................................................................................... 9230 Power Steering Pump and Associated Parts............................................................................................ 9230 Removal............................................................................................................................. 9230 Installation........................................................................................................................ 9230 Power Steering Pump Disassembled View............................................................................................... 9231 Disassembly......................................................................................................................... 9231 Inspection and Repair............................................................................................................... 9232 Reassembly.......................................................................................................................... 9232 Main Data and Specifications........................................................................................................ 9234 Transfer Gear Assembly.................................................................................................................. 9235 Transfer Gear Assembly and Associated Parts......................................................................................... 9235 Removal............................................................................................................................. 9235 Inspection and Repair............................................................................................................... 9235 Installation........................................................................................................................ 9235 Supplemental Restraint System Steering Wheel & Column................................................................................... 9236 Service Precaution.................................................................................................................. 9236 SRS Connectors...................................................................................................................... 9236 Inflator Module......................................................................................................................... 9238 Inflator Module and Associated Parts................................................................................................ 9238 Removal............................................................................................................................. 9238 Inspection and Repair............................................................................................................... 9239 Installation........................................................................................................................ 9239 Steering Wheel.......................................................................................................................... 9240 Steering Wheel and Associated Parts................................................................................................. 9240 Removal............................................................................................................................. 9240 Installation........................................................................................................................ 9242 Combination Switch...................................................................................................................... 9243 Combination Switch and Associated Parts............................................................................................. 9243 Removal............................................................................................................................. 9243 Installation........................................................................................................................ 9245 Lock Cylinder........................................................................................................................... 9247 Lock Cylinder and Associated Parts.................................................................................................. 9247 Removal............................................................................................................................. 9247 System Inspection................................................................................................................... 9250 Steering Column......................................................................................................................... 9251 Steering Column and Associated Parts................................................................................................ 9251 Removal............................................................................................................................. 9251 Insepction.......................................................................................................................... 9253 Installation........................................................................................................................ 9255 System Inspection................................................................................................................... 9256 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 9257 Main Data and Specifications........................................................................................................ 9257 Special Tools....................................................................................................................... 9257 Sec.3 SUSPENSION.............................................................................................................................. 9314 3C FRONT SUSPENSION....................................................................................................................... 9258 Service Precaution...................................................................................................................... 9258 General Description..................................................................................................................... 9259 Diagnosis............................................................................................................................... 9259 Shock Absorber.......................................................................................................................... 9262 Shock Absorber and Associated Parts................................................................................................. 9262 Removal............................................................................................................................. 9262 Inspection and Repair............................................................................................................... 9262 Installation........................................................................................................................ 9262 Stabilizer Bar.......................................................................................................................... 9263 Stabilizer Bar and Associated Parts................................................................................................. 9263 Removal............................................................................................................................. 9263 Inspection and Repair............................................................................................................... 9263 Installation........................................................................................................................ 9263 Torsion Bar............................................................................................................................. 9264 Torsion Bar and Associated Parts.................................................................................................... 9264 Removal............................................................................................................................. 9264 Inspection and Repair............................................................................................................... 9265 Installation........................................................................................................................ 9265 Knuckle................................................................................................................................. 9267 Knuckle and Associated Parts........................................................................................................ 9267 Removal............................................................................................................................. 9267 Inspection and Repair............................................................................................................... 9268 Installation........................................................................................................................ 9268 Upper Control Arm....................................................................................................................... 9270 Upper Control Arm and Associated Parts.............................................................................................. 9270 Removal............................................................................................................................. 9270 Inspection and Repair............................................................................................................... 9271 Installation........................................................................................................................ 9271 Lower Control Arm....................................................................................................................... 9273 Lower Control Arm and Associated Parts.............................................................................................. 9273 Removal............................................................................................................................. 9273 Inspection and Repair............................................................................................................... 9274 Installation........................................................................................................................ 9275 Upper Ball Joint........................................................................................................................ 9276 Upper Ball Joint and Associated Parts............................................................................................... 9276 Removal............................................................................................................................. 9276 Inspection and Repair............................................................................................................... 9277 Installation........................................................................................................................ 9277 Lower Ball Joint........................................................................................................................ 9278 Lower Ball Joint and Associated Parts............................................................................................... 9278 Removal............................................................................................................................. 9278 Inspection and Repair............................................................................................................... 9279 Installation........................................................................................................................ 9279 Main Data and Specifications............................................................................................................ 9280 Special Tools........................................................................................................................... 9281 3D REAR SUSPENSION........................................................................................................................ 9282 Service Precaution...................................................................................................................... 9282 General Description..................................................................................................................... 9282 Diagnosis............................................................................................................................... 9283 Coil Spring............................................................................................................................. 9286 Coil Spring and Associated Parts.................................................................................................... 9286 Removal............................................................................................................................. 9286 Inspection and Repair............................................................................................................... 9287 Installation........................................................................................................................ 9287 Shock Absorber.......................................................................................................................... 9288 Shock Absorber and Associated Parts................................................................................................. 9288 Removal............................................................................................................................. 9288 Inspection and Repair............................................................................................................... 9288 Installation........................................................................................................................ 9288 Trailing Link........................................................................................................................... 9289 Trailing Link and Associated Parts.................................................................................................. 9289 Removal............................................................................................................................. 9289 Inspection and Repair............................................................................................................... 9289 Installation........................................................................................................................ 9290 Upper Link.............................................................................................................................. 9291 Upper Link and Associated Parts..................................................................................................... 9291 Removal............................................................................................................................. 9291 Inspection and Repair............................................................................................................... 9291 Installation........................................................................................................................ 9292 Lateral Rod............................................................................................................................. 9293 Lateral Rod and Associated Parts.................................................................................................... 9293 Removal............................................................................................................................. 9293 Inspection and Repair............................................................................................................... 9293 Installation........................................................................................................................ 9294 Stabilizer Bar.......................................................................................................................... 9295 Stabilizer Bar and Associated Parts................................................................................................. 9295 Removal............................................................................................................................. 9295 Inspection and Repair............................................................................................................... 9295 Installation........................................................................................................................ 9296 Main Data and Specifications............................................................................................................ 9297 Special Tools........................................................................................................................... 9299 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 9300 Service Precaution...................................................................................................................... 9300 General Description..................................................................................................................... 9301 Diagnosis............................................................................................................................... 9302 Wheel................................................................................................................................... 9310 Wheel and Associated Parts.......................................................................................................... 9310 Removal............................................................................................................................. 9310 Installation........................................................................................................................ 9310 Tire.................................................................................................................................... 9311 Tire Replacement.................................................................................................................... 9311 General Balance Procedure............................................................................................................... 9311 Balancing Wheel and Tire................................................................................................................ 9312 Main Data and Specifications............................................................................................................ 9313 3F INTELLIGENT SUSPENSION SYSTEM.......................................................................................................... 9314 Service Precaution...................................................................................................................... 9315 General Description..................................................................................................................... 9315 PIN ASSIGNMENT TABLE................................................................................................................ 9317 System Components................................................................................................................... 9317 Control Unit........................................................................................................................ 9317 Actuator............................................................................................................................ 9317 Adjustable Damping Force Shock Absorber............................................................................................. 9317 Warning Lamp........................................................................................................................ 9317 Vertical G-Sensor................................................................................................................... 9318 Horizontal G-Sensor................................................................................................................. 9318 Acronyms and Abbreviations.......................................................................................................... 9318 General Diagnosis....................................................................................................................... 9318 General Information................................................................................................................. 9318 Service Precautions................................................................................................................. 9318 Computer System Service Precautions................................................................................................. 9318 General Service Precautions......................................................................................................... 9318 Parts Handling...................................................................................................................... 9318 FLASHING CODES...................................................................................................................... 9319 CLEAR DTC........................................................................................................................... 9320 INTERMITTENT CONDITIONS............................................................................................................. 9321 BULB CHECK.......................................................................................................................... 9321 DTC CHECK........................................................................................................................... 9321 Basic Diagnosis Flow................................................................................................................ 9322 Circuit Diagram..................................................................................................................... 9323 Parts Location...................................................................................................................... 9326 Connector List...................................................................................................................... 9327 Diagnostic Trouble Code (DTC) Identification........................................................................................ 9329 DTC2 Actuator Coil Over Current......................................................................................................... 9330 Circuit Description................................................................................................................. 9330 Diagnostic Aids..................................................................................................................... 9330 DTC2 Actuator Coil Over Current..................................................................................................... 9330 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................ 9332 Circuit Description................................................................................................................. 9332 Diagnostic Aids..................................................................................................................... 9332 DTC3 Actuator Coil/Position Sensor Open Circuit or Short............................................................................ 9332 DTC4 G-Sensor Open Circuit or Short..................................................................................................... 9335 Circuit Description................................................................................................................. 9335 Diagnostic Aids..................................................................................................................... 9335 DTC4 G-Sensor Open Circuit or Short................................................................................................. 9335 DTC5 Vehicle Speed Sensor Open Circuit or Short......................................................................................... 9336 Circuit Description................................................................................................................. 9336 Diagnostic Aids..................................................................................................................... 9336 DTC5 Vehicle Speed Sensor Open Circuit or Short..................................................................................... 9337 DTC6 Stop Lamp Switch Open Circuit or Short............................................................................................. 9338 Circuit Description................................................................................................................. 9338 Diagnostic Aids..................................................................................................................... 9338 DTC6 Stop Lamp Switch Open Circuit or Short......................................................................................... 9338 DTC7 Engine Speed Signal Open Circuit or Short.......................................................................................... 9340 Circuit Description................................................................................................................. 9340 Diagnostic Aids..................................................................................................................... 9340 DTC7 Engine Speed Signal Open Circuit or Short...................................................................................... 9340 DTC9 Control Unit Abnormality....................................................................................................... 9341 DTC9-1 Control Unit Blown Fuse for FR Actuator...................................................................................... 9341 DTC9-2 Control Unit Blown Fuse for FL Actuator...................................................................................... 9342 DTC9-3 Control Unit Blown Fuse for RR Shock Absorber................................................................................ 9343 DTC9-4 Control Unit Blown Fuse for RL Shock Absorber................................................................................ 9344 Control Unit........................................................................................................................ 9345 Control Unit and Associated Parts................................................................................................... 9345 Removal............................................................................................................................. 9345 Installation........................................................................................................................ 9346 Front Actuator...................................................................................................................... 9347 Front Actuator and Associated Parts................................................................................................. 9347 Removal............................................................................................................................. 9348 View B.............................................................................................................................. 9348 Inspection and Repair............................................................................................................... 9348 Installation........................................................................................................................ 9348 Rear Shock Absorber................................................................................................................. 9349 Rear Shock Absorber and Associated Parts............................................................................................ 9349 Removal............................................................................................................................. 9350 Inspection and Repair............................................................................................................... 9350 Installation........................................................................................................................ 9350 Sec.4 DRIVELINE/AXLE.......................................................................................................................... 9479 4A1 DIFFERENTIAL (FRONT).................................................................................................................. 9351 Service Precaution...................................................................................................................... 9351 Front Drive Axle........................................................................................................................ 9352 Diagnosis............................................................................................................................... 9352 Pinion Shaft Oil Seal................................................................................................................... 9353 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 9353 Removal............................................................................................................................. 9353 Inspection and Repair............................................................................................................... 9354 Installation........................................................................................................................ 9354 Front Drive Axle Assembly............................................................................................................... 9355 Front Drive Axle Assembly and Associated Parts...................................................................................... 9355 Removal............................................................................................................................. 9356 Installation........................................................................................................................ 9356 Differential Assembly................................................................................................................... 9358 Disassembled View................................................................................................................... 9358 Disassembly......................................................................................................................... 9359 Reassembly.......................................................................................................................... 9361 Differential Cage Assembly.............................................................................................................. 9369 Disassembled View................................................................................................................... 9369 Disassembly......................................................................................................................... 9369 Inspection and Repair............................................................................................................... 9370 Reassembly.......................................................................................................................... 9370 Main Data and Specifications............................................................................................................ 9372 Special Tools........................................................................................................................... 9375 4A2 DIFFERENTIAL (REAR)................................................................................................................... 9377 Service Precaution...................................................................................................................... 9377 General Description..................................................................................................................... 9378 Diagnosis............................................................................................................................... 9379 Axle Housing............................................................................................................................ 9381 Axle Housing and Associated Parts................................................................................................... 9381 Removal............................................................................................................................. 9381 Installation........................................................................................................................ 9383 Axle Shaft, Oil Seal and Bearing........................................................................................................ 9383 Axle Shaft and Associated Parts..................................................................................................... 9383 Removal............................................................................................................................. 9384 Inspection.......................................................................................................................... 9384 Installation........................................................................................................................ 9384 Pinion Oil Seal......................................................................................................................... 9386 Pinion Oil Seal and Associated Parts................................................................................................ 9386 Removal............................................................................................................................. 9386 Inspection and Repair............................................................................................................... 9387 Installation........................................................................................................................ 9387 Differential Assembly................................................................................................................... 9389 Disassembled View................................................................................................................... 9389 Inspecting the Axle Before Disassembly.............................................................................................. 9390 Disassembly......................................................................................................................... 9390 Inspection and Repair............................................................................................................... 9392 Reassembly.......................................................................................................................... 9392 Side Bearing Preload Adjustment..................................................................................................... 9396 Pinion Installation................................................................................................................. 9397 Determination of Backlash & Preload Shims........................................................................................... 9398 Backlash Adjustment................................................................................................................. 9399 Gear Tooth Pattern Check............................................................................................................ 9399 Adjustments Affecting Tooth Contact................................................................................................. 9400 Differential Case Assembly.............................................................................................................. 9401 Disassembled View................................................................................................................... 9401 Disassembly......................................................................................................................... 9402 Inspection and Repair............................................................................................................... 9402 Reassembly.......................................................................................................................... 9402 Limited Slip Differential Assembly...................................................................................................... 9403 Disassembled View................................................................................................................... 9403 Disassembly......................................................................................................................... 9403 Inspection and Repair............................................................................................................... 9405 Reassembly.......................................................................................................................... 9405 Main Data And Specifications............................................................................................................ 9407 Special Tools........................................................................................................................... 9409 4B DRIVELINE CONTROL SYSTEM.............................................................................................................. 9411 Service Precaution...................................................................................................................... 9411 Shift On The Fly System................................................................................................................. 9412 Outline of Shift on The Fly System...................................................................................................... 9412 Functions of Indicator Lamp............................................................................................................. 9416 Diagnosis............................................................................................................................... 9417 Shift On The Fly Electrical Equipment................................................................................................... 9427 Axle Shaft Connection and Disconnection................................................................................................. 9427 4WD Control Unit........................................................................................................................ 9430 4WD Control Unit Associated Parts................................................................................................... 9430 Removal............................................................................................................................. 9430 Installation........................................................................................................................ 9431 Shift On The Fly Controller............................................................................................................. 9432 Shift On The Fly Controller and Associated Parts.................................................................................... 9432 Removal............................................................................................................................. 9432 Installation........................................................................................................................ 9432 4C DRIVE SHAFT SYSTEM.................................................................................................................... 9433 Service Precaution...................................................................................................................... 9433 General Description..................................................................................................................... 9434 Diagnosis............................................................................................................................... 9434 Front Hub and Disc (2WD Model).......................................................................................................... 9435 Disassembled View................................................................................................................... 9435 Disassembly......................................................................................................................... 9435 Inspection and Repair............................................................................................................... 9436 Reassembly.......................................................................................................................... 9437 Front Hub and Disc (4WD Model).......................................................................................................... 9440 Disassembled View................................................................................................................... 9440 Disassembly......................................................................................................................... 9440 Inspection and Repair............................................................................................................... 9441 Reassembly.......................................................................................................................... 9442 Front Drive Shaft Joint................................................................................................................. 9445 Front Drive Shaft Joints Replacement................................................................................................ 9445 Front Axle Drive Shaft.................................................................................................................. 9446 Front Axle Drive Shaft and Associated Parts......................................................................................... 9446 Disassembly......................................................................................................................... 9447 Inspection And Repair............................................................................................................... 9448 Bushing Replacement................................................................................................................. 9448 Reassembly.......................................................................................................................... 9448 Shift On The Fly System................................................................................................................. 9451 Shift On The Fly System and Associated Parts........................................................................................ 9451 Disassembly......................................................................................................................... 9451 Inspection And Repair............................................................................................................... 9453 Reassembly.......................................................................................................................... 9455 Main Data and Specifications........................................................................................................ 9458 Special Tools....................................................................................................................... 9460 Propeller Shaft......................................................................................................................... 9461 General Description..................................................................................................................... 9461 Universal Joint......................................................................................................................... 9462 Diagnosis of Propeller Shaft and Universal Joint........................................................................................ 9463 Front Propeller Shaft................................................................................................................... 9464 Front Propeller Shaft and Associated Parts.......................................................................................... 9464 Removal............................................................................................................................. 9464 Installation........................................................................................................................ 9464 Disassembly......................................................................................................................... 9465 Universal Joint Disassembly......................................................................................................... 9466 Inspection and Repair............................................................................................................... 9467 Universal Joint Reassembly.......................................................................................................... 9468 Reassembly.......................................................................................................................... 9469 Main Data and Specifications........................................................................................................ 9470 Rear Propeller Shaft.................................................................................................................... 9471 Rear Propeller Shaft and Associated Parts........................................................................................... 9471 Removal............................................................................................................................. 9471 Installation........................................................................................................................ 9471 Slip Joint Disassembly.............................................................................................................. 9472 Universal Joint Disassembly......................................................................................................... 9473 Inspection.......................................................................................................................... 9475 Universal Joint Reassembly.......................................................................................................... 9476 Slip Joint Reassembly............................................................................................................... 9477 Main Data and Specifications........................................................................................................ 9478 4D TRANSFER CASE......................................................................................................................... 9479 Service Precaution...................................................................................................................... 9479 General Description..................................................................................................................... 9480 Transfer Rear Oil Seal.................................................................................................................. 9482 Transfer Rear Oil Seal and Associated Parts......................................................................................... 9482 Removal............................................................................................................................. 9482 Installation........................................................................................................................ 9482 Transfer Case Assembly (A/T)............................................................................................................ 9484 Transfer Case Assembly (A/T) and Associated Parts................................................................................... 9484 Removal............................................................................................................................. 9484 Installation........................................................................................................................ 9486 Transfer Rear Case Assembly (A/T)....................................................................................................... 9489 Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 9489 Removal............................................................................................................................. 9489 Installation........................................................................................................................ 9491 Transfer Rear Cover Assembly........................................................................................................ 9494 Disassembly......................................................................................................................... 9494 Inspection and Repair............................................................................................................... 9495 Reassembly.......................................................................................................................... 9495 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 9497 Disassembled View................................................................................................................... 9497 Disassembly......................................................................................................................... 9498 Inspection and Repair............................................................................................................... 9499 Reassembly.......................................................................................................................... 9499 Transfer Case Assembly.................................................................................................................. 9501 Disassembled View................................................................................................................... 9501 Disassembly......................................................................................................................... 9502 Inspection and Repair............................................................................................................... 9505 Reassembly.......................................................................................................................... 9508 Main Data and Specifications............................................................................................................ 9515 Special Tools........................................................................................................................... 9518 Sec.5 BRAKES.................................................................................................................................. 9519 5A BRAKE CONTROL SYSTEM.................................................................................................................. 9519 Service Precaution...................................................................................................................... 9520 General Description..................................................................................................................... 9521 Functional Description.............................................................................................................. 9522 System Components................................................................................................................... 9528 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 9528 ABS Warning Light................................................................................................................... 9528 Wheel Speed Sensor.................................................................................................................. 9528 G-Sensor............................................................................................................................ 9528 Normal and Anti-lock Braking........................................................................................................ 9528 Brake Pedal Travel.................................................................................................................. 9528 Acronyms and Abbreviations.......................................................................................................... 9528 General Diagnosis....................................................................................................................... 9529 General Information................................................................................................................. 9529 ABS Service Precautions............................................................................................................. 9529 Computer System Service Precautions................................................................................................. 9529 General Service Precautions......................................................................................................... 9529 Note on Intermittents............................................................................................................... 9529 Test Driving ABS Complaint Vehicles................................................................................................. 9530 "ABS" Warning Light................................................................................................................. 9530 Normal Operation.................................................................................................................... 9530 Tech 2 Scan Tool.................................................................................................................... 9531 DATA LIST........................................................................................................................... 9534 ACTUATOR TEST....................................................................................................................... 9535 Tech 2 Service Bleed................................................................................................................ 9539 Basic Diagnostic Flow Chart......................................................................................................... 9540 Basic Inspection Procedure.......................................................................................................... 9541 EHCU Connector Pin-out Checks........................................................................................................... 9542 Circuit Diagram..................................................................................................................... 9543 Connector List...................................................................................................................... 9546 Part Location....................................................................................................................... 9547 Symptom Diagnosis....................................................................................................................... 9548 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 9548 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 9549 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 9549 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2)....................................................................... 9549 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 9550 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 9551 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................ 9552 Diagnostic Trouble Codes................................................................................................................ 9553 Diagnosis By "ABS" Warning Light Illumination Pattern................................................................................... 9555 Diagnostic Trouble Codes (DTCs)..................................................................................................... 9556 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 9558 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications))....................................... 9559 Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))................................... 9559 Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications)).................................................. 9559 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications))............................................. 9560 Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications)).............................................. 9560 Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications))................................................. 9560 Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal .... 9561 Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................ 9561 Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))........................... 9562 Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................ 9562 Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))........................... 9563 Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications))................................. 9563 Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications))......................... 9563 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications)).............................. 9564 Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications))..................................... 9564 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications))..................................... 9565 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))................................... 9566 Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...................................... 9567 Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...................................... 9568 Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).................................... 9569 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications)).................. 9570 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications))....................................... 9571 Unit Inspection Procedure............................................................................................................... 9572 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 9572 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 9573 Chart C-1-3 Rear Sensor Output Inspection Procedure................................................................................. 9573 Chart TC-1 Sensor Output Inspection Procedure....................................................................................... 9574 Special Tools........................................................................................................................... 9575 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................ 9576 Service Precaution...................................................................................................................... 9576 Electronic Hydraulic Control Unit....................................................................................................... 9577 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 9577 Removal............................................................................................................................. 9577 Disassembled View................................................................................................................... 9578 Disassembly......................................................................................................................... 9578 Reassembly.......................................................................................................................... 9578 Installation........................................................................................................................ 9578 Front Wheel Speed Sensor................................................................................................................ 9579 Front Wheel Speed Sensor and Associated Parts....................................................................................... 9579 Removal............................................................................................................................. 9579 Inspection and Repair............................................................................................................... 9579 Installation........................................................................................................................ 9579 Rear Wheel Speed Sensor................................................................................................................. 9580 Removal............................................................................................................................. 9580 Inspection and Repair............................................................................................................... 9580 Installation........................................................................................................................ 9580 5C POWER-ASSISTED BRAKE SYSTEM........................................................................................................... 9581 Service Precaution...................................................................................................................... 9582 General Description..................................................................................................................... 9582 Diagnosis............................................................................................................................... 9586 General Diagnosis....................................................................................................................... 9587 Hydraulic Brakes........................................................................................................................ 9590 Filling Master Cylinder Reservoir................................................................................................... 9590 Deterioration of Brake Fluid........................................................................................................ 9590 Leakage of Brake Fluid.............................................................................................................. 9590 Bleeding Brake Hydraulic System..................................................................................................... 9590 Flushing Brake Hydraulic System..................................................................................................... 9591 Brake Pipes and Hoses............................................................................................................... 9591 Brake Hose Inspection............................................................................................................... 9591 Front Caliper Brake Hose................................................................................................................ 9592 Front Caliper Brake Hose and Associated Parts....................................................................................... 9592 Removal............................................................................................................................. 9592 Installation........................................................................................................................ 9592 Rear Axle Brake Hose.................................................................................................................... 9593 Rear Axle Brake Hose and Associated Parts........................................................................................... 9593 Removal............................................................................................................................. 9593 Installation........................................................................................................................ 9593 Brake Pipe.............................................................................................................................. 9594 Removal............................................................................................................................. 9594 Installation........................................................................................................................ 9594 P & B (Proportioning and Bypass) Valve.................................................................................................. 9595 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 9595 Removal............................................................................................................................. 9595 Installation........................................................................................................................ 9595 Main Data and Specifications............................................................................................................ 9596 Brake Pedal............................................................................................................................. 9597 Checking Pedal Height............................................................................................................... 9597 Checking Pedal Travel............................................................................................................... 9597 Brake Pedal and Associated Parts.................................................................................................... 9598 Removal............................................................................................................................. 9598 Installation........................................................................................................................ 9598 Stoplight Switch........................................................................................................................ 9599 Parts Location...................................................................................................................... 9599 Removal............................................................................................................................. 9599 Installation........................................................................................................................ 9599 Main Data and Specifications............................................................................................................ 9600 Fluid Reservoir Tank.................................................................................................................... 9601 Fluid Reservoir Tank and Associated Parts........................................................................................... 9601 Removal............................................................................................................................. 9601 Installation........................................................................................................................ 9601 Master Cylinder Assembly................................................................................................................ 9602 Master Cylinder Assembly and Associated Parts....................................................................................... 9602 Removal............................................................................................................................. 9602 Inspection and Repair............................................................................................................... 9602 Installation........................................................................................................................ 9603 Main Data and Specifications............................................................................................................ 9604 Special Tools........................................................................................................................... 9604 Vacuum Booster Assembly................................................................................................................. 9605 Vacuum Booster Assembly and Associated Parts........................................................................................ 9605 Removal............................................................................................................................. 9605 Inspection and Repair............................................................................................................... 9605 Installation........................................................................................................................ 9606 Exterior Components..................................................................................................................... 9608 Exterior Components and Associated Parts............................................................................................ 9608 Removal............................................................................................................................. 9608 Inspection and Repair............................................................................................................... 9609 Installation........................................................................................................................ 9609 Vacuum Booster Overhaul................................................................................................................. 9609 Vacuum Booster...................................................................................................................... 9609 Main Data and Specifications............................................................................................................ 9610 Special Tools........................................................................................................................... 9611 Front Disc Brake Pads................................................................................................................... 9612 Front Disc Brake Pads Inspection.................................................................................................... 9612 Front Disc Brake Pads and Associated Parts.......................................................................................... 9612 Removal............................................................................................................................. 9613 Installation........................................................................................................................ 9613 Front Disc Brake Rotor.................................................................................................................. 9615 Inspection.......................................................................................................................... 9615 Replacing Brake Rotors.............................................................................................................. 9615 Refinishing Brake Rotors............................................................................................................ 9615 Front Disc Brake Caliper Assembly....................................................................................................... 9616 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 9616 Removal............................................................................................................................. 9617 Installation........................................................................................................................ 9617 Front Disc Brake Caliper................................................................................................................ 9619 Front Disc Brake Caliper Disassembled View.......................................................................................... 9619 Disassembly......................................................................................................................... 9619 Inspection and Repair............................................................................................................... 9620 Reassembly.......................................................................................................................... 9620 Main Data and Specifications............................................................................................................ 9622 Rear Disc Brake Pads (4 × 4 Model)...................................................................................................... 9623 Brake Pads Inspection............................................................................................................... 9623 Brake Pads and Associated Parts..................................................................................................... 9623 Removal............................................................................................................................. 9624 Installation........................................................................................................................ 9624 Rear Disc Brake Rotor (4 × 4 Model)..................................................................................................... 9626 Inspection.......................................................................................................................... 9626 Replacing Brake Rotors.............................................................................................................. 9626 Refinishing Brake Rotors............................................................................................................ 9626 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 9627 Rear Disc Brake Caliper Assembly (4 × 4 Model).......................................................................................... 9628 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 9628 Removal............................................................................................................................. 9628 Installation........................................................................................................................ 9629 Rear Disc Brake Caliper (4 × 4 Model)................................................................................................... 9630 Rear Disc Brake Caliper Disassembled View........................................................................................... 9630 Disassembly......................................................................................................................... 9631 Inspection and Repair............................................................................................................... 9631 Reassembly.......................................................................................................................... 9631 Main Data and Specifications (4 × 4 Model).............................................................................................. 9633 Brake Lining............................................................................................................................ 9634 Brake Lining and Associated Parts................................................................................................... 9634 Removal............................................................................................................................. 9634 Brake Lining Inspection............................................................................................................. 9635 Installation........................................................................................................................ 9635 Drum Brake Adjustment (4 × 2 Model)................................................................................................. 9636 Servicing The Brake Drum............................................................................................................ 9636 Wheel Cylinder Assembly (4 × 2 Model)................................................................................................... 9637 Wheel Cylinder Assembly and Associated Parts........................................................................................ 9637 Removal............................................................................................................................. 9637 Installation........................................................................................................................ 9637 Disassembled View................................................................................................................... 9638 Disassembly......................................................................................................................... 9638 Inspection and Repair............................................................................................................... 9638 Reassembly.......................................................................................................................... 9638 Main Data and Specifications............................................................................................................ 9640 5D1 PARKING BRAKE SYSTEM (4x4 Model)...................................................................................................... 9641 Service Precaution...................................................................................................................... 9641 General Description..................................................................................................................... 9641 Operation............................................................................................................................... 9642 Parking Brake Lever and Front Cable..................................................................................................... 9643 Parking Brake Lever Assembly and Associated Parts................................................................................... 9643 Removal............................................................................................................................. 9643 Installation........................................................................................................................ 9643 Parking Brake Rear Cable................................................................................................................ 9644 Parking Brake Rear Cable and Associated Parts....................................................................................... 9644 Removal............................................................................................................................. 9645 Installation........................................................................................................................ 9645 Inspection and Repair............................................................................................................... 9646 Parking Brake Adjustment............................................................................................................ 9646 Main Data and Specifications............................................................................................................ 9647 5D2 PARKING BRAKE SYSTEM (4x2 Model)...................................................................................................... 9648 Service Precaution...................................................................................................................... 9648 General Description..................................................................................................................... 9648 Parking Brake Lever..................................................................................................................... 9649 Parking Brake Lever Assembly and Associated Parts................................................................................... 9649 Removal............................................................................................................................. 9649 Installation........................................................................................................................ 9649 Parking Brake Rear Cable................................................................................................................ 9650 Parking Brake Rear Cable and Associated Parts....................................................................................... 9650 Removal............................................................................................................................. 9651 Installation........................................................................................................................ 9651 Parking Brake Adjustment............................................................................................................ 9651 Main Data and Specifications............................................................................................................ 9652 Sec.6 ENGINE.................................................................................................................................. 9653 X22SE 2.2L ENGINE........................................................................................................................... 9653 6A ENGINE MECHANICAL.................................................................................................................. 9653 Service Precaution.................................................................................................................. 9654 General Description................................................................................................................. 9654 Engine Diagnosis.................................................................................................................... 9655 Cylinder Head Cover................................................................................................................. 9668 Removal......................................................................................................................... 9668 Installation.................................................................................................................... 9669 Exhaust Manifold.................................................................................................................... 9670 Removal......................................................................................................................... 9670 Installation.................................................................................................................... 9670 Crankshaft Pulley................................................................................................................... 9671 Removal......................................................................................................................... 9671 Installation.................................................................................................................... 9671 Intake Manifold..................................................................................................................... 9672 Removal......................................................................................................................... 9672 Installation.................................................................................................................... 9673 Cylinder Head Assembly.............................................................................................................. 9674 Removal......................................................................................................................... 9674 Installation.................................................................................................................... 9676 Timing Belt......................................................................................................................... 9680 Removal......................................................................................................................... 9680 Installation.................................................................................................................... 9681 Camshaft............................................................................................................................ 9684 Removal......................................................................................................................... 9684 Installation.................................................................................................................... 9685 Engine Assembly..................................................................................................................... 9687 Removal......................................................................................................................... 9688 Installation.................................................................................................................... 9689 Cylinder Head....................................................................................................................... 9691 Cylinder Head and Associated Parts.............................................................................................. 9691 Disassembly..................................................................................................................... 9691 Inspection and Repair........................................................................................................... 9692 Reassembly...................................................................................................................... 9693 Valve Spring, Valve, Valve Guide.................................................................................................... 9694 Valve Spring, Valve, Valve Guide and Associated Parts........................................................................... 9694 Disassembly..................................................................................................................... 9694 Inspection and Repair........................................................................................................... 9695 Reassembly...................................................................................................................... 9696 Camshaft............................................................................................................................ 9697 Camshaft and Associated Parts................................................................................................... 9697 Disassembly..................................................................................................................... 9697 Reassembly...................................................................................................................... 9698 Crankshaft.......................................................................................................................... 9699 Crankshaft and Associated Parts................................................................................................. 9699 Disassembly..................................................................................................................... 9699 Inspection and Repair........................................................................................................... 9700 Inspection and Repair........................................................................................................... 9701 Reassembly...................................................................................................................... 9702 Piston and Connecting Rod........................................................................................................... 9705 Piston, Connecting Rod and Associate Parts...................................................................................... 9705 Disassembly..................................................................................................................... 9705 Inspection and Repair........................................................................................................... 9706 Reassembly...................................................................................................................... 9708 Cylinder Block...................................................................................................................... 9709 Cylinder Block and Associated Parts............................................................................................. 9709 Disassembly..................................................................................................................... 9710 Inspection and Repair........................................................................................................... 9710 Reassembly...................................................................................................................... 9711 Cylinder Head Cover................................................................................................................. 9712 Cylinder Head Cover and Associated parts........................................................................................ 9712 Removal......................................................................................................................... 9713 Installation.................................................................................................................... 9713 Balance Unit Assembly............................................................................................................... 9715 Balance Unit Assembly Associated Parts.......................................................................................... 9715 Disassembly..................................................................................................................... 9716 Adjustment...................................................................................................................... 9716 Reassembly...................................................................................................................... 9718 Main Data and Specifications........................................................................................................ 9720 Special Tools....................................................................................................................... 9725 6B ENGINE COOLING..................................................................................................................... 9726 Service Precaution.................................................................................................................. 9726 General Description................................................................................................................. 9727 Diagnosis........................................................................................................................... 9729 Draining and Refilling Cooling System............................................................................................... 9729 Water Pump.......................................................................................................................... 9730 Water Pump and Associated Parts..................................................................................................... 9730 Removal......................................................................................................................... 9730 Inspection...................................................................................................................... 9730 Installation.................................................................................................................... 9730 Thermostat.......................................................................................................................... 9731 Removal......................................................................................................................... 9731 Inspection...................................................................................................................... 9731 Installation.................................................................................................................... 9731 Radiator............................................................................................................................ 9732 Radiator and Associated Parts................................................................................................... 9732 Removal......................................................................................................................... 9732 Inspection...................................................................................................................... 9733 Installation.................................................................................................................... 9733 Main Data and Specifications........................................................................................................ 9734 Special Tool........................................................................................................................ 9734 6C ENGINE FUEL........................................................................................................................ 9735 Service Precaution.................................................................................................................. 9735 General Description................................................................................................................. 9736 Fuel Metering....................................................................................................................... 9737 Fuel Filter......................................................................................................................... 9738 Fuel Filter and Associated Parts................................................................................................ 9738 Removal......................................................................................................................... 9738 Inspection...................................................................................................................... 9738 Installation.................................................................................................................... 9738 Inspection...................................................................................................................... 9738 In-Tank Fuel Filter............................................................................................................. 9738 Fuel Pump Flow Test............................................................................................................. 9739 Fuel Pump........................................................................................................................... 9740 Fuel Pump and Associated Parts.................................................................................................. 9740 Removal......................................................................................................................... 9740 Installation.................................................................................................................... 9740 Fuel Tube / Quick-Connector Fittings................................................................................................ 9741 Precautions..................................................................................................................... 9741 Cautions During Work............................................................................................................ 9741 Removal......................................................................................................................... 9741 Reuse of Quick-Connector........................................................................................................ 9743 Assembling Advice............................................................................................................... 9743 Fuel Pump Relay..................................................................................................................... 9744 General Description............................................................................................................. 9744 Fuel Tank........................................................................................................................... 9744 Fuel Tank and Associated Parts.................................................................................................. 9744 Removal......................................................................................................................... 9745 Installation.................................................................................................................... 9745 Fuel Gage Unit...................................................................................................................... 9745 Removal and Installation........................................................................................................ 9745 Fuel Filler Cap..................................................................................................................... 9746 General Description............................................................................................................. 9746 Inspection...................................................................................................................... 9746 Main Data and Specifications........................................................................................................ 9747 Special Tool........................................................................................................................ 9747 6D1 ENGINE ELECTRICAL.................................................................................................................. 9748 Service Precaution.................................................................................................................. 9748 Battery............................................................................................................................. 9749 General Description............................................................................................................. 9749 Diagnosis....................................................................................................................... 9749 Battery Charging................................................................................................................ 9750 Jump Starting................................................................................................................... 9750 Battery Removal................................................................................................................. 9751 Battery Installation............................................................................................................ 9751 Main Data and Specifications........................................................................................................ 9752 6D2 IGNITION SYSTEM.................................................................................................................... 9753 Service Precaution.................................................................................................................. 9753 General Description................................................................................................................. 9753 Diagnosis........................................................................................................................... 9753 Ignition Module..................................................................................................................... 9754 Removal......................................................................................................................... 9754 Installation.................................................................................................................... 9754 Spark Plug.......................................................................................................................... 9754 Removal......................................................................................................................... 9754 Inspection and Repair........................................................................................................... 9754 Installation.................................................................................................................... 9755 Crankshaft Angle Sensor............................................................................................................. 9755 Removal......................................................................................................................... 9755 Installation.................................................................................................................... 9755 Main Data and Specifications........................................................................................................ 9756 6D3 STARTING AND CHARGING SYSTEM....................................................................................................... 9757 Service Precaution.................................................................................................................. 9757 Starting System..................................................................................................................... 9758 General Description............................................................................................................. 9758 Diagnosis....................................................................................................................... 9758 Starter............................................................................................................................. 9759 Removal......................................................................................................................... 9759 Installation.................................................................................................................... 9759 Disassembled View............................................................................................................... 9760 Inspection and Repair........................................................................................................... 9761 Characteristic Test............................................................................................................. 9762 Charging System..................................................................................................................... 9763 General Description................................................................................................................. 9763 General On-Vehicle Inspection....................................................................................................... 9763 Generator........................................................................................................................... 9764 Removal......................................................................................................................... 9764 Inspection...................................................................................................................... 9764 Installation.................................................................................................................... 9765 Disassembly..................................................................................................................... 9765 Inspection and Repair........................................................................................................... 9767 Reassembly...................................................................................................................... 9769 Main Data and Specifications........................................................................................................ 9770 6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................. 9771 SPECIFICATIONS...................................................................................................................... 9776 TIGHTENING SPECIFICATIONS....................................................................................................... 9776 DIAGRAMS AND SCHEMATICS............................................................................................................. 9777 PCM WIRING DIAGRAM (1 of 10).................................................................................................... 9777 PCM WIRING DIAGRAM (2 of 10).................................................................................................... 9778 PCM WIRING DIAGRAM (3 of 10).................................................................................................... 9779 PCM WIRING DIAGRAM (4 of 10).................................................................................................... 9780 PCM WIRING DIAGRAM (5 of 10).................................................................................................... 9781 PCM WIRING DIAGRAM (6 of 10).................................................................................................... 9782 PCM WIRING DIAGRAM (7 of 10).................................................................................................... 9783 PCM WIRING DIAGRAM (8 of 10).................................................................................................... 9784 PCM WIRING DIAGRAM (9 of 10).................................................................................................... 9785 PCM WIRING DIAGRAM (10 of 10)................................................................................................... 9786 PCM PINOUTS......................................................................................................................... 9787 PCM Pinout Table, 32-Pin Red Connector - Row "A"................................................................................ 9787 PCM Pinout Table, 32-Pin Red Connector - Row "B"................................................................................ 9788 PCM Pinout Table, 32-Pin White Connector - Row "C".............................................................................. 9789 PCM Pinout Table, 32-Pin White Connector - Row "D".............................................................................. 9790 PCM Pinout Table, 32-Pin White Connector - Row "E".............................................................................. 9791 PCM Pinout Table, 32-Pin White Connector - Row "F".............................................................................. 9792 COMPONENT LOCATOR................................................................................................................... 9793 Engine Component Locator Table.................................................................................................. 9795 Undercarriage Component Locator Table........................................................................................... 9795 Fuse And Relay Panel (Underhood Electrical Center).............................................................................. 9795 DIAGNOSIS Strategy-Based Diagnostics................................................................................................ 9797 Strategy-Based Diagnostics...................................................................................................... 9797 DTC Stored...................................................................................................................... 9797 No DTC.......................................................................................................................... 9797 No Matching Symptom............................................................................................................. 9797 Intermittents................................................................................................................... 9797 No Trouble Found................................................................................................................ 9797 Verifying Vehicle Repair........................................................................................................ 9797 GENERAL SERVICE INFORMATION......................................................................................................... 9798 OBD II Serviceability Issues.................................................................................................... 9798 Emissions Control Information Label............................................................................................. 9798 Maintenance Schedule............................................................................................................ 9799 Visual/Physical Engine Compartment Inspection................................................................................... 9799 Basic Knowledge Of Tools Required............................................................................................... 9799 SERIAL DATA COMMUNICATIONS.......................................................................................................... 9799 Class II Serial Data Communications............................................................................................. 9799 ON-BOARD DIAGNOSTIC (OBD II)........................................................................................................ 9799 On-Board Diagnostic Tests....................................................................................................... 9799 Comprehensive Component Monitor Diagnostic Operation............................................................................ 9799 System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations............................... 9800 Common OBD II Terms............................................................................................................. 9800 The Diagnostic Executive........................................................................................................ 9801 DTC Types....................................................................................................................... 9802 Decimal/Binary/Hexadecimal Conversions.......................................................................................... 9803 Verifying Vehicle Repair........................................................................................................ 9803 Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool....................................................................... 9803 Tech 2 Features................................................................................................................. 9805 Getting Started................................................................................................................. 9805 Operating Procedure (Example)................................................................................................... 9806 DTC Modes....................................................................................................................... 9807 DTC Information Mode............................................................................................................ 9807 Miscellaneous Test.............................................................................................................. 9808 Lamps Test...................................................................................................................... 9808 Relays Test..................................................................................................................... 9809 EVAP Test....................................................................................................................... 9811 Idle Air Control System Test.................................................................................................... 9812 Fuel System Test................................................................................................................ 9814 EGR Control Test................................................................................................................ 9815 Injector Balance Test........................................................................................................... 9816 Plotting Snapshot Graph............................................................................................................. 9817 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information).................................................. 9818 Flow Chart for Snapshot Replay (Plotting Graph)................................................................................. 9819 PRIMARY SYSTEM-BASED DIAGNOSTICS.................................................................................................... 9820 Primary System-Based Diagnostics................................................................................................ 9820 Fuel Control Heated Oxygen Sensors.............................................................................................. 9820 HO2S Heater..................................................................................................................... 9820 Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation................................................................. 9820 MISFIRE MONITOR DIAGNOSTIC OPERATION................................................................................................ 9821 Misfire Monitor Diagnostic Operation............................................................................................ 9821 Misfire Counters................................................................................................................ 9821 FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION....................................................................................... 9822 Fuel Trim System Monitor Diagnostic Operation................................................................................... 9822 Fuel Trim Cell Diagnostic Weights............................................................................................... 9822 ON-BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK........................................................................................... 9823 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................ 9826 ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................ 9829 EVAP CANISTER PURGE SOLENOID........................................................................................................ 9829 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER................................................................................... 9829 IDLE AIR CONTROL (IAC) VALVE........................................................................................................ 9829 FUEL SYSTEM PRESSURE TEST........................................................................................................... 9829 FUEL METERING SYSTEM CHECK.......................................................................................................... 9829 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE.......................................................... 9830 Test Description................................................................................................................ 9830 Injector Coil Test Procedure (Steps 1-6) And Injector Balance Test Procedure (Steps 7-11)....................................... 9831 POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS........................................................................................... 9835 MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................ 9835 EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS........................................................................................... 9839 ENGINE Tech 2 DATA DEFINITIONS AND RANGES........................................................................................... 9839 TYPICAL SCAN DATA VALUES............................................................................................................ 9842 NO MALFUNCTION INDICATOR LAMP (MIL)................................................................................................. 9846 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY.......................................................................................... 9849 ENGINE CRANKS BUT WILL NOT RUN...................................................................................................... 9851 FUEL SYSTEM ELECTRICAL TEST......................................................................................................... 9857 FUEL SYSTEM DIAGNOSIS............................................................................................................... 9860 IDLE AIR CONTROL (IAC) SYSTEM CHECK................................................................................................. 9865 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................ 9868 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK....................................................................................... 9870 EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK.................................................................... 9872 Upshift Lamp System Check (Manual Transmission Only)................................................................................ 9875 PCM DIAGNOSTIC TROUBLE CODES........................................................................................................ 9878 DTC P0106 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9881 DTC P0107 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9884 DTC P0108 MANIFOLD ABSOLUTE PRESSURE................................................................................................ 9887 DTC P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT..................................................................... 9890 DTC P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT.................................................................... 9893 DTC P0117 ENGINE COOLANT TEMPERATURE................................................................................................ 9896 DTC P0118 ENGINE COOLANT TEMPERATURE................................................................................................ 9899 DTC P0121 THROTTLE POSITION (TP) SENSOR............................................................................................. 9902 DTC P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT............................................................................ 9905 DTC P0123 THROTTLE POSITION (TP) SENSOR............................................................................................. 9908 DTC P0125 INSUFFICIENT COOLANT TEMPERATURE.......................................................................................... 9911 DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE............................................................................................. 9914 DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE............................................................................................ 9917 DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE........................................................................................... 9920 DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY............................................................................................. 9923 DTC P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1).................................................................... 9926 DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)........................................................................... 9929 DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2).......................................................................... 9932 DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2).................................................................. 9935 DTC P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2).................................................................... 9938 DTC P0171 SYSTEM TOO LEAN (BANK 1).................................................................................................. 9941 DTC P0172 SYSTEM TOO RICH (BANK 1).................................................................................................. 9945 DTC P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1................................................................................. 9949 DTC P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2................................................................................. 9952 DTC P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3................................................................................. 9955 DTC P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4................................................................................. 9958 DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9961 DTC P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9965 DTC P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9969 DTC P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9973 DTC P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED................................................................................. 9977 DTC P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION..................................................................................... 9981 DTC P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT....................................................................................... 9984 DTC P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................ 9987 DTC P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT........................................................................ 9989 DTC P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE.................................................................. 9992 DTC P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT.......................................................................... 9995 DTC P0351 IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT MALFUNCTION................................................................... 9998 DTC P0352 IGNITION COIL "B" PRIMARY/SECONDARY CIRCUIT MALFUNCTION...................................................................10000 DTC P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED................................................................10002 DTC P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED...................................................................10005 DTC P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE.................................................................10007 DTC P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW........................................................................10011 DTC P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.......................................................................10014 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD................................................................................10018 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION....................................................................10021 DTC P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED............................................................10026 DTC P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION........................................10030 DTC P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION...............................................10033 DTC P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION........................................10037 DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE...............................................................................10040 DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.......................................................................................10042 DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT......................................................................................10044 DTC P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION.................................................................................10046 DTC P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION.................................................................................10049 DTC P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT..............................................................................10052 DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED...............................................................................10054 DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED..............................................................................10057 DTC P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.........................................................................10060 DTC P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT........................................................................10063 DTC P0562 SYSTEM VOLTAGE LOW........................................................................................................10066 DTC P0563 SYSTEM VOLTAGE HIGH.......................................................................................................10068 DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR............................................................................10070 DTC P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.................................................10072 DTC P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..................................................10074 DTC P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.....................................................10076 DTC P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE......................................................10079 DTC P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..................................................10081 DTC P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.................................................10083 DTC P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...........................................................10086 DTC P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE............................................................10088 DTC P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)........................................................................10090 DTC P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).........................................................................10093 DTC P1171 FUEL SYSTEM LEAN DURING ACCELERATION......................................................................................10096 DTC P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED.............................................................10099 DTC P1380 ABS ROUGH ROAD SYSTEM FAULT...............................................................................................10102 DTC P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT..................................................................................10104 DTC 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE...............................................................................10107 DTC P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON-PURGE..................................................................10110 DTC P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION .........................................................................10113 DTC P1625 PCM Unexpected Reset......................................................................................................10116 DTC P1627 PCM A/D CONVERSION MALFUNCTION............................................................................................10118 DTC P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION..............................................................................10120 DTC P1640 ODM OUTPUT CIRCUIT FAULT..................................................................................................10122 SYMPTOM DIAGNOSIS...................................................................................................................10125 DEFAULT MATRIX TABLE................................................................................................................10148 Camshaft Position (CMP) Sensor......................................................................................................10151 Crankshaft Position (CKP) Sensor....................................................................................................10152 EEPROM..............................................................................................................................10154 Engine Coolant Temperature (ECT) Sensor.............................................................................................10154 Heated Oxygen Sensor (HO2S).........................................................................................................10155 Intake Air Temperature (IAT) Sensor.................................................................................................10156 Manifold Absolute Pressure (MAP) Sensor.............................................................................................10157 Malfunction Indicator Lamp (MIL)....................................................................................................10158 Powertrain Control Module (PCM).....................................................................................................10158 Throttle Position (TP) Sensor.......................................................................................................10161 Vehicle Speed Sensor (VSS)..........................................................................................................10162 Air Filter..........................................................................................................................10163 Idle Air Control (IAC) Valve........................................................................................................10164 Intake Air Duct.....................................................................................................................10165 Knock Sensor........................................................................................................................10167 Oil Pressure Switch.................................................................................................................10168 FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................10168 Fuel Filler Cap.....................................................................................................................10171 Fuel Filter.........................................................................................................................10171 Fuel Injectors......................................................................................................................10173 Fuel Pressure Regulator.............................................................................................................10174 Fuel Pump Assembly..................................................................................................................10176 Fuel Pump Relay.....................................................................................................................10178 Fuel Rail Assembly..................................................................................................................10178 Fuel Tank...........................................................................................................................10180 Throttle body (TB)..................................................................................................................10181 ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................10183 Ignition Coil.......................................................................................................................10183 Spark Plugs.........................................................................................................................10184 Spark Plug Cables...................................................................................................................10185 EMISSIONS Catalytic Converter.......................................................................................................10186 Air Conditioning Relay..............................................................................................................10186 Ignition Timing Adjustment..........................................................................................................10186 EVAP Canister Hoses.................................................................................................................10186 EVAP Canister.......................................................................................................................10186 EVAP Canister Vent Solenoid.........................................................................................................10187 EVAP Canister Purge Valve Solenoid..................................................................................................10187 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................10188 Wiring and Connectors...............................................................................................................10190 PCM Connectors And Terminals........................................................................................................10190 Connectors And Terminals............................................................................................................10190 Wire Harness Repair: Twisted Shielded Cable.........................................................................................10190 Twisted Leads.......................................................................................................................10191 Weather-Pack Connector..............................................................................................................10192 Com-Pack III........................................................................................................................10194 Metri-Pack..........................................................................................................................10194 GENERAL DESCRIPTION - PCM AND SENSORS...............................................................................................10195 58X Reference PCM Input.........................................................................................................10195 A/C Request Signal..............................................................................................................10195 Crankshaft Position (CKP) Sensor................................................................................................10195 Camshaft Position (CMP) Sensor And Signal.......................................................................................10195 Engine Coolant Temperature (ECT) Sensor.........................................................................................10195 Electrically Erasable Programmable Read Only Memory (EEPROM)....................................................................10196 Fuel Control Heated Oxygen Sensor (Pre Catalyst)................................................................................10196 Catalyst Monitor Heated Oxygen Sensor (Post Catalyst)...........................................................................10196 Intake Air Temperature (IAT) Sensor.............................................................................................10197 Linear Exhaust Gas Recirculation (EGR) Control..................................................................................10197 Manifold Absolute Pressure (MAP) Sensor.........................................................................................10197 Powertrain Control Module (PCM).................................................................................................10198 PCM Function....................................................................................................................10198 PCM Components..................................................................................................................10198 PCM Voltage Description.........................................................................................................10198 PCM Inputs/Outputs..............................................................................................................10198 PCM Service Precautions.........................................................................................................10199 Reprogramming the PCM...........................................................................................................10199 Tooth Error Correction (TEC) Service Bay Guidelines.............................................................................10199 Throttle Position (TP) Sensor...................................................................................................10200 Transmission Range Switch.......................................................................................................10200 Vehicle Speed Sensor (VSS)......................................................................................................10200 Use of Circuit Testing Tools....................................................................................................10201 Aftermarket Electrical And Vacuum Equipment.....................................................................................10201 Electrostatic Discharge Damage..................................................................................................10201 Upshift Lamp....................................................................................................................10201 GENERAL DESCRIPTION - AIR INDUCTION.................................................................................................10201 Air Induction System............................................................................................................10201 GENERAL DESCRIPTION - FUEL METERING.................................................................................................10202 Acceleration Mode...............................................................................................................10202 Accelerator Controls............................................................................................................10202 Battery Voltage Correction Mode.................................................................................................10202 CMP Signal......................................................................................................................10202 Clear Flood Mode................................................................................................................10202 Deceleration Fuel Cutoff (DFCO) Mode............................................................................................10202 Engine Speed/Vehicle Speed/ Fuel Disable Mode...................................................................................10202 Fuel Cutoff Mode................................................................................................................10202 Fuel Injector...................................................................................................................10202 Fuel Metering System Components.................................................................................................10203 Fuel Metering System Purpose....................................................................................................10203 Fuel Pressure Regulator.........................................................................................................10203 Fuel Pump Electrical Circuit....................................................................................................10203 Fuel Rail.......................................................................................................................10203 Idle Air Control (IAC) Valve....................................................................................................10204 Run Mode........................................................................................................................10204 Starting Mode...................................................................................................................10204 Throttle Body Unit..............................................................................................................10204 GENERAL DESCRIPTION - ELECTRONIC IGNITION SYSTEM...................................................................................10205 Camshaft Position (CMP) Sensor..................................................................................................10205 Crankshaft Position (CKP) Sensor................................................................................................10205 Electronic Ignition.............................................................................................................10205 Ignition Coils..................................................................................................................10205 Ignition Control................................................................................................................10205 Ignition Control Module (ICM)...................................................................................................10206 Ignition Control PCM Output.....................................................................................................10206 Powertrain Control Module (PCM).................................................................................................10206 Spark Plug......................................................................................................................10207 A/C CLUTCH DIAGNOSIS................................................................................................................10208 A/C Clutch Circuit Operation....................................................................................................10208 A/C Clutch Circuit Purpose......................................................................................................10208 A/C Request Signal..............................................................................................................10208 GENERAL DESCRIPTION - EVAPORATIVE EMISSION (EVAP) SYSTEM............................................................................10209 EVAP Emission Control System Purpose............................................................................................10209 EVAP Emission Control System Operation..........................................................................................10209 Enhanced Evaporative Emission Control System....................................................................................10209 Enhanced Evaporative Emission Control System....................................................................................10209 System Fault Detection..........................................................................................................10210 GENERAL DESCRIPTION - EXHAUST GAS RECIRCULATION (EGR) SYSTEM........................................................................10210 EGR Purpose.....................................................................................................................10210 Linear EGR Valve................................................................................................................10210 Linear EGR Control..............................................................................................................10210 Linear EGR Valve Operation And Results Of Incorrect Operation...................................................................10211 EGR Pintle Position Sensor......................................................................................................10211 GENERAL DESCRIPTION - POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM...................................................................10211 Crankcase Ventilation System Purpose............................................................................................10211 SPECIAL TOOLS.......................................................................................................................10212 6F ENGINE EXHAUST.....................................................................................................................10214 Service Precaution..................................................................................................................10214 General Description.................................................................................................................10215 Front Exhaust Pipe..................................................................................................................10216 Front Exhaust Pipe and Associated Parts.........................................................................................10216 Removal.........................................................................................................................10216 Installation....................................................................................................................10216 Exhaust Silencer....................................................................................................................10217 Exhaust Silencer and Associated Parts...........................................................................................10217 Removal.........................................................................................................................10217 Installation....................................................................................................................10217 Rear Exhaust pipe...................................................................................................................10218 Rear Exhaust pipe and Associated Parts..........................................................................................10218 Removal.........................................................................................................................10218 Installation....................................................................................................................10218 Main Data and Specifications........................................................................................................10219 6G ENGINE LUBRICATION.................................................................................................................10220 Service Precaution..................................................................................................................10220 General Description.................................................................................................................10221 Oil Pump............................................................................................................................10222 Oil Pump and Associated Parts...................................................................................................10222 Disassembly.....................................................................................................................10223 Inspection and Repair...........................................................................................................10223 Reassembly......................................................................................................................10223 6H ENGINE SPEED CONTROL SYSTEM........................................................................................................10224 Service Precaution..................................................................................................................10224 Accelerator Pedal Control Cable.....................................................................................................10225 Removal.........................................................................................................................10225 Inspection......................................................................................................................10225 Installation....................................................................................................................10225 Accelerator Pedal...................................................................................................................10226 Accelerator Pedal and Associated Parts..........................................................................................10226 Removal.........................................................................................................................10226 Installation....................................................................................................................10226 6J INDUCTION..........................................................................................................................10227 Service Precaution..................................................................................................................10227 Air Cleaner Filter..................................................................................................................10228 Removal.........................................................................................................................10228 Inspection......................................................................................................................10228 Installation....................................................................................................................10228 6VD1 3.2L ENGINE...........................................................................................................................10229 6A ENGINE MECHANICAL..................................................................................................................10229 Service Precaution..................................................................................................................10230 General Description.................................................................................................................10231 Engine Diagnosis....................................................................................................................10232 Cylinder Head Cover LH..............................................................................................................10247 Removal.........................................................................................................................10247 Installation....................................................................................................................10248 Cylinder Head Cover RH..............................................................................................................10249 Removal.........................................................................................................................10249 Installation....................................................................................................................10249 Common Chamber......................................................................................................................10250 Removal.........................................................................................................................10250 Installation....................................................................................................................10250 Exhaust Manifold LH.................................................................................................................10252 Removal.........................................................................................................................10252 Installation....................................................................................................................10252 Exhaust Manifold RH.................................................................................................................10253 Removal.........................................................................................................................10253 Installation....................................................................................................................10253 Crankshaft Pulley...................................................................................................................10254 Removal.........................................................................................................................10254 Installation....................................................................................................................10254 Timing Belt.........................................................................................................................10255 Removal.........................................................................................................................10255 Installation....................................................................................................................10256 Camshaft............................................................................................................................10260 Removal.........................................................................................................................10260 Installation....................................................................................................................10261 Cylinder Head.......................................................................................................................10263 Removal.........................................................................................................................10263 Installation....................................................................................................................10263 Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................10265 Removal.........................................................................................................................10265 Installation....................................................................................................................10265 Piston, Piston Ring and Connecting Rod..............................................................................................10266 Removal.........................................................................................................................10266 Installation....................................................................................................................10267 Crankshaft and Main Bearings........................................................................................................10268 Removal.........................................................................................................................10268 Installation....................................................................................................................10269 Rear Oil Seal.......................................................................................................................10273 Removal.........................................................................................................................10273 Installation....................................................................................................................10273 Engine Assembly.....................................................................................................................10274 Removal.........................................................................................................................10274 Installation....................................................................................................................10275 Cylinder Head.......................................................................................................................10277 Cylinder Head and Associated Parts..............................................................................................10277 Disassembly.....................................................................................................................10277 Clean...........................................................................................................................10278 Inspection and Repair...........................................................................................................10278 Reassembly......................................................................................................................10279 Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................10281 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................10281 Disassembly.....................................................................................................................10281 Inspection and Repair...........................................................................................................10282 Reassembly......................................................................................................................10285 Camshaft............................................................................................................................10288 Camshaft and Associated Parts...................................................................................................10288 Disassembly.....................................................................................................................10288 Inspection and Repair...........................................................................................................10289 Reassembly......................................................................................................................10291 Crankshaft..........................................................................................................................10294 Crankshaft and Associated Parts.................................................................................................10294 Disassembly.....................................................................................................................10294 Inspection and Repair...........................................................................................................10295 Inspection and Repair...........................................................................................................10297 Reassembly......................................................................................................................10298 Piston and Connecting Rod...........................................................................................................10302 Piston, Connecting Rod and Associate Parts......................................................................................10302 Disassembly.....................................................................................................................10302 Inspection and Repair...........................................................................................................10303 Reassembly......................................................................................................................10307 Cylinder Block......................................................................................................................10309 Cylinder Block and Associated Parts.............................................................................................10309 Disassembly.....................................................................................................................10309 Inspection and Repair...........................................................................................................10310 Reassembly......................................................................................................................10311 Main Data and Specification.........................................................................................................10314 Special Tool........................................................................................................................10320 6B ENGINE COOLING.....................................................................................................................10322 Service Precaution..................................................................................................................10322 General Description.................................................................................................................10323 Diagnosis...........................................................................................................................10325 Draining and Refilling Cooling System...............................................................................................10326 Water Pump..........................................................................................................................10327 Water Pump and Associated Parts.................................................................................................10327 Removal.........................................................................................................................10327 Inspection......................................................................................................................10327 Installation....................................................................................................................10327 Thermostat..........................................................................................................................10328 Thermostat and Associated Parts.................................................................................................10328 Removal.........................................................................................................................10328 Inspection......................................................................................................................10328 Installation....................................................................................................................10328 Radiator............................................................................................................................10329 Radiator and Associated Parts...................................................................................................10329 Removal.........................................................................................................................10329 Inspection......................................................................................................................10330 Installation....................................................................................................................10331 Drive Belt and Cooling Fan..........................................................................................................10332 Drive Belt and Associated Parts.................................................................................................10332 Inspection......................................................................................................................10332 Installation....................................................................................................................10332 Main Data and Specifications........................................................................................................10333 Special Tool........................................................................................................................10334 6C ENGINE FUEL........................................................................................................................10335 Service Precaution..................................................................................................................10335 General Description.................................................................................................................10336 Fuel Metering.......................................................................................................................10337 Fuel Filter.........................................................................................................................10338 Removal.............................................................................................................................10338 Inspection..........................................................................................................................10338 Installation........................................................................................................................10338 Inspection..........................................................................................................................10338 In-Tank Fuel Filter.................................................................................................................10338 Fuel Pump Flow Test.................................................................................................................10339 Fuel Pump...........................................................................................................................10340 Fuel Pump and Associated Parts..................................................................................................10340 Removal.........................................................................................................................10340 Installation....................................................................................................................10340 Fuel Tube / Quick - Connector Fittings..............................................................................................10341 Precautions.....................................................................................................................10341 Cautions During Work............................................................................................................10341 Removal.........................................................................................................................10341 Reuse of Quick-Connector........................................................................................................10342 Assembling Advice...............................................................................................................10343 Fuel Pump Relay.....................................................................................................................10343 General Description.............................................................................................................10343 Fuel Tank...........................................................................................................................10344 Fuel Tank and Associated Parts..................................................................................................10344 Removal.........................................................................................................................10344 Installation....................................................................................................................10345 Fuel Gauge Unit.....................................................................................................................10345 Removal and Installation........................................................................................................10345 Fuel Filler Cap.....................................................................................................................10345 General Description.............................................................................................................10345 Inspection......................................................................................................................10345 Main Data and Specifications........................................................................................................10346 6D1 ENGINE ELECTRICAL..................................................................................................................10347 Service Precaution..................................................................................................................10347 Battery.............................................................................................................................10348 General Description.............................................................................................................10348 Diagnosis.......................................................................................................................10348 Battery Charging................................................................................................................10349 Jump Starting...................................................................................................................10349 Battery Removal.................................................................................................................10350 Battery Installation............................................................................................................10350 Main Data and Specifications........................................................................................................10351 6D2 IGNITION SYSTEM....................................................................................................................10352 Service Precaution..................................................................................................................10352 General Description.................................................................................................................10353 Diagnosis...........................................................................................................................10353 Ignition Coil.......................................................................................................................10354 Removal.........................................................................................................................10354 Inspection and Repair...........................................................................................................10354 Installation....................................................................................................................10354 Spark Plug..........................................................................................................................10356 Removal.........................................................................................................................10356 Inspection and Repair...........................................................................................................10356 Installation....................................................................................................................10356 Crankshaft Position Sensor..........................................................................................................10357 Removal.........................................................................................................................10357 Installation....................................................................................................................10357 Main Data and Specifications........................................................................................................10358 6D3 STARTING AND CHARGING SYSTEM.......................................................................................................10359 Service Precaution..................................................................................................................10359 Starting System.....................................................................................................................10360 General Description.................................................................................................................10360 Diagnosis...........................................................................................................................10362 Starter.............................................................................................................................10363 Removal.........................................................................................................................10363 Installation....................................................................................................................10363 Disassembled View...............................................................................................................10364 Disassembly.....................................................................................................................10365 Inspection and Repair...........................................................................................................10367 Reassembly......................................................................................................................10371 Main Data and Specifications....................................................................................................10373 Charging System.....................................................................................................................10376 General Description.................................................................................................................10376 General On-Vehicle Inspection.......................................................................................................10376 Generator...........................................................................................................................10377 Removal.........................................................................................................................10377 Inspection......................................................................................................................10377 Installation....................................................................................................................10378 Disassembled View...............................................................................................................10378 Disassembly.....................................................................................................................10379 Inspection and Repair...........................................................................................................10380 Reassembly......................................................................................................................10382 Bench Test......................................................................................................................10383 Main Data and Specifications........................................................................................................10384 6E2 RODEO 3.2L ENGINE..................................................................................................................10385 Specifications......................................................................................................................10390 Tightening Specifications.......................................................................................................10390 Diagrams and Schematics.............................................................................................................10391 PCM Wiring Diagram (1 of 7).....................................................................................................10391 PCM Wiring Diagram (2 of 7).....................................................................................................10392 PCM Wiring Diagram (3 of 7).....................................................................................................10393 PCM Wiring Diagram (4 of 7).....................................................................................................10394 PCM Wiring Diagram (5 of 7).....................................................................................................10395 PCM Wiring Diagram (6 of 7).....................................................................................................10396 PCM Wiring Diagram (7 of 7).....................................................................................................10397 PCM Pinouts.........................................................................................................................10398 PCM Pinout Table, 80-Way Blue Connector-Row "F1 ~ 20"...........................................................................10398 PCM Pinout Table, 80-Way Blue Connector-Row "F20 ~ 40"..........................................................................10400 PCM Pinout Table, 80-Way Blue Connector-Row "F41 ~ 60"..........................................................................10401 PCM Pinout Table, 80-Way Blue Connector-Row "F61 ~ 80"..........................................................................10402 PCM Pinout Table, 80-Way Red Connector-Row "S1 ~ 20"............................................................................10404 PCM Pinout Table, 80-Way Red Connector-Row "S21 ~ 40"...........................................................................10406 PCM Pinout Table, 80-Way Red Connector-Row "S41 ~ 60"...........................................................................10408 PCM Pinout Table, 80-Way Red Connector-Row "S61 ~ 80"...........................................................................10410 Component Locators..................................................................................................................10412 Engine Component Locator........................................................................................................10412 Engine Component Locator Table..................................................................................................10413 Undercarriage Component Locator.................................................................................................10414 Undercarriage Component Locator Table...........................................................................................10414 Fuse and Relay Panel (Underhood Electrical Center)..............................................................................10415 Sensors and Miscellaneous Component Locators....................................................................................10416 Diagnosis...........................................................................................................................10419 Strategy-Based Diagnostics......................................................................................................10419 DTC Stored......................................................................................................................10419 No DTC..........................................................................................................................10419 No Matching Symptom.............................................................................................................10419 Intermittents...................................................................................................................10419 No Trouble Found................................................................................................................10419 Verifying Vehicle Repair........................................................................................................10419 General Service Information.........................................................................................................10419 OBD II Serviceablity Issues.....................................................................................................10419 Emissions Control Information Label.............................................................................................10420 Visual / Physical Engine Compartment Inspection.................................................................................10420 Basic Knowledge of Tools Required...............................................................................................10421 Serial Data Communications..........................................................................................................10421 Class II Serial Data Communications.............................................................................................10421 On-Board Diagnostic (OBD II)........................................................................................................10421 On-Board Diagnostic Tests.......................................................................................................10421 Comprehensive Component Monitor Diagnostic Operation............................................................................10421 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................10422 Common OBD II Terms.............................................................................................................10422 The Diagnostic Executive........................................................................................................10422 DTC Types.......................................................................................................................10423 Decimal/Binary/Hexadecimal Conversions..........................................................................................10425 Verifying Vehicle Repair........................................................................................................10425 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.....................................................................10425 Tech 2..........................................................................................................................10426 Tech 2 Features.................................................................................................................10427 Getting Started.................................................................................................................10427 Operating Procedure (For Example)...............................................................................................10428 DTC Modes.......................................................................................................................10429 DTC Information Mode............................................................................................................10429 Miscellaneous Test..............................................................................................................10430 Lamps Test......................................................................................................................10430 Relays Test.....................................................................................................................10432 EVAP Test.......................................................................................................................10433 Fuel System Test................................................................................................................10434 Instruments Test................................................................................................................10436 EGR Control Test................................................................................................................10438 Variable Intake Manifold Solenoid Test..........................................................................................10438 Injector Balance Test...........................................................................................................10440 Plotting Snapshot Graph.............................................................................................................10440 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................10441 Flow Chart for Snapshot Replay (Plotting Graph).................................................................................10442 Primary System-Based Diagnostic.....................................................................................................10443 Fuel Control Heated Oxygen Sensor...............................................................................................10443 HO2S Heater.....................................................................................................................10443 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................10443 Evaporative Emission (EVAP) Purge System Vacuum Switch..........................................................................10444 Misfire Monitor Diagnostic Operation................................................................................................10444 Misfire Counters................................................................................................................10445 Fuel Trim System Monitor Diagnostic Operation.......................................................................................10445 Fuel Trim Cell Diagnostic Weights...............................................................................................10445 On-Board Diagnostic (OBD II) System Check...........................................................................................10446 A/C Clutch Control Circuit Diagnosis................................................................................................10449 Electronic Ignition System Diagnosis................................................................................................10454 EVAP Canister Purge Solenoid and EVAP Vacuum Switch.................................................................................10454 Visual Check of The Evaporative Emission Canister...................................................................................10454 Fuel Metering System Check..........................................................................................................10454 Fuel System Pressure Test...........................................................................................................10454 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................10454 Powertrain Control Module (PCM) Diagnosis...........................................................................................10459 Multiple PCM Information Sensor DTCs Set............................................................................................10459 Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................10463 Engine Tech 2 Data Definitions and Ranges...........................................................................................10463 Typical Scan Data Values............................................................................................................10465 No Malfunction Indicator Lamp (MIL).................................................................................................10471 Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................10474 No Reduced Power Lamp (RPL).........................................................................................................10476 Reduced Power Lamp (RPL) "ON" Steady................................................................................................10480 Engine Cranks But Will Not Run......................................................................................................10483 Fuel System Electrical Test.........................................................................................................10490 Electric Throttle Control (ETC) System Check........................................................................................10494 Fuel System Diagnosis...............................................................................................................10498 Exhaust Gas Recirculation (EGR) System Check........................................................................................10503 Manifold Absolute Pressure (MAP) Output Check.......................................................................................10505 Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................10507 Upshift Lamp System Check (Manual Transmission Only)................................................................................10510 PCM Diagnostic Trouble Codes........................................................................................................10514 Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................10518 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................10521 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................10524 Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................10527 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................10530 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................10533 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................10536 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................10539 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................10542 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................10545 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................10548 Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation........................................10551 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................10554 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................10557 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................10560 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................10564 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................10567 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................10570 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................10573 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................10576 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................10579 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................10582 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.......................................................10585 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................10588 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................10592 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1.............................................................10595 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................10598 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................10601 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................10604 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................10607 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....................................................................10610 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....................................................................10614 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....................................................................10618 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....................................................................10622 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................10626 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................10629 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................10632 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................10635 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................10638 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................10641 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................10644 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................10648 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................10650 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................10652 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................10654 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................10656 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................10658 Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....................................10660 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................10663 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................10666 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance..................................................................10669 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low..........................................................................10673 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................10677 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................10680 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................10683 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................10686 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................10689 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................10692 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................10695 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................10698 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................10700 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................10702 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................10705 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................10708 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................10711 Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................10714 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................10717 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked......................................................................10720 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...........................................................10723 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor pressure Sensor) High Voltage..................................10726 Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................10729 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage...........................................................10732 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voltage..........................................................10735 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................10737 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.................................................................10740 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................10743 Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................10746 Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................10748 Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................10750 Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................10752 Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................10754 Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................10756 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....................................................10758 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage............................................................10760 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....................................................10762 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................10765 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................10767 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....................................................10769 Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault..............................................10772 Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode..........................................10775 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................10778 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................10782 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................10786 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................10790 Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................10794 Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................10796 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration............................................................10798 Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................10801 Diagnosis Truble Code(DTC) P1221 TPS1-TPS2 correlation(Circuit Performance).........................................................10804 Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error.......................................................................10807 Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error.......................................................................10810 Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error.......................................................................10813 Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault.............................................................................10816 Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault.............................................................................10818 Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault.............................................................................10820 Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................10822 Diagnostic Trouble Code (DTC) P1295 Power Management Mode...........................................................................10825 Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.................................................................10829 Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................10833 Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC line 1 Circuit Fault.....................................................10836 Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC line 2 Circuit Fault.....................................................10839 Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................10842 Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................10845 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................10848 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................10851 Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................10854 Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..........................................................10858 Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..........................................................10861 Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.............................................................10864 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................10867 Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.............................................................10868 Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.............................................................10870 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).............................................................10872 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault....................................................................10875 Symptom Diagnosis...................................................................................................................10878 Default Matrix Table................................................................................................................10907 On-Vehicle Service Camshaft Position (CMP) Sensor...................................................................................10910 Crankshaft Position (CKP) Sensor....................................................................................................10911 Engine Coolant Temperature (ECT) Sensor.............................................................................................10911 Heated Oxygen Sensor (HO2S).........................................................................................................10912 Intake Air Temperature (IAT) Sensor.................................................................................................10915 ION Sensing Module..................................................................................................................10915 Mass Air Flow (MAF) Sensor..........................................................................................................10916 Manifold Absolute Pressure (MAP) Sensor.............................................................................................10917 Malfunction Indicator Lamp (MIL)....................................................................................................10918 Reduced Power Lamp..................................................................................................................10918 Powertrain Control Module (PCM).....................................................................................................10918 EEPROM..............................................................................................................................10919 Throttle Position (TP) Sensor.......................................................................................................10920 Vehicle Speed Sensor (VSS)..........................................................................................................10920 Air Cleaner/Air Filter..............................................................................................................10922 Common Chamber......................................................................................................................10922 Accelerator Pedal Replacement.......................................................................................................10923 Fuel Filler Cap.....................................................................................................................10924 Fuel Filter.........................................................................................................................10924 Fuel Gauge Unit.....................................................................................................................10925 Fuel Injectors......................................................................................................................10926 Fuel Metering System................................................................................................................10927 Fuel Pump Assembly..................................................................................................................10927 Fuel Pump Relay.....................................................................................................................10927 Fuel Rail Assembly..................................................................................................................10928 Fuel Tank...........................................................................................................................10929 Throttle Body (TB)..................................................................................................................10929 Electronic Ignition System..........................................................................................................10931 Catalytic Converter.................................................................................................................10932 Air Conditioning Thermo Relay.......................................................................................................10932 EVAP Canister Hoses.................................................................................................................10933 EVAP Canister.......................................................................................................................10933 EVAP Canister Vent Solenoid.........................................................................................................10935 Fuel Tank Pressure Sensor...........................................................................................................10936 EVAP Canister Purge Solenoid........................................................................................................10936 Fuel Tank Vent Valve................................................................................................................10937 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................10938 Positive Crankcase Ventilation (PCV) Valve..........................................................................................10939 Wiring and Connectors...............................................................................................................10939 PCM Connectors and Terminals........................................................................................................10940 Wire Harness Repair: Twisted Shielded Cable.........................................................................................10940 Twisted Leads.......................................................................................................................10941 Weather-Pack Connector..............................................................................................................10942 Com-Pack III........................................................................................................................10943 Metri-Pack..........................................................................................................................10943 General Description (PCM and Sensors)...............................................................................................10945 58X Reference PCM Input.........................................................................................................10945 A/C Request Signal..............................................................................................................10945 Crankshaft Position (CKP) Sensor................................................................................................10945 Camshaft Position (CMP) Sensor and Signal.......................................................................................10945 Engine Coolant Temperature (ECT) Sensor.........................................................................................10945 Electrically Erasable Programmable Read Only Memory (EEPROM)....................................................................10946 Fuel Control Heated Oxygen Sensors..............................................................................................10946 Catalyst Monitor Heated Oxygen Sensors..........................................................................................10946 Intake Air Temperature (IAT) Sensor.............................................................................................10947 Linear Exhaust Gas Recirculation (EGR) Control..................................................................................10947 Mass Air Flow (MAF) Sensor......................................................................................................10947 Manifold Absolute Pressure (MAP) Sensor.........................................................................................10947 Powertrain Control Module (PCM).................................................................................................10948 PCM Function....................................................................................................................10948 PCM Components..................................................................................................................10948 PCM Voltage Description.........................................................................................................10948 PCM Input/Outputs...............................................................................................................10949 PCM Service Precautions.........................................................................................................10949 Reprogramming The PCM...........................................................................................................10949 Throttle Position (TP) Sensor...................................................................................................10949 Transmission Fluid Temperature (TFT) Sensor.....................................................................................10949 Transmission Range Switch.......................................................................................................10949 Vehicle Speed Sensor (VSS)......................................................................................................10950 Use of Circuit Testing Tools....................................................................................................10950 Aftermarket Electrical and Vacuum Equipment.....................................................................................10950 Electrostatic Discharge Damage..................................................................................................10950 Upshift Lamp....................................................................................................................10950 General Description (Air Induction).................................................................................................10950 Air Induction System............................................................................................................10950 General Description (Fuel Metering).................................................................................................10951 Acceleration Mode...............................................................................................................10951 Battery Voltage Correction Mode.................................................................................................10951 CMP Signal......................................................................................................................10951 Clear Flood Mode................................................................................................................10951 Deceleration Mode...............................................................................................................10951 Engine Speed/Vehicle Speed/Fuel Disable Mode....................................................................................10951 Fuel Cutoff Mode................................................................................................................10951 Fuel Injector...................................................................................................................10951 Fuel Metering System Components.................................................................................................10951 Basic System Operation..........................................................................................................10952 Fuel Metering System Purpose....................................................................................................10952 Fuel Pressure Regulator.........................................................................................................10952 Fuel Pump Electrical Circuit....................................................................................................10952 Fuel Rail.......................................................................................................................10952 Run Mode........................................................................................................................10953 Starting Mode...................................................................................................................10953 Throttle Body Unit..............................................................................................................10953 General Description (Electronic Ignition System)....................................................................................10953 Camshaft Position (CMP) Sensor..................................................................................................10953 Crankshaft Position (CKP) Sensor................................................................................................10953 Electronic Ignition.............................................................................................................10954 Ignition Coils..................................................................................................................10954 Ignition Control................................................................................................................10954 Ignition Control PCM Output.....................................................................................................10955 Powertrain Control Module (PCM).................................................................................................10955 Spark Plug......................................................................................................................10956 A/C Clutch Diagnosis................................................................................................................10957 A/C Clutch Circuit Operation....................................................................................................10957 A/C Clutch Circuit Purpose......................................................................................................10957 A/C Request Signal..............................................................................................................10957 General Description (Evaporative (EVAP) Emission System)............................................................................10958 EVAP Emission Control System Purpose............................................................................................10958 EVAP Emission Control System Operation..........................................................................................10958 Enhanced Evaporative Emission Control System....................................................................................10958 General Description (Exhaust Gas Recirculation (EGR) System)........................................................................10961 EGR Purpose.....................................................................................................................10961 Linear EGR Valve................................................................................................................10962 Linear EGR Control..............................................................................................................10962 Linear EGR Valve Operation and Results of Incorrect Operation...................................................................10962 EGR Pintle Position Sensor......................................................................................................10962 General Description (Positive Crankcase Ventilation (PCV) System)...................................................................10962 Crankcase Ventilation System Purpose............................................................................................10962 Crankcase Ventilation System Operation..........................................................................................10962 Special Tools.......................................................................................................................10964 6F ENGINE EXHAUST.....................................................................................................................10966 Service Precaution..................................................................................................................10966 General Description.................................................................................................................10967 Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................10968 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts...................................................10968 Removal.........................................................................................................................10968 Installation....................................................................................................................10968 Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................10969 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts...................................................10969 Removal.........................................................................................................................10969 Installation....................................................................................................................10969 Forked Exhaust Pipe.................................................................................................................10970 Forked Exhaust Pipe and Associated Parts........................................................................................10970 Removal.........................................................................................................................10970 Installation....................................................................................................................10970 Exhaust Silencer....................................................................................................................10971 Exhaust Silencer and Associated Parts...........................................................................................10971 Removal.........................................................................................................................10971 Installation....................................................................................................................10971 Rear Exhaust pipe...................................................................................................................10972 Rear Exhaust pipe and Associated Parts..........................................................................................10972 Removal.........................................................................................................................10972 Installation....................................................................................................................10972 Main Data and Specifications........................................................................................................10973 6G ENGINE LUBRICATION.................................................................................................................10974 Service Precaution..................................................................................................................10974 General Description.................................................................................................................10975 Oil Pump............................................................................................................................10976 Oil Pump and Associated Parts...................................................................................................10976 Disassembly.....................................................................................................................10977 Inspection and Repair...........................................................................................................10977 Reassembly......................................................................................................................10978 Oil Pan and Crankcase...............................................................................................................10980 Removal.........................................................................................................................10980 Installation....................................................................................................................10980 Oil Pump............................................................................................................................10982 Removal.........................................................................................................................10982 Installation....................................................................................................................10982 Oil Pump Oil Seal...................................................................................................................10984 Removal.........................................................................................................................10984 Installation....................................................................................................................10984 Oil Filter..........................................................................................................................10985 Removal.........................................................................................................................10985 Installation....................................................................................................................10985 Main Data and Specification.........................................................................................................10986 6H ENGINE SPEED CONTROL SYSTEM........................................................................................................10987 Service Precaution..................................................................................................................10987 Accelerator Pedal...................................................................................................................10988 Accelerator Pedal and Associated Parts..........................................................................................10988 Removal.........................................................................................................................10988 Installation....................................................................................................................10988 6J INDUCTION..........................................................................................................................10989 Service Precaution..................................................................................................................10989 Air Cleaner Element.................................................................................................................10990 Removal.........................................................................................................................10990 Inspection......................................................................................................................10990 Installation....................................................................................................................10990 Sec.7 TRANSMISSION............................................................................................................................11234 7A AUTOMATIC TRANSMISSION (4L30-E).......................................................................................................10991 Service Precaution......................................................................................................................10992 Construction............................................................................................................................10993 Range Reference Chart...................................................................................................................10994 Normal Operation of 2000 4L30-E Transmission............................................................................................10995 Diagnosis...............................................................................................................................10995 Driver Information......................................................................................................................10995 General Diagnosis Procedure.............................................................................................................10998 Preliminary Inspection Chart............................................................................................................10999 Checking Transmission Fluid and Condition...............................................................................................11000 Test Driving............................................................................................................................11001 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................11002 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................11003 Possible Causes of Fluid Leaks Due To Sealing Malfunction...............................................................................11012 Stall Test..............................................................................................................................11012 Line Pressure Test......................................................................................................................11013 Shift Speed Chart.......................................................................................................................11014 Lockup Speed Chart......................................................................................................................11015 Changing Transmission Fluid.............................................................................................................11016 Selector Lever..........................................................................................................................11016 Inspection..........................................................................................................................11016 Removal.............................................................................................................................11016 Installation........................................................................................................................11018 Select Cable............................................................................................................................11018 Removal.............................................................................................................................11018 Installation........................................................................................................................11021 Shift Lock Cable........................................................................................................................11023 Removal.............................................................................................................................11023 Installation........................................................................................................................11023 Mode Switch.............................................................................................................................11024 Removal.............................................................................................................................11024 Installation........................................................................................................................11025 Transmission (With Transfer Case).......................................................................................................11026 Transmission and Associated Parts...................................................................................................11026 Removal.............................................................................................................................11027 Installation........................................................................................................................11032 Solenoid (Main Case Valve...............................................................................................................11036 Removal.............................................................................................................................11036 Installation........................................................................................................................11036 Solenoid (Adapter Case Valve Body)......................................................................................................11037 Removal.............................................................................................................................11037 Installation........................................................................................................................11037 Valve Body Assembly (Main Case).........................................................................................................11038 Removal.............................................................................................................................11038 Installation........................................................................................................................11038 Valve Body Assembly (Adapter Case)......................................................................................................11039 Removal.............................................................................................................................11039 Installation........................................................................................................................11039 Powertrain Control Module (PCM).........................................................................................................11039 Removal.............................................................................................................................11039 Installation........................................................................................................................11039 Speed Sensor (Extension Housing)........................................................................................................11040 Removal.............................................................................................................................11040 Installation........................................................................................................................11040 Transmission Oil Temperature Sensor (Main Case).........................................................................................11041 Removal.............................................................................................................................11041 Installation........................................................................................................................11041 Front Oil Seal (Converter Housing)......................................................................................................11042 Removal.............................................................................................................................11042 Installation........................................................................................................................11042 Rear Oil Seal (Extension Housing).......................................................................................................11042 Removal.............................................................................................................................11042 Installation........................................................................................................................11042 Transmission (4L30-E)...................................................................................................................11043 Disassembly.........................................................................................................................11043 Reassembly..........................................................................................................................11047 Converter Housing and Oil Pump Assembly.................................................................................................11057 Disassembled View...................................................................................................................11057 Disassembly.........................................................................................................................11057 Inspection and Repair...............................................................................................................11057 Reassembly..........................................................................................................................11057 Oil Pump................................................................................................................................11058 Disassembled View...................................................................................................................11058 Disassembly.........................................................................................................................11058 Inspection and Repair...............................................................................................................11058 Reassembly..........................................................................................................................11058 Main Case Valve.........................................................................................................................11059 Disassembled View...................................................................................................................11059 Disassembly.........................................................................................................................11060 Inspection and Repair...............................................................................................................11060 Reassembly..........................................................................................................................11060 Adapter Case Valve Body.................................................................................................................11061 Disassembled View...................................................................................................................11061 Disassembly.........................................................................................................................11061 Inspection and Repair...............................................................................................................11061 Reassembly..........................................................................................................................11061 Third Clutch and Sprag Unit.............................................................................................................11062 Disassembled View...................................................................................................................11062 Disassembly.........................................................................................................................11062 Inspection and......................................................................................................................11063 Reassembly..........................................................................................................................11063 Third Clutch............................................................................................................................11063 Disassembled View...................................................................................................................11063 Disassemble.........................................................................................................................11064 Inspection and Repair...............................................................................................................11064 Reassembly..........................................................................................................................11064 Sprag Unit..............................................................................................................................11065 Disassembled View...................................................................................................................11065 Disassembly.........................................................................................................................11065 Inspection and Repair...............................................................................................................11065 Reassembly..........................................................................................................................11065 Second Clutch...........................................................................................................................11066 Disassembled View...................................................................................................................11066 Disassembly.........................................................................................................................11066 Inspection and Repair...............................................................................................................11067 Reassembly..........................................................................................................................11067 3-4 Accumulator Piston..................................................................................................................11068 Disassembled View...................................................................................................................11068 Disassembly.........................................................................................................................11068 Inspection and Repair...............................................................................................................11069 Reassembly..........................................................................................................................11069 Reverse Clutch Piston and Center Support................................................................................................11070 Disassembled View...................................................................................................................11070 Disassembly.........................................................................................................................11071 Inspection and Repair...............................................................................................................11071 Reassembly..........................................................................................................................11071 Overrun Clutch and Turbine Shaft........................................................................................................11072 Disassembled View...................................................................................................................11072 Disassembly.........................................................................................................................11073 Inspection and Repair...............................................................................................................11073 Reassembly..........................................................................................................................11073 Main Data and Specification.............................................................................................................11075 Special Tools...........................................................................................................................11079 4L30-E Parts List.......................................................................................................................11082 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................11089 Service Precaution......................................................................................................................11090 General Description.....................................................................................................................11090 Electronic Control Diagram..........................................................................................................11091 Powertrain Control Module (PCM).....................................................................................................11092 Control System Diagram..............................................................................................................11093 Shift Control.......................................................................................................................11094 Band Apply Control..................................................................................................................11094 Torque Converter Clutch Control.....................................................................................................11094 Line Pressure.......................................................................................................................11094 On-Board Diagnostic System..........................................................................................................11094 Fail-Safe Mechanism.................................................................................................................11094 Torque Management Control...........................................................................................................11094 ATF Warning Control.................................................................................................................11094 Reverse Lock Out Control............................................................................................................11094 Downhill Control....................................................................................................................11094 Uphill Control......................................................................................................................11094 Shift Mode Control..................................................................................................................11095 Gear Shift Control..................................................................................................................11096 Winter Drive Mode...................................................................................................................11097 Backup Mode.........................................................................................................................11097 Functions of Input / Output Components..............................................................................................11098 Diagnosis...............................................................................................................................11099 Electronic Diagnosis................................................................................................................11099 How To Diagnose The Problem.........................................................................................................11099 Check Trans Indicator...............................................................................................................11099 Diagnostic Check....................................................................................................................11099 "Check Trans" Check.................................................................................................................11100 Tech 2 OBD II Connection............................................................................................................11101 Transmission Data...................................................................................................................11106 OBD II Diagnostic Management System.................................................................................................11107 16-Terminal Data Link Connector (DLC)...............................................................................................11108 Malfunction Indicator Lamp (MIL)....................................................................................................11109 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................11109 Clear DTC...........................................................................................................................11109 DTC Check...........................................................................................................................11110 PCM Precaution......................................................................................................................11110 Information On PCM..................................................................................................................11110 Intermittent Conditions.............................................................................................................11111 Transmission and PCM Identification.................................................................................................11112 Isuzu Rodeo.........................................................................................................................11112 Diagnostic Trouble Code (DTC) Identification........................................................................................11113 DTC P0218 Transmission Fluid Over Temperature...........................................................................................11114 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................11116 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................11119 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................11122 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................11125 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................11128 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................11131 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................11134 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................11137 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................11140 DTC P0730 Gear Error Without Input Speed................................................................................................11142 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................11145 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................11147 DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................11149 DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................11151 DTC P0753 Shift Solenoid A Electrical...................................................................................................11153 DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................11156 DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................11158 DTC P0758 Shift Solenoid B Electrical...................................................................................................11160 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................11164 DTC P1860 TCC Solenoid Electrical.......................................................................................................11168 DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................11171 Connector List..........................................................................................................................11173 7B MANUAL TRANSMISSION MUA 5C............................................................................................................11174 Service Precaution......................................................................................................................11174 General Description.....................................................................................................................11175 Diagnosis...............................................................................................................................11177 Rear Oil Seal (4X2).....................................................................................................................11178 Disassembled View...................................................................................................................11178 Removal.............................................................................................................................11178 Installation........................................................................................................................11178 Transmission............................................................................................................................11179 Disassembled View...................................................................................................................11179 Removal.............................................................................................................................11180 Installation........................................................................................................................11184 Transmission Case.......................................................................................................................11189 Major Component (4X2)...............................................................................................................11189 Disassembly.........................................................................................................................11190 Reassembly..........................................................................................................................11191 Transmission Case and Transfer Case.....................................................................................................11194 Major Component (4X4)...............................................................................................................11194 Disassembly.........................................................................................................................11195 Reassembly..........................................................................................................................11198 Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin.............................................................11204 Disassembled View...................................................................................................................11204 Disassembly.........................................................................................................................11205 Inspection and Repair...............................................................................................................11206 Reassembly..........................................................................................................................11207 Reverse Gear and 5th Gear...............................................................................................................11208 Disassembled View...................................................................................................................11208 Disassembly.........................................................................................................................11209 Inspection and Repair...............................................................................................................11211 Reassembly..........................................................................................................................11211 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................11217 Disassmebled View...................................................................................................................11217 Disassembly.........................................................................................................................11218 Inspection and Repair...............................................................................................................11219 Reassembly..........................................................................................................................11222 Main Data and Specifications............................................................................................................11228 Special Tools (MUA).....................................................................................................................11232 7C CLUTCH................................................................................................................................11234 Service Precaution......................................................................................................................11234 General Description.....................................................................................................................11235 Diagnosis...............................................................................................................................11240 Clutch Assembly (X22SE).................................................................................................................11241 Clutch Assembly (X22SE) and Associated Parts........................................................................................11241 Removal.............................................................................................................................11241 Inspection and Repair...............................................................................................................11242 Installation........................................................................................................................11246 Clutch Assembly (6VD1)..................................................................................................................11248 Clutch Assembly (6VD1) and Associated Parts.........................................................................................11248 Removal.............................................................................................................................11248 Inspection and Repair...............................................................................................................11250 Installation........................................................................................................................11254 Clutch Control..........................................................................................................................11256 Parts Location View.................................................................................................................11256 Removal.............................................................................................................................11257 Inspection and Repair...............................................................................................................11257 Installation........................................................................................................................11257 Master Cylinder.........................................................................................................................11260 Slave Cylinder..........................................................................................................................11261 Disassembled View...................................................................................................................11261 Disassembly.........................................................................................................................11261 Inspection and Repair...............................................................................................................11261 Reassembly..........................................................................................................................11262 Main Data and Specifications............................................................................................................11263 Special Tools...........................................................................................................................11266 Sec.8 BODY AND ACCESSORIES....................................................................................................................11299 8A LIGHTING SYSTEM........................................................................................................................11267 Service Precaution......................................................................................................................11267 Headlight Bulb..........................................................................................................................11268 Headlight Assembly......................................................................................................................11268 Headlight Adjustment................................................................................................................11269 Fog Light Bulb..........................................................................................................................11269 Fog Light Assembly......................................................................................................................11270 Fog Light Adjustment................................................................................................................11270 Side Marker Light Bulb..................................................................................................................11270 Taillight Bulb..........................................................................................................................11271 License Plate Light Bulb (Bumper Type)..................................................................................................11271 License Plate Light Bulb (Tailgate Type)................................................................................................11272 Stoplight Bulb..........................................................................................................................11272 High Mounted Stoplight Assembly.........................................................................................................11273 High Mounted Stoplight Bulb.............................................................................................................11273 Backup Light Bulb.......................................................................................................................11274 Front Turn Signal Light Bulb............................................................................................................11274 Rear Turn Signal Light Bulb.............................................................................................................11275 Dome Light Bulb.........................................................................................................................11275 Courtesy Light Bulb.....................................................................................................................11276 Spotlight Bulb..........................................................................................................................11276 Luggage Room Light Bulb.................................................................................................................11277 HVAC Bezel Illumination Light Bulb......................................................................................................11277 Shift Lever Illumination Light Bulb (A/T)...............................................................................................11278 Vanity Mirror Illumination Light Bulb...................................................................................................11278 Starter Switch..........................................................................................................................11279 Lighting Switch (Combination Switch)....................................................................................................11279 Dimmer-Passing Switch (Combination Switch)..............................................................................................11279 Door Switch.............................................................................................................................11279 Rear Defogger Switch....................................................................................................................11280 Key Remind Switch (Starter Switch)......................................................................................................11280 Hazard Warning Light Switch.............................................................................................................11281 Stoplight Switch........................................................................................................................11281 Backup Light Switch.....................................................................................................................11282 Turn Signal Light Switch (Combination Switch)...........................................................................................11282 Illumination Controller.................................................................................................................11283 Light and Bulb Specifications...........................................................................................................11284 8B WIPER / WASHER SYSTEM..................................................................................................................11286 Service Precaution......................................................................................................................11286 Windshield Wiper/Washer System..........................................................................................................11287 General Description.....................................................................................................................11287 Windshield Wiper And Washer Switch......................................................................................................11287 Removal and Installation............................................................................................................11287 Windshield Wiper Motor..................................................................................................................11287 Removal.............................................................................................................................11287 Installation........................................................................................................................11287 Windshield Washer Motor.................................................................................................................11288 Removal.............................................................................................................................11288 Installation........................................................................................................................11288 Windshield Washer Spray Pattern.........................................................................................................11289 Windshield Wiper Linkage................................................................................................................11290 Windshield Wiper Linkage and Associated Parts.......................................................................................11290 Removal.............................................................................................................................11290 Installation........................................................................................................................11290 Windshield Wiper Arm/Blade..............................................................................................................11291 Removal.............................................................................................................................11291 Installation........................................................................................................................11291 Windshield Wiper Blade Rubber...........................................................................................................11292 Removal.............................................................................................................................11292 Installation........................................................................................................................11292 Rear Wiper/Washer System................................................................................................................11293 General Description.....................................................................................................................11293 Rear Wiper and Washer Switch............................................................................................................11293 Removal.............................................................................................................................11293 Installation........................................................................................................................11293 Rear Wiper Motor........................................................................................................................11294 Removal.............................................................................................................................11294 Installation........................................................................................................................11294 Rear Washer Motor.......................................................................................................................11295 Removal.............................................................................................................................11295 Installation........................................................................................................................11295 Alarm and Relay Control Unit............................................................................................................11295 Removal.............................................................................................................................11295 Installation........................................................................................................................11295 Rear Wiper Arm/Blade....................................................................................................................11296 Removal.............................................................................................................................11296 Installation........................................................................................................................11296 Rear Washer Nozzle......................................................................................................................11296 Removal.............................................................................................................................11296 Installation........................................................................................................................11296 Rear Washer Spray Pattern...........................................................................................................11296 Rear Wiper Blade Rubber.................................................................................................................11297 Removal.............................................................................................................................11297 Installation........................................................................................................................11297 Main Data and Specifications............................................................................................................11298 8C ENTERTAINMENT..........................................................................................................................11299 Service Precaution......................................................................................................................11299 Cigarette Lighter.......................................................................................................................11300 General Description.................................................................................................................11300 Removal.............................................................................................................................11300 Installation........................................................................................................................11300 Digital Clock...........................................................................................................................11300 Removal.............................................................................................................................11300 Installation........................................................................................................................11301 Rod Type Antenna........................................................................................................................11301 Removal.............................................................................................................................11301 Installation........................................................................................................................11301 Accessory Socket........................................................................................................................11302 Front Accessory Socket..............................................................................................................11302 Rear Accessory Socket...............................................................................................................11302 Radio...................................................................................................................................11303 Removal.............................................................................................................................11303 Installation........................................................................................................................11303 Speaker.................................................................................................................................11304 Front Speaker.......................................................................................................................11304 Tweeter Assembly....................................................................................................................11304 Rear Speaker........................................................................................................................11304 Horn....................................................................................................................................11305 Removal.............................................................................................................................11305 Installation........................................................................................................................11305 8D WIRING SYSTEM..........................................................................................................................11306 Fuse, Relay and Diode...................................................................................................................11307 Relay / Fuse Box Location...........................................................................................................11307 Relay / Fuse Box (Instrument Panel).................................................................................................11308 Relay / Fuse Box (L4 Engine Room)...................................................................................................11309 Relay / Fuse Box (V6 Engine Room)...................................................................................................11310 Circuit Diagram.........................................................................................................................11311 8E METER AND GAUGE........................................................................................................................11338 Service Precaution......................................................................................................................11338 General Description.....................................................................................................................11338 Meter Assembly..........................................................................................................................11339 General Description.................................................................................................................11339 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................11339 Table for Meter/Gauge Connector Terminal Connections................................................................................11341 Removal.............................................................................................................................11343 Installation........................................................................................................................11343 Warning Light Bulb and Indicator Light Bulb.............................................................................................11343 Removal.............................................................................................................................11343 Installation........................................................................................................................11343 A/T Shift Indicator Light Bulb..........................................................................................................11344 Removal.............................................................................................................................11344 Installation........................................................................................................................11345 Vehicle Speed Sensor....................................................................................................................11345 Removal.............................................................................................................................11345 Installation........................................................................................................................11345 Fuel Tank Unit..........................................................................................................................11346 Removal.............................................................................................................................11346 Installation........................................................................................................................11346 Main Data and Specifications............................................................................................................11347 8F BODY STRUCTURE.........................................................................................................................11348 Service Precaution......................................................................................................................11349 Frame...................................................................................................................................11349 General Description.................................................................................................................11349 Frame Dimensions (LWB)..............................................................................................................11350 Frame Dimensions (SWB)..............................................................................................................11351 General Description (Bumper)............................................................................................................11352 Front Bumper............................................................................................................................11352 Parts Location......................................................................................................................11352 Removal.............................................................................................................................11353 Installation........................................................................................................................11353 Front Bumper Slider Bracket.............................................................................................................11354 Removal.............................................................................................................................11354 Installation........................................................................................................................11354 Rear Bumper.............................................................................................................................11355 Parts Location (Spare tire mounted tailgate model)..................................................................................11355 Removal.............................................................................................................................11356 Installation........................................................................................................................11356 Parts Location (Spare tire mounted under floor model)...............................................................................11358 Removal.............................................................................................................................11359 Installation........................................................................................................................11359 Rear Bumper Slider......................................................................................................................11360 Removal.............................................................................................................................11360 Installation........................................................................................................................11360 General Description (Sheet Metal).......................................................................................................11361 Engine Hood.............................................................................................................................11361 Parts Location......................................................................................................................11361 Removal.............................................................................................................................11362 Installation........................................................................................................................11362 Engine Hood Lock........................................................................................................................11364 Parts Location......................................................................................................................11364 Removal.............................................................................................................................11364 Installation........................................................................................................................11365 Radiator Grille.........................................................................................................................11366 Parts Location......................................................................................................................11366 Removal.............................................................................................................................11366 Installation........................................................................................................................11367 Front Fender Panel......................................................................................................................11368 Parts Location......................................................................................................................11368 Removal.............................................................................................................................11368 Installation........................................................................................................................11369 Body Mounting...........................................................................................................................11371 Parts Location......................................................................................................................11371 Tightening Torque...................................................................................................................11371 Body Dimension..........................................................................................................................11372 General Description (Body)..............................................................................................................11387 Instrument Panel Assembly...............................................................................................................11387 Parts Location......................................................................................................................11387 Removal.............................................................................................................................11388 Installation........................................................................................................................11390 Front Door Assembly.....................................................................................................................11391 Parts Location......................................................................................................................11391 Removal.............................................................................................................................11391 Installation........................................................................................................................11392 Rear Door Assembly......................................................................................................................11393 Parts Location......................................................................................................................11393 Removal.............................................................................................................................11393 Installation........................................................................................................................11394 Front Window Regulator, Glass and Glass Run.............................................................................................11395 Parts Location......................................................................................................................11395 Removal.............................................................................................................................11396 Installation........................................................................................................................11398 Rear Window Regulator, Glass and Glass Run..............................................................................................11399 Parts Location......................................................................................................................11399 Removal.............................................................................................................................11400 Installation........................................................................................................................11402 Tailgate (LWB)..........................................................................................................................11403 Parts Location......................................................................................................................11403 Removal.............................................................................................................................11404 Installation........................................................................................................................11404 Tailgate (SWB)..........................................................................................................................11406 Parts Location......................................................................................................................11406 Removal.............................................................................................................................11406 Installation........................................................................................................................11407 Rear Hatchgate (LWB)....................................................................................................................11408 Parts Location......................................................................................................................11408 Removal.............................................................................................................................11409 Installation........................................................................................................................11409 Adjustment..........................................................................................................................11411 Tailgate Glass (Resin Top)..............................................................................................................11412 Parts Location......................................................................................................................11412 Removal.............................................................................................................................11412 Installation........................................................................................................................11413 Spare Tire Carrier......................................................................................................................11414 Parts Location......................................................................................................................11414 Removal.............................................................................................................................11414 Installation........................................................................................................................11414 Spare Tire Hanger.......................................................................................................................11415 Parts Location......................................................................................................................11415 Removal.............................................................................................................................11416 Installation........................................................................................................................11416 Windshield..............................................................................................................................11417 Parts Location......................................................................................................................11417 Removal.............................................................................................................................11417 Installation........................................................................................................................11418 Rear Quarter Glass (LWB)................................................................................................................11421 Parts Location......................................................................................................................11421 Removal.............................................................................................................................11421 Installation........................................................................................................................11422 Rear Quarter Glass (Resin Top)..........................................................................................................11423 Parts Location......................................................................................................................11423 Removal.............................................................................................................................11423 Installation........................................................................................................................11423 Side Window Glass (SWB).................................................................................................................11425 Parts Location......................................................................................................................11425 Removal.............................................................................................................................11425 Installation........................................................................................................................11425 Main Data and Specifications............................................................................................................11427 Special Tools...........................................................................................................................11430 8G SEATS..................................................................................................................................11431 Service Precaution......................................................................................................................11431 Front Seat Assembly.....................................................................................................................11432 Front Seat Assembly and Associated Parts............................................................................................11432 Removal.............................................................................................................................11432 Installation........................................................................................................................11434 Rear Seat Assembly (LWB)................................................................................................................11435 Rear Seat Cushion Assembly and Associated Parts.....................................................................................11435 Removal.............................................................................................................................11435 Installation........................................................................................................................11436 Rear Seat Back Assembly and Associated Parts........................................................................................11437 Removal.............................................................................................................................11437 Installation........................................................................................................................11438 Rear Seat Assembly (SWB)................................................................................................................11439 Rear Seat Assembly and Associated Parts.............................................................................................11439 Removal.............................................................................................................................11440 Installation........................................................................................................................11440 Main Data and Specifications............................................................................................................11441 8H SECURITY AND LOCKS.....................................................................................................................11443 Service Precaution......................................................................................................................11443 Front Door Lock Assembly................................................................................................................11444 Front Door Lock Assembly and Associated Parts.......................................................................................11444 Removal.............................................................................................................................11445 Installation........................................................................................................................11446 Front Outside Handle....................................................................................................................11447 Front Outside Handle and Associated Parts...........................................................................................11447 Removal.............................................................................................................................11447 Installation........................................................................................................................11447 Rear Door Lock Assembly.................................................................................................................11448 Rear Door Lock Assembly and Associated Parts........................................................................................11448 Removal.............................................................................................................................11449 Installation........................................................................................................................11449 Rear Outside Handle.....................................................................................................................11451 Rear Outside Handle and Associated Parts............................................................................................11451 Removal.............................................................................................................................11451 Installation........................................................................................................................11451 Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................11452 Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................11452 Removal.............................................................................................................................11453 Installation........................................................................................................................11453 Tailgate Lock (SWB).....................................................................................................................11454 Tailgate Lock and Associated Parts..................................................................................................11454 Removal.............................................................................................................................11454 Installation........................................................................................................................11455 Key.....................................................................................................................................11456 Key Coding..........................................................................................................................11456 Key Styles..........................................................................................................................11456 Power Door Lock System..................................................................................................................11457 General Description.................................................................................................................11457 Door Lock Key Switch................................................................................................................11457 Front Door Lock Actuator............................................................................................................11457 Rear Door Lock Actuator.............................................................................................................11457 Tailgate Lock Actuator..............................................................................................................11457 Anti-Theft System.......................................................................................................................11457 General Description.................................................................................................................11457 Anti-Theft & Keyless Entry Controller...............................................................................................11457 Anti-Theft Indicator................................................................................................................11458 Anti-Theft Horn.....................................................................................................................11458 Engine Hood Switch..................................................................................................................11459 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................11459 Main Data and Specifications............................................................................................................11460 8I SUNROOF/CONVERTIBLE TOP...............................................................................................................11461 Service Precaution......................................................................................................................11461 Sunroof Glass (LWB).....................................................................................................................11462 Sunroof Glass and Associated Parts..................................................................................................11462 Removal.............................................................................................................................11462 Installation........................................................................................................................11463 Sunroof Glass (SWB).....................................................................................................................11463 Sunroof Glass and Associated Parts..................................................................................................11463 Removal.............................................................................................................................11464 Installation........................................................................................................................11464 Sunroof Deflector (LWB).................................................................................................................11465 Removal.............................................................................................................................11465 Installation........................................................................................................................11465 Sunroof Deflector (SWB).................................................................................................................11466 Parts Location......................................................................................................................11466 Removal.............................................................................................................................11466 Installation........................................................................................................................11466 Sunshade (LWB)..........................................................................................................................11467 Disassembled View...................................................................................................................11467 Removal.............................................................................................................................11467 Installation........................................................................................................................11468 Sunroof Frame Complete Assembly (LWB)...................................................................................................11469 Sunroof Frame Complete Assembly and Associated Parts................................................................................11469 Removal.............................................................................................................................11469 Installation........................................................................................................................11470 Sunroof Switch..........................................................................................................................11470 Removal.............................................................................................................................11470 Installation........................................................................................................................11470 Sunroof Control Unit....................................................................................................................11471 Removal.............................................................................................................................11471 Installation........................................................................................................................11471 Safety Stop Switch......................................................................................................................11471 Removal.............................................................................................................................11471 Installation........................................................................................................................11471 Limit Switch............................................................................................................................11472 Removal.............................................................................................................................11472 Installation........................................................................................................................11472 Sunroof Motor...........................................................................................................................11472 Removal.............................................................................................................................11472 Installation........................................................................................................................11472 Soft Top Assembly.......................................................................................................................11473 Soft Top Assembly and Associated Parts..............................................................................................11473 Removal.............................................................................................................................11474 Installation........................................................................................................................11474 Resin Top Assembly......................................................................................................................11475 Resin Top Assembly and Associated Parts.............................................................................................11475 Removal.............................................................................................................................11475 Installation........................................................................................................................11476 Seat Belt Cross Bar Assembly............................................................................................................11477 Seat Belt Cross Bar Assembly and Associated Parts...................................................................................11477 Removal.............................................................................................................................11477 Installation........................................................................................................................11478 Main Data and Specifications............................................................................................................11479 8J EXTERIOR / INTERIOR TRIM...............................................................................................................11480 Service Precaution......................................................................................................................11481 Consoles................................................................................................................................11482 Consoles and Associated Parts.......................................................................................................11482 Removal.............................................................................................................................11482 Installation........................................................................................................................11482 Front Door Trim Panel...................................................................................................................11483 Front Door Trim Panel and Associated Parts..........................................................................................11483 Removal.............................................................................................................................11484 Installation........................................................................................................................11484 Rear Door Trim Panel....................................................................................................................11485 Rear Door Trim Panel and Associated Parts...........................................................................................11485 Removal.............................................................................................................................11485 Installation........................................................................................................................11486 Door Mirror Assembly....................................................................................................................11487 Removal.............................................................................................................................11487 Installation........................................................................................................................11487 Interior Trim Panels (LWB)..............................................................................................................11488 Interior Trim Panels and Associated Parts...........................................................................................11488 Removal.............................................................................................................................11488 Installation........................................................................................................................11490 Interior Trim Panels (SWB)..............................................................................................................11491 Interior Trim Panels and Associated Parts...........................................................................................11491 Removal.............................................................................................................................11491 Installation........................................................................................................................11492 Headlining (LWB)........................................................................................................................11493 Parts Location......................................................................................................................11493 Removal.............................................................................................................................11493 Installation........................................................................................................................11494 Headlining (SWB)........................................................................................................................11495 Parts Location......................................................................................................................11495 Removal.............................................................................................................................11496 Installation........................................................................................................................11497 Wheel Arch Protector (LWB)..............................................................................................................11498 Wheel Arch Protector and Associated Parts...........................................................................................11498 Removal.............................................................................................................................11498 Installation........................................................................................................................11498 Wheel Arch Protector (SWB)..............................................................................................................11499 Wheel Arch Protector and Associated Parts...........................................................................................11499 Removal.............................................................................................................................11499 Installation........................................................................................................................11499 Wheel Arch Molding (SWB)................................................................................................................11500 Wheel Arch Molding and Associated Parts.............................................................................................11500 Removal.............................................................................................................................11500 Installation........................................................................................................................11501 Wheel Arch Molding (LWB)................................................................................................................11502 Wheel Arch Molding and Associated Parts.............................................................................................11502 Removal.............................................................................................................................11502 Installation........................................................................................................................11503 Fuel Filler Door........................................................................................................................11504 Parts Location......................................................................................................................11504 Removal.............................................................................................................................11504 Installation........................................................................................................................11504 Roof Rail...............................................................................................................................11505 Parts Location......................................................................................................................11505 Removal.............................................................................................................................11505 Installation........................................................................................................................11505 Power Door Mirror System................................................................................................................11506 General Description.................................................................................................................11506 Door Mirror Switch..................................................................................................................11506 Power Window System.....................................................................................................................11507 General Description.................................................................................................................11507 Power Window Switch Driver Seat Side................................................................................................11507 Power Window Motor..................................................................................................................11508 Main Data and Specifications............................................................................................................11509 Sec.9 RESTRAINTS..............................................................................................................................11561 9A SEAT BELT SYSTEM......................................................................................................................11510 Service Precaution......................................................................................................................11510 Front Seat Belt (LWB)...................................................................................................................11511 Front Seat Belt and Associated Parts................................................................................................11511 Removal.............................................................................................................................11511 Inspection..........................................................................................................................11511 Installation........................................................................................................................11512 Front Seat Belt (SWB)...................................................................................................................11513 Front Seat Belt and Associated Parts................................................................................................11513 Removal.............................................................................................................................11513 Inspection..........................................................................................................................11514 Installation........................................................................................................................11514 Rear Seat Belt (LWB)....................................................................................................................11515 Rear Seat Belt and Associated Parts.................................................................................................11515 Removal.............................................................................................................................11515 Inspection..........................................................................................................................11516 Installation........................................................................................................................11516 Rear Seat Belt (SWB)....................................................................................................................11517 Rear Seat Belt and Associated Parts.................................................................................................11517 Removal.............................................................................................................................11517 Inspection..........................................................................................................................11519 Installation........................................................................................................................11519 Front Seat Buckle Assembly..............................................................................................................11520 Removal.............................................................................................................................11520 Installation........................................................................................................................11520 Rear Center Seat Belt / Buckle Assembly.................................................................................................11521 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................11521 Removal.............................................................................................................................11521 Installation........................................................................................................................11521 Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................11522 General Description.................................................................................................................11522 Child Seat Tether Anchor Bracket and Associated Parts...............................................................................11522 Installation........................................................................................................................11522 Main Data and Specifications............................................................................................................11523 9J SEAT BELT SYSTEM......................................................................................................................11525 Service Precaution......................................................................................................................11526 General Description.....................................................................................................................11526 Restraint Devices...................................................................................................................11526 System Description..................................................................................................................11527 SRS Component and Wiring Location View..................................................................................................11528 Component Description...............................................................................................................11528 SDM (Sensing and Diagnostic Module).................................................................................................11528 "Air Bag" Warning Lamp..............................................................................................................11529 SRS Coil Assembly...................................................................................................................11529 Air Bag Assemblies..................................................................................................................11529 Steering Column.....................................................................................................................11530 Knee Bolster........................................................................................................................11530 Definition..............................................................................................................................11530 Diagnosis...............................................................................................................................11531 Diagnostic Trouble Codes............................................................................................................11531 Scan Tool Diagnostics...............................................................................................................11531 Use of Special Tools................................................................................................................11532 SRS Connector Body Face Views...........................................................................................................11532 Repairs and Inspections Required After an Accident......................................................................................11532 Accident With Deployment - Component Replacement and Inspections....................................................................11533 Accident With or Without Deployment佑omponent Inspection.............................................................................11533 SDM Replacement Guidelines..........................................................................................................11533 Wiring Damage.......................................................................................................................11533 SRS Connector (Plastic Body And Terminal Metal Pin) Damage..........................................................................11533 SRS Wire Pigtail Damage.............................................................................................................11533 On-Vehicle Service......................................................................................................................11533 Service Precautions.................................................................................................................11533 Disabling The SRS...................................................................................................................11533 Enabling The SRS....................................................................................................................11533 Handling / Installation / Diagnosis.................................................................................................11534 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................11534 Live (Undeployed) Air Bag Assembly..................................................................................................11534 Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................11535 Deployed Air Bag Assembly...........................................................................................................11535 Air Bag Assembly Scrapping Procedure................................................................................................11535 Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................11535 Deployment Outside Vehicle (Passenger Air Bag Assembly).............................................................................11537 Deployment Inside Vehicle (Vehicle Scrapping Procedure).............................................................................11539 Deployed Air Bag Assembly Handling..................................................................................................11542 Special Tools...........................................................................................................................11542 J-41433 SRS Driver/Passenger Load Tool..............................................................................................11542 J-39200 DVM.........................................................................................................................11543 Scan Tool...........................................................................................................................11543 J-35616-A Connector Test Adapter Kit................................................................................................11543 J-42986 SRS Deployment Tool.........................................................................................................11543 J-42987 SRS Adapter For Load Tool...................................................................................................11544 J-41497 SRS Deployment Fixture......................................................................................................11544 Tech 2 Scan Tool....................................................................................................................11545 DTC Modes...........................................................................................................................11548 Plottong Snapshot Graph.................................................................................................................11548 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................11549 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................11550 Service Precaution......................................................................................................................11551 Disabling The SRS...................................................................................................................11551 Enabling The SRS....................................................................................................................11551 Handling / Installation / Diagnosis.................................................................................................11551 Inspections Required After An Accident..............................................................................................11551 Sensing and Diagnostic Module (SDM).....................................................................................................11552 Service Precautions.................................................................................................................11552 Removal.............................................................................................................................11552 Installation........................................................................................................................11553 Driver Air Bag Assembly.................................................................................................................11553 Service Precautions.................................................................................................................11553 Removal.............................................................................................................................11553 Installation........................................................................................................................11554 Steering Wheel..........................................................................................................................11554 Service Precautions.................................................................................................................11554 Removal.............................................................................................................................11554 Installation........................................................................................................................11555 SRS Coil Assembly.......................................................................................................................11556 Service Precaution..................................................................................................................11556 Removal.............................................................................................................................11556 Installation........................................................................................................................11556 Steering Column.........................................................................................................................11558 Service Precaution..................................................................................................................11558 Removal.............................................................................................................................11558 Installation........................................................................................................................11559 Passenger Air Bag Assembly..............................................................................................................11560 Service Precaution..................................................................................................................11560 Removal.............................................................................................................................11560 Installation........................................................................................................................11560 9J1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................11561 Service Precaution......................................................................................................................11561 Diagnostic Information..................................................................................................................11562 Diagnostic Procedures...............................................................................................................11562 Diagnostic Codes....................................................................................................................11562 How To Read Trouble Codes...........................................................................................................11562 How To Clear Trouble Codes..........................................................................................................11562 Scan Tool Diagnostics...............................................................................................................11562 Basic Knowledge Required............................................................................................................11562 Basic Electrical Circuits...........................................................................................................11562 "Flash Code" Diagnostics............................................................................................................11562 System Schematic........................................................................................................................11563 SRS Diagnostic System Check.............................................................................................................11564 Chart A SDM Integrity Check.............................................................................................................11566 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................11568 Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady...............................................................................11570 DTC 15 Passenger Deployment Loop Resistance High........................................................................................11573 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................11576 DTC 17 Passenger Deployment Loop Open...................................................................................................11579 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................11581 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................11583 DTC 21 Driver Deployment Loop Resistance High...........................................................................................11585 DTC 22 Driver Deployment Loop Resistance Low............................................................................................11588 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................11591 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................11593 DTC 26 Driver Deployment Loop Open......................................................................................................11596 DTC 51 Deployment Event Commanded.......................................................................................................11599 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................11601 DTC 61 Warning Lamp Circuit Failure.....................................................................................................11603 DTC 71 Internal SDM Fault...............................................................................................................11605 Sec.10 CONTROL SYSTEM..........................................................................................................................11607 10A CRUISE CONTROL SYSTEM.................................................................................................................11607 Service Precaution......................................................................................................................11607 General Description.....................................................................................................................11607 Brake Switch............................................................................................................................11608 Removal and Installation............................................................................................................11608 Adjustment..........................................................................................................................11608 Clutch Switch...........................................................................................................................11609 Removal and Installation............................................................................................................11609 Adjustment..........................................................................................................................11609 Powertrain Control Module (PCM) Removal and Installation................................................................................11609 Mode Switch Removal and Installation................................................................................................11609 Cruise Control Main Switch..............................................................................................................11610 Removal.............................................................................................................................11610 Installation........................................................................................................................11610 Cruise Control Switch (Combination Switch)..............................................................................................11610 Removal and Installation............................................................................................................11610 Diagnosis...............................................................................................................................11611 (UA) AMIGO..........................................................................................................................................11612 Sec.0 GENERAL INFORMATION.....................................................................................................................11628 0A GENERAL INFORMATION.....................................................................................................................11613 General Repair Instruction..............................................................................................................11613 Illustration Arrows.....................................................................................................................11614 Identification..........................................................................................................................11615 Theft Prevention Standard...............................................................................................................11618 Lifting Instructions....................................................................................................................11623 Standard Bolts Torque Specifications....................................................................................................11625 Abbreviations Charts....................................................................................................................11626 Service Parts Identification Plate......................................................................................................11627 0B MAINTENANCE AND LUBRICATION.............................................................................................................11628 Maintenance Schedule List...............................................................................................................11628 Explanation of Complete Vehicle Maintenance Schedule....................................................................................11632 Recommended Fluids and Lubricants...................................................................................................11635 Lubricant Viscosity Chart...............................................................................................................11636 Recommended Liquid Gasket...........................................................................................................11638 Recommended Thread Locking Agents...................................................................................................11638 Maintenance Service Data................................................................................................................11639 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................11640 1A HVAC SYSTEMS...........................................................................................................................11640 Sec.2 STEERING................................................................................................................................11641 2A POWER-ASSISTED STEERING SYSTEM.........................................................................................................11641 Service Precaution......................................................................................................................11642 Diagnosis...............................................................................................................................11642 General Description.....................................................................................................................11648 Power Steering System Test..............................................................................................................11650 Maintenance.............................................................................................................................11651 Fluid Level.............................................................................................................................11651 Bleeding The Power Steering System......................................................................................................11651 Bleeding Procedure......................................................................................................................11651 Flushing The Power Steering System......................................................................................................11651 Steering Wheel Free Play Inspection.....................................................................................................11652 Front End Alignment Inspection and Adjustment...........................................................................................11652 Main Data and Specifications............................................................................................................11656 Special Tools...........................................................................................................................11657 Power Steering Unit.....................................................................................................................11658 Power Steering Unit and Associated Parts............................................................................................11658 Removal.............................................................................................................................11658 Installation (4 × 2 Model)..........................................................................................................11659 Installation (4 × 4 Model)..........................................................................................................11659 Power Steering Unit Disassembled View...............................................................................................11660 Disassembly.........................................................................................................................11660 Inspection and Repair...............................................................................................................11660 Reassembly..........................................................................................................................11660 Main Data and Specifications........................................................................................................11661 Special Tools.......................................................................................................................11661 Power Steering Pump.....................................................................................................................11662 Power Steering Pump and Associated Parts............................................................................................11662 Removal.............................................................................................................................11662 Installation........................................................................................................................11662 Power Steering Pump Disassembled View...............................................................................................11663 Disassembly.........................................................................................................................11663 Inspection and Repair...............................................................................................................11664 Reassembly..........................................................................................................................11664 Main Data and Specifications........................................................................................................11666 Transfer Gear Assembly..................................................................................................................11667 Transfer Gear Assembly and Associated Parts.........................................................................................11667 Removal.............................................................................................................................11667 Inspection and Repair...............................................................................................................11667 Installation........................................................................................................................11667 Supplemental Restraint System Steering Wheel & Column...................................................................................11668 Service Precaution..................................................................................................................11668 Inflator Module.........................................................................................................................11669 Inflator Module and Associated Parts................................................................................................11669 Removal.............................................................................................................................11669 Inspection and Repair...............................................................................................................11670 Installation........................................................................................................................11670 Steering Wheel..........................................................................................................................11671 Steering Wheel and Associated Parts.................................................................................................11671 Removal.............................................................................................................................11671 Installation........................................................................................................................11673 Combination Switch......................................................................................................................11674 Combination Switch and Associated Parts.............................................................................................11674 Removal.............................................................................................................................11674 Installation........................................................................................................................11676 Lock Cylinder...........................................................................................................................11678 Lock Cylinder and Associated Parts..................................................................................................11678 Removal.............................................................................................................................11678 Installation........................................................................................................................11680 System Inspection...................................................................................................................11681 Steering Column.........................................................................................................................11682 Steering Column and Associated Parts................................................................................................11682 Removal.............................................................................................................................11682 Installation........................................................................................................................11684 System Inspection...................................................................................................................11685 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................11686 Main Data and Specifications........................................................................................................11686 Special Tools.......................................................................................................................11686 Sec.3 SUSPENSION..............................................................................................................................11687 3C FRONT SUSPENSION.......................................................................................................................11687 Service Precaution......................................................................................................................11687 General Description.....................................................................................................................11688 Diagnosis...............................................................................................................................11688 Shock Absorber..........................................................................................................................11691 Shock Absorber and Associated Parts.................................................................................................11691 Removal.............................................................................................................................11691 Inspection and Repair...............................................................................................................11691 Installation........................................................................................................................11691 Stabilizer Bar..........................................................................................................................11692 Stabilizer Bar and Associated Parts.................................................................................................11692 Removal.............................................................................................................................11692 Inspection and Repair...............................................................................................................11692 Installation........................................................................................................................11692 Torsion Bar.............................................................................................................................11693 Torsion Bar and Associated Parts....................................................................................................11693 Removal.............................................................................................................................11693 Inspection and Repair...............................................................................................................11694 Installation........................................................................................................................11694 Knuckle.................................................................................................................................11696 Knuckle and Associated Parts........................................................................................................11696 Removal.............................................................................................................................11696 Inspection and Repair...............................................................................................................11697 Installation........................................................................................................................11697 Upper Control Arm.......................................................................................................................11699 Upper Control Arm and Associated Parts..............................................................................................11699 Removal.............................................................................................................................11699 Inspection and Repair...............................................................................................................11700 Installation........................................................................................................................11700 Lower Control Arm.......................................................................................................................11702 Lower Control Arm and Associated Parts..............................................................................................11702 Removal.............................................................................................................................11702 Inspection and Repair...............................................................................................................11703 Installation........................................................................................................................11704 Upper Ball Joint........................................................................................................................11705 Upper Ball Joint and Associated Parts...............................................................................................11705 Removal.............................................................................................................................11705 Inspection and Repair...............................................................................................................11706 Installation........................................................................................................................11706 Lower Ball Joint........................................................................................................................11707 Lower Ball Joint and Associated Parts...............................................................................................11707 Removal.............................................................................................................................11707 Inspection and Repair...............................................................................................................11708 Installation........................................................................................................................11708 Main Data and Specifications............................................................................................................11709 Special Tools...........................................................................................................................11710 3D REAR SUSPENSION........................................................................................................................11711 Service Precaution......................................................................................................................11711 General Description.....................................................................................................................11711 Diagnosis...............................................................................................................................11712 Coil Spring.............................................................................................................................11715 Coil Spring and Associated Parts....................................................................................................11715 Removal.............................................................................................................................11715 Inspection and Repair...............................................................................................................11716 Installation........................................................................................................................11716 Shock Absorber..........................................................................................................................11717 Shock Absorber and Associated Parts.................................................................................................11717 Removal.............................................................................................................................11717 Inspection and Repair...............................................................................................................11717 Installation........................................................................................................................11717 Trailing Link...........................................................................................................................11718 Trailing Link and Associated Parts..................................................................................................11718 Removal.............................................................................................................................11718 Inspection and Repair...............................................................................................................11718 Installation........................................................................................................................11719 Upper Link..............................................................................................................................11720 Upper Link and Associated Parts.....................................................................................................11720 Removal.............................................................................................................................11720 Inspection and Repair...............................................................................................................11720 Installation........................................................................................................................11721 Lateral Rod.............................................................................................................................11722 Lateral Rod and Associated Parts....................................................................................................11722 Removal.............................................................................................................................11722 Inspection and Repair...............................................................................................................11722 Installation........................................................................................................................11723 Stabilizer Bar..........................................................................................................................11724 Stabilizer Bar and Associated Parts.................................................................................................11724 Removal.............................................................................................................................11724 Inspection and Repair...............................................................................................................11724 Installation........................................................................................................................11725 Main Data and Specifications............................................................................................................11725 Special Tools...........................................................................................................................11727 3E WHEEL AND TIRE SYSTEM..................................................................................................................11728 3F INTELLIGENT SUSPENSION SYSTEM..........................................................................................................11729 Service Precaution......................................................................................................................11730 General Description.....................................................................................................................11730 PIN ASSIGNMENT TABLE................................................................................................................11732 System Components...................................................................................................................11732 Control Unit........................................................................................................................11732 Actuator............................................................................................................................11732 Adjustable Damping Force Shock Absorber.............................................................................................11732 Warning Lamp........................................................................................................................11732 Vertical G-Sensor...................................................................................................................11733 Horizontal G-Sensor.................................................................................................................11733 Acronyms and Abbreviations..........................................................................................................11733 General Diagnosis.......................................................................................................................11733 General Information.................................................................................................................11733 Service Precautions.................................................................................................................11733 Computer System Service Precautions.................................................................................................11733 General Service Precautions.........................................................................................................11733 Parts Handling......................................................................................................................11733 FLASHING CODES......................................................................................................................11734 CLEAR DTC...........................................................................................................................11735 INTERMITTENT CONDITIONS.............................................................................................................11736 BULB CHECK..........................................................................................................................11736 DTC CHECK...........................................................................................................................11736 Basic Diagnosis Flow................................................................................................................11737 Circuit Diagram.....................................................................................................................11738 Parts Location......................................................................................................................11741 Connector List......................................................................................................................11742 Diagnostic Trouble Code (DTC) Identification........................................................................................11744 DTC2 Actuator Coil Over Current.........................................................................................................11745 Circuit Description.................................................................................................................11745 Diagnostic Aids.....................................................................................................................11745 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................11747 Circuit Description.................................................................................................................11747 Diagnostic Aids.....................................................................................................................11747 DTC4 G-Sensor Open Circuit or Short.....................................................................................................11750 Circuit Description.................................................................................................................11750 Diagnostic Aids.....................................................................................................................11750 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................11751 Circuit Description.................................................................................................................11751 Diagnostic Aids.....................................................................................................................11751 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................11753 Circuit Description.................................................................................................................11753 Diagnostic Aids.....................................................................................................................11753 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................11755 Circuit Description.................................................................................................................11755 Diagnostic Aids.....................................................................................................................11755 DTC9 Control Unit Abnormality.......................................................................................................11756 Control Unit............................................................................................................................11760 Control Unit and Associated Parts...................................................................................................11760 Removal.............................................................................................................................11760 Installation........................................................................................................................11761 Front Actuator..........................................................................................................................11762 Front Actuator and Associated Parts.................................................................................................11762 Removal.............................................................................................................................11763 Inspection and Repair...............................................................................................................11763 Installation........................................................................................................................11763 Rear Shock Absorber.....................................................................................................................11764 Rear Shock Absorber and Associated Parts............................................................................................11764 Removal.............................................................................................................................11765 Inspection and Repair...............................................................................................................11765 Installation........................................................................................................................11765 Sec.4 DRIVELINE/AXLE..........................................................................................................................11766 4A1 DIFFERENTIAL (FRONT)..................................................................................................................11766 Main Data And Specifications............................................................................................................11767 4A2 DIFFERENTIAL (REAR)...................................................................................................................11768 Main Data And Specifications............................................................................................................11769 4B DRIVELINE CONTROL SYSTEM..............................................................................................................11770 4C DRIVE SHAFT SYSTEM....................................................................................................................11771 Service Precaution......................................................................................................................11772 Front Propeller Shaft...................................................................................................................11773 General Description.................................................................................................................11773 Diagnosis of Propeller Shaft and Universal Joint....................................................................................11775 Front Propeller Shaft and Associated Parts..........................................................................................11776 Removal.............................................................................................................................11776 Installation........................................................................................................................11776 Slip Joint Disassembly..............................................................................................................11777 Universal Joint Disassembly(Single Cardan Type).....................................................................................11778 Universal Joint Reassembly(Single Cardan Type)......................................................................................11780 Slip Joint Reassembly...............................................................................................................11782 Main Data And Specifications........................................................................................................11783 Rear Propeller Shaft....................................................................................................................11784 General Description.................................................................................................................11784 Diagnosis of Propeller Shaft and Universal Joint....................................................................................11786 Rear Propeller Shaft and Associated Parts...........................................................................................11787 Removal.............................................................................................................................11787 Installation........................................................................................................................11787 Slip Joint Disassembly (6VD1 Model Only)............................................................................................11788 Universal Joint Disassembly.........................................................................................................11789 Inspection..........................................................................................................................11791 Universal Joint Reassembly..........................................................................................................11792 Slip Joint Reassembly (6VD1 Model Only).............................................................................................11793 Main Data and Specifications........................................................................................................11794 4D TRANSFER CASE.........................................................................................................................11795 Sec.5 BRAKE...................................................................................................................................11796 5A BRAKE CONTROL SYSTEM..................................................................................................................11796 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................11796 5C POWER-ASSISTED BRAKE SYSTEM...........................................................................................................11796 5D1 PARKING BRAKE SYSTEM (4x4 Model)......................................................................................................11796 5D2 PARKING BRAKE SYSTEM (4x2 Model)......................................................................................................11796 Sec.6 ENGINE..................................................................................................................................11797 X22SE 2.2L ENGINE...........................................................................................................................11797 6A ENGINE MECHANICAL..................................................................................................................11797 6B ENGINE COOLING.....................................................................................................................11797 6C ENGINE FUEL........................................................................................................................11797 6D1 ENGINE ELECTRICAL..................................................................................................................11797 6D2 IGNITION SYSTEM....................................................................................................................11797 6D3 STARTING AND CHARGING SYSTEM.......................................................................................................11797 6E1 DRIVEABILITY AND EMISSIONS.........................................................................................................11797 6F ENGINE EXHAUST.....................................................................................................................11797 6G ENGINE LUBRICATION.................................................................................................................11797 6H ENGINE SPEED CONTROL SYSTEM........................................................................................................11797 6J INDUCTION..........................................................................................................................11797 6VD1 3.2L ENGINE...........................................................................................................................11797 6A ENGINE MECHANICAL..................................................................................................................11797 6B ENGINE COOLING.....................................................................................................................11797 6C ENGINE FUEL........................................................................................................................11797 6D1 ENGINE ELECTRICAL..................................................................................................................11797 6D2 IGNITION SYSTEM....................................................................................................................11797 6D3 STARTING AND CHARGING SYSTEM.......................................................................................................11797 6E2 DRIVEABILITY AND EMISSIONS.........................................................................................................11797 6F ENGINE EXHAUST.....................................................................................................................11797 6G ENGINE LUBRICATION.................................................................................................................11797 6H ENGINE SPEED CONTROL SYSTEM........................................................................................................11797 6J INDUCTION..........................................................................................................................11797 Sec.7 AUTOMATIC TRANSMISSION..................................................................................................................11798 7B MANUAL TRANSMISSION MUA 5C..............................................................................................................11798 7C CLUTCH..................................................................................................................................11798 Sec.8 LIGHTING SYSTME.........................................................................................................................11799 8A LIGHTING SYSTEM........................................................................................................................11799 8B WIPER / WASHER SYSTEM..................................................................................................................11799 8C ENTERTAINMENT..........................................................................................................................11799 8D WIRING SYSTEM..........................................................................................................................11799 8E METER AND GAUGE........................................................................................................................11799 8F BODY STRUCTURE.........................................................................................................................11799 8G SEATS..................................................................................................................................11799 8H SECURITY AND LOCKS.....................................................................................................................11799 8I SUNROOF/CONVERTIBLE TOP...............................................................................................................11799 8J EXTERIOR / INTERIOR TRIM...............................................................................................................11799 Sec.9 SEAT BELT SYSTEM........................................................................................................................11800 9A SEAT BELT SYSTEM......................................................................................................................11800 9J SEAT BELT SYSTEM......................................................................................................................11800 9J1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................11800 Sec.10 CRUISE CONTROL SYSTEM...................................................................................................................11801 10A CRUISE CONTROL SYSTEM.................................................................................................................11801 (VX) VEHICROSS......................................................................................................................................11802 Sec.0 GENERAL INFORMATION.....................................................................................................................11803 0A GENERAL INFORMATION....................................................................................................................11803 General Repair Instruction..............................................................................................................11803 Illustration Arrows.....................................................................................................................11804 Identification..........................................................................................................................11805 Theft Prevention Standard...............................................................................................................11807 Lifting Instructions....................................................................................................................11811 Standard Bolts Torque Specifications....................................................................................................11814 Abbreviations Charts....................................................................................................................11815 Service Parts Identification Plate......................................................................................................11816 0B MAINTENANCE AND LUBRICATION............................................................................................................11817 Maintenance Schedule List...............................................................................................................11817 Explanation of Complete Vehicle Maintenance Schedule....................................................................................11820 Recommended Fluids and Lubricants...................................................................................................11823 Lubricant Viscosity Chart...............................................................................................................11824 Recommended Thread Locking Agents.......................................................................................................11826 Maintenance Service Data................................................................................................................11827 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................11828 1A HVAC SYSTEMS...........................................................................................................................11828 Service Precaution......................................................................................................................11830 Heating and Ventilation System..........................................................................................................11830 General Description.................................................................................................................11830 Wiring Diagram......................................................................................................................11834 Diagnosis...........................................................................................................................11835 Individual Inspection...............................................................................................................11839 Heater Unit.............................................................................................................................11841 Heater Unit and Associated Parts....................................................................................................11841 Removal.............................................................................................................................11841 Installation........................................................................................................................11842 Heater Core and / or Mode Door..........................................................................................................11842 Disassembled View...................................................................................................................11842 Removal.............................................................................................................................11843 Inspection..........................................................................................................................11843 Installation........................................................................................................................11843 Heater Mode Control Link Unit...........................................................................................................11844 Disassembled View...................................................................................................................11844 Removal.............................................................................................................................11844 Installation........................................................................................................................11845 Heater Temperature Control Link Unit....................................................................................................11845 Disassembled View...................................................................................................................11845 Removal.............................................................................................................................11845 Installation........................................................................................................................11845 Blower Assembly.........................................................................................................................11846 Blower Assembly and Associated Parts................................................................................................11846 Removal.............................................................................................................................11846 Installation........................................................................................................................11847 Blower Link Unit and / or Mode door.....................................................................................................11847 Disassembled View...................................................................................................................11847 Removal.............................................................................................................................11847 Installation........................................................................................................................11848 Blower Motor............................................................................................................................11849 Blower Motor and Associated Parts...................................................................................................11849 Removal.............................................................................................................................11849 Installation........................................................................................................................11849 Defroster Nozzle and Ventilation Duct...................................................................................................11850 Defroster Nozzle, Ventilation Duct and Associated Parts.............................................................................11850 Removal.............................................................................................................................11850 Installation........................................................................................................................11851 Control Lever Assembly and / or Control Cable...........................................................................................11851 Control Lever Assembly, Control Cable and Associated Parts..........................................................................11851 Removal.............................................................................................................................11852 Installation........................................................................................................................11853 Heater Bezel Illumination Bulb..........................................................................................................11854 Heater Bezel Illumination Bulb and Associated Parts.................................................................................11854 Removal.............................................................................................................................11854 Installation........................................................................................................................11854 Resistor................................................................................................................................11855 Resistor and Associated Parts.......................................................................................................11855 Removal.............................................................................................................................11855 Installation........................................................................................................................11855 Air Conditioning System.................................................................................................................11856 General Description.................................................................................................................11856 Air Conditioning Refrigerant Cycle Construction.....................................................................................11857 Wiring Diagram......................................................................................................................11864 Connector List......................................................................................................................11868 Diagnosis...........................................................................................................................11870 Individual Inspection...............................................................................................................11880 General Repair Procedure............................................................................................................11881 Leak Check..........................................................................................................................11884 Compressor Assembly.....................................................................................................................11889 Compressor Assembly and Associated Parts............................................................................................11889 Removal.............................................................................................................................11889 Installation........................................................................................................................11890 New Compressor Installation.........................................................................................................11890 Condenser Assembly......................................................................................................................11891 Condenser Assembly and Associated Parts.............................................................................................11891 Removal.............................................................................................................................11891 Installation........................................................................................................................11891 Condenser Fan Motor.....................................................................................................................11892 Condenser Fan Motor and Associated Parts............................................................................................11892 Removal.............................................................................................................................11893 Installation........................................................................................................................11893 Receiver / Drier........................................................................................................................11893 Receiver / Drier and Associated Parts...............................................................................................11893 Removal.............................................................................................................................11893 Installation........................................................................................................................11893 Pressure Switch.........................................................................................................................11894 Pressure Switch and Associated Parts................................................................................................11894 Removal.............................................................................................................................11894 Installation........................................................................................................................11894 Evaporator Assembly.....................................................................................................................11895 Evaporator Assembly and Associated Parts............................................................................................11895 Removal.............................................................................................................................11895 Installation........................................................................................................................11896 Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................11896 Disassembled View...................................................................................................................11896 Removal.............................................................................................................................11897 Installation........................................................................................................................11897 Refrigerant Line........................................................................................................................11898 Refrigerant Line and Associated Parts...............................................................................................11898 Removal.............................................................................................................................11899 Installation........................................................................................................................11899 Main Data And Specifications............................................................................................................11900 Compressor..............................................................................................................................11903 Service Precaution..................................................................................................................11903 General Description.................................................................................................................11903 Diagnosis...........................................................................................................................11904 Magnetic Clutch Assembly (DKV-14D Type).................................................................................................11905 Parts Location View.................................................................................................................11905 Removal.............................................................................................................................11905 Inspection and Repair...............................................................................................................11907 Installation........................................................................................................................11907 Compressor Oil..........................................................................................................................11909 Oil Specification...................................................................................................................11909 Handling of Oil.....................................................................................................................11909 Compressor Oil Check................................................................................................................11909 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................11909 Checking and Adjusting for Compressor Replacement...................................................................................11910 Contamination of Compressor Oil.....................................................................................................11910 Oil Return Operation................................................................................................................11910 Replacement of Component Parts......................................................................................................11910 Main Data and Specifications............................................................................................................11911 Special Tools...........................................................................................................................11913 Automatic Air Conditioning System.......................................................................................................11914 General Description.................................................................................................................11914 Full Automatic Air Conditioner Parts Configuration..................................................................................11914 Refrigerant Line and Associated Parts...............................................................................................11915 Circuit Diagram.....................................................................................................................11916 Functions and Features..............................................................................................................11921 Automatic Air Conditioner Block Diagram.............................................................................................11922 Control Panel Layout................................................................................................................11923 Air Control Functions...............................................................................................................11924 Operation and Functions of Control Panel Switches...................................................................................11925 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System..................................11927 Overview of Automatic Control of Automatic Air Conditioner..........................................................................11931 Troubleshooting, Its Overview and Procedures............................................................................................11935 Auto Air Conditioner Control Unit Power Supply Diagnosis................................................................................11936 Performance and Movement checklist for Automatic Air Conditioner Related Parts..........................................................11938 Troubleshooting With Self-Diagnosis Function............................................................................................11940 Inspection By Failed Location...........................................................................................................11944 Inspection of the Sensors...........................................................................................................11944 Inspection of the Intake Actuator System................................................................................................11948 Inspection of the Mix Actuator System...................................................................................................11951 Inspection of the Mode Actuator System..................................................................................................11954 Inspection of the Fan Motor System......................................................................................................11957 Inspection of the Magnetic Clutch System................................................................................................11962 Individual Inspection...................................................................................................................11965 On-Vehicle Service......................................................................................................................11968 Power Transistor....................................................................................................................11968 Automatic Heater/Air Conditioner Control Unit.......................................................................................11968 In Car Sensor.......................................................................................................................11969 Ambient Sensor......................................................................................................................11969 Sun Sensor..........................................................................................................................11970 Electronic Thermostat...............................................................................................................11970 Mode Actuator.......................................................................................................................11971 Mix Actuator........................................................................................................................11971 Intake Actuator.....................................................................................................................11972 Sec.2 STEERING................................................................................................................................11973 2A POWER ASSISTED SYSTEM...................................................................................................................11973 Service Precaution......................................................................................................................11974 General Description.....................................................................................................................11974 Diagnosis...............................................................................................................................11977 Power Steering System Test..............................................................................................................11983 Maintenance.............................................................................................................................11983 Fluid Level.............................................................................................................................11984 Bleeding The Power Steering System......................................................................................................11984 Bleeding Procedure......................................................................................................................11984 Flushing The Power Steering System......................................................................................................11984 Steering Wheel Free Play Adjustment.....................................................................................................11984 Front End Alignment Inspection and Adjustment...........................................................................................11985 Main Data and Specifications............................................................................................................11990 Special Tools...........................................................................................................................11991 Power Steering Gear.....................................................................................................................11992 Power Steering Gear and Associated Parts............................................................................................11992 Removal.............................................................................................................................11992 Installation........................................................................................................................11993 Steering Gear Disassembled View.....................................................................................................11994 Disassembly.........................................................................................................................11994 Inspection and Repair...............................................................................................................11996 Reassembly..........................................................................................................................11997 Main Data and Specifications........................................................................................................11999 Special Tools.......................................................................................................................12000 Power Steering Pump.....................................................................................................................12001 Power Steering Pump and Associated Parts............................................................................................12001 Removal.............................................................................................................................12001 Installation........................................................................................................................12002 Power Steering Pump Disassembled View...............................................................................................12003 Disassembly.........................................................................................................................12003 Inspection and Repair...............................................................................................................12004 Reassembly..........................................................................................................................12005 Main Data and Specifications........................................................................................................12006 Center Track Rod Assembly...............................................................................................................12007 Center Track Rod Assembly and Associated Parts......................................................................................12007 Removal.............................................................................................................................12007 Inspection and Repair...............................................................................................................12008 Installation........................................................................................................................12008 Outer Track Rod Assembly................................................................................................................12009 Outer Track Rod Assembly and Associated Parts.......................................................................................12009 Removal.............................................................................................................................12009 Inspection and Repair...............................................................................................................12011 Installation........................................................................................................................12011 Relay Lever.............................................................................................................................12012 Relay Lever and Associated Parts....................................................................................................12012 Removal.............................................................................................................................12012 Installation........................................................................................................................12013 Steering Linkage and Associated Parts...................................................................................................12014 Main Data and Specifications........................................................................................................12014 Special Tools.......................................................................................................................12015 Supplemental Restraint System Steering Wheel & Column...................................................................................12016 Service Precaution..................................................................................................................12016 SRS Connectors (3 pin)..............................................................................................................12016 SRS Connectors (2 pin)..............................................................................................................12016 Inflator Module.........................................................................................................................12018 Inflator Module and Associated Parts................................................................................................12018 Removal.............................................................................................................................12018 Inspection and Repair...............................................................................................................12019 Installation........................................................................................................................12019 Steering Wheel..........................................................................................................................12020 Steering Wheel and Associated Parts.................................................................................................12020 Removal.............................................................................................................................12020 Installation........................................................................................................................12022 Combination Switch......................................................................................................................12023 Combination Switch and Associated Parts.............................................................................................12023 Removal.............................................................................................................................12023 Installation........................................................................................................................12025 Lock Cylinder...........................................................................................................................12027 Lock Cylinder and Associated Parts..................................................................................................12027 Removal.............................................................................................................................12027 Installation........................................................................................................................12029 System Inspection...................................................................................................................12030 Steering Column.........................................................................................................................12031 Steering Column and Associated Parts................................................................................................12031 Removal.............................................................................................................................12031 Inspection..........................................................................................................................12033 Installation........................................................................................................................12035 System Inspection...................................................................................................................12036 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................12037 Main Data and Specifications........................................................................................................12037 Special Tools.......................................................................................................................12038 Sec.3 SUSPENSION..............................................................................................................................12083 3C FRONT SUSPENSION.......................................................................................................................12039 Service Precaution......................................................................................................................12039 General Description.....................................................................................................................12040 General Diagnosis.......................................................................................................................12041 Shock Absorber..........................................................................................................................12044 Shock Absorber and Associated Parts.................................................................................................12044 Removal.............................................................................................................................12044 Inspection and Repair...............................................................................................................12045 Installation........................................................................................................................12045 Stabilizer Bar..........................................................................................................................12046 Stabilizer Bar and Associated Parts.................................................................................................12046 Removal.............................................................................................................................12046 Inspection and Repair...............................................................................................................12046 Installation........................................................................................................................12046 Torsion Bar.............................................................................................................................12047 Torsion Bar and Associated Parts....................................................................................................12047 Removal.............................................................................................................................12047 Inspection and Repair...............................................................................................................12048 Installation........................................................................................................................12048 Special Tools...........................................................................................................................12065 3D REAR SUSPENSION........................................................................................................................12066 Service Precaution......................................................................................................................12066 General Description.....................................................................................................................12067 Coil Spring.............................................................................................................................12068 Coil Spring and Associated Parts....................................................................................................12068 Removal.............................................................................................................................12068 Inspection and Repair...............................................................................................................12069 Installation........................................................................................................................12069 Shock Absorber..........................................................................................................................12070 Shock Absorber and Associated Parts.................................................................................................12070 Removal.............................................................................................................................12070 Inspection and Repair...............................................................................................................12070 Installation........................................................................................................................12071 Trailing Link...........................................................................................................................12072 Trailing Link and Associated Parts..................................................................................................12072 Removal.............................................................................................................................12072 Inspection and Repair...............................................................................................................12072 Installation........................................................................................................................12073 Center Link.............................................................................................................................12074 Center Link and Associated Parts....................................................................................................12074 Removal.............................................................................................................................12074 Inspection and Repair...............................................................................................................12074 Installation........................................................................................................................12075 Lateral Rod.............................................................................................................................12076 Lateral Rod and Associated Parts....................................................................................................12076 Removal.............................................................................................................................12076 Inspection and Repair...............................................................................................................12076 Installation........................................................................................................................12077 Stabilizer Bar..........................................................................................................................12078 Stabilizer Bar and Associated Parts.................................................................................................12078 Removal.............................................................................................................................12078 Inspection and Repair...............................................................................................................12078 Installation........................................................................................................................12079 Main Data and Specifications............................................................................................................12080 Special Tools...........................................................................................................................12082 3E WHEEL AND TIRE SYSTEM..................................................................................................................12083 Service Precaution......................................................................................................................12083 General Description.....................................................................................................................12084 Diagnosis...............................................................................................................................12085 Wheel...................................................................................................................................12091 Wheel and Associated Parts..........................................................................................................12091 Removal.............................................................................................................................12091 Installation........................................................................................................................12091 Tire....................................................................................................................................12092 Tire Replacement....................................................................................................................12092 Temporary Spare Tire................................................................................................................12092 General Balance Procedure...........................................................................................................12092 Balancing Wheel and Tire............................................................................................................12093 Main Data and Specifications............................................................................................................12094 Sec.4 DRIVELINE/AXLE..........................................................................................................................12095 4A1 DIFFERENTIAL (FRONT)..................................................................................................................12095 Service Precaution......................................................................................................................12095 Front Drive Axle........................................................................................................................12096 Diagnosis...........................................................................................................................12096 Pinion Shaft Oil Seal...................................................................................................................12097 Pinion Shaft Oil Seal and Associated Parts..........................................................................................12097 Removal.............................................................................................................................12097 Inspection and Repair...............................................................................................................12098 Installation........................................................................................................................12098 Front Drive Axle Assembly...............................................................................................................12099 Front Drive Axle Assembly and Associated Parts......................................................................................12099 Removal.............................................................................................................................12099 Installation........................................................................................................................12100 Differential Assembly...................................................................................................................12102 Disassembled View...................................................................................................................12102 Disassembly.........................................................................................................................12103 Reassembly..........................................................................................................................12105 Differential Cage Assembly..............................................................................................................12114 Disassembled View...................................................................................................................12114 Disassembly.........................................................................................................................12114 Inspection and Repair...............................................................................................................12115 Reassembly..........................................................................................................................12116 Main Data and Specifications............................................................................................................12118 Special Tools...........................................................................................................................12120 4A2 DIFFERENTIAL (REAR)...................................................................................................................12122 Service Precaution......................................................................................................................12122 General Description.....................................................................................................................12123 Diagnosis...............................................................................................................................12124 Axle Housing............................................................................................................................12125 Axle Housing and Associated Parts...................................................................................................12125 Removal.............................................................................................................................12125 Oil Seal Replacement................................................................................................................12126 Installation........................................................................................................................12126 Pinion Oil Seal.........................................................................................................................12127 Pinion Oil Seal and Associated Parts................................................................................................12127 Removal.............................................................................................................................12127 Inspection and Repair...............................................................................................................12128 Installation........................................................................................................................12128 Differential Assembly...................................................................................................................12129 Differential Assembly and Associated Parts..........................................................................................12129 Removal.............................................................................................................................12129 Installation........................................................................................................................12130 Disassembled View...................................................................................................................12131 Disassembly.........................................................................................................................12132 Reassembly..........................................................................................................................12134 Limited Slip Differential...............................................................................................................12142 Disassembled View...................................................................................................................12142 Disassembly.........................................................................................................................12143 Inspection and Repair...............................................................................................................12143 Reassembly..........................................................................................................................12145 Main Data and Specifications............................................................................................................12148 Special Tools...........................................................................................................................12149 4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................................12151 Service Precaution......................................................................................................................12151 General Description.....................................................................................................................12152 System Components.......................................................................................................................12154 Parts Location......................................................................................................................12154 Functions of Indicator Lamp.............................................................................................................12158 Diagnosis...............................................................................................................................12162 Basic Diagnostic Flow Chart.............................................................................................................12165 Parts Location..........................................................................................................................12166 Circuit Diagram.........................................................................................................................12167 Connector List..........................................................................................................................12170 Checking Failed Pin.....................................................................................................................12171 Checking Failed TOD Control Unit Pin....................................................................................................12174 Tech 2 Scan Tool....................................................................................................................12175 Diagnostic Trouble Codes................................................................................................................12178 Diagnosis from Trouble Codes............................................................................................................12179 Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................12196 Diagnosis from Symptom..................................................................................................................12215 4C DRIVE SHAFT SYSTEM....................................................................................................................12223 Service Precaution......................................................................................................................12223 General Description.....................................................................................................................12223 Diagnosis...............................................................................................................................12224 Front Hub and Disc......................................................................................................................12225 Disassembled View...................................................................................................................12225 Disassembly.........................................................................................................................12225 Inspection and Repair...............................................................................................................12226 Reassembly..........................................................................................................................12227 Main Data and Specifications........................................................................................................12230 Special Tools.......................................................................................................................12231 Front Drive Shaft Joint.................................................................................................................12232 Front Drive Shaft Joints Replacement................................................................................................12232 Front Axle Drive Shaft..................................................................................................................12233 Front Axle Drive Shaft and Associated Parts.........................................................................................12233 Disassembly.........................................................................................................................12234 Inspection and Repair...............................................................................................................12235 Bushing Replacement.................................................................................................................12235 Reassembly..........................................................................................................................12236 Front Propeller Shaft...................................................................................................................12238 General Description.................................................................................................................12238 Front Propeller Shaft and Associated Parts..........................................................................................12238 Removal.............................................................................................................................12239 Installation........................................................................................................................12239 Inspection and Repair...............................................................................................................12240 Main Data and Specifications........................................................................................................12242 Rear Propeller Shaft....................................................................................................................12243 General Description.................................................................................................................12243 Rear Propeller Shaft and Associated Parts...........................................................................................12243 Removal.............................................................................................................................12244 Installation........................................................................................................................12244 Disassembly.........................................................................................................................12245 Universal Joint Disassembly.........................................................................................................12246 Inspection and Repair...............................................................................................................12247 Universal Joint Reassembly..........................................................................................................12248 Reassembly..........................................................................................................................12249 Main Data and Specifications........................................................................................................12250 4D2 TRANSFER CASE (TOD)...................................................................................................................12251 Service Precaution......................................................................................................................12251 Transfer Case Assembly..................................................................................................................12252 Removal.............................................................................................................................12253 Installation........................................................................................................................12253 Transfer Rear Oil Seal..................................................................................................................12255 Transfer Rear Oil Seal and Associated Parts.........................................................................................12255 Removal.............................................................................................................................12255 Installation........................................................................................................................12255 TOD ECU.................................................................................................................................12257 Removal.............................................................................................................................12257 Installation........................................................................................................................12257 Unit Repair.............................................................................................................................12258 Inspection..........................................................................................................................12258 Transfer Case...........................................................................................................................12259 Disassembled View...................................................................................................................12259 Disassembly.........................................................................................................................12259 Reassembly..........................................................................................................................12260 Transfer Cover Assembly.................................................................................................................12262 Disassembled View...................................................................................................................12262 Disassembly.........................................................................................................................12262 Reassembly..........................................................................................................................12264 Transfer Case Assembly Clutch Pack and Clutch Cam.......................................................................................12266 Disassembled View...................................................................................................................12266 Disassembly.........................................................................................................................12266 Sprocket and Mechanical Lock............................................................................................................12268 Disassembled View...................................................................................................................12268 Disassembly.........................................................................................................................12268 Output Shafts and Shift Control Shaft...................................................................................................12270 Disassembled View...................................................................................................................12270 Disassembly.........................................................................................................................12271 Transfer Case...........................................................................................................................12273 Disassembled View...................................................................................................................12273 Disassembly.........................................................................................................................12274 Inspection and Repair...............................................................................................................12276 Transfer Case...........................................................................................................................12280 Disassembled View...................................................................................................................12280 Reassembly..........................................................................................................................12280 Output Shafts and Shift Control Shaft...................................................................................................12284 Disassembled View...................................................................................................................12284 Reassembly..........................................................................................................................12284 Sprocket and Mechanical Lock............................................................................................................12287 Disassembled View...................................................................................................................12287 Reassembly..........................................................................................................................12287 Clutch Pack and Clutch Cam..............................................................................................................12289 Disassembled View...................................................................................................................12289 Reassembly..........................................................................................................................12289 Main Data and Specifications............................................................................................................12291 Special Tools...........................................................................................................................12293 Sec.5 BRAKES..................................................................................................................................12402 5A BRAKE CONTROL SYSTEM...................................................................................................................12294 Service Precaution......................................................................................................................12295 General Description.....................................................................................................................12296 System Components...................................................................................................................12297 Electronic Hydraulic Control Unit (EHCU)............................................................................................12297 ABS Warning Light...................................................................................................................12297 Wheel Speed Sensor..................................................................................................................12297 G-Sensor............................................................................................................................12297 Normal and Anti-lock Braking........................................................................................................12297 Brake Pedal Travel..................................................................................................................12297 Acronyms and Abbreviations..........................................................................................................12297 General Diagnosis.......................................................................................................................12298 General Information.................................................................................................................12298 ABS Service Precautions.............................................................................................................12298 General Service Precautions.........................................................................................................12298 Note on Intermittents...............................................................................................................12298 Test Driving ABS Complaint Vehicles.................................................................................................12299 "ABS" Warning Light.................................................................................................................12299 Normal Operation....................................................................................................................12299 Basic Diagnostic Flow Chart.........................................................................................................12299 Basic Inspection Procedure..........................................................................................................12300 Tech 2 Scan Tool....................................................................................................................12301 Getting Started.....................................................................................................................12302 Operating Procedure.................................................................................................................12302 Data List...............................................................................................................................12304 EHCU Connector Pin-out Checks...........................................................................................................12305 Circuit Diagram.....................................................................................................................12306 Connector List......................................................................................................................12308 Part Location.......................................................................................................................12310 Symptom Diagnosis.......................................................................................................................12311 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................12312 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................12313 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................12313 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................12314 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................12315 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking.................................................................12316 Diagnostic Trouble Codes................................................................................................................12317 Diagnosis By "ABS" Warning Light Illumination Pattern...................................................................................12318 Diagnostic Trouble Codes (DTCs).....................................................................................................12319 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................12322 Chart B-2 EHCU Abnormality (DTC 14).................................................................................................12322 Chart B-3 Power Voltage Drop (DTC 15)...............................................................................................12323 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)...........................................................................12323 Chart B-5 G-Sensor Circuit (DTC 21).................................................................................................12324 Chart B-6 Abnormal Transmission Input (DTC 23)......................................................................................12325 Chart B-7 Transfer Monitor (DTC 24).................................................................................................12325 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)..........................................................................12326 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)..........................................................................12326 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41).........................................................................12326 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)..............................................................................12327 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43).........................................................................12327 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)..............................................................................12327 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45).......................................................................12328 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................12328 Chart B-16 FL Speed Sensor Disconnection (DTC 51)...................................................................................12328 Chart B-17 FR Speed Sensor Disconnection (DTC 52)...................................................................................12329 Chart B-18 RL Speed Sensor Disconnection (DTC 53)...................................................................................12329 Chart B-19 RR Speed Sensor Disconnection (DTC 54)...................................................................................12330 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)...................................................................................12331 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)...................................................................................12332 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)...................................................................................12333 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)...................................................................................12334 Chart B-24 Sensor Signal Input Abnormality (DTC 65).................................................................................12335 Sensor Signal Abnormality Criteria using TECH 2.....................................................................................12335 Unit Inspection Procedure...............................................................................................................12336 Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................12336 Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................12337 Chart C-1-3 RL Sensor Output Inspection Procedure...................................................................................12337 Chart C-1-4 RR Sensor Output Inspection Procedure...................................................................................12338 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)..........................................................................12338 Chart C-2 Transmission Input Inspection Procedure...................................................................................12339 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2).....................................................................12339 Special Tools...........................................................................................................................12340 5B ANTI-LOCK BRAKE SYSTEM.................................................................................................................12341 Service Precaution......................................................................................................................12341 Electronic Hydraulic Control Unit.......................................................................................................12342 Electronic Hydraulic Control Unit and Associated Parts..............................................................................12342 Removal.............................................................................................................................12342 Installation........................................................................................................................12342 G-Sensor................................................................................................................................12343 Removal.............................................................................................................................12343 Inspection and Repair...............................................................................................................12343 Installation........................................................................................................................12343 Front Wheel Speed Sensor................................................................................................................12344 Front Wheel Speed Sensor and Associated Parts.......................................................................................12344 Removal.............................................................................................................................12344 Inspection and Repair...............................................................................................................12345 Installation........................................................................................................................12345 Rear Wheel Speed Sensor.................................................................................................................12346 Rear Wheel Speed Sensor and Associated Parts........................................................................................12346 Removal.............................................................................................................................12346 Inspection and Repair...............................................................................................................12346 Installation........................................................................................................................12346 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................12347 Service Precaution......................................................................................................................12348 General Description.....................................................................................................................12348 Diagnosis...............................................................................................................................12351 General Diagnosis.......................................................................................................................12352 Hydraulic Brakes........................................................................................................................12355 Filling Master Cylinder Reservoir...................................................................................................12355 Deterioration of Brake Fluid........................................................................................................12355 Leakage of Brake Fluid..............................................................................................................12355 Bleeding Brake Hydraulic System.....................................................................................................12355 Flushing Brake Hydraulic System.....................................................................................................12356 Brake Pipes and Hoses...............................................................................................................12356 Brake Hose Inspection...............................................................................................................12356 Front / Rear Caliper Brake Hose.........................................................................................................12357 Front / Rear Caliper Brake Hose and Associated Parts................................................................................12357 Removal.............................................................................................................................12357 Installation........................................................................................................................12357 Rear Axle Brake Hose....................................................................................................................12358 Rear Axle Brake Hose and Associated Parts...........................................................................................12358 Removal.............................................................................................................................12358 Installation........................................................................................................................12358 Brake Pipe..............................................................................................................................12359 Removal.............................................................................................................................12359 Installation........................................................................................................................12359 P & B (Proportioning and Bypass) Valve..................................................................................................12360 P & B (Proportioning and Bypass) Valve Sectional View...............................................................................12360 Removal.............................................................................................................................12360 Installation........................................................................................................................12360 Main Data and Specifications........................................................................................................12361 Brake Pedal.............................................................................................................................12362 Checking Pedal Height...............................................................................................................12362 Checking Pedal Travel...............................................................................................................12362 Brake Pedal and Associated Parts....................................................................................................12363 Removal.............................................................................................................................12363 Installation........................................................................................................................12363 Stoplight Switch........................................................................................................................12364 Removal.............................................................................................................................12364 Installation........................................................................................................................12364 Main Data and Specifications........................................................................................................12365 Fluid Reservoir Tank....................................................................................................................12366 Fluid Reservoir Tank and Associated Parts...........................................................................................12366 Removal.............................................................................................................................12366 Installation........................................................................................................................12366 Master Cylinder Assembly................................................................................................................12367 Master Cylinder Assembly and Associated Parts.......................................................................................12367 Removal.............................................................................................................................12367 Inspection and Repair...............................................................................................................12367 Installation........................................................................................................................12368 Main Data and Specifications........................................................................................................12369 Special Tools.......................................................................................................................12370 Vacuum Booster Assembly.................................................................................................................12371 Vacuum Booster Assembly and Associated Parts........................................................................................12371 Removal.............................................................................................................................12371 Inspection and Repair...............................................................................................................12371 Installation........................................................................................................................12372 Exterior Components.....................................................................................................................12374 Exterior Components and Associated Parts............................................................................................12374 Removal.............................................................................................................................12374 Inspection and Repair...............................................................................................................12375 Installation........................................................................................................................12375 Vacuum Booster Overhaul.................................................................................................................12375 Vacuum Booster......................................................................................................................12375 Main Data and Specifications........................................................................................................12376 Special Tools.......................................................................................................................12377 Front Disc Brake Pads...................................................................................................................12378 Front Disc Brake Pads Inspection....................................................................................................12378 Front Disc Brake Pads and Associated Parts..........................................................................................12378 Removal.............................................................................................................................12379 Installation........................................................................................................................12379 Front Disc Brake Rotor..................................................................................................................12381 Inspection..........................................................................................................................12381 Replacing Brake Rotors..............................................................................................................12381 Front Disc Brake Caliper Assembly.......................................................................................................12383 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................12383 Removal.............................................................................................................................12383 Installation........................................................................................................................12384 Front Disc Brake Caliper................................................................................................................12386 Front Disc Brake Caliper Disassembled View..........................................................................................12386 Disassembly.........................................................................................................................12386 Inspection and Repair...............................................................................................................12387 Reassembly..........................................................................................................................12387 Main Data and Specifications........................................................................................................12389 Rear Disc Brake Pads....................................................................................................................12390 Brake Pads Inspection...............................................................................................................12390 Brake Pads and Associated Parts.....................................................................................................12390 Removal.............................................................................................................................12391 Installation........................................................................................................................12391 Rear Disc Brake Rotor...................................................................................................................12393 Inspection..........................................................................................................................12393 Replacing Brake Rotors..............................................................................................................12393 Refinishing Brake Rotors............................................................................................................12393 Rear Drum (In Disc) Inside Diameter Check...........................................................................................12394 Rear Disc Brake Caliper Assembly........................................................................................................12395 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................12395 Removal.............................................................................................................................12395 Installation........................................................................................................................12396 Rear Disc Brake Caliper.................................................................................................................12398 Rear Disc Brake Caliper Disassembled View...........................................................................................12398 Disassembly.........................................................................................................................12398 Inspection and Repair...............................................................................................................12399 Reassembly..........................................................................................................................12399 Main Data and Specifications........................................................................................................12401 5D PARKING BRAKE SYSTEM...................................................................................................................12402 Service Precaution......................................................................................................................12402 General Description.....................................................................................................................12402 Operation...............................................................................................................................12403 Parking Brake Lever and Front Cable.....................................................................................................12404 Parking Brake Lever, Front Cable and Associated Parts...............................................................................12404 Removal.............................................................................................................................12404 Installation........................................................................................................................12405 Parking Brake Rear Cable................................................................................................................12406 Parking Brake Rear Cable and Associated Parts.......................................................................................12406 Removal.............................................................................................................................12406 Installation........................................................................................................................12407 Inspection and Repair...............................................................................................................12408 Parking Brake Adjustment............................................................................................................12408 Main Data and Specifications............................................................................................................12409 Sec.6 ENGINE..................................................................................................................................13101 6A ENGINE MECHANICAL......................................................................................................................12410 Service Precaution......................................................................................................................12411 General Description.....................................................................................................................12412 Engine Diagnosis........................................................................................................................12413 Cylinder Head Cover LH..................................................................................................................12427 Removal.............................................................................................................................12427 Installation........................................................................................................................12428 Cylinder Head Cover RH..................................................................................................................12430 Removal.............................................................................................................................12430 Installation........................................................................................................................12431 Common Chamber..........................................................................................................................12433 Removal.............................................................................................................................12433 Installation........................................................................................................................12433 Exhaust Manifold LH.....................................................................................................................12435 Removal.............................................................................................................................12435 Installation........................................................................................................................12435 Exhaust Manifold RH.....................................................................................................................12437 Removal.............................................................................................................................12437 Installation........................................................................................................................12438 Crankshaft Pulley.......................................................................................................................12439 Removal.............................................................................................................................12439 Installation........................................................................................................................12439 Timing Belt.............................................................................................................................12440 Removal.............................................................................................................................12440 Installation........................................................................................................................12441 Camshaft................................................................................................................................12444 Removal.............................................................................................................................12444 Installation........................................................................................................................12444 Cylinder Head...........................................................................................................................12447 Removal.............................................................................................................................12447 Installation........................................................................................................................12447 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................12449 Removal.............................................................................................................................12449 Installation........................................................................................................................12449 Piston, Piston Ring and Connecting Rod..................................................................................................12450 Removal.............................................................................................................................12450 Installation........................................................................................................................12451 Crankshaft and Main Bearings............................................................................................................12452 Removal.............................................................................................................................12452 Installation........................................................................................................................12453 Rear Oil Seal...........................................................................................................................12457 Removal.............................................................................................................................12457 Installation........................................................................................................................12457 Engine Assembly.........................................................................................................................12458 Removal.............................................................................................................................12458 Installation........................................................................................................................12458 Cylinder Head...........................................................................................................................12461 Cylinder Head and Associated Parts..................................................................................................12461 Disassembly.........................................................................................................................12461 Clean...............................................................................................................................12462 Inspection and Repair...............................................................................................................12462 Reassembly..........................................................................................................................12462 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................12465 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................12465 Disassembly.........................................................................................................................12465 Inspection and Repair...............................................................................................................12466 Reassembly..........................................................................................................................12469 Valve Clearance Adjustments.........................................................................................................12470 Camshaft................................................................................................................................12472 Camshaft and Associated Parts.......................................................................................................12472 Disassembly.........................................................................................................................12472 Inspection and Repair...............................................................................................................12473 Reassembly..........................................................................................................................12475 Crankshaft..............................................................................................................................12478 Crankshaft and Associated Parts.....................................................................................................12478 Disassembly.........................................................................................................................12478 Inspection and Repair...............................................................................................................12479 Inspection and Repair...............................................................................................................12480 Reassembly..........................................................................................................................12482 Piston and Connecting Rod...............................................................................................................12486 Piston, Connecting Rod and Associate Parts..........................................................................................12486 Disassembly.........................................................................................................................12486 Inspection and Repair...............................................................................................................12487 Reassembly..........................................................................................................................12491 Cylinder Block..........................................................................................................................12494 Cylinder Block and Associated Parts.................................................................................................12494 Disassembly.........................................................................................................................12494 Inspection and Repair...............................................................................................................12495 Reassembly..........................................................................................................................12496 Main Data and Specification.............................................................................................................12499 Special Tool............................................................................................................................12505 6B ENGINE COOLING.........................................................................................................................12507 Service Precaution......................................................................................................................12507 General Description.....................................................................................................................12508 Diagnosis...............................................................................................................................12511 Draining and Refilling Cooling System...................................................................................................12512 Engine coolant change...................................................................................................................12512 Water Pump..............................................................................................................................12513 Water Pump and Associated Parts.....................................................................................................12513 Removal.............................................................................................................................12513 Inspection..........................................................................................................................12513 Installation........................................................................................................................12513 Thermostat..............................................................................................................................12514 Thermostat and Associated Parts.....................................................................................................12514 Removal.............................................................................................................................12514 Inspection..........................................................................................................................12514 Installation........................................................................................................................12514 Radiator................................................................................................................................12515 Radiator and Associated Parts.......................................................................................................12515 Removal.............................................................................................................................12515 Inspection..........................................................................................................................12516 Installation........................................................................................................................12517 Drive Belt and Cooling Fan..............................................................................................................12518 Drive Belt and Associated Parts.....................................................................................................12518 Inspection..........................................................................................................................12518 Installation........................................................................................................................12518 Main Data and Specifications............................................................................................................12519 Special Tool............................................................................................................................12520 6C ENGINE FUEL............................................................................................................................12521 Service Precaution......................................................................................................................12521 General Description.....................................................................................................................12522 Fuel Metering...........................................................................................................................12523 Fuel Filter.............................................................................................................................12524 Fuel Filter and Associated Parts....................................................................................................12524 Removal.............................................................................................................................12524 Inspection..........................................................................................................................12524 Installation........................................................................................................................12524 Inspection..........................................................................................................................12525 In-Tank Fuel Filter.................................................................................................................12525 Fuel Pump Flow Test.................................................................................................................12525 Fuel Pump...............................................................................................................................12526 Fuel Pump and Associated Parts......................................................................................................12526 Removal.............................................................................................................................12526 Installation........................................................................................................................12526 Fuel Pump Relay.........................................................................................................................12527 General Description.................................................................................................................12527 Fuel Tank...............................................................................................................................12527 Fuel Tank and Associated Parts......................................................................................................12527 Removal.............................................................................................................................12528 Installation........................................................................................................................12528 Fuel Tube / Quick-Connect Fittings......................................................................................................12528 Precautions.........................................................................................................................12528 Cautions During Work................................................................................................................12528 Removal.............................................................................................................................12528 Reuse of Quick-Connector............................................................................................................12530 Assembling Advice...................................................................................................................12530 Fuel Gauge Unit.........................................................................................................................12531 Fuel Gauge Unit and Associated Parts................................................................................................12531 Removal.............................................................................................................................12531 Installation........................................................................................................................12531 Fuel Filler Cap.........................................................................................................................12532 General Description.................................................................................................................12532 Inspection..........................................................................................................................12532 Main Data and Specifications............................................................................................................12532 6D1 ENGINE ELECTRICAL......................................................................................................................12533 Battery.................................................................................................................................12533 General Description.....................................................................................................................12533 Diagnosis...............................................................................................................................12533 Battery Charging....................................................................................................................12534 Jump Starting.......................................................................................................................12534 Battery Removal.....................................................................................................................12535 Battery Installation................................................................................................................12535 Main Data and Specifications............................................................................................................12536 6D2 IGNITION SYSTEM........................................................................................................................12537 Service Precaution......................................................................................................................12537 General Description.....................................................................................................................12538 Diagnosis...............................................................................................................................12541 Ignition Coil...........................................................................................................................12541 Removal.............................................................................................................................12541 Inspection and Repair...............................................................................................................12541 Installation........................................................................................................................12541 Spark Plug..............................................................................................................................12542 Removal.............................................................................................................................12542 Inspection and Repair...............................................................................................................12542 Installation........................................................................................................................12542 Crankshaft Position Sensor..............................................................................................................12543 Removal.............................................................................................................................12543 Installation........................................................................................................................12543 Main Data and Specifications............................................................................................................12544 6D3 STARTING AND CHARGING SYSTEM...........................................................................................................12545 Service Precaution......................................................................................................................12545 Starting System.........................................................................................................................12546 General Description.....................................................................................................................12546 Diagnosis...............................................................................................................................12548 Starter.................................................................................................................................12549 Removal.............................................................................................................................12549 Installation........................................................................................................................12549 Disassembled View...................................................................................................................12550 Disassembly.........................................................................................................................12551 Inspection and Repair...............................................................................................................12553 Reassembly..........................................................................................................................12557 Main Data and Specifications........................................................................................................12559 Charging System.........................................................................................................................12562 General Description.....................................................................................................................12562 General On-Vehicle Inspection...........................................................................................................12562 Generator...............................................................................................................................12563 Removal.............................................................................................................................12563 Inspection..........................................................................................................................12563 Installation........................................................................................................................12563 Disassembled View...................................................................................................................12564 Disassembly.........................................................................................................................12565 Inspection and Repair...............................................................................................................12567 Reassembly..........................................................................................................................12569 Bench Test..........................................................................................................................12569 Main Data and Specifications............................................................................................................12570 6E 6VE1 3.5L ENGINE DRIVEABILITY AND EMISSIONS............................................................................................12571 Specifications..........................................................................................................................12575 Tightening Specifications...........................................................................................................12575 Diagrams and Schematics.................................................................................................................12576 PCM Wiring Diagram (1 of 8).........................................................................................................12576 PCM Wiring Diagram (2 of 8).........................................................................................................12577 PCM Wiring Diagram (3 of 8).........................................................................................................12578 PCM Wiring Diagram (4 of 8).........................................................................................................12579 PCM Wiring Diagram (5 of 8).........................................................................................................12580 PCM Wiring Diagram (6 of 8).........................................................................................................12581 PCM Wiring Diagram (7 of 8).........................................................................................................12582 PCM Wiring Diagram (8 of 8).........................................................................................................12583 PCM Pinouts.............................................................................................................................12584 PCM Pinout Table, 32-Way Red Connector-Row "A"......................................................................................12584 PCM Pinout Table, 32-Way Red Connector-Row "B"......................................................................................12586 PCM Pinout Table, 32-Way White Connector-Row "C"....................................................................................12587 PCM Pinout Table, 32-Way White Connector-Row "D"....................................................................................12588 PCM Pinout Table, 32-Way Blue Connector-Row "E".....................................................................................12590 PCM Pinout Table, 32-Way Blue Connector-Row "F".....................................................................................12591 Component Locators......................................................................................................................12592 Engine Component Locator............................................................................................................12592 Engine Component Locator Table......................................................................................................12592 Undercarriage Component Locator.....................................................................................................12593 Undercarriage Component Locator Table...............................................................................................12593 Fuse and Relay Panel (Underhood Electrical Center)..................................................................................12594 Sensors and Miscellaneous Component Locators........................................................................................12595 Diagnosis...............................................................................................................................12597 Strategy-Based Diagnostics..........................................................................................................12597 DTC Stored..........................................................................................................................12597 No DTC..............................................................................................................................12597 No Matching Symptom.................................................................................................................12597 Intermittents.......................................................................................................................12597 No Trouble Found....................................................................................................................12597 Verifying Vehicle Repair............................................................................................................12597 General Service Information.............................................................................................................12597 OBD II Serviceablity Issues.........................................................................................................12597 Emissions Control Information Label.................................................................................................12598 Maintenance Schedule................................................................................................................12598 Visual / Physical Engine Compartment Inspection.....................................................................................12598 Basic Knowledge of Tools Required...................................................................................................12599 Serial Data Communications..............................................................................................................12599 Class II Serial Data Communications.................................................................................................12599 On-Board Diagnostic (OBD) II............................................................................................................12599 On-Board Diagnostic Tests...........................................................................................................12599 Comprehensive Component Monitor Diagnostic Operation................................................................................12599 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................12600 Common OBD II Terms.................................................................................................................12600 The Diagnostic Executive............................................................................................................12600 DTC Types...........................................................................................................................12601 Decimal/Binary/Hexadecimal Conversions..............................................................................................12603 Verifying Vehicle Repair............................................................................................................12603 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................12603 Tech 2..............................................................................................................................12604 Tech 2 Features.....................................................................................................................12604 Getting Started.....................................................................................................................12605 Operating Procedure (For Example)...................................................................................................12605 DTC Modes...........................................................................................................................12606 DTC Information Mode................................................................................................................12607 Miscellaneous Test..................................................................................................................12607 Lamps Test..........................................................................................................................12608 Relays Test.........................................................................................................................12609 EVAP Test...........................................................................................................................12610 Idle Air Control (IAC) System Test..................................................................................................12611 Fuel System Test....................................................................................................................12613 EGR Control Test....................................................................................................................12614 Variable Intake Manifold Solenoid Test..............................................................................................12615 Injector Balance Test...............................................................................................................12616 Plotting Snapshot Graph.................................................................................................................12617 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................12618 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................12619 Primary System-Based Diagnostic.........................................................................................................12620 Fuel Control Heated Oxygen Sensor...................................................................................................12620 HO2S Heater.........................................................................................................................12620 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................12620 Misfire Monitor Diagnostic Operation....................................................................................................12621 Misfire Counters....................................................................................................................12621 Fuel Trim System Monitor Diagnostic Operation...........................................................................................12622 Fuel Trim Cell Diagnostic Weights...................................................................................................12622 On-Board Diagnostic (OBD II) System Check...............................................................................................12623 A/C Clutch Control Circuit Diagnosis....................................................................................................12626 Electronic Ignition System Diagnosis....................................................................................................12632 Visual Check of The Evaporative Emission Canister.......................................................................................12632 Fuel Metering System Check..............................................................................................................12632 Idle Air Control (IAC) Valve............................................................................................................12632 Fuel System Pressure Test...............................................................................................................12632 Fuel Injector Coil Test Procedure Fuel Injector Balance Test Procedure..................................................................12632 Knock Sensor Diagnosis..................................................................................................................12637 Powertrain Control Module (PCM) Diagnosis...............................................................................................12637 Multiple PCM Information Sensor DTCS Set................................................................................................12637 Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................12640 Engine Tech 2 Data Definitions and Ranges...............................................................................................12640 Typical Scan Data Values................................................................................................................12643 No Malfunction Indicator Lamp (MIL).....................................................................................................12649 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................12652 Engine Cranks But Will Not Run..........................................................................................................12654 Fuel System Electrical Test.............................................................................................................12660 Fuel System Diagnosis...................................................................................................................12663 Idle Air Control (IAC) System Check.....................................................................................................12668 Knock Sensor (KS) System Check (Engine Knock, Poor Performance, or Poor Economy)........................................................12671 Exhaust Gas Recirculation (EGR) System Check............................................................................................12673 Manifold Absolute Pressure (MAP) Output Check...........................................................................................12675 Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................12677 PCM Diagnostic Trouble Codes............................................................................................................12680 Diagnostic Trouble Code (DTC) P0101 MAF System Performance..............................................................................12684 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....................................................................12687 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...................................................................12690 Diagnostic Trouble Code (DTC) P0106 MAP System Performance..............................................................................12693 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage......................................................................12696 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.....................................................................12699 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage......................................................................12702 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.....................................................................12705 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage......................................................................12708 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.....................................................................12711 Diagnostic Trouble Code (DTC) P0121 TP System Performance...............................................................................12714 Diagnostic Trouble Code (DTC) P0122 TP Sensor Circuit Low Voltage.......................................................................12717 Diagnostic Trouble Code (DTC) P0123 TP Sensor Circuit High Voltage......................................................................12720 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control......................................................12723 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................12726 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1...........................................................12729 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..................................................................12732 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..................................................12736 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.................................................................12739 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................12742 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2...........................................................12745 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...................................................12748 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.................................................................12751 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................12754 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1...........................................................12757 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..................................................................12760 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..................................................12764 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Bank 2 Sensor 1.................................................................12767 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................12770 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2...........................................................12773 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..................................................12776 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.................................................................12779 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................12782 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................12786 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................12790 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................12794 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit..........................................................................12798 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit..........................................................................12801 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit..........................................................................12804 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit..........................................................................12807 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit..........................................................................12810 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit..........................................................................12813 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.............................................................................12816 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected...........................................................................12820 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected...........................................................................12822 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected...........................................................................12824 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected...........................................................................12826 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected...........................................................................12828 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected...........................................................................12830 Diagnostic Trouble Code (DTC) P0325 KS Module Circuit...................................................................................12832 Diagnostic Trouble Code (DTC) P0327 KS Sensor Circuit...................................................................................12834 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................12837 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....................................................................12840 Diagnostic Trouble Code (DTC) P0341 CMP Sensor Circuit Performance......................................................................12843 Diagnostic Trouble Code (DTC) P0342 CMP Sensor Circuit Low..............................................................................12847 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit..........................................................................12851 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit..........................................................................12854 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit..........................................................................12857 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit..........................................................................12860 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit..........................................................................12863 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit..........................................................................12866 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...............................................................................12869 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Position Error...........................................................................12872 Diagnostic Trouble Code (DTC) P0404 EGR Pintle Open/Stuck...............................................................................12874 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.....................................................................................12876 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....................................................................................12879 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1....................................................................12882 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2....................................................................12885 Diagnostic Trouble Code (DTC) P0440 EVAP System.........................................................................................12887 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.....................................................................12891 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Blocked..........................................................................12894 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...............................................................12897 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor High Voltage..............................................................12900 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit豊ow Voltage................................................................12903 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit蓬igh Voktage...............................................................12905 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...............................................................................12907 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.....................................................................12910 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM....................................................................12913 Diagnostic Trouble Code (DTC) P0562 System Voltage Low..................................................................................12916 Diagnostic Trouble Code (DTC) P0563 System Voltage High.................................................................................12918 Diagnostic Trouble Code (DTC) P0601 PCM Memory..........................................................................................12920 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................12921 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................12923 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................12925 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.........................................................12928 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.........................................................12930 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................12932 Diagnostic Trouble Code (DTC) P1121 TP Sensor Circuit Intermittent High Voltage.........................................................12935 Diagnostic Trouble Code (DTC) P1122 TP Sensor Circuit Intermittent Low Voltage..........................................................12937 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.........................................................12939 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1..........................................................12943 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.........................................................12947 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..................................................12951 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................12955 Diagnostic Trouble Code (DTC) P1380 ABS Rough Road ABS System Fault.....................................................................12958 Diagnostic Trouble Code (DTC) P1381 ABS Rough Road Class 2 Serial Link Error............................................................12960 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....................................................................................12961 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...................................................................12964 Diagnostic Trouble Code (DTC) P1508 IAC System Low RPM..................................................................................12967 Diagnostic Trouble Code (DTC) P1509 IAC System High RPM.................................................................................12970 Diagnostic Trouble Code (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error............................12973 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................12974 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).................................................................12975 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault........................................................................12978 Symptom Diagnosis.......................................................................................................................12981 Default Matrix Table....................................................................................................................13008 On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................13011 Crankshaft Position (CKP) Sensor........................................................................................................13011 Engine Coolant Temperature (ECT) Sensor.................................................................................................13012 Heated Oxygen Sensor (HO2S).............................................................................................................13013 Intake Air Temperature (IAT) Sensor.....................................................................................................13015 Knock Sensor (KS).......................................................................................................................13016 Mass Air Flow (MAF) Sensor..............................................................................................................13017 Manifold Absolute Pressure (MAP) Sensor.................................................................................................13018 Malfunction Indicator Lamp (MIL)........................................................................................................13019 Powertrain Control Module (PCM).........................................................................................................13019 EEPROM..................................................................................................................................13020 Throttle Position (TP) Sensor...........................................................................................................13020 Vehicle Speed Sensor (VSS)..............................................................................................................13021 Air Cleaner/Air Filter..................................................................................................................13022 Idle Air Control (IAC) Valve............................................................................................................13023 Common Chamber..........................................................................................................................13024 Accelerator Cable Assembly..............................................................................................................13024 Accelerator Pedal Replacement...........................................................................................................13027 Fuel Filter Cap.........................................................................................................................13029 Fuel Filter.............................................................................................................................13029 Fuel Gauge Unit.........................................................................................................................13031 Fuel Injectors..........................................................................................................................13032 Fuel Pressure Regulator.................................................................................................................13034 Fuel Metering System....................................................................................................................13036 Fuel Pump Assembly......................................................................................................................13036 Fuel Pump Relay.........................................................................................................................13037 Fuel Rail Assembly......................................................................................................................13037 Fuel Tank...............................................................................................................................13038 Throttle Body (TB)......................................................................................................................13040 Electronic Ignition System..............................................................................................................13042 Catalytic Converter.....................................................................................................................13043 Air Conditioning Relay..................................................................................................................13043 EVAP Canister Hoses.....................................................................................................................13044 EVAP Canister...........................................................................................................................13044 EVAP Canister Vent Solenoid.............................................................................................................13045 Fuel Tank Pressure Sensor...............................................................................................................13046 EVAP Canister Purge Solenoid............................................................................................................13046 Fuel Tank Vent Valve....................................................................................................................13047 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................13047 Positive Crankcase Ventilation (PCV) Valve..............................................................................................13048 Wiring and Connectors...................................................................................................................13049 PCM Connectors and Terminals............................................................................................................13049 Wire Harness Repair: Twisted Shielded Cable.............................................................................................13049 Twisted Leads...........................................................................................................................13050 Weather-Pack Connector..................................................................................................................13052 Com-Pack III............................................................................................................................13053 Metri-Pack..............................................................................................................................13053 General Description (PCM and Sensors)...................................................................................................13054 Catalyst Monitor Heated Oxygen Sensors..................................................................................................13055 58X Reference PCM Input.............................................................................................................13054 A/C Request Signal..................................................................................................................13054 Crankshaft Position (CKP) Sensor....................................................................................................13054 Camshaft Position (CMP) Sensor and Signal...........................................................................................13054 Engine Coolant Temperature (ECT) Sensor.............................................................................................13054 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................13055 Fuel Control Heated Oxygen Sensors..................................................................................................13055 Intake Air Temperature (IAT) Sensor.................................................................................................13056 Knock Sensor........................................................................................................................13056 Linear Exhaust Gas Recirculation (EGR) Control......................................................................................13057 Mass Air Flow (MAF) Sensor..........................................................................................................13057 Manifold Absolute Pressure (MAP) Sensor.............................................................................................13057 Manifold Absolute Pressure (MAP) Sensor.............................................................................................13057 Powertrain Control Module (PCM).....................................................................................................13058 PCM Function........................................................................................................................13058 PCM Components......................................................................................................................13058 PCM Voltage Description.............................................................................................................13058 PCM Input/Outputs...................................................................................................................13058 PCM Service Precautions.............................................................................................................13059 Reprogramming The PCM...............................................................................................................13059 Throttle Position (TP) Sensor.......................................................................................................13059 Transmission Fluid Temperature (TFT) Sensor.........................................................................................13059 Transmission Range Switch...........................................................................................................13059 Vehicle Speed Sensor (VSS)..........................................................................................................13060 Use of Circuit Testing Tools........................................................................................................13060 Aftermarket Electrical and Vacuum Equipment.........................................................................................13060 Electrostatic Discharge Damage......................................................................................................13060 General Description (Air Induction).....................................................................................................13061 Air Induction System................................................................................................................13061 General Description (Fuel Metering).....................................................................................................13061 Acceleration Mode...................................................................................................................13061 Accelerator Controls................................................................................................................13061 Battery Voltage Correction Mode.....................................................................................................13061 CMP Signal..........................................................................................................................13061 Clear Flood Mode....................................................................................................................13061 Deceleration Mode...................................................................................................................13061 Engine Speed/Fuel Disable Mode......................................................................................................13061 Fuel Cutoff Mode....................................................................................................................13061 Fuel Injector.......................................................................................................................13061 Fuel Metering System Components.....................................................................................................13062 Fuel Metering System Purpose........................................................................................................13062 Fuel Pressure Regulator.............................................................................................................13062 Fuel Pump Electrical Circuit........................................................................................................13062 Fuel Rail...........................................................................................................................13062 Idle Air Control (IAC) Valve........................................................................................................13063 Run Mode............................................................................................................................13063 Starting Mode.......................................................................................................................13063 Throttle Body Unit..................................................................................................................13064 General Description (Electronic Ignition System)........................................................................................13064 Camshaft Position (CMP) Sensor......................................................................................................13064 Crankshaft Position (CKP) Sensor....................................................................................................13064 Electronic Ignition.................................................................................................................13065 Ignition Coils......................................................................................................................13065 Ignition Control....................................................................................................................13065 Knock Sensor (KS) PCM Input.........................................................................................................13066 Powertrain Control Module (PCM).....................................................................................................13066 Spark Plug..........................................................................................................................13066 A/C Clutch Diagnosis....................................................................................................................13068 A/C Clutch Circuit Operation........................................................................................................13068 A/C Clutch Circuit Purpose..........................................................................................................13068 A/C Request Signal..................................................................................................................13068 General Description (Evaporative (EVAP) Emission System)................................................................................13069 EVAP Emission Control System Purpose................................................................................................13069 EVAP Emission Control System Operation..............................................................................................13069 Enhanced Evaporative Emission Control System........................................................................................13070 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................13073 EGR Purpose.........................................................................................................................13073 Linear EGR Valve....................................................................................................................13073 Linear EGR Control..................................................................................................................13073 Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................13073 EGR Pintle Position Sensor..........................................................................................................13073 General Description (Positive Crankcase Ventilation (PCV) System).......................................................................13074 Crankcase Ventilation System Purpose................................................................................................13074 Crankcase Ventilation System Operation..............................................................................................13074 Special Tools...........................................................................................................................13075 6F ENGINE EXHAUST.........................................................................................................................13077 General Description.....................................................................................................................13078 Three Way Catalytic Converter LH........................................................................................................13079 Removal.............................................................................................................................13079 Installation........................................................................................................................13079 Three Way Catalytic Converter RH........................................................................................................13080 Removal.............................................................................................................................13080 Installation........................................................................................................................13080 Exhaust Silencer........................................................................................................................13081 Exhaust Silencer and Associated Parts...............................................................................................13081 Removal.............................................................................................................................13081 Installation........................................................................................................................13081 Rear Exhaust pipe.......................................................................................................................13082 Rear Exhaust pipe and Associated Parts..............................................................................................13082 Removal.............................................................................................................................13082 Installation........................................................................................................................13082 Main Data and Specifications............................................................................................................13083 6G ENGINE LUBRICATION.....................................................................................................................13084 Service Precaution......................................................................................................................13084 General Description.....................................................................................................................13085 Oil Pump................................................................................................................................13086 Oil Pump and Associated Parts.......................................................................................................13086 Oil Pump and Associated Parts.......................................................................................................13086 Inspection and Repair...............................................................................................................13087 Reassembly..........................................................................................................................13088 Oil Pan and Crankcase...................................................................................................................13090 Removal.............................................................................................................................13090 Installation........................................................................................................................13090 Oil Pump................................................................................................................................13092 Removal.............................................................................................................................13092 Installation........................................................................................................................13092 Oil Pump Oil Seal.......................................................................................................................13094 Removal.............................................................................................................................13094 Installation........................................................................................................................13094 Oil Filter..............................................................................................................................13095 Removal.............................................................................................................................13095 Installation........................................................................................................................13095 Main Data and Specification.............................................................................................................13096 Special Tool............................................................................................................................13097 6H ENGINE SPEED CONTROL SYSTEM............................................................................................................13098 Service Precaution......................................................................................................................13098 Accelerator Pedal Control Cable.........................................................................................................13099 Removal.............................................................................................................................13099 Inspection..........................................................................................................................13099 Installation........................................................................................................................13099 Accelerator Pedal.......................................................................................................................13100 Accelerator Pedal and Associated Parts..............................................................................................13100 Removal.............................................................................................................................13100 Installation........................................................................................................................13100 6J INDUCTION..............................................................................................................................13101 Service Precaution......................................................................................................................13101 Air Cleaner Element.....................................................................................................................13102 Removal.............................................................................................................................13102 Inspection..........................................................................................................................13102 Installation........................................................................................................................13102 Sec.7 TRANSMISSION............................................................................................................................13198 7A AUTOMATIC TRANSMISSION (4L30-E)........................................................................................................13103 Service Precaution......................................................................................................................13105 Construction............................................................................................................................13105 Range Reference Chart...................................................................................................................13106 Normal Operation Of 1999 4L30-E Transmission............................................................................................13107 Diagnosis...............................................................................................................................13107 Driver Information......................................................................................................................13107 General Diagnosis Procedure.............................................................................................................13110 Preliminary Inspection Chart............................................................................................................13111 Checking Transmission Fluid Level and Condition.........................................................................................13112 Test Driving............................................................................................................................13113 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................13114 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................13115 Stall Test..............................................................................................................................13125 Line Pressure Test......................................................................................................................13125 Shift Speed Chart.......................................................................................................................13126 Lockup Speed Chart......................................................................................................................13128 Changing Transmission Fluid.............................................................................................................13129 Selector Lever..........................................................................................................................13129 Inspection..........................................................................................................................13129 Removal.............................................................................................................................13130 Installation........................................................................................................................13130 Mode Switch.............................................................................................................................13131 Removal.............................................................................................................................13131 Installation........................................................................................................................13131 Transmission (With Transfer Case).......................................................................................................13133 Transmission And Associated Parts...................................................................................................13133 Removal.............................................................................................................................13133 Installation........................................................................................................................13137 Solenoid (Main Case Valve Body).........................................................................................................13141 Removal.............................................................................................................................13141 Installation........................................................................................................................13141 Solenoid (Adapter Case Valve Body)......................................................................................................13142 Removal.............................................................................................................................13142 Installation........................................................................................................................13142 Valve Body Assembly (Main Case).........................................................................................................13143 Removal.............................................................................................................................13143 Installation........................................................................................................................13143 Valve Body Assembly (Adapter Case)......................................................................................................13145 Removal.............................................................................................................................13145 Installation........................................................................................................................13145 Powertrain Control Module (PCM).........................................................................................................13145 Removal.............................................................................................................................13145 Installation........................................................................................................................13145 Speed Sensor (Extension Housing)........................................................................................................13146 Removal.............................................................................................................................13146 Installation........................................................................................................................13146 Transmission Oil Temperature Sensor (Adapter Case)......................................................................................13146 Removal.............................................................................................................................13146 Installation........................................................................................................................13146 Front Oil Seal (Converter Housing)......................................................................................................13147 Removal.............................................................................................................................13147 Installation........................................................................................................................13147 Rear Oil Seal (Extension Housing).......................................................................................................13147 Removal.............................................................................................................................13147 Installation........................................................................................................................13148 Transmission (4L30-E)...................................................................................................................13148 Disassembly.........................................................................................................................13148 Reassembly..........................................................................................................................13152 Converter Housing And Oil Pump Assembly.................................................................................................13163 Disassembled View...................................................................................................................13163 Disassembly.........................................................................................................................13163 Inspection And Repair...............................................................................................................13163 Reassembly..........................................................................................................................13163 Oil Pump................................................................................................................................13164 Disassembled View...................................................................................................................13164 Disassembly.........................................................................................................................13164 Inspection And Repair...............................................................................................................13164 Reassembly..........................................................................................................................13164 Main Case Valve Body....................................................................................................................13165 Disassembled View...................................................................................................................13165 Disassembly.........................................................................................................................13165 Inspection And Repair...............................................................................................................13166 Reassembly..........................................................................................................................13166 Adapter Case Valve Body.................................................................................................................13167 Disassembled View...................................................................................................................13167 Disassembly.........................................................................................................................13167 Inspection And Repair...............................................................................................................13167 Reassembly..........................................................................................................................13167 Third Clutch And Sprag Unit.............................................................................................................13169 Disassembled View...................................................................................................................13169 Disassembly.........................................................................................................................13169 Inspection And Repair...............................................................................................................13170 Reassembly..........................................................................................................................13170 Third Clutch............................................................................................................................13171 Disassembled View...................................................................................................................13171 Disassemble.........................................................................................................................13171 Inspection And Repair...............................................................................................................13171 Reassembly..........................................................................................................................13171 Sprag Unit..............................................................................................................................13173 Disassembled View...................................................................................................................13173 Disassembly.........................................................................................................................13173 Inspection And Repair...............................................................................................................13173 Reassembly..........................................................................................................................13173 Second Clutch...........................................................................................................................13174 Disassembled View...................................................................................................................13174 Disassembly.........................................................................................................................13174 Inspection And Repair...............................................................................................................13175 Reassembly..........................................................................................................................13175 3-4 Accumulator Piston..................................................................................................................13176 Disassembled View...................................................................................................................13176 Disassembly.........................................................................................................................13176 Inspection And Repair...............................................................................................................13176 Reassembly..........................................................................................................................13177 Reverse Clutch Piston And Center Support................................................................................................13178 Disassembled View...................................................................................................................13178 Disassembly.........................................................................................................................13178 Inspection And Repair...............................................................................................................13179 Reassembly..........................................................................................................................13179 Overrun Clutch And Turbine Shaft........................................................................................................13180 Disassembled View...................................................................................................................13180 Disassembly.........................................................................................................................13180 Inspection And Repair...............................................................................................................13181 Reassembly..........................................................................................................................13181 Main Data And Specification.............................................................................................................13183 Special Tools...........................................................................................................................13187 4L30-E Parts List.......................................................................................................................13190 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................13198 Service Precaution......................................................................................................................13199 General Description.....................................................................................................................13199 Electronic Control Diagram..........................................................................................................13200 Powertrain Control Module (PCM).....................................................................................................13201 Control System Diagram..............................................................................................................13202 Shift Control.......................................................................................................................13203 Band Apply Control..................................................................................................................13203 Torque Converter Clutch Control.....................................................................................................13203 Line Pressure Control...............................................................................................................13203 On-Board Diagnostic System..........................................................................................................13203 Fail Safe Mechanism.................................................................................................................13203 Torque Management Control...........................................................................................................13203 ATF Warning Control.................................................................................................................13203 ABS Control.........................................................................................................................13203 Shift Mode Control..................................................................................................................13204 Gear Shift Control..................................................................................................................13205 Winter Drive Mode...................................................................................................................13206 Backup Mode.........................................................................................................................13206 Functions of Input / Output Components..............................................................................................13207 Diagnosis...............................................................................................................................13208 Electronic Diagnosis................................................................................................................13208 How To Diagnose The Problem.........................................................................................................13208 Check Trans Indicator...............................................................................................................13208 Diagnostic Check....................................................................................................................13208 "Check Trans" Check.................................................................................................................13209 Tech 2 OBD II Connection............................................................................................................13210 F0: Transmission Data...............................................................................................................13214 F1: PC Solenoid Data................................................................................................................13215 OBD II Diagnostic Management System.................................................................................................13216 16-Terminal Data Link Connector (DLC)...............................................................................................13217 Malfunction Indicator Lamp (MIL)....................................................................................................13218 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................13218 Clear DTC...........................................................................................................................13218 DTC Check...........................................................................................................................13219 PCM Precaution......................................................................................................................13219 Information On PCM..................................................................................................................13219 Intermittent Conditions.............................................................................................................13219 Transmission And PCM Identification.................................................................................................13220 Diagnostic Trouble Code (DTC) Identification........................................................................................13221 DTC P0218 Transmission Fluid Over Temperature...........................................................................................13222 DTC P0560 System Voltage Malfunction....................................................................................................13224 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................13227 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................13230 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Circuit Range/Performance.........................................................13233 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................13236 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................13239 DTC P0719 TCC Brake Switch Circuit High (Stuck On)......................................................................................13242 DTC P0722 Transmission Output Speed Sensor (OSS) Low Input..............................................................................13245 DTC P0723 Transmission Output Speed Sensor (OSS) Intermittent...........................................................................13248 DTC P0724 TCC Brake Switch Circuit Low (Stuck Off)......................................................................................13251 DTC P0730 Transmission Incorrect Gear Ratio.............................................................................................13253 DTC P0742 Torque Converter Clutch (TCC) Circuit Stuck On................................................................................13256 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................13258 DTC P0751 Shift Solenoid A Performance Without Input Speed..............................................................................13260 DTC P0753 Shift Solenoid A Electrical...................................................................................................13262 DTC P0756 Shift Solenoid B Performance Without Input Speed..............................................................................13265 DTC P0758 Shift Solenoid B Electrical...................................................................................................13267 DTC P1790 ROM Transmission Side Bad Check Sum...........................................................................................13271 DTC P1792 EEPROM Transmission Side Bad Check Sum........................................................................................13272 DTC P1835 Kickdown Switch Always On.....................................................................................................13273 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................13275 DTC P1860 TCC Solenoid Electrical.......................................................................................................13279 DTC P1870 Transmission Component Slipping...............................................................................................13282 Circuit Diagram.........................................................................................................................13284 Parts Location..........................................................................................................................13286 Harness Connector Faces.................................................................................................................13287 Sec.8 BODY AND ACCESSORIES....................................................................................................................13289 8A LIGHTING SYSTEM........................................................................................................................13289 Service Precaution......................................................................................................................13290 Headlight Bulb..........................................................................................................................13290 Removal.............................................................................................................................13290 Installation........................................................................................................................13290 Headlight...............................................................................................................................13291 Removal.............................................................................................................................13291 Installation........................................................................................................................13291 Headlight Adjustment................................................................................................................13291 Fender Marker Light Bulb................................................................................................................13293 Removal.............................................................................................................................13293 Installation........................................................................................................................13293 Front Side Marker Light Bulb............................................................................................................13293 Removal.............................................................................................................................13293 Installation........................................................................................................................13293 Rear Side Marker Light Bulb.............................................................................................................13294 Removal.............................................................................................................................13294 Installation........................................................................................................................13294 Parking Light Bulb......................................................................................................................13294 Removal.............................................................................................................................13294 Installation........................................................................................................................13294 Taillight Bulb..........................................................................................................................13295 Removal.............................................................................................................................13295 Installation........................................................................................................................13295 License Plate Light Bulb................................................................................................................13295 Removal.............................................................................................................................13295 Installation........................................................................................................................13295 Stoplight Bulb..........................................................................................................................13296 Removal and Installation............................................................................................................13296 High Mounted Stop Light.................................................................................................................13296 Removal.............................................................................................................................13296 Installation........................................................................................................................13296 Front Turn Signal Light Bulb............................................................................................................13297 Removal.............................................................................................................................13297 Installation........................................................................................................................13297 Rear Turn Signal Light Bulb.............................................................................................................13297 Removal.............................................................................................................................13297 Installation........................................................................................................................13297 Backup Light Bulb.......................................................................................................................13298 Removal.............................................................................................................................13298 Installation........................................................................................................................13298 Dome Light Bulb.........................................................................................................................13298 Removal.............................................................................................................................13298 Installation........................................................................................................................13298 Map Light Switch/Bulb...................................................................................................................13299 Removal.............................................................................................................................13299 Installation........................................................................................................................13299 Cigarette Lighter Illumination Bulb.....................................................................................................13299 Removal.............................................................................................................................13299 Installation........................................................................................................................13299 Ashtray Illumination Bulb...............................................................................................................13300 Removal.............................................................................................................................13300 Installation........................................................................................................................13300 HVAC Bezel Illumination Light Bulb......................................................................................................13300 Removal and Installation............................................................................................................13300 Shift Lever Illumination Light Bulb (A/T)...............................................................................................13301 Removal.............................................................................................................................13301 Installation........................................................................................................................13301 Starter Switch..........................................................................................................................13301 Removal.............................................................................................................................13301 Installation........................................................................................................................13301 Lighting Switch (Combination Switch)....................................................................................................13302 Removal.............................................................................................................................13302 Installation........................................................................................................................13302 Stoplight Switch........................................................................................................................13303 Removal.............................................................................................................................13303 Installation........................................................................................................................13303 Turn Signal Switch(Combination Switch)..................................................................................................13304 Removal and Installation............................................................................................................13304 Hazard Warning Switch...................................................................................................................13304 Removal.............................................................................................................................13304 Installation........................................................................................................................13304 Key Remind Switch(Starter Switch).......................................................................................................13304 Removal and Installation............................................................................................................13304 Door Switch.............................................................................................................................13305 Removal.............................................................................................................................13305 Installation........................................................................................................................13305 Rear Defogger Switch....................................................................................................................13305 Removal.............................................................................................................................13305 Installation........................................................................................................................13305 Illumination Controller.................................................................................................................13306 Removal.............................................................................................................................13306 Installation........................................................................................................................13306 Main Data and Specifications............................................................................................................13307 8B WIPER / WASHER SYSTEM..................................................................................................................13310 Service Precaution......................................................................................................................13310 Windshield Wiper/Washer System..........................................................................................................13311 General Description.................................................................................................................13311 Windshield Wiper And Washer Switch......................................................................................................13311 Removal and Installation............................................................................................................13311 Windshield Wiper Motor..................................................................................................................13311 Removal.............................................................................................................................13311 Installation........................................................................................................................13311 Windshield Washer Motor.................................................................................................................13312 Removal.............................................................................................................................13312 Installation........................................................................................................................13312 Washer Nozzle Angle Adjustment......................................................................................................13312 Windshield Wiper Linkage................................................................................................................13313 Windshield Wiper Linkage and Associated Parts.......................................................................................13313 Removal.............................................................................................................................13313 Installation........................................................................................................................13313 Windshield Wiper Arm/Blade..............................................................................................................13314 Removal.............................................................................................................................13314 Installation........................................................................................................................13314 Windshield Wiper Blade Rubber...........................................................................................................13315 Removal.............................................................................................................................13315 Installation........................................................................................................................13315 Alarm & Relay Control Unit..............................................................................................................13316 Removal.............................................................................................................................13316 Installation........................................................................................................................13316 Intermittent Relay......................................................................................................................13316 Removal.............................................................................................................................13316 Installation........................................................................................................................13316 Main Data and Specifications............................................................................................................13317 8C ENTERTAINMENT..........................................................................................................................13318 Service Precaution......................................................................................................................13318 Cigarette Lighter.......................................................................................................................13319 General Description.................................................................................................................13319 Removal.............................................................................................................................13319 Installation........................................................................................................................13319 Antenna.................................................................................................................................13320 Removal.............................................................................................................................13320 Installation........................................................................................................................13320 Radio...................................................................................................................................13321 Removal.............................................................................................................................13321 Installation........................................................................................................................13321 Front Speaker...........................................................................................................................13321 Removal.............................................................................................................................13321 Installation........................................................................................................................13321 Tweeter Assembly........................................................................................................................13322 Removal.............................................................................................................................13322 Installation........................................................................................................................13322 Rear Speaker............................................................................................................................13322 Removal.............................................................................................................................13322 Installation........................................................................................................................13322 Horn (Low note).........................................................................................................................13323 Removal.............................................................................................................................13323 Installation........................................................................................................................13323 Horn (High note)........................................................................................................................13323 Removal.............................................................................................................................13323 Installation........................................................................................................................13323 8D WIRING SYSTEM..........................................................................................................................13324 Fuse, Relay and Diode...................................................................................................................13325 Relay and Fuse Box / Relay Box Location.............................................................................................13325 Fuse Layout.........................................................................................................................13326 Relay Layout........................................................................................................................13327 Diode Layout........................................................................................................................13328 Circuit Diagram.........................................................................................................................13329 Harness and Connector Location..........................................................................................................13353 8E METER AND GAUGE........................................................................................................................13372 Service Precaution......................................................................................................................13372 Meter Assembly..........................................................................................................................13373 General Description.................................................................................................................13373 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................13373 Table for Meter/Gauge Connector Terminal Connections................................................................................13375 Removal.............................................................................................................................13377 Installation........................................................................................................................13377 Speedometer.............................................................................................................................13378 Removal.............................................................................................................................13378 Installation........................................................................................................................13378 Tachometer..............................................................................................................................13379 Removal.............................................................................................................................13379 Installation........................................................................................................................13379 Coolant Temperature gauge and Fuel Gauge................................................................................................13380 Removal.............................................................................................................................13380 Installation........................................................................................................................13380 TOD Indicator Assembly..................................................................................................................13381 Removal.............................................................................................................................13381 Installation........................................................................................................................13381 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb.......................................................................13382 Removal.............................................................................................................................13382 Installation........................................................................................................................13382 A/T Indicator Light Bulb................................................................................................................13382 Removal.............................................................................................................................13382 Installation........................................................................................................................13382 Vehicle Speed Sensor....................................................................................................................13383 Removal.............................................................................................................................13383 Installation........................................................................................................................13383 Thermo Unit.............................................................................................................................13383 Removal.............................................................................................................................13383 Installation........................................................................................................................13383 Fuel Tank Unit..........................................................................................................................13384 Removal.............................................................................................................................13384 Installation........................................................................................................................13384 Main Data and Specifications............................................................................................................13385 8F BODY STRUCTURE.........................................................................................................................13386 Service Precaution......................................................................................................................13387 Frame...................................................................................................................................13387 General Description.................................................................................................................13387 Frame Dimensions....................................................................................................................13388 Front Bumper............................................................................................................................13389 Parts Location......................................................................................................................13389 Removal.............................................................................................................................13390 Installation........................................................................................................................13390 Rear Bumper.............................................................................................................................13391 Parts Location......................................................................................................................13391 Removal.............................................................................................................................13391 Installation........................................................................................................................13391 Engine Hood.............................................................................................................................13392 Parts Location......................................................................................................................13392 Removal.............................................................................................................................13392 Installation........................................................................................................................13393 Engine Hood Cover.......................................................................................................................13394 Parts Location......................................................................................................................13394 Removal.............................................................................................................................13394 Installation........................................................................................................................13394 Engine Hood Lock........................................................................................................................13395 Parts Location......................................................................................................................13395 Removal.............................................................................................................................13395 Installation........................................................................................................................13396 Radiator Grille.........................................................................................................................13396 Parts Location......................................................................................................................13396 Removal.............................................................................................................................13396 Installation........................................................................................................................13396 Front Fender Panel......................................................................................................................13397 Parts Location......................................................................................................................13397 Removal.............................................................................................................................13397 Installation........................................................................................................................13398 Body Mounting...........................................................................................................................13399 Parts Location......................................................................................................................13399 Tightening Torque...................................................................................................................13399 Body Dimension......................................................................................................................13400 Instrument Panel Assembly and Cross Beam Assembly.......................................................................................13410 Parts Location......................................................................................................................13410 Removal.............................................................................................................................13411 Installation........................................................................................................................13414 Front Door Assembly.....................................................................................................................13416 Parts Location......................................................................................................................13416 Removal.............................................................................................................................13416 Installation........................................................................................................................13417 Door Strikers...........................................................................................................................13418 Adjustment..........................................................................................................................13418 Front Window Regulator, Glass and Glass Run.............................................................................................13419 Parts Location......................................................................................................................13419 Removal.............................................................................................................................13420 Installation........................................................................................................................13422 Tailgate Assembly.......................................................................................................................13423 Parts Location......................................................................................................................13423 Removal.............................................................................................................................13423 Installation........................................................................................................................13424 Tailgate Dove-Tail......................................................................................................................13425 Parts Location......................................................................................................................13425 Removal.............................................................................................................................13425 Installation........................................................................................................................13425 Spare Tire Carrier......................................................................................................................13426 Parts Location......................................................................................................................13426 Removal.............................................................................................................................13426 Installation........................................................................................................................13426 Windshield..............................................................................................................................13427 Parts Location......................................................................................................................13427 Removal.............................................................................................................................13427 Installation........................................................................................................................13428 Rear Quarter............................................................................................................................13432 Parts Location......................................................................................................................13432 Removal.............................................................................................................................13432 Installation........................................................................................................................13433 Center Glass............................................................................................................................13434 Parts Location......................................................................................................................13434 Removal.............................................................................................................................13434 Installation........................................................................................................................13435 Tailgate Glass..........................................................................................................................13436 Parts Location......................................................................................................................13436 Removal.............................................................................................................................13436 Installation........................................................................................................................13436 Main Data and Specifications............................................................................................................13438 8G SEATS..................................................................................................................................13439 Service Precaution......................................................................................................................13439 Front Seat Assembly.....................................................................................................................13440 Disassembled View...................................................................................................................13440 Removal.............................................................................................................................13440 Installation........................................................................................................................13441 Disassembly.........................................................................................................................13441 Reassembly..........................................................................................................................13441 Rear Seat Assembly......................................................................................................................13442 Disassembled View...................................................................................................................13442 Removal.............................................................................................................................13442 Installation........................................................................................................................13442 Disassembly.........................................................................................................................13443 Reassembly..........................................................................................................................13443 Main Data and Specifications............................................................................................................13444 8H SECURITY AND LOCKS.....................................................................................................................13445 Service Precaution......................................................................................................................13445 Front Door Lock Assembly................................................................................................................13446 Front Door Lock Assembly and Associated Parts.......................................................................................13446 Removal.............................................................................................................................13446 Installation........................................................................................................................13447 Front Outside Handle and Door Lock Cylinder.............................................................................................13448 Front Outside Handle, Door Lock Cylinder and Associated Parts.......................................................................13448 Removal.............................................................................................................................13448 Installation........................................................................................................................13449 Tailgate Lock and Lock Cylinder.........................................................................................................13450 Tailgate Lock, Lock Cylinder and Associated Parts...................................................................................13450 Removal.............................................................................................................................13450 Installation........................................................................................................................13451 Key.....................................................................................................................................13452 Key Coding..........................................................................................................................13452 Key Styles..........................................................................................................................13452 Power Door Lock System..................................................................................................................13453 General Description.................................................................................................................13453 Front Door Lock Actuator Removal....................................................................................................13453 Front Door Lock Actuator Installation...............................................................................................13453 Main Data and Specifications............................................................................................................13454 8J EXTERIOR / INTERIOR TRIM...............................................................................................................13455 Service Precaution......................................................................................................................13455 Consoles................................................................................................................................13456 Consoles and Associated Parts.......................................................................................................13456 Removal.............................................................................................................................13456 Installation........................................................................................................................13456 Front Door Trim Assembly................................................................................................................13457 Front Door Trim Assembly and Associated Parts.......................................................................................13457 Removal.............................................................................................................................13457 Installation........................................................................................................................13458 Door Mirror.............................................................................................................................13458 Door Mirror and Associated Parts....................................................................................................13458 Removal.............................................................................................................................13458 Installation........................................................................................................................13458 Interior Trim Cover and Assist Grip.....................................................................................................13459 Interior Trim Cover, Assist Grip and Associated Parts...............................................................................13459 Removal.............................................................................................................................13459 Installation........................................................................................................................13460 Headlining..............................................................................................................................13461 Parts Location......................................................................................................................13461 Removal.............................................................................................................................13461 Installation........................................................................................................................13462 Tailgate Trim Cover.....................................................................................................................13462 Tailgate Trim Cover and Associated Parts............................................................................................13462 Removal.............................................................................................................................13462 Installation........................................................................................................................13462 Body Side Protectors....................................................................................................................13463 Body Side Protectors and Associated Parts...........................................................................................13463 Removal.............................................................................................................................13464 Installation........................................................................................................................13464 Tailgate Protector......................................................................................................................13465 Parts Location......................................................................................................................13465 Removal.............................................................................................................................13465 Installation........................................................................................................................13465 Fuel Filler Lid.........................................................................................................................13466 Parts Location......................................................................................................................13466 Removal.............................................................................................................................13466 Installation........................................................................................................................13466 Roof Rail Assembly......................................................................................................................13467 Parts Location......................................................................................................................13467 Removal.............................................................................................................................13467 Installation........................................................................................................................13467 Rear Roof Spoiler.......................................................................................................................13468 Parts Location......................................................................................................................13468 Removal.............................................................................................................................13468 Installation........................................................................................................................13468 Power Door Mirror System................................................................................................................13469 General Description.................................................................................................................13469 Door Mirror Control Switch and Door Mirror Defogger Switch Removal..................................................................13469 Installation........................................................................................................................13469 Power Door Mirror.......................................................................................................................13469 General Description.................................................................................................................13469 Removal and Installation............................................................................................................13469 Power Window System.....................................................................................................................13470 General Description.................................................................................................................13470 Power Window Switch Removal and Installation........................................................................................13470 Power Window Motor Removal and Installation.........................................................................................13471 Main Data and Specifications............................................................................................................13472 Sec.9 RESTRAINTS..............................................................................................................................13530 9A SEAT BELT SYSTEM.......................................................................................................................13473 Service Precaution......................................................................................................................13473 Front Seat Belt.........................................................................................................................13474 Front Seat Belt and Associated Parts................................................................................................13474 Removal.............................................................................................................................13474 Inspection..........................................................................................................................13474 Installation........................................................................................................................13475 Rear Seat Belt..........................................................................................................................13476 Rear Seat Belt and Associated Parts.................................................................................................13476 Removal.............................................................................................................................13476 Inspection..........................................................................................................................13477 Installation........................................................................................................................13477 Front Seat Belt Buckle Assembly.........................................................................................................13478 Front Seat Belt Buckle Assembly and Associated Parts................................................................................13478 Removal.............................................................................................................................13478 Installation........................................................................................................................13478 Rear Seat Belt Buckle Assembly..........................................................................................................13479 Removal.............................................................................................................................13479 Installation........................................................................................................................13479 Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................13480 General Description.................................................................................................................13480 Child Seat Tether Anchor Bracket and Associated Parts...............................................................................13480 Installation........................................................................................................................13480 Main Data and Specifications............................................................................................................13481 9J SUPPLEMENTAL RESTRAINT SYSTEM..........................................................................................................13482 Service Precaution......................................................................................................................13482 General Description.....................................................................................................................13483 SRS Component and Wiring Location View..............................................................................................13485 Component Description...................................................................................................................13485 Definition..............................................................................................................................13488 Diagnosis...............................................................................................................................13489 SRS Connector Body Face Views...........................................................................................................13490 Repairs and Inspections Required After an Accident......................................................................................13490 On-Vehicle Service......................................................................................................................13491 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................13492 Special Tools...........................................................................................................................13508 Service Precaution......................................................................................................................13513 Sensing and Diagnostic Module (SDM).....................................................................................................13515 Service Precautions.................................................................................................................13515 Removal.............................................................................................................................13515 Installation........................................................................................................................13515 Driver Air Bag Assembly.................................................................................................................13517 Service Precautions.................................................................................................................13517 Removal.............................................................................................................................13517 Installation........................................................................................................................13517 Steering Wheel..........................................................................................................................13518 Service Precautions.................................................................................................................13518 Removal.............................................................................................................................13518 Installation........................................................................................................................13519 SRS Coil Assembly.......................................................................................................................13520 Service Precaution..................................................................................................................13520 Removal.............................................................................................................................13520 Installation........................................................................................................................13521 Steering Column.........................................................................................................................13523 Service Precaution..................................................................................................................13523 Removal.............................................................................................................................13523 Installation........................................................................................................................13525 Passenger Air Bag Assembly..............................................................................................................13527 Service Precaution..................................................................................................................13527 Removal.............................................................................................................................13527 Installation........................................................................................................................13527 Main Data and Specifications............................................................................................................13528 SRS Air Bag System Inspection Standards For Repair......................................................................................13529 9J1 SRS CONTROL SYSTEM.....................................................................................................................13530 Service Precaution......................................................................................................................13530 Diagnostic Information..................................................................................................................13531 Parts For Electrical Circuit............................................................................................................13533 System Schematic........................................................................................................................13534 SRS Diagnostic System Check.............................................................................................................13534 Chart A SDM Integrity Check.............................................................................................................13537 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................13539 Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady...............................................................................13541 DTC 15 Passenger Deployment Loop Resistance High........................................................................................13544 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................13547 DTC 17 Passenger Deployment Loop Open...................................................................................................13550 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................13552 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................13554 DTC 21 Driver Deployment Loop Resistance High...........................................................................................13556 DTC 22 Driver Deployment Loop Resistance Low............................................................................................13559 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................13562 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................13564 DTC 26 Driver Deployment Loop Open......................................................................................................13567 DTC 51 Deployment Event Commanded.......................................................................................................13570 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................13572 DTC 61 Warning Lamp Circuit Failure.....................................................................................................13574 DTC 71 Internal SDM Fault...............................................................................................................13576 Sec.10 CONTROL SYSTEM..........................................................................................................................13578 10A CRUISE CONTROL SYSTEM..................................................................................................................13578 Service Precaution......................................................................................................................13578 General Description.....................................................................................................................13579 Diagnosis...............................................................................................................................13579 Brake Switch............................................................................................................................13580 Removal and Installation............................................................................................................13580 Adjustment..........................................................................................................................13580 Cruise Control Unit.....................................................................................................................13580 Removal.............................................................................................................................13580 Installation........................................................................................................................13580 Cruise Actuator.........................................................................................................................13581 Actuator Cable Diagram..............................................................................................................13581 Removal.............................................................................................................................13581 Installation........................................................................................................................13582 Adjustment..........................................................................................................................13582 Mode Switch.............................................................................................................................13583 Removal and Installation............................................................................................................13583 Cruise Control Main Switch..............................................................................................................13583 Removal.............................................................................................................................13583 Installation........................................................................................................................13583 Cruise Control Switch (Combination Switch)..............................................................................................13583 Removal and Installation............................................................................................................13583 2001 MODEL.............................................................................................................................................. 2 (UE) RODEO..........................................................................................................................................13584 Sec.0 GENERAL INFORMATION.......................................................................................................................13585 0A GENERAL INFORMATION......................................................................................................................13585 GENERAL INFORMATION.....................................................................................................................13585 Illustration Arrows.....................................................................................................................13586 Identification..........................................................................................................................13587 Theft Prevention Standard...............................................................................................................13590 Lifting Instructions....................................................................................................................13595 Standard Bolts Torque Specifications....................................................................................................13597 Abbreviations Charts....................................................................................................................13598 Service Parts Identification Plate......................................................................................................13599 0B Maintenance and Lubrication..............................................................................................................13600 Maintenance and Lubrication.............................................................................................................13600 Explanation of Complete Vehicle Maintenance Schedule....................................................................................13604 Recommended Fluids and Lubricants...................................................................................................13607 Lubricant Viscosity Chart...............................................................................................................13608 Recommended Liquid Gasket...........................................................................................................13610 Recommended Thread Locking Agents...................................................................................................13610 Maintenance Service Data................................................................................................................13611 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)..........................................................................................13612 1A HVAC SYSTEMS.............................................................................................................................13612 Service Precaution......................................................................................................................13613 Heating and Ventilation System..........................................................................................................13613 General Description.....................................................................................................................13613 Wiring Diagram..........................................................................................................................13617 Diagnosis...............................................................................................................................13618 Individual Inspection...................................................................................................................13622 Heater Unit.............................................................................................................................13624 Heater Unit and Associated Parts....................................................................................................13624 Removal.............................................................................................................................13624 Installation........................................................................................................................13625 Heater Core and / or Mode Door..........................................................................................................13625 Disassembled View...................................................................................................................13625 Removal.............................................................................................................................13626 Inspection..........................................................................................................................13626 Installation........................................................................................................................13626 Heater Mode Control Link Unit...........................................................................................................13627 Disassembled View...................................................................................................................13627 Removal.............................................................................................................................13627 Installation........................................................................................................................13628 Heater Temperature Control Link Unit....................................................................................................13628 Disassembled View...................................................................................................................13628 Removal.............................................................................................................................13628 Installation........................................................................................................................13629 Blower Assembly.........................................................................................................................13629 Blower Assembly and Associated Parts................................................................................................13629 Removal.............................................................................................................................13630 Installation........................................................................................................................13630 Blower Link Unit and / or Mode door.....................................................................................................13630 Disassembled View...................................................................................................................13630 Removal.............................................................................................................................13630 Installation........................................................................................................................13631 Blower Motor............................................................................................................................13632 Blower Motor and Associated Parts...................................................................................................13632 Removal.............................................................................................................................13632 Installation........................................................................................................................13632 Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................13633 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................13633 Removal.............................................................................................................................13633 Installation........................................................................................................................13634 Control Lever Assembly and / or Control Cable...........................................................................................13634 Control Lever Assembly, Control Cable and Associated Parts..........................................................................13634 Removal.............................................................................................................................13635 Installation........................................................................................................................13636 Control Panel Illumination Bulb.........................................................................................................13637 Control Panel Illumination Bulb and Associated Parts................................................................................13637 Removal.............................................................................................................................13637 Installation........................................................................................................................13637 Resistor................................................................................................................................13637 Resistor and Associated Parts.......................................................................................................13637 Removal.............................................................................................................................13637 Installation........................................................................................................................13637 Air Conditioning System.................................................................................................................13638 General Description.....................................................................................................................13638 Diagnosis...............................................................................................................................13648 Air Source Select Lever Diagnosis.......................................................................................................13658 Air Conditioning System.................................................................................................................13661 Individual Inspection...................................................................................................................13661 General Repair Procedure............................................................................................................13662 Leak Check..........................................................................................................................13664 Compressor Assembly.....................................................................................................................13669 Compressor Assembly and Associated Parts (6VD1).....................................................................................13669 Removal.............................................................................................................................13669 Installation........................................................................................................................13670 New Compressor Installation.........................................................................................................13670 Compressor Assembly.....................................................................................................................13671 Compressor Assembly and Associated Parts (X22SE)....................................................................................13671 Removal.............................................................................................................................13671 Installation........................................................................................................................13672 New Compressor Installation.........................................................................................................13672 Condenser Assembly......................................................................................................................13673 Condenser Assembly and Associated Parts.............................................................................................13673 Removal.............................................................................................................................13673 Installation........................................................................................................................13673 Condenser Fan Motor.....................................................................................................................13674 Condenser Fan Motor and Associated Parts............................................................................................13674 Removal.............................................................................................................................13674 Installation........................................................................................................................13674 Receiver / Drier........................................................................................................................13675 Receiver / Drier and Associated Parts...............................................................................................13675 Removal.............................................................................................................................13675 Installation........................................................................................................................13675 Pressure Switch.........................................................................................................................13676 Pressure Switch and Associated Parts................................................................................................13676 Removal.............................................................................................................................13676 Installation........................................................................................................................13676 Evaporator Assembly.....................................................................................................................13677 Evaporator Assembly and Associated Parts............................................................................................13677 Removal.............................................................................................................................13677 Installation........................................................................................................................13678 Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................13679 Disassembled View...................................................................................................................13679 Removal.............................................................................................................................13679 Installation........................................................................................................................13680 Refrigerant Line........................................................................................................................13681 Refrigerant Line and Associated Parts...............................................................................................13681 Removal.............................................................................................................................13681 Installation........................................................................................................................13682 Main Data And Specifications............................................................................................................13683 Compressor..............................................................................................................................13686 Service Precaution..................................................................................................................13686 General Description.....................................................................................................................13686 Diagnosis...............................................................................................................................13687 Magnetic Clutch Assembly (DKV-14G Type).................................................................................................13688 Parts Location View.................................................................................................................13688 Removal.............................................................................................................................13688 Inspection and Repair...............................................................................................................13690 Installation........................................................................................................................13690 Compressor Oil..........................................................................................................................13692 Oil Specification...................................................................................................................13692 Handling of Oil.....................................................................................................................13692 Compressor Oil Check................................................................................................................13692 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................13692 Checking and Adjusting for Compressor Replacement...................................................................................13693 Contamination of Compressor Oil.....................................................................................................13693 Oil Return Operation................................................................................................................13693 Replacement of Component Parts......................................................................................................13693 Main Data and Specifications............................................................................................................13694 Special Tools...........................................................................................................................13696 Sec.2 STEERING..................................................................................................................................13697 2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................13697 Service Precaution......................................................................................................................13698 Diagnosis...............................................................................................................................13698 General Description.....................................................................................................................13704 Power Steering System Test..............................................................................................................13706 Maintenance.............................................................................................................................13707 Fluid Level.............................................................................................................................13707 Bleeding The Power Steering System......................................................................................................13707 Bleeding Procedure......................................................................................................................13707 Flushing The Power Steering System......................................................................................................13707 Steering Wheel Free Play Inspection.....................................................................................................13708 Front End Alignment Inspection and Adjustment...........................................................................................13708 Main Data and Specifications............................................................................................................13712 Special Tools.......................................................................................................................13713 Power Steering Unit.....................................................................................................................13714 Power Steering Unit and Associated Parts............................................................................................13714 Removal.............................................................................................................................13714 Installation (4×2 Model)............................................................................................................13715 Installation (4×4 Model)............................................................................................................13715 Power Steering Unit Disassembled View...............................................................................................13716 Disassembly.........................................................................................................................13716 Inspection and Repair...............................................................................................................13716 Reassembly..........................................................................................................................13716 Main Data and Specifications........................................................................................................13717 Special Tools.......................................................................................................................13717 Power Steering Pump.....................................................................................................................13718 Power Steering Pump and Associated Parts............................................................................................13718 Removal.............................................................................................................................13718 Installation........................................................................................................................13718 Power Steering Pump Disassembled View...............................................................................................13719 Disassembly.........................................................................................................................13719 Inspection and Repair...............................................................................................................13720 Reassembly..........................................................................................................................13720 Main Data and Specifications............................................................................................................13722 Transfer Gear Assembly..................................................................................................................13723 Transfer Gear Assembly and Associated Parts.........................................................................................13723 Removal.............................................................................................................................13723 Inspection and Repair...............................................................................................................13723 Installation........................................................................................................................13723 Supplemental Restraint System Steering Wheel & Column...................................................................................13724 Service Precaution..................................................................................................................13724 SRS Connectors......................................................................................................................13724 Inflator Module.........................................................................................................................13726 Inflator Module and Associated Parts................................................................................................13726 Removal.............................................................................................................................13726 Inspection and Repair...............................................................................................................13727 Installation........................................................................................................................13727 Steering Wheel..........................................................................................................................13728 Steering Wheel and Associated Parts.................................................................................................13728 Removal.............................................................................................................................13728 Installation........................................................................................................................13730 Combination Switch......................................................................................................................13731 Combination Switch and Associated Parts.............................................................................................13731 Removal.............................................................................................................................13731 Installation........................................................................................................................13733 Lock Cylinder...........................................................................................................................13735 Lock Cylinder and Associated Parts..................................................................................................13735 Removal.............................................................................................................................13735 Installation........................................................................................................................13737 System Inspection...................................................................................................................13738 Steering Column.........................................................................................................................13739 Steering Column and Associated Parts................................................................................................13739 Removal.............................................................................................................................13739 Insepction..........................................................................................................................13741 Installation........................................................................................................................13743 System Inspection...................................................................................................................13744 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................13745 Main Data and Specifications............................................................................................................13745 Special Tools.......................................................................................................................13745 Sec.3 SUSPENSION................................................................................................................................13746 3C FRONT SUSPENSION.........................................................................................................................13746 Service Precaution......................................................................................................................13746 General Description.....................................................................................................................13747 Diagnosis...............................................................................................................................13747 Shock Absorber..........................................................................................................................13750 Shock Absorber and Associated Parts.................................................................................................13750 Removal.............................................................................................................................13750 Inspection and Repair...............................................................................................................13750 Installation........................................................................................................................13750 Stabilizer Bar..........................................................................................................................13751 Stabilizer Bar and Associated Parts.................................................................................................13751 Removal.............................................................................................................................13751 Inspection and Repair...............................................................................................................13751 Installation........................................................................................................................13751 Torsion Bar.............................................................................................................................13752 Torsion Bar and Associated Parts....................................................................................................13752 Removal.............................................................................................................................13752 Inspection and Repair...............................................................................................................13753 Installation........................................................................................................................13753 Knuckle.................................................................................................................................13755 Knuckle and Associated Parts........................................................................................................13755 Removal.............................................................................................................................13755 Inspection and Repair...............................................................................................................13756 Installation........................................................................................................................13756 Upper Control Arm.......................................................................................................................13758 Upper Control Arm and Associated Parts..............................................................................................13758 Removal.............................................................................................................................13758 Inspection and Repair...............................................................................................................13759 Installation........................................................................................................................13759 Lower Control Arm.......................................................................................................................13761 Lower Control Arm and Associated Parts..............................................................................................13761 Removal.............................................................................................................................13761 Inspection and Repair...............................................................................................................13762 Installation........................................................................................................................13763 Upper Ball Joint........................................................................................................................13764 Upper Ball Joint and Associated Parts...............................................................................................13764 Removal.............................................................................................................................13764 Inspection and Repair...............................................................................................................13765 Installation........................................................................................................................13765 Lower Ball Joint........................................................................................................................13766 Lower Ball Joint and Associated Parts...............................................................................................13766 Removal.............................................................................................................................13766 Inspection and Repair...............................................................................................................13767 Installation........................................................................................................................13767 Main Data and Specifications............................................................................................................13768 Special Tools.......................................................................................................................13770 3D REAR SUSPENSION..........................................................................................................................13771 Service Precaution......................................................................................................................13771 General Description.....................................................................................................................13771 Diagnosis...............................................................................................................................13772 Coil Spring.............................................................................................................................13775 Coil Spring and Associated Parts....................................................................................................13775 Removal.............................................................................................................................13775 Inspection and Repair...............................................................................................................13776 Installation........................................................................................................................13776 Shock Absorber..........................................................................................................................13777 Shock Absorber and Associated Parts.................................................................................................13777 Removal.............................................................................................................................13777 Inspection and Repair...............................................................................................................13777 Installation........................................................................................................................13777 Trailing Link...........................................................................................................................13778 Trailing Link and Associated Parts..................................................................................................13778 Removal.............................................................................................................................13778 Inspection and Repair...............................................................................................................13778 Installation........................................................................................................................13779 Upper Link..............................................................................................................................13780 Upper Link and Associated Parts.....................................................................................................13780 Removal.............................................................................................................................13780 Inspection and Repair...............................................................................................................13780 Installation........................................................................................................................13781 Lateral Rod.............................................................................................................................13782 Lateral Rod and Associated Parts....................................................................................................13782 Removal.............................................................................................................................13782 Inspection and Repair...............................................................................................................13782 Installation........................................................................................................................13783 Stabilizer Bar..........................................................................................................................13784 Stabilizer Bar and Associated Parts.................................................................................................13784 Removal.............................................................................................................................13784 Inspection and Repair...............................................................................................................13784 Installation........................................................................................................................13785 Main Data and Specifications............................................................................................................13786 Special Tools...........................................................................................................................13788 3E WHEEL AND TIRE SYSTEM....................................................................................................................13789 Service Precaution......................................................................................................................13789 General Description.....................................................................................................................13790 Diagnosis...............................................................................................................................13791 Wheel...................................................................................................................................13799 Wheel and Associated Parts..........................................................................................................13799 Removal.............................................................................................................................13799 Installation........................................................................................................................13799 Tire....................................................................................................................................13800 Tire Replacement....................................................................................................................13800 General Balance Procedure...........................................................................................................13800 Balancing Wheel and Tire............................................................................................................13801 Main Data and Specifications............................................................................................................13802 3F SUSPENSION...............................................................................................................................13803 Service Precaution......................................................................................................................13804 General Description.....................................................................................................................13804 PIN ASSIGNMENT TABLE................................................................................................................13806 System Components...................................................................................................................13806 Control Unit........................................................................................................................13806 Actuator............................................................................................................................13806 Adjustable Damping Force Shock Absorber.............................................................................................13806 Warning Lamp........................................................................................................................13806 Vertical G-Sensor...................................................................................................................13807 Lateral G-Sensor....................................................................................................................13807 Acronyms and Abbreviations..........................................................................................................13807 General Diagnosis.......................................................................................................................13807 General Information.................................................................................................................13807 Service Precautions.................................................................................................................13807 Computer System Service Precautions.................................................................................................13807 General Service Precautions.........................................................................................................13807 Parts Handling......................................................................................................................13807 FLASHING CODES......................................................................................................................13808 CLEAR DTC...........................................................................................................................13809 INTERMITTENT CONDITIONS.............................................................................................................13810 BULB CHECK..........................................................................................................................13810 DTC CHECK...........................................................................................................................13810 Basic Diagnosis Flow................................................................................................................13811 Circuit Diagram.....................................................................................................................13812 Parts Location......................................................................................................................13815 Connector List......................................................................................................................13816 Diagnostic Trouble Code (DTC) Identification........................................................................................13818 DTC2 Actuator Coil Over Current.........................................................................................................13819 Circuit Description.................................................................................................................13819 Diagnostic Aids.....................................................................................................................13819 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................13821 Circuit Description.................................................................................................................13821 Diagnostic Aids.....................................................................................................................13821 DTC4 G-Sensor Open Circuit or Short.....................................................................................................13824 Circuit Description.................................................................................................................13824 Diagnostic Aids.....................................................................................................................13824 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................13825 Circuit Description.................................................................................................................13825 Diagnostic Aids.....................................................................................................................13825 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................13827 Circuit Description.................................................................................................................13827 Diagnostic Aids.....................................................................................................................13827 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................13829 Circuit Description.................................................................................................................13829 Diagnostic Aids.....................................................................................................................13829 DTC9 Control Unit Abnormality.......................................................................................................13830 Control Unit............................................................................................................................13834 Control Unit and Associated Parts...................................................................................................13834 Removal.................................................................................................................................13835 Installation............................................................................................................................13835 Front Actuator..........................................................................................................................13836 Front Actuator and Associated Parts.................................................................................................13836 Removal.................................................................................................................................13837 View B..............................................................................................................................13837 Inspection and Repair...................................................................................................................13837 Installation............................................................................................................................13837 Rear Shock Absorber.....................................................................................................................13838 Rear Shock Absorber and Associated Parts............................................................................................13838 Removal.................................................................................................................................13839 Inspection and Repair...................................................................................................................13839 Installation............................................................................................................................13839 Sec.4 DRIVELINE/AXLE............................................................................................................................13840 4A1 Differential (Front)....................................................................................................................13840 Service Precaution......................................................................................................................13840 Front Drive Axle........................................................................................................................13841 Diagnosis...............................................................................................................................13841 Pinion Shaft Oil Seal...................................................................................................................13842 Pinion Shaft Oil Seal and Associated Parts..........................................................................................13842 Removal.............................................................................................................................13842 Inspection and Repair...............................................................................................................13843 Installation........................................................................................................................13843 Front Drive Axle Assembly...............................................................................................................13844 Front Drive Axle Assembly and Associated Parts......................................................................................13844 Removal.............................................................................................................................13845 Installation........................................................................................................................13845 Differential Assembly...................................................................................................................13847 Disassembled View...................................................................................................................13847 Disassembly.........................................................................................................................13848 Reassembly..........................................................................................................................13850 Differential Cage Assembly..............................................................................................................13858 Disassembled View...................................................................................................................13858 Disassembly.........................................................................................................................13858 Inspection and Repair...............................................................................................................13859 Reassembly..........................................................................................................................13859 Main Data and Specifications........................................................................................................13861 Special Tools.......................................................................................................................13864 4A2 Differential (Rear).....................................................................................................................13866 Service Precaution......................................................................................................................13866 General Description.....................................................................................................................13867 Diagnosis...............................................................................................................................13868 Axle Housing............................................................................................................................13870 Axle Housing and Associated Parts...................................................................................................13870 Removal.............................................................................................................................13870 Installation........................................................................................................................13872 Axle Shaft, Oil Seal and Bearing........................................................................................................13872 Axle Shaft and Associated Parts.....................................................................................................13872 Removal.............................................................................................................................13873 Inspection..........................................................................................................................13873 Installation........................................................................................................................13873 Pinion Oil Seal.........................................................................................................................13875 Pinion Oil Seal and Associated Parts................................................................................................13875 Removal.............................................................................................................................13875 Inspection and Repair...............................................................................................................13876 Installation........................................................................................................................13876 Differential Assembly...................................................................................................................13878 Disassembled View...................................................................................................................13878 Inspecting the Axle Before Disassembly..............................................................................................13879 Disassembly.........................................................................................................................13879 Inspection and Repair...............................................................................................................13881 Reassembly..........................................................................................................................13881 Side Bearing Preload Adjustment.....................................................................................................13885 Pinion Installation.................................................................................................................13886 Determination of Backlash & Preload Shims...........................................................................................13887 Backlash Adjustment.................................................................................................................13888 Gear Tooth Pattern Check............................................................................................................13888 Adjustments Affecting Tooth Contact.................................................................................................13889 Differential Case Assembly..............................................................................................................13890 Disassembled View...................................................................................................................13890 Disassembly.........................................................................................................................13891 Inspection and Repair...............................................................................................................13891 Reassembly..........................................................................................................................13891 Limited Slip Differential Assembly......................................................................................................13892 Disassembled View...................................................................................................................13892 Disassembly.........................................................................................................................13892 Inspection and Repair...............................................................................................................13894 Reassembly..........................................................................................................................13894 Main Data And Specifications............................................................................................................13896 Special Tools...........................................................................................................................13898 4B DRIVELINE CONTROL SYSTEM................................................................................................................13900 Service Precaution......................................................................................................................13900 Shift On The Fly System.................................................................................................................13901 Outline of Shift on The Fly System......................................................................................................13901 Functions of Indicator Lamp.............................................................................................................13905 Diagnosis...............................................................................................................................13906 Shift On The Fly Electrical Equipment...................................................................................................13916 Axle Shaft Connection and Disconnection.................................................................................................13916 4WD Control Unit........................................................................................................................13919 4WD Control Unit Associated Parts.......................................................................................................13919 Removal.................................................................................................................................13919 Installation............................................................................................................................13920 Shift On The Fly Controller.............................................................................................................13921 Shift On The Fly Controller and Associated Parts........................................................................................13921 Removal.................................................................................................................................13921 Installation............................................................................................................................13921 4C DRIVE SHAFT SYSTEM......................................................................................................................13922 Service Precaution......................................................................................................................13922 General Description.....................................................................................................................13923 Diagnosis...............................................................................................................................13923 Front Hub and Disc (2WD Model)..........................................................................................................13924 Disassembled View...................................................................................................................13924 Disassembly.........................................................................................................................13924 Inspection and Repair...............................................................................................................13925 Reassembly..........................................................................................................................13926 Front Hub and Disc (4WD Model)..........................................................................................................13929 Disassembled View...................................................................................................................13929 Disassembly.........................................................................................................................13929 Inspection and Repair...............................................................................................................13930 Reassembly..........................................................................................................................13931 Front Drive Shaft Joint.................................................................................................................13934 Front Drive Shaft Joints Replace-ment...............................................................................................13934 Front Axle Drive Shaft..................................................................................................................13935 Front Axle Drive Shaft and Associated Parts.........................................................................................13935 Disassembly.........................................................................................................................13936 Inspection And Repair...............................................................................................................13937 Bushing Replacement.................................................................................................................13937 Reassembly..........................................................................................................................13938 Shift On The Fly System.................................................................................................................13940 Shift On The Fly System and Associated Parts........................................................................................13940 Disassembly.........................................................................................................................13941 Inspection And Repair...............................................................................................................13942 Reassembly..........................................................................................................................13944 Main Data and Specifications........................................................................................................13947 Special Tools.......................................................................................................................13949 Propeller Shaft.........................................................................................................................13950 General Description.................................................................................................................13950 Universal Joint.....................................................................................................................13951 Diagnosis of Propeller Shaft and Universal Joint....................................................................................13952 Front Propeller Shaft...................................................................................................................13953 Front Propeller Shaft and Associated Parts..........................................................................................13953 Removal.............................................................................................................................13953 Installation........................................................................................................................13953 Disassembly.........................................................................................................................13954 Universal Joint Disassembly.........................................................................................................13955 Inspection and Repair...............................................................................................................13956 Universal Joint Reassembly..........................................................................................................13957 Reassembly..........................................................................................................................13958 Main Data and Specifications............................................................................................................13959 Rear Propeller Shaft....................................................................................................................13960 Rear Propeller Shaft and Associated Parts...........................................................................................13960 Removal.............................................................................................................................13960 Installation........................................................................................................................13960 Slip Joint Disassembly..............................................................................................................13961 Universal Joint Disassembly.........................................................................................................13962 Inspection..........................................................................................................................13964 Universal Joint Reassembly..........................................................................................................13965 Slip Joint Reassembly...............................................................................................................13966 Main Data and Specifications........................................................................................................13967 4D TRANSFER CASE...........................................................................................................................13968 Service Precaution......................................................................................................................13968 General Description.....................................................................................................................13969 Transfer Rear Oil Seal..................................................................................................................13971 Transfer Rear Oil Seal and Associated Parts.........................................................................................13971 Removal.............................................................................................................................13971 Installation........................................................................................................................13971 Transfer Case Assembly (A/T)............................................................................................................13973 Transfer Case Assembly (A/T) and Associated Parts...................................................................................13973 Removal.............................................................................................................................13973 Installation........................................................................................................................13975 Transfer Rear Case Assembly (A/T).......................................................................................................13978 Transfer Rear Case Assembly (A/T) and Associated Parts..............................................................................13978 Removal.............................................................................................................................13978 Installation........................................................................................................................13980 Transfer Rear Cover Assembly........................................................................................................13983 Disassembly.........................................................................................................................13983 Inspection and Repair...............................................................................................................13984 Reassembly..........................................................................................................................13984 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)...........................................................................13986 Disassembled View...................................................................................................................13986 Disassembly.........................................................................................................................13987 Inspection and Repair...............................................................................................................13988 Reassembly..........................................................................................................................13988 Transfer Case Assembly..................................................................................................................13990 Disassembled View...................................................................................................................13990 Disassembly.........................................................................................................................13991 Inspection and Repair...............................................................................................................13994 Reassembly..........................................................................................................................13997 Main Data and Specifications............................................................................................................14004 Special Tools...........................................................................................................................14007 Sec.5 BRAKES....................................................................................................................................14008 5A Brake Control System....................................................................................................................14008 Service Precaution......................................................................................................................14009 General Description.....................................................................................................................14010 Functional Description..............................................................................................................14011 System Components...................................................................................................................14017 Electronic Hydraulic Control Unit (EHCU)............................................................................................14017 ABS Warning Light...................................................................................................................14017 Wheel Speed Sensor..................................................................................................................14017 G-Sensor............................................................................................................................14017 Normal and Anti-lock Braking........................................................................................................14017 Brake Pedal Travel..................................................................................................................14017 Acronyms and Abbreviations..........................................................................................................14017 General Diagnosis.......................................................................................................................14018 General Information.................................................................................................................14018 ABS Service Precautions.............................................................................................................14018 Computer System Service Precautions.................................................................................................14018 General Service Precautions.........................................................................................................14018 Note on Intermittents...............................................................................................................14018 Test Driving ABS Complaint Vehicles.................................................................................................14019 “ABS” Warning Light.................................................................................................................14019 Normal Operation....................................................................................................................14019 Tech 2 Scan Tool....................................................................................................................14020 DATA LIST...........................................................................................................................14023 ACTUATOR TEST.......................................................................................................................14024 Tech 2 Service Bleed................................................................................................................14028 Basic Diagnostic Flow Chart.........................................................................................................14029 Basic Inspection Procedure..........................................................................................................14030 EHCU Connector Pin-out Checks...........................................................................................................14031 Circuit Diagram.....................................................................................................................14032 Connector List......................................................................................................................14035 Part Location.......................................................................................................................14037 Symptom Diagnosis.......................................................................................................................14038 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................14038 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................14039 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................14039 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................14039 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................14040 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................14040 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................14041 Diagnostic Trouble Codes................................................................................................................14042 Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................14044 Diagnostic Trouble Codes (DTCs).....................................................................................................14045 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................14047 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)).......................................14047 Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))...................................14048 Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))..................................................14048 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)).............................................14048 Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))..............................................14049 Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)).................................................14049 Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Sig........14050 Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................14050 Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)).....................................14051 Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))...........................14051 Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................14051 5B ANTI-LOCK BRAKE SYSTEM..................................................................................................................14065 Service Precaution......................................................................................................................14065 Electronic Hydraulic Control Unit.......................................................................................................14066 Electronic Hydraulic Control Unit and Associated Parts..............................................................................14066 Removal.............................................................................................................................14066 Disassembled View...................................................................................................................14067 Disassembly.........................................................................................................................14067 Reassembly..........................................................................................................................14067 Installation........................................................................................................................14067 Front Wheel Speed Sensor................................................................................................................14068 Front Wheel Speed Sensor and Associated Parts.......................................................................................14068 Removal.............................................................................................................................14068 Inspection and Repair...............................................................................................................14068 Installation........................................................................................................................14068 Rear Wheel Speed Sensor.................................................................................................................14069 Removal.............................................................................................................................14069 Inspection and Repair...............................................................................................................14069 Installation........................................................................................................................14069 5C POWER-ASSISTED BRAKE SYSTEM.............................................................................................................14070 Service Precaution......................................................................................................................14071 General Description.....................................................................................................................14071 Diagnosis...............................................................................................................................14075 General Diagnosis.......................................................................................................................14076 Hydraulic Brakes........................................................................................................................14079 Filling Master Cylinder Reservoir...................................................................................................14079 Deterioration of Brake Fluid........................................................................................................14079 Leakage of Brake Fluid..............................................................................................................14079 Bleeding Brake Hydraulic System.....................................................................................................14079 Flushing Brake Hydraulic System.....................................................................................................14080 Brake Pipes and Hoses...............................................................................................................14080 Brake Hose Inspection...............................................................................................................14080 Front Caliper Brake Hose................................................................................................................14081 Front Caliper Brake Hose and Associated Parts.......................................................................................14081 Removal.............................................................................................................................14081 Installation........................................................................................................................14081 Rear Axle Brake Hose....................................................................................................................14082 Rear Axle Brake Hose and Associated Parts...........................................................................................14082 Removal.............................................................................................................................14082 Installation........................................................................................................................14082 Brake Pipe..............................................................................................................................14083 Removal.............................................................................................................................14083 Installation........................................................................................................................14083 P & B (Proportioning and Bypass) Valve..................................................................................................14084 P & B (Proportioning and Bypass) Valve Sectional View...............................................................................14084 Removal.............................................................................................................................14084 Installation........................................................................................................................14084 Main Data and Specifications............................................................................................................14085 Brake Pedal.............................................................................................................................14086 Checking Pedal Height...............................................................................................................14086 Checking Pedal Travel...............................................................................................................14086 Brake Pedal and Associated Parts....................................................................................................14087 Removal.............................................................................................................................14087 Installation........................................................................................................................14087 Stoplight Switch........................................................................................................................14088 Parts Location......................................................................................................................14088 Removal.............................................................................................................................14088 Installation........................................................................................................................14088 Main Data and Specifications............................................................................................................14089 Fluid Reservoir Tank....................................................................................................................14090 Fluid Reservoir Tank and Associated Parts...........................................................................................14090 Removal.............................................................................................................................14090 Installation........................................................................................................................14090 Master Cylinder Assembly................................................................................................................14091 Master Cylinder Assembly and Associated Parts.......................................................................................14091 Removal.............................................................................................................................14091 Inspection and Repair...............................................................................................................14091 Installation........................................................................................................................14092 Main Data and Specifications........................................................................................................14093 Special Tools.......................................................................................................................14093 Vacuum Booster Assembly.................................................................................................................14094 Vacuum Booster Assembly and Associated Parts........................................................................................14094 Removal.............................................................................................................................14094 Inspection and Repair...............................................................................................................14094 Installation........................................................................................................................14095 Exterior Components.....................................................................................................................14097 Exterior Components and Associated Parts............................................................................................14097 Removal.............................................................................................................................14097 Inspection and Repair...............................................................................................................14098 Installation........................................................................................................................14098 Vacuum Booster Overhaul.................................................................................................................14098 Vacuum Booster......................................................................................................................14098 Main Data and Specifications............................................................................................................14099 Special Tools...........................................................................................................................14100 Front Disc Brake Pads...................................................................................................................14101 Front Disc Brake Pads Inspection....................................................................................................14101 Front Disc Brake Pads and Associated Parts..........................................................................................14101 Removal.............................................................................................................................14102 Installation........................................................................................................................14102 Front Disc Brake Rotor..................................................................................................................14104 Inspection..........................................................................................................................14104 Replacing Brake Rotors..............................................................................................................14104 Refinishing Brake Rotors............................................................................................................14104 Front Disc Brake Caliper Assembly.......................................................................................................14105 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................14105 Removal.............................................................................................................................14106 Installation........................................................................................................................14106 Front Disc Brake Caliper................................................................................................................14108 Front Disc Brake Caliper Disassembled View..........................................................................................14108 Disassembly.........................................................................................................................14108 Inspection and Repair...............................................................................................................14109 Reassembly..........................................................................................................................14109 Main Data and Specifications........................................................................................................14111 Rear Disc Brake Pads (4×4 Model)........................................................................................................14112 Brake Pads Inspection...............................................................................................................14112 Brake Pads and Associated Parts.....................................................................................................14112 Removal.............................................................................................................................14113 Installation........................................................................................................................14113 Rear Disc Brake Rotor (4×4 Model).......................................................................................................14115 Inspection..........................................................................................................................14115 Replacing Brake Rotors..............................................................................................................14115 Refinishing Brake Rotors............................................................................................................14115 Rear Drum (In Disc) Inside Diameter Check...........................................................................................14116 Rear Disc Brake Caliper Assembly (4×4 Model)............................................................................................14117 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................14117 Removal.............................................................................................................................14117 Installation........................................................................................................................14118 Rear Disc Brake Caliper (4×4 Model).....................................................................................................14119 Rear Disc Brake Caliper Disassembled View...........................................................................................14119 Disassembly.........................................................................................................................14120 Inspection and Repair...............................................................................................................14120 Reassembly..........................................................................................................................14120 Main Data and Specifications (4×4 Model)............................................................................................14122 Brake Lining............................................................................................................................14123 Brake Lining and Associated Parts...................................................................................................14123 Removal.............................................................................................................................14123 Brake Lining Inspection.............................................................................................................14124 Installation........................................................................................................................14124 Drum Brake Adjustment (4×2 Model)...................................................................................................14125 Servicing The Brake Drum............................................................................................................14125 Wheel Cylinder Assembly (4×2 Model).....................................................................................................14126 Wheel Cylinder Assembly and Associated Parts........................................................................................14126 Removal.............................................................................................................................14126 Installation........................................................................................................................14126 Disassembled View...................................................................................................................14127 Disassembly.........................................................................................................................14127 Inspection and Repair...............................................................................................................14127 Reassembly..........................................................................................................................14127 Main Data and Specifications........................................................................................................14129 5D1 PARKING BRAKE SYSTEM (4×4 Model)........................................................................................................14130 Service Precaution......................................................................................................................14130 General Description.....................................................................................................................14130 Operation...............................................................................................................................14131 Parking Brake Lever and Front Cable.....................................................................................................14132 Parking Brake Lever Assembly and Associated Parts...................................................................................14132 Removal.............................................................................................................................14132 Installation........................................................................................................................14132 Parking Brake Rear Cable................................................................................................................14133 Parking Brake Rear Cable and Associated Parts.......................................................................................14133 Removal.............................................................................................................................14134 Installation........................................................................................................................14134 Inspection and Repair...............................................................................................................14135 Parking Brake Adjustment................................................................................................................14135 Main Data and Specifications............................................................................................................14136 5D2 PARKING BRAKE SYSTEM (4×2 Model)........................................................................................................14137 Service Precaution......................................................................................................................14137 General Description.....................................................................................................................14137 Parking Brake Lever.....................................................................................................................14138 Parking Brake Lever Assembly and Associated Parts...................................................................................14138 Removal.............................................................................................................................14138 Installation........................................................................................................................14138 Parking Brake Rear Cable................................................................................................................14139 Parking Brake Rear Cable and Associated Parts.......................................................................................14139 Removal.............................................................................................................................14140 Installation........................................................................................................................14140 Parking Brake Adjustment................................................................................................................14140 Main Data and Specifications............................................................................................................14141 Sec.6 ENGINE....................................................................................................................................14142 Y22SE 2.2L ENGINE..........................................................................................................................14142 6A ENGINE MECHANICAL...................................................................................................................14142 Service Precaution..................................................................................................................14143 General Description.................................................................................................................14143 Engine Diagnosis....................................................................................................................14144 Cylinder Head Cover.................................................................................................................14157 Cylinder Head Cover and Associated Parts........................................................................................14157 Removal.........................................................................................................................14157 Installation....................................................................................................................14158 Exhaust Manifold....................................................................................................................14160 Removal.........................................................................................................................14160 Installation....................................................................................................................14160 Crankshaft Pulley...................................................................................................................14161 Removal.........................................................................................................................14161 Installation....................................................................................................................14161 Intake Manifold.....................................................................................................................14162 Removal.........................................................................................................................14162 Installation....................................................................................................................14163 Cylinder Head Assembly..............................................................................................................14165 Removal.........................................................................................................................14165 Installation....................................................................................................................14167 Timing Belt.........................................................................................................................14170 Removal.........................................................................................................................14170 Installation....................................................................................................................14170 Camshaft............................................................................................................................14176 Camshaft and Associated Parts...................................................................................................14176 Removal.........................................................................................................................14176 Installation....................................................................................................................14177 Engine Assembly.....................................................................................................................14180 Removal.........................................................................................................................14180 Installation....................................................................................................................14182 Cylinder Head.......................................................................................................................14184 Cylinder Head and Associated Parts..............................................................................................14184 Disassembly.....................................................................................................................14184 Inspection and Repair...........................................................................................................14185 Reassembly......................................................................................................................14186 Valve Spring, Valve, Valve Guide....................................................................................................14187 Valve Spring, Valve, Valve Guide and Associated Parts...........................................................................14187 Disassembly.....................................................................................................................14188 Inspection and Repair...........................................................................................................14188 Reassembly......................................................................................................................14189 Crankshaft..........................................................................................................................14190 Crankshaft and Associated Parts.................................................................................................14190 Disassembly.....................................................................................................................14190 Inspection and Repair for Bearing...............................................................................................14191 Inspection and Repair for Crankshaft............................................................................................14192 Reassembly......................................................................................................................14193 Piston and Connecting Rod...........................................................................................................14196 Piston, Connecting Rod and Associate Parts......................................................................................14196 Disassembly.....................................................................................................................14196 Inspection and Repair...........................................................................................................14197 Reassembly......................................................................................................................14199 Cylinder Block......................................................................................................................14201 Cylinder Block and Associated Parts.............................................................................................14201 Disassembly.....................................................................................................................14201 Inspection and Repair...........................................................................................................14202 Reassembly......................................................................................................................14202 Balance Unit Assembly...............................................................................................................14204 Balance Unit Assembly and Associated Parts......................................................................................14204 Disassembly.....................................................................................................................14204 Adjustment......................................................................................................................14205 Reassembly......................................................................................................................14207 Main Data and Specifications........................................................................................................14208 Special Tools.......................................................................................................................14214 6B ENGINE COOLING......................................................................................................................14215 Service Precaution..................................................................................................................14215 General Description.................................................................................................................14216 Diagnosis...........................................................................................................................14218 Draining and Refilling Cooling......................................................................................................14218 Water Pump..........................................................................................................................14219 Water Pump and Associated Parts.................................................................................................14219 Removal.........................................................................................................................14219 Inspection......................................................................................................................14219 Installation....................................................................................................................14219 Thermostat..........................................................................................................................14220 Removal.........................................................................................................................14220 Inspection......................................................................................................................14220 Installation....................................................................................................................14220 Radiator............................................................................................................................14221 Radiator and Associated Parts...................................................................................................14221 Removal.........................................................................................................................14222 Inspection......................................................................................................................14223 Installation....................................................................................................................14224 Main Data and Specifications........................................................................................................14225 Special Tool........................................................................................................................14226 6C ENGINE FUEL.........................................................................................................................14227 Service Precaution..................................................................................................................14227 General Description.................................................................................................................14228 Fuel Metering.......................................................................................................................14229 Fuel Filter.........................................................................................................................14230 Fuel Filter and Associated Parts................................................................................................14230 Removal.........................................................................................................................14230 Inspection......................................................................................................................14231 Installation....................................................................................................................14231 Inspection......................................................................................................................14231 In–Tank Fuel Filter.............................................................................................................14231 Fuel Pump Flow Test.............................................................................................................14231 Pressure test...................................................................................................................14231 Fuel Pump...........................................................................................................................14232 Fuel Pump and Associated Parts..................................................................................................14232 Removal.........................................................................................................................14232 Installation....................................................................................................................14233 Fuel Tube / Quick – Connector Fittings..............................................................................................14233 Precautions.....................................................................................................................14233 Cautions During Work............................................................................................................14233 Removal.........................................................................................................................14233 Reuse of Quick–Connector........................................................................................................14234 Assembling Advice...............................................................................................................14234 Fuel Pump Relay.....................................................................................................................14234 General Description.............................................................................................................14234 Fuel Tank...........................................................................................................................14235 Fuel Tank and Associated Parts..................................................................................................14235 Removal.........................................................................................................................14235 Installation....................................................................................................................14235 Fuel Gage Unit......................................................................................................................14236 Removal and Installation........................................................................................................14236 Fuel Filler Cap.....................................................................................................................14236 General Description.............................................................................................................14236 Inspection......................................................................................................................14236 Main Data and Specifications........................................................................................................14237 Torque Specification............................................................................................................14237 Special Tool........................................................................................................................14237 6D1 ENGINE ELECTRICAL...................................................................................................................14238 Service Precaution..................................................................................................................14238 Battery.............................................................................................................................14239 General Description.................................................................................................................14239 Diagnosis...........................................................................................................................14239 Battery Charging................................................................................................................14240 Jump Starting...................................................................................................................14240 Battery Removal.................................................................................................................14241 Battery Installation............................................................................................................14241 Main Data and Specifications....................................................................................................14242 6D2 IGNITION SYSTEM.....................................................................................................................14243 Service Precaution..................................................................................................................14243 General Description.................................................................................................................14244 Diagnosis...........................................................................................................................14244 Ignition Module.....................................................................................................................14245 Removal.........................................................................................................................14245 Installation....................................................................................................................14245 Spark Plug..........................................................................................................................14246 Removal.........................................................................................................................14246 Inspection and Repair...........................................................................................................14246 Installation....................................................................................................................14246 Crankshaft Position Sensor..........................................................................................................14247 Removal.........................................................................................................................14247 Installation....................................................................................................................14247 Main Data and Specifications........................................................................................................14248 6D3 STARTING AND CHARGING SYSTEM........................................................................................................14249 Service Precaution..................................................................................................................14249 Starting System.....................................................................................................................14250 General Description.................................................................................................................14250 Diagnosis...........................................................................................................................14250 Starter.............................................................................................................................14251 Removal.........................................................................................................................14251 Installation....................................................................................................................14251 Disassembled View...............................................................................................................14252 Inspection and Repair...........................................................................................................14253 Characteristic Test.............................................................................................................14254 Charging System.....................................................................................................................14255 General Description.............................................................................................................14255 General On–Vehicle Inspection...................................................................................................14255 Generator...........................................................................................................................14256 Removal.........................................................................................................................14256 Inspection......................................................................................................................14256 Installation....................................................................................................................14257 Disassembled View...............................................................................................................14258 Disassembly.....................................................................................................................14259 Inspection and Repair...........................................................................................................14260 Reassembly......................................................................................................................14261 Main Data and Specifications....................................................................................................14262 6E1 RODEO 2.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................14263 SPECIFICATIONS......................................................................................................................14268 DIAGRAMS AND SCHEMATICS.............................................................................................................14269 PCM PINOUTS.........................................................................................................................14282 COMPONENT LOCATOR...............................................................................................................14288 Undercarriage Component Locator Table...........................................................................................14290 Fuse And Relay Panel (Underhood Electrical Center)..............................................................................14291 DIAGNOSIS Strategy-Based Diagnostics................................................................................................14292 Strategy-Based Diagnostics......................................................................................................14292 DTC Stored......................................................................................................................14292 No DTC..........................................................................................................................14292 No Matching Symptom.............................................................................................................14292 Intermittents...................................................................................................................14292 No Trouble Found................................................................................................................14292 Verifying Vehicle Repair........................................................................................................14292 GENERAL SERVICE INFORMATION.........................................................................................................14293 OBD II Serviceability Issues....................................................................................................14293 Emissions Control Information Label.............................................................................................14293 Maintenance Schedule............................................................................................................14294 Visual/Physical Engine Compartment Inspection...................................................................................14294 Basic Knowledge Of Tools Required...............................................................................................14294 SERIAL DATA COMMUNICATIONS..........................................................................................................14294 Class II Serial Data Communications.............................................................................................14294 ON-BOARDDIAGNOSTIC (OBD II).........................................................................................................14294 O-Board Diagnostic Tests........................................................................................................14294 Comprehensive Component Monitor Diagnostic Operation............................................................................14294 System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................14295 Common OBD II Terms.............................................................................................................14295 The Diagnostic Executive........................................................................................................14296 DTC Types.......................................................................................................................14297 Decimal/Binary/Hexadecimal Conversions..........................................................................................14298 Verifying Vehicle Repair........................................................................................................14298 Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool.......................................................................14298 Tech 2 Features.................................................................................................................14300 Getting Started.................................................................................................................14300 Operating Procedure (Example)...................................................................................................14301 DTC Modes.......................................................................................................................14302 DTC Information Mode............................................................................................................14302 Miscellaneous Test..............................................................................................................14303 Lamps Test......................................................................................................................14303 Relays Test.....................................................................................................................14304 EVAP Test.......................................................................................................................14306 Idle Air Control System Test....................................................................................................14307 Fuel System Test................................................................................................................14309 EGR Control Test................................................................................................................14310 Injector Balance Test...........................................................................................................14311 Plotting Snapshot Graph.............................................................................................................14312 System Check at Tech 2..............................................................................................................14313 General Description.............................................................................................................14313 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................14317 Flow Chart for Snapshot Replay (Plotting Graph).................................................................................14318 PRIMARY SYSTE-BASED DIAGNOSTICS.....................................................................................................14319 Primary System-Based Diagnostics................................................................................................14319 Fuel Control Heated Oxygen Sensors..............................................................................................14319 HO2S Heater.....................................................................................................................14319 Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation.................................................................14319 MISFIRE MONITOR following conditions: DIAGNOSTIC OPERATION..........................................................................14320 Misfire Monitor Diagnostic Operation............................................................................................14320 Misfire Counters................................................................................................................14320 FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION.......................................................................................14321 Fuel Trim System Monitor Diagnostic Operation...................................................................................14321 Fuel Trim Cell Diagnostic Weights...............................................................................................14321 ON‐BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK...........................................................................................14322 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................14325 ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................14328 EVAP CANISTER PURGE SOLENOID........................................................................................................14328 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER...................................................................................14328 IDLE AIR CONTROL (IAC) VALVE........................................................................................................14328 FUEL SYSTEM PRESSURE TEST...........................................................................................................14328 FUEL METERING SYSTEM CHECK..........................................................................................................14329 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE..........................................................14329 POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS...........................................................................................14334 MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................14335 EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS...........................................................................................14338 ENGINE Tech 2 DATA DEFINITIONS AND RANGES...........................................................................................14338 TYPICAL SCAN DATA VALUES............................................................................................................14341 NO MALFUNCTION INDICATOR LAMP (MIL).................................................................................................14345 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY..........................................................................................14348 ENGINE CRANKS BUT WILL NOT RUN......................................................................................................14350 FUEL SYSTEM ELECTRICAL TEST.........................................................................................................14356 FUEL SYSTEM DIAGNOSIS...............................................................................................................14359 IDLE AIR CONTROL (IAC) SYSTEM CHECK.................................................................................................14364 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................14367 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK.......................................................................................14369 EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK....................................................................14371 Upshift Lamp System Check (Manual Transmission Only)................................................................................14374 PCM DIAGNOSTIC TROUBLE CODES........................................................................................................14377 (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM......................................................14380 (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT...............................................................14383 (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT.....................................................................14386 (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT...................................................................14389 (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT..................................................................14392 (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT...............................................................14395 (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT..............................................................14398 (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM.........................................................14401 (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT..........................................................................14404 (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT........................................................................14407 (DTC) P0125 INSUFFICIENT COOLANT TEM-PERATURE FOR CLOSED LOOP FUEL CONTROL..........................................................14410 (DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation...............................................................14413 (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1).........................................................................14415 (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)........................................................................14418 (DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1).......................................................................14421 (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)................................................................14424 (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1)..................................................................14427 (DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2).........................................................................14430 (DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)........................................................................14433 (DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)................................................................14436 (DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)..................................................................14439 (DTC) P0171 SYSTEM TOO LEAN (BANK 1)................................................................................................14442 (DTC) P0172 SYSTEM TOO RICH (BANK 1)................................................................................................14446 (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1...............................................................................14450 (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2...............................................................................14453 (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3...............................................................................14456 (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4...............................................................................14459 (DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14462 (DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14466 (DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14470 (DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14474 (DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................14478 (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION...................................................................................14482 (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT.....................................................................................14485 (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE..............................................................14488 (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT......................................................................14490 (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................14493 (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT........................................................................14496 (DTC) P0351 IGNITION COIL ”A” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................14499 (DTC) P0352 IGNITION COIL ”B” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................14501 (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED..............................................................14503 (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED.................................................................14506 (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE...............................................................14508 (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW......................................................................14512 (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.....................................................................14515 (DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD..............................................................................14519 (DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION..................................................................14522 (DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED..........................................................14527 (DTC) P0456 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VERY SMALL LEAK DETECTED.....................................................14531 (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION......................................14535 (DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION.............................................14538 (DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION......................................14542 (DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE.............................................................................14545 (DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.....................................................................................14547 (DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT....................................................................................14549 (DTC) P0464 Fuel Level Sensor Noisy Signal..........................................................................................14551 (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION...............................................................................14553 (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION...............................................................................14556 (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT............................................................................14559 (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED.............................................................................14561 (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED............................................................................14564 (DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.......................................................................14567 (DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT......................................................................14570 (DTC) P0562 SYSTEM VOLTAGE LOW......................................................................................................14573 (DTC) P0563 SYSTEM VOLTAGE HIGH.....................................................................................................14575 (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR..........................................................................14577 (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................14579 (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................14581 (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...................................................14583 (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....................................................14586 (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................14588 (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................14590 (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.........................................................14593 (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..........................................................14595 (DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)......................................................................14597 (DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).......................................................................14600 (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....................................................................................14603 (DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED...........................................................14606 (DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT.............................................................................................14609 (DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT................................................................................14611 (DTC) P1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE............................................................................14614 (DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NO-PURGE.................................................................14617 (DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION........................................................................14620 (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error................................................14623 (DTC) P1625 PCM Unexpected Reset....................................................................................................14624 (DTC) P1627 PCM A/D CONVERSION MALFUNCTION..........................................................................................14626 (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION............................................................................14628 SYMPTOM DIAGNOSIS...................................................................................................................14630 DEFAULT MATRIX TABLE................................................................................................................14653 Camshaft Position (CMP) Sensor......................................................................................................14656 Removal Procedure...............................................................................................................14656 Installation Procedure..........................................................................................................14656 Crankshaft Position (CKP) Sensor....................................................................................................14657 Removal Procedure...............................................................................................................14657 Installation Procedure..........................................................................................................14658 EEPROM..............................................................................................................................14659 EEPROM..........................................................................................................................14659 EEPROM Programming..............................................................................................................14659 Engine Coolant Temperature (ECT) Sensor.............................................................................................14659 Removal Procedure...............................................................................................................14659 Installation Procedure..........................................................................................................14660 Heated Oxygen Sensor (HO2S).........................................................................................................14660 Removal Procedure...............................................................................................................14660 Inspection Procedure............................................................................................................14660 Installation Procedure..........................................................................................................14661 Intake Air Temperature (IAT) Sensor.................................................................................................14661 Removal Procedure...............................................................................................................14661 Installation Procedure..........................................................................................................14662 Manifold Absolute Pressure (MAP) Sensor.............................................................................................14662 Removal Procedure...............................................................................................................14662 Installation Procedure..........................................................................................................14662 Malfunction Indicator Lamp (MIL)....................................................................................................14663 Malfunction Indicator Lamp (MIL)................................................................................................14663 Powertrain Control Module (PCM).....................................................................................................14663 Electrostatic Discharge (ESD) Damage............................................................................................14663 Removal Procedure...............................................................................................................14663 Installation Procedure..........................................................................................................14665 Throttle Position (TP) Sensor.......................................................................................................14666 Removal Procedure...............................................................................................................14666 Function Check..................................................................................................................14666 Installation Procedure..........................................................................................................14666 Vehicle Speed Sensor (VSS)..........................................................................................................14667 Removal Procedure...............................................................................................................14667 Inspection Procedure............................................................................................................14667 Installation Procedure..........................................................................................................14667 Air Filter..........................................................................................................................14668 Removal Procedure...............................................................................................................14668 Installation Procedure..........................................................................................................14668 Idle Air Control (IAC) Valve........................................................................................................14669 Removal Procedure...............................................................................................................14669 Cleaning and Inspection Procedure...............................................................................................14669 Measurement Procedure...........................................................................................................14670 Installation Procedure..........................................................................................................14670 Intake Air Duct.....................................................................................................................14670 Removal Procedure...............................................................................................................14670 Installation Procedure..........................................................................................................14671 Knock Sensor........................................................................................................................14672 Removal Procedure...............................................................................................................14672 Installation Procedure..........................................................................................................14672 Oil Pressure Switch.................................................................................................................14673 Removal Procedure...............................................................................................................14673 Installation Procedure..........................................................................................................14673 FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................14673 Removal Procedure...............................................................................................................14673 Inspection Procedure............................................................................................................14674 Installation Procedure..........................................................................................................14674 Accelerator Cable Adjustment....................................................................................................14675 Accelerator Pedal Replacement.......................................................................................................14675 Removal Procedure...............................................................................................................14675 Installation Procedure..........................................................................................................14675 Fuel Filler Cap.....................................................................................................................14676 Fuel Filler Cap.....................................................................................................................14676 Inspection Procedure............................................................................................................14676 Fuel Filter.........................................................................................................................14676 Removal Procedure...............................................................................................................14676 Inspection Procedure............................................................................................................14677 Installation Procedure..........................................................................................................14677 Fuel Injectors......................................................................................................................14678 Removal Procedure...............................................................................................................14678 Inspection Procedure............................................................................................................14678 Installation Procedure..........................................................................................................14678 Fuel Pressure Regulator.............................................................................................................14679 Removal Procedure...............................................................................................................14679 Installation Procedure..........................................................................................................14680 Fuel Pressure Relief Procedure..................................................................................................14680 Fuel Pump Assembly..................................................................................................................14681 Removal Procedure...............................................................................................................14681 Inspection Procedure............................................................................................................14682 Installation Procedure..........................................................................................................14682 Fuel Pump Relay.....................................................................................................................14683 Removal Procedure...............................................................................................................14683 Installation Procedure..........................................................................................................14683 Fuel Rail Assembly..................................................................................................................14683 Removal Procedure...............................................................................................................14683 Installation Procedure..........................................................................................................14684 Fuel Tank...........................................................................................................................14685 Removal Procedure...............................................................................................................14685 Installation Procedure..........................................................................................................14685 Throttle body (TB)..................................................................................................................14686 Removal Procedure...............................................................................................................14686 Inspection Procedure............................................................................................................14686 Installation Procedure..........................................................................................................14687 ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................14688 Removal Procedure...............................................................................................................14688 Installation Procedure..........................................................................................................14688 Ignition Coil.......................................................................................................................14688 Removal Procedure...............................................................................................................14688 Installation Procedure..........................................................................................................14688 Spark Plugs.........................................................................................................................14689 Removal Procedure...............................................................................................................14689 Inspection Procedure............................................................................................................14689 Installation Procedure..........................................................................................................14690 Spark Plug Cables...................................................................................................................14690 Spark Plug Cables...................................................................................................................14690 Inspection Procedure............................................................................................................14690 EMISSIONS Catalytic Converter.......................................................................................................14691 Catalytic Converter.............................................................................................................14691 Air Conditioning Relay..............................................................................................................14691 Removal Procedure...............................................................................................................14691 Installation Procedure..........................................................................................................14691 Ignition Timing Adjustment..........................................................................................................14691 Ignition Timing Adjustment......................................................................................................14691 EVAP Canister Hoses.................................................................................................................14691 EVAP Canister Hoses.............................................................................................................14691 EVAP Canister.......................................................................................................................14691 Removal Procedure...............................................................................................................14691 Inspection Procedure............................................................................................................14691 Installation Procedure..........................................................................................................14691 EVAP Canister Vent Solenoid.........................................................................................................14692 Removal Procedure...............................................................................................................14692 Installation Procedure..........................................................................................................14692 EVAP Canister Purge Valve Solenoid..................................................................................................14692 Removal Procedure...............................................................................................................14692 Installation Procedure..........................................................................................................14693 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................14693 Removal Procedure...............................................................................................................14693 Inspection Procedure............................................................................................................14693 Installation Procedure..........................................................................................................14694 Wiring and Connectors...............................................................................................................14695 Wiring Harness Service..........................................................................................................14695 PCM Connectors And Terminals........................................................................................................14695 Removal Procedure...............................................................................................................14695 Installation Procedure..........................................................................................................14695 Connectors And Terminals............................................................................................................14695 Connectors And Terminals........................................................................................................14695 Wire Harness Repair: Twisted Shielded Cable.........................................................................................14695 Removal Procedure...............................................................................................................14695 Installation Procedure..........................................................................................................14696 Twisted Leads.......................................................................................................................14696 Removal Procedure...............................................................................................................14696 Installation Procedure..........................................................................................................14696 Weathe-Pack Connector...............................................................................................................14697 Tools Required..................................................................................................................14697 Removal Procedure...............................................................................................................14697 Installation Procedure..........................................................................................................14698 Com-Pack III........................................................................................................................14698 Com-Pack III....................................................................................................................14698 Metri-Pack..........................................................................................................................14699 Tools Required..................................................................................................................14699 Removal Procedure...............................................................................................................14699 Installation Procedure..........................................................................................................14699 GENERAL DESCRIPTION-PCM AND SENSORS.................................................................................................14699 GENERAL DESCRIPTION-AIRINDUCTION....................................................................................................14707 GENERAL DESCRIPTION-FUELMETERING....................................................................................................14707 GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM......................................................................................14710 A/C CLUTCH DIAGNOSIS................................................................................................................14714 GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP)SYSTEM...............................................................................14714 GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION(EGR) SYSTEM...........................................................................14716 GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM.....................................................................14717 SPECIAL TOOLS.......................................................................................................................14718 6F ENGINE EXHAUST......................................................................................................................14720 Service Precaution..................................................................................................................14720 General Description.................................................................................................................14721 Front Exhaust Pipe..................................................................................................................14722 Front Exhaust Pipe and Associated Parts.........................................................................................14722 Removal.........................................................................................................................14722 Installation....................................................................................................................14722 Exhaust Silencer....................................................................................................................14723 Exhaust Silencer and Associated Parts...........................................................................................14723 Removal.........................................................................................................................14723 Installation....................................................................................................................14723 Rear Exhaust pipe...................................................................................................................14724 Rear Exhaust pipe and Associated Parts..........................................................................................14724 Removal.........................................................................................................................14724 Installation....................................................................................................................14724 Main Data and Specifications........................................................................................................14725 6G ENGINE LUBRICATION..................................................................................................................14726 Service Precaution..................................................................................................................14726 General Description.................................................................................................................14727 Oil Pump............................................................................................................................14728 Oil Pump and Associated Parts...................................................................................................14728 Disassembly.....................................................................................................................14729 Inspection and Repair...........................................................................................................14729 Reassembly......................................................................................................................14729 6H ENGINE SPEED CONTROL SYSTEM.........................................................................................................14730 Service Precaution..................................................................................................................14730 Accelerator Pedal Control Cable.....................................................................................................14731 Removal.........................................................................................................................14731 Inspection......................................................................................................................14731 Installation....................................................................................................................14731 Adjustment......................................................................................................................14731 Accelerator Pedal...................................................................................................................14732 Accelerator Pedal and Associated Parts..........................................................................................14732 Removal.........................................................................................................................14732 Installation....................................................................................................................14732 6J INDUCTION...........................................................................................................................14733 Service Precaution..................................................................................................................14733 Air Cleaner Filter..................................................................................................................14734 Removal.........................................................................................................................14734 Inspection......................................................................................................................14734 Installation....................................................................................................................14734 6VD1 3.2L ENGINE..........................................................................................................................14735 6A ENGINE MECHANICAL...................................................................................................................14735 Service Precaution..................................................................................................................14736 General Description.................................................................................................................14737 Engine Diagnosis....................................................................................................................14738 Cylinder Head Cover LH..............................................................................................................14753 Removal.........................................................................................................................14753 Installation....................................................................................................................14754 Cylinder Head Cover RH..............................................................................................................14755 Removal.........................................................................................................................14755 Installation....................................................................................................................14755 Common Chamber......................................................................................................................14756 Removal.........................................................................................................................14756 Installation....................................................................................................................14756 Exhaust Manifold LH.................................................................................................................14758 Removal.........................................................................................................................14758 Installation....................................................................................................................14758 Exhaust Manifold RH.................................................................................................................14759 Removal.........................................................................................................................14759 Installation....................................................................................................................14759 Crankshaft Pulley...................................................................................................................14760 Removal.........................................................................................................................14760 Installation....................................................................................................................14760 Timing Belt.........................................................................................................................14761 Removal.........................................................................................................................14761 Installation....................................................................................................................14762 Camshaft............................................................................................................................14765 Removal.........................................................................................................................14765 Installation....................................................................................................................14766 Cylinder Head.......................................................................................................................14768 Removal.........................................................................................................................14768 Installation....................................................................................................................14768 Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................14770 Removal.........................................................................................................................14770 Installation....................................................................................................................14770 Piston, Piston Ring and Connecting Rod..............................................................................................14771 Removal.........................................................................................................................14771 Installation....................................................................................................................14772 Crankshaft and Main Bearings........................................................................................................14773 Removal.........................................................................................................................14773 Installation....................................................................................................................14774 Rear Oil Seal.......................................................................................................................14778 Removal.........................................................................................................................14778 Installation....................................................................................................................14778 Engine Assembly.....................................................................................................................14779 Removal.........................................................................................................................14779 Installation....................................................................................................................14780 Cylinder Head.......................................................................................................................14782 Cylinder Head and Associated Parts..............................................................................................14782 Disassembly.....................................................................................................................14782 Clean...........................................................................................................................14783 Inspection and Repair...........................................................................................................14783 Reassembly......................................................................................................................14784 Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................14786 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................14786 Disassembly.....................................................................................................................14786 Inspection and Repair...........................................................................................................14787 Reassembly......................................................................................................................14790 Camshaft............................................................................................................................14793 Camshaft and Associated Parts...................................................................................................14793 Disassembly.....................................................................................................................14793 Inspection and Repair...........................................................................................................14794 Reassembly......................................................................................................................14796 Crankshaft..........................................................................................................................14799 Crankshaft and Associated Parts.................................................................................................14799 Disassembly.....................................................................................................................14799 Inspection and Repair for Bearings..............................................................................................14800 Inspection and Repair for Crankshaft............................................................................................14802 Reassembly......................................................................................................................14803 Piston and Connecting Rod...........................................................................................................14807 Piston, Connecting Rod and Associate Parts......................................................................................14807 Disassembly.....................................................................................................................14807 Inspection and Repair...........................................................................................................14808 Reassembly......................................................................................................................14812 Cylinder Block......................................................................................................................14814 Cylinder Block and Associated Parts.............................................................................................14814 Disassembly.....................................................................................................................14814 Inspection and Repair...........................................................................................................14815 Reassembly......................................................................................................................14816 Main Data and Specification.........................................................................................................14819 Special Tool........................................................................................................................14825 6B ENGINE COOLING......................................................................................................................14827 Service Precaution..................................................................................................................14827 General Description.................................................................................................................14828 Diagnosis...........................................................................................................................14830 Draining and Refilling Cooling System...............................................................................................14831 Water Pump..........................................................................................................................14832 Water Pump and Associated Parts.................................................................................................14832 Removal.........................................................................................................................14832 Inspection......................................................................................................................14832 Installation....................................................................................................................14832 Thermostat..........................................................................................................................14833 Thermostat and Associated Parts.................................................................................................14833 Removal.........................................................................................................................14833 Inspection......................................................................................................................14833 Installation....................................................................................................................14833 Radiator............................................................................................................................14834 Radiator and Associated Parts...................................................................................................14834 Removal.........................................................................................................................14834 Inspection......................................................................................................................14835 Installation....................................................................................................................14836 Drive Belt and Cooling Fan..........................................................................................................14837 Drive Belt and Associated Parts.................................................................................................14837 Removal.........................................................................................................................14837 Inspection......................................................................................................................14837 Installation....................................................................................................................14837 Main Data and Specifications........................................................................................................14838 Special Tool........................................................................................................................14839 6C ENGINE FUEL FOR LONG WHEEL BASE.....................................................................................................14840 Service Precaution..................................................................................................................14840 General Description.................................................................................................................14841 Fuel Metering.......................................................................................................................14842 Fuel Filter.........................................................................................................................14843 Removal.........................................................................................................................14843 Inspection......................................................................................................................14843 Installation....................................................................................................................14844 Inspection......................................................................................................................14844 In–Tank Fuel Filter.............................................................................................................14844 Fuel Pump Flow Test.............................................................................................................14844 Fuel Pump...........................................................................................................................14845 Fuel Pump and Associated Parts..................................................................................................14845 Removal.........................................................................................................................14845 Installation....................................................................................................................14846 Fuel Tube / Quick – Connector Fittings..............................................................................................14846 Precautions.....................................................................................................................14846 Cautions During Work............................................................................................................14846 Removal.........................................................................................................................14846 Reuse of Quick–Connector........................................................................................................14847 Assembling Advice...............................................................................................................14847 Fuel Pump Relay.....................................................................................................................14848 General Description.............................................................................................................14848 Fuel Tank...........................................................................................................................14848 Fuel Tank and Associated Parts..................................................................................................14848 Removal.........................................................................................................................14848 Installation....................................................................................................................14849 Fuel Gauge Unit.....................................................................................................................14849 Removal and Installation........................................................................................................14849 Fuel Filler Cap.....................................................................................................................14849 General Description.............................................................................................................14849 Inspection......................................................................................................................14849 Main Data and Specifications........................................................................................................14850 Special Tool....................................................................................................................14850 6D1 ENGINE ELECTRICAL...................................................................................................................14851 Service Precaution..................................................................................................................14851 Battery.............................................................................................................................14852 General Description.................................................................................................................14852 Diagnosis...........................................................................................................................14852 Battery Charging....................................................................................................................14853 Jump Starting.......................................................................................................................14853 Battery Removal.....................................................................................................................14854 Battery Installation................................................................................................................14854 Main Data and Specifications........................................................................................................14855 6D2 IGNITION SYSTEM.....................................................................................................................14856 Service Precaution..................................................................................................................14856 General Description.................................................................................................................14857 Diagnosis...........................................................................................................................14857 Ignition Coil.......................................................................................................................14858 Removal.........................................................................................................................14858 Inspection and Repair...........................................................................................................14858 Installation....................................................................................................................14858 Spark Plug..........................................................................................................................14860 Removal.........................................................................................................................14860 Inspection and Repair...........................................................................................................14860 Installation....................................................................................................................14860 Crankshaft Position Sensor..........................................................................................................14861 Removal.........................................................................................................................14861 Installation....................................................................................................................14861 Main Data and Specifications........................................................................................................14862 6D3 STARTING AND CHARGING SYSTEM........................................................................................................14863 Service Precaution..................................................................................................................14863 Starting System.....................................................................................................................14864 General Description.................................................................................................................14864 Diagnosis...........................................................................................................................14866 Starter.............................................................................................................................14867 Removal.........................................................................................................................14867 Installation....................................................................................................................14867 Disassembled View...............................................................................................................14869 Disassembly.....................................................................................................................14870 Inspection and Repair...........................................................................................................14872 Reassembly......................................................................................................................14875 Main Data and Specifications....................................................................................................14876 Charging System.....................................................................................................................14879 General Description.............................................................................................................14879 General On–Vehicle Inspection...................................................................................................14879 Generator...........................................................................................................................14880 Removal.........................................................................................................................14880 Inspection......................................................................................................................14880 Installation....................................................................................................................14881 Disassembled View...............................................................................................................14881 Disassembly.....................................................................................................................14882 Inspection and Repair...........................................................................................................14883 Reassembly......................................................................................................................14885 Bench Test......................................................................................................................14886 Main Data and Specifications........................................................................................................14887 6E2 RODEO 3.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................14888 Specifications......................................................................................................................14893 Tightening Specifications.......................................................................................................14893 Diagrams and Schematics.............................................................................................................14894 PCM Wiring Diagram (1 of 7).....................................................................................................14894 PCM Wiring Diagram (2 of 7).....................................................................................................14895 PCM Wiring Diagram (3 of 7).....................................................................................................14896 PCM Wiring Diagram (4 of 7).....................................................................................................14897 PCM Wiring Diagram (5 of 7).....................................................................................................14898 PCM Wiring Diagram (6 of 7).....................................................................................................14899 PCM Wiring Diagram (7 of 7).....................................................................................................14900 PCM Pinouts.........................................................................................................................14901 PCM Pinout Table, 80-Way Blue Connector – Row “F1 ~ 20”.........................................................................14901 PCM Pinout Table, 80-Way Blue Connector – Row “F20 ~ 40”........................................................................14902 PCM Pinout Table, 80-Way Blue Connector – Row “F41 ~ 60”........................................................................14903 PCM Pinout Table, 80-Way Blue Connector – Row “F61 ~ 80”........................................................................14904 PCM Pinout Table, 80-Way Red Connector – Row “S1 ~ 20”..........................................................................14906 PCM Pinout Table, 80-Way Red Connector – Row “S21 ~ 40”.........................................................................14908 PCM Pinout Table, 80-Way Red Connector – Row “S41 ~ 60”.........................................................................14910 PCM Pinout Table, 80-Way Red Connector – Row “S61 ~ 80”.........................................................................14912 Component Locators..............................................................................................................14914 Undercarriage Component Locator.................................................................................................14916 Fuse and Relay Panel (Underhood Electrical Center)..............................................................................14917 Sensors and Miscellaneous Component Locators....................................................................................14918 Diagnosis...........................................................................................................................14920 Strategy-Based Diagnostics......................................................................................................14920 DTC Stored......................................................................................................................14920 No DTC..........................................................................................................................14920 No Matching Symptom.............................................................................................................14920 Intermittents...................................................................................................................14920 No Trouble Found................................................................................................................14920 Verifying Vehicle Repair........................................................................................................14920 General Service Information.........................................................................................................14920 OBD II Serviceablity Issues.....................................................................................................14920 Emissions Control Information Label.............................................................................................14921 Visual / Physical Engine Compartment Inspection.................................................................................14921 Basic Knowledge of Tools Required...............................................................................................14922 Serial Data Communications..........................................................................................................14922 Class II Serial Data Communications.............................................................................................14922 On-Board Diagnostic (OBD II)........................................................................................................14922 On-Board Diagnostic Tests.......................................................................................................14922 Comprehensive Component Monitor Diagnostic Operation............................................................................14922 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................14923 Common OBD II Terms.............................................................................................................14923 The Diagnostic Executive........................................................................................................14923 DTC Types.......................................................................................................................14924 Decimal/Binary/Hexadecimal Conversions..........................................................................................14926 Verifying Vehicle Repair........................................................................................................14926 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.....................................................................14926 Tech 2..........................................................................................................................14927 Tech 2 Features.................................................................................................................14928 Getting Started.................................................................................................................14928 Operating Procedure (For Example)...............................................................................................14929 DTC Modes.......................................................................................................................14930 DTC Information Mode............................................................................................................14930 Miscellaneous Test..............................................................................................................14931 Lamps Test......................................................................................................................14931 Relays Test.....................................................................................................................14933 EVAP Test.......................................................................................................................14934 Fuel System Test................................................................................................................14935 Instruments Test................................................................................................................14937 EGR Control Test................................................................................................................14939 Variable Intake Manifold Solenoid Test..........................................................................................14939 Injector Balance Test...........................................................................................................14941 Plotting Snapshot Graph.............................................................................................................14941 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................14942 Flow Chart for Snapshot Replay (Plotting Graph).................................................................................14943 Primary System-Based Diagnostic.....................................................................................................14944 Primary System-Based Diagnostic.................................................................................................14944 Fuel Control Heated Oxygen Sensor...............................................................................................14944 HO2S Heater.....................................................................................................................14944 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................14944 Evaporative Emission (EVAP) Purge System Vacuum Switch..........................................................................14945 Misfire Monitor Diagnostic Operation................................................................................................14945 Misfire Monitor Diagnostic Operation............................................................................................14945 Misfire Counters................................................................................................................14946 Fuel Trim System Monitor Diagnostic Operation.......................................................................................14946 Fuel Trim System Monitor Diagnostic Operation...................................................................................14946 Fuel Trim Cell Diagnostic Weights...............................................................................................14946 On-Board Diagnostic (OBD II) System Check...........................................................................................14947 A/C Clutch Control Circuit Diagnosis................................................................................................14950 Electronic Ignition System Diagnosis................................................................................................14955 EVAP Canister Purge Solenoid and EVAP Vacuum Switch.................................................................................14955 Visual Check of The Evaporative Emission Canister...................................................................................14955 Fuel Metering System Check..........................................................................................................14955 Fuel System Pressure Test...........................................................................................................14955 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................14955 Powertrain Control Module (PCM) Diagnosis...........................................................................................14960 Multiple PCM Information Sensor DTCs Set............................................................................................14960 Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................14963 Engine Tech 2 Data Definitions and Ranges...........................................................................................14963 Typical Scan Data Values............................................................................................................14965 No Malfunction Indicator Lamp (MIL).................................................................................................14971 Malfunction Indicator Lamp (MIL) “ON” Steady........................................................................................14974 No Reduced Power Lamp (RPL).........................................................................................................14976 Reduced Power Lamp (RPL) “ON” Steady................................................................................................14980 Engine Cranks But Will Not Run......................................................................................................14983 Fuel System Electrical Test.........................................................................................................14990 Electric Throttle Control (ETC) System Check........................................................................................14994 Exhaust Gas Recirculation (EGR) System Check........................................................................................15003 Circuit Description.............................................................................................................15003 Manifold Absolute Pressure (MAP) Output Check.......................................................................................15005 Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................15007 Upshift Lamp System Check (Manual Transmisssion Only)...............................................................................15010 PCM Diagnostic Trouble Codes........................................................................................................15014 Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................15018 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................15021 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................15024 Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................15027 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................15030 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................15033 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................15036 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................15039 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................15042 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................15045 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................15048 Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation........................................15051 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................15054 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................15057 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................15060 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................15064 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................15067 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................15070 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................15073 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................15076 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................15079 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................15082 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.......................................................15085 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................15088 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................15092 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1........................................................15095 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................15098 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................15101 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................15104 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................15107 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....................................................................15110 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....................................................................15114 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....................................................................15118 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....................................................................15122 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................15126 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................15129 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................15132 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................15135 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................15138 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................15141 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................15144 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................15148 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................15150 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................15152 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................15154 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................15156 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................15158 Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....................................15160 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................15163 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................15166 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................15169 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................15172 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................15175 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................15178 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................15181 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................15184 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................15187 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................15190 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................15192 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................15194 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................15197 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................15200 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................15203 Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................15206 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................15209 Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.................................................................15212 Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short................................................................15214 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..........................................................15216 Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.................................................................15219 Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short................................................................15221 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor Low Voltage...........................................................15223 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor pressure Sensor) High Voltage..................................15226 Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................15229 Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance...................................................................15232 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit–Low Voltage...........................................................15234 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit–High Voltage..........................................................15237 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal..................................................................15239 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................15241 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.................................................................15244 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................15247 Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................15250 Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................15252 Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error................................................................15254 Diagnostic Trouble Code (DTC) P0566 Cruise Cansel Switch Circuit Error..............................................................15256 Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error..............................................................15258 Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error.................................................................15260 Diagnostic Trouble Code (DTC) P0571 No Break Switch Signal..........................................................................15262 Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................15264 Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................15266 Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................15268 Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................15270 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....................................................15272 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage............................................................15274 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....................................................15276 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................15279 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................15281 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....................................................15283 Diagnostic Trouble Code (DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal...........................................15286 Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode..........................................15289 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................15292 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................15296 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................15300 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................15304 Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................15308 Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................15310 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration............................................................15312 Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................15315 Diagnosis Truble Code(DTC) P1221 TPS1 – TPS2 correlation(Circuit Performance).......................................................15318 Diagnostic Trouble Code (DTC) P1271 APS 1– 2 Correlation Error......................................................................15321 Diagnostic Trouble Code (DTC) P1272 APS 2 – 3 Correlation Error.....................................................................15324 Diagnostic Trouble Code (DTC) P1273 APS 1 – 3 Correlation Error.....................................................................15327 Diagnostic Trouble Code (DTC) P1275 APS 1 Output Fault..............................................................................15330 Diagnostic Trouble Code (DTC) P1280 APS 2 Output Fault..............................................................................15332 Diagnostic Trouble Code (DTC) P1285 APS 3 Output Fault..............................................................................15334 Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................15336 Diagnostic Trouble Code (DTC) P1295 ETC Power Management Mode.......................................................................15339 Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.................................................................15343 Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................15347 Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC line 1 Circuit Fault.....................................................15350 Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC line 2 Circuit Fault.....................................................15353 Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................15356 Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................15359 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................15362 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................15365 Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................15368 Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..........................................................15372 Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..........................................................15375 Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.............................................................15378 Diagnostic Trouble Code (DTC) P1571 Break Switch No Operation.......................................................................15381 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................15383 Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.............................................................15384 Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.............................................................15386 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).............................................................15388 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault....................................................................15391 Default Matrix Table................................................................................................................15423 Crankshaft Position (CKP) Sensor....................................................................................................15426 Engine Coolant Temperature (ECT) Sensor.............................................................................................15426 Heated Oxygen Sensor (HO2S).........................................................................................................15427 Intake Air Temperature (IAT) Sensor.................................................................................................15430 ION Sensing Module..................................................................................................................15430 Mass Air Flow (MAF) Sensor..........................................................................................................15431 Manifold Absolute Pressure (MAP) Sensor.............................................................................................15432 Malfunction Indicator Lamp (MIL)....................................................................................................15433 Reduced Power Lamp..................................................................................................................15433 Powertrain Control Module (PCM).....................................................................................................15433 Service Precaution..............................................................................................................15433 Installation Procedure..........................................................................................................15434 EEPROM..............................................................................................................................15435 Throttle Position (TP) Sensor.......................................................................................................15436 Vehicle Speed Sensor (VSS)..........................................................................................................15436 Air Cleaner/Air Filter..............................................................................................................15438 Common Chamber......................................................................................................................15438 Accelerator Pedal Replacement.......................................................................................................15439 Accelerator Position Sensor Replacement.............................................................................................15440 Accelerator Position Sensor Adjustment..............................................................................................15440 Fuel Filler Cap.....................................................................................................................15441 Fuel Filter.........................................................................................................................15441 Fuel Gauge Unit.....................................................................................................................15442 Fuel Injectors......................................................................................................................15443 Fuel Metering System................................................................................................................15444 Fuel Pump Assembly..................................................................................................................15444 Fuel Pump Relay.....................................................................................................................15444 Fuel Rail Assembly..................................................................................................................15445 Fuel Tank...........................................................................................................................15446 Throttle Body (TB)..................................................................................................................15446 Electronic Ignition System..........................................................................................................15448 Catalytic Converter.................................................................................................................15449 Air Conditioning Thermo Relay.......................................................................................................15449 EVAP Canister Hoses.................................................................................................................15450 EVAP Canister.......................................................................................................................15450 EVAP Canister Vent Solenoid.........................................................................................................15452 Fuel Tank Pressure Sensor...........................................................................................................15453 EVAP Canister Purge Solenoid........................................................................................................15453 Fuel Tank Vent Valve................................................................................................................15454 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................15455 Positive Crankcase Ventilation (PCV) Valve..........................................................................................15456 Wiring and Connectors...............................................................................................................15456 PCM Connectors and Terminals........................................................................................................15457 Wire Harness Repair: Twisted Shielded Cable.........................................................................................15457 Twisted Leads.......................................................................................................................15458 Weather-Pack Connector..............................................................................................................15459 Com-Pack III........................................................................................................................15460 Metri-Pack..........................................................................................................................15460 General Description (PCM and Sensors)...............................................................................................15462 A/C Request Signal..............................................................................................................15462 Crankshaft Position (CKP) Sensor................................................................................................15462 Engine Coolant Temperature (ECT) Sensor.........................................................................................15462 Electrically Erasable Programmable Read Only Memory (EEPROM)....................................................................15462 Fuel Control Heated Oxygen Sensors..............................................................................................15462 Catalyst Monitor Heated Oxygen Sensors..........................................................................................15463 Intake Air Temperature (IAT) Sensor.............................................................................................15463 Linear Exhaust Gas Recirculation (EGR) Control..................................................................................15464 Mass Air Flow (MAF) Sensor......................................................................................................15464 Manifold Absolute Pressure (MAP) Sensor.........................................................................................15464 Powertrain Control Module (PCM).................................................................................................15465 PCM Function....................................................................................................................15465 PCM Components..................................................................................................................15465 PCM Voltage Description.........................................................................................................15465 PCM Input/Outputs...............................................................................................................15465 PCM Service Precautions.........................................................................................................15466 Reprogramming The PCM...........................................................................................................15466 Throttle Position (TP) Sensor...................................................................................................15466 Transmission Fluid Temperature (TFT) Sensor.....................................................................................15466 Transmission Range Switch.......................................................................................................15466 Vehicle Speed Sensor (VSS)......................................................................................................15466 Use of Circuit Testing Tools....................................................................................................15466 Aftermarket Electrical and Vacuum Equipment.....................................................................................15467 Electrostatic Discharge Damage..................................................................................................15467 Upshift Lamp....................................................................................................................15467 General Description (Air Induction).................................................................................................15467 General Description (Fuel Metering).................................................................................................15468 Battery Voltage Correction Mode.................................................................................................15468 Clear Flood Mode................................................................................................................15468 Deceleration Mode...............................................................................................................15468 Engine Speed/Vehicle Speed/Fuel Disable Mode....................................................................................15468 Fuel Cutoff Mode................................................................................................................15468 Fuel Injector...................................................................................................................15468 Fuel Metering System Components.................................................................................................15468 Fuel Metering System Purpose....................................................................................................15468 Fuel Pressure Regulator.........................................................................................................15469 Fuel Pump Electrical Circuit....................................................................................................15469 Fuel Rail.......................................................................................................................15469 Run Mode........................................................................................................................15469 Starting Mode...................................................................................................................15469 Throttle Body Unit..............................................................................................................15470 General Description (Electronic Ignition System)....................................................................................15470 Electronic Ignition.............................................................................................................15470 Ignition Coils..................................................................................................................15470 Ignition Control................................................................................................................15470 Ignition Control PCM Output.....................................................................................................15471 Powertrain Control Module (PCM).................................................................................................15471 Spark Plug......................................................................................................................15472 A/C Clutch Diagnosis................................................................................................................15473 A/C Clutch Circuit Purpose......................................................................................................15473 A/C Request Signal..............................................................................................................15473 General Description (Evaporative (EVAP) Emission System)............................................................................15474 EVAP Emission Control System Operation..........................................................................................15474 General Description (Exhaust Gas Recirculation (EGR) System)........................................................................15479 Linear EGR Valve................................................................................................................15479 Linear EGR Control..............................................................................................................15479 Linear EGR Valve Operation and Results of Incorrect Operation...................................................................15479 EGR Pintle Position Sensor......................................................................................................15480 General Description (Positive Crankcase Ventilation (PCV) System)...................................................................15480 Crankcase Ventilation System Operation..........................................................................................15480 Special Tools.......................................................................................................................15482 6F ENGINE EXHAUST......................................................................................................................15484 Service Precaution..................................................................................................................15484 General Description.................................................................................................................15485 Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................15486 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts...................................................15486 Removal.........................................................................................................................15486 Installation....................................................................................................................15486 Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................15487 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts...................................................15487 Removal.........................................................................................................................15487 Installation....................................................................................................................15487 Forked Exhaust Pipe.................................................................................................................15488 Forked Exhaust Pipe and Associated Parts........................................................................................15488 Removal.........................................................................................................................15488 Installation....................................................................................................................15488 Exhaust Silencer....................................................................................................................15489 Exhaust Silencer and Associated Parts...........................................................................................15489 Removal.........................................................................................................................15489 Installation....................................................................................................................15489 Rear Exhaust pipe...................................................................................................................15490 Rear Exhaust pipe and Associated Parts..........................................................................................15490 Removal.........................................................................................................................15490 Installation....................................................................................................................15490 Main Data and Specifications........................................................................................................15491 6G ENGINE LUBRICATION..................................................................................................................15492 Service Precaution..................................................................................................................15492 General Description.................................................................................................................15493 Oil Pump............................................................................................................................15494 Oil Pump and Associated Parts...................................................................................................15494 Disassembly.....................................................................................................................15495 Inspection and Repair...........................................................................................................15495 Reassembly......................................................................................................................15496 Oil Pan and Crankcase...............................................................................................................15498 Removal.........................................................................................................................15498 Installation....................................................................................................................15498 Oil Pump............................................................................................................................15500 Removal.........................................................................................................................15500 Installation....................................................................................................................15500 Oil Pump Oil Seal...................................................................................................................15502 Removal.........................................................................................................................15502 Installation....................................................................................................................15502 Oil Filter..........................................................................................................................15503 Removal.........................................................................................................................15503 Installation....................................................................................................................15503 Main Data and Specification.........................................................................................................15504 6H ENGINE SPEED CONTROL SYSTEM.........................................................................................................15505 Service Precaution..................................................................................................................15505 Accelerator Pedal...................................................................................................................15506 Accelerator Pedal and Associated Parts..........................................................................................15506 Removal.........................................................................................................................15506 Installation....................................................................................................................15506 6J INDUCTION...........................................................................................................................15507 Service Precaution..................................................................................................................15507 Air Cleaner Element.................................................................................................................15508 Removal.........................................................................................................................15508 Inspection......................................................................................................................15508 Installation....................................................................................................................15508 Sec.7 TRANSMISSION..............................................................................................................................15509 7A AUTOMATIC TRANSMISSION..................................................................................................................15509 Service Precaution......................................................................................................................15510 Construction............................................................................................................................15511 Range Reference Chart...................................................................................................................15512 Normal Operation of 2001 4L30–E Transmission............................................................................................15513 Diagnosis...............................................................................................................................15513 Driver Information......................................................................................................................15513 General Diagnosis Procedure.............................................................................................................15516 Preliminary Inspection Chart............................................................................................................15517 Checking Transmission Fluid Level and Condition.........................................................................................15518 Test Driving............................................................................................................................15519 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................15520 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................15521 Stall Test..............................................................................................................................15530 Line Pressure Test......................................................................................................................15531 Shift Speed Chart (V6)..................................................................................................................15533 Lockup Speed Chart (V6).................................................................................................................15534 Shift Speed Chart (HEC).................................................................................................................15535 Lockup Speed Chart (HEC)................................................................................................................15536 Changing Transmission Fluid.............................................................................................................15537 Selector Lever..........................................................................................................................15537 Inspection..........................................................................................................................15537 Removal.............................................................................................................................15537 Installation........................................................................................................................15539 Select Cable............................................................................................................................15539 Removal.............................................................................................................................15539 Installation........................................................................................................................15542 Shift Lock Cable........................................................................................................................15544 Removal.............................................................................................................................15544 Installation........................................................................................................................15544 Mode Switch.............................................................................................................................15545 Removal.............................................................................................................................15545 Installation........................................................................................................................15546 Transmission Assembly...................................................................................................................15547 Transmission and Associated Parts...................................................................................................15547 Removal.............................................................................................................................15549 Installation........................................................................................................................15556 Solenoid (Main Case Valve Body).........................................................................................................15563 Removal.............................................................................................................................15563 Installation........................................................................................................................15563 Solenoid (Adapter Case Valve Body)......................................................................................................15564 Removal.............................................................................................................................15564 Installation........................................................................................................................15564 Valve Body Assembly (Main Case).........................................................................................................15565 Removal.............................................................................................................................15565 Installation........................................................................................................................15565 Valve Body Assembly (Adapter Case)......................................................................................................15566 Removal.............................................................................................................................15566 Installation........................................................................................................................15566 Powertrain Control Module (PCM) (V6)....................................................................................................15567 Removal.............................................................................................................................15567 Installation........................................................................................................................15567 Powertrain Control Module (PCM) (HEC)...................................................................................................15568 Removal.............................................................................................................................15568 Installation........................................................................................................................15568 Speed Sensor (Extension Assembly).......................................................................................................15569 Removal.............................................................................................................................15569 Installation........................................................................................................................15569 Transmission Oil Temperature Sensor (Main Case) (V6)....................................................................................15570 Removal.............................................................................................................................15570 Installation........................................................................................................................15570 Transmission Oil Temperature Sensor (Adapter Case) (HEC)................................................................................15571 Removal.............................................................................................................................15571 Installation........................................................................................................................15571 Front Oil Seal (Converter Housing)......................................................................................................15572 Removal.............................................................................................................................15572 Installation........................................................................................................................15572 Rear Oil Seal (Extension Assembly)......................................................................................................15573 Removal.............................................................................................................................15573 Installation........................................................................................................................15573 Transmission (4L30–E)...................................................................................................................15574 Disassembly.........................................................................................................................15574 Reassembly..........................................................................................................................15579 Converter Housing and Oil Pump Assembly.................................................................................................15590 Disassembled View...................................................................................................................15590 Disassembly.........................................................................................................................15590 Inspection and Repair...............................................................................................................15590 Reassembly..........................................................................................................................15590 Oil Pump................................................................................................................................15591 Disassembled View...................................................................................................................15591 Disassembly.........................................................................................................................15591 Inspection and Repair...............................................................................................................15591 Reassembly..........................................................................................................................15591 Main Case Valve Body....................................................................................................................15592 Disassembled View...................................................................................................................15592 Disassembly.........................................................................................................................15593 Inspection and Repair...............................................................................................................15593 Reassembly..........................................................................................................................15593 Adapter Case Valve Body.................................................................................................................15594 Disassembled View...................................................................................................................15594 Disassembly.........................................................................................................................15594 Inspection and Repair...............................................................................................................15594 Reassembly..........................................................................................................................15594 Third Clutch and Sprag Unit.............................................................................................................15595 Disassembled View...................................................................................................................15595 Disassembly.........................................................................................................................15595 Inspection and Repair...............................................................................................................15596 Reassembly..........................................................................................................................15596 Third Clutch............................................................................................................................15596 Disassembled View...................................................................................................................15596 Disassemble.........................................................................................................................15597 Inspection and Repair...............................................................................................................15597 Reassembly..........................................................................................................................15597 Sprag Unit..............................................................................................................................15598 Disassembled View...................................................................................................................15598 Disassembly.........................................................................................................................15598 Inspection and Repair...............................................................................................................15598 Reassembly..........................................................................................................................15598 Second Clutch...........................................................................................................................15599 Disassembled View...................................................................................................................15599 Disassembly.........................................................................................................................15599 Inspection and Repair...............................................................................................................15600 Reassembly..........................................................................................................................15600 3–4 Accumulator Piston..................................................................................................................15601 Disassembled View...................................................................................................................15601 Disassembly.........................................................................................................................15601 Inspection and Repair...............................................................................................................15602 Reassembly..........................................................................................................................15602 Reverse Clutch Piston and Center Support................................................................................................15603 Disassembled View...................................................................................................................15603 Disassembly.........................................................................................................................15604 Inspection and Repair...............................................................................................................15604 Reassembly..........................................................................................................................15604 Overrun Clutch and Turbine Shaft........................................................................................................15605 Disassembled View...................................................................................................................15605 Disassembly.........................................................................................................................15606 Inspection and Repair...............................................................................................................15606 Reassembly..........................................................................................................................15606 Main Data and Specification.............................................................................................................15608 General Specifications..............................................................................................................15608 Torque Specifications...............................................................................................................15609 Special Tools...........................................................................................................................15614 4L30–E Parts List.......................................................................................................................15617 7A1 TRANSMISSION CONTROL SYSTEM.............................................................................................................15624 Service Precaution......................................................................................................................15625 General Description.....................................................................................................................15625 Electronic Control Diagram..........................................................................................................15626 Powertrain Control Module (PCM).....................................................................................................15627 Control System Diagram..............................................................................................................15628 Shift Control.......................................................................................................................15629 Band Apply Control..................................................................................................................15629 Torque Converter Clutch Control.....................................................................................................15629 Line Pressure Control...............................................................................................................15629 On–Board Diagnostic System..........................................................................................................15629 Fail–Safe Mechanism.................................................................................................................15629 Torque Management Control...........................................................................................................15629 ATF Warning Control.................................................................................................................15629 Reverse Lock Out Control............................................................................................................15629 Downhill Control....................................................................................................................15629 Uphill Control......................................................................................................................15629 Shift Mode Control..................................................................................................................15630 Gear Shift Control..................................................................................................................15631 Winter Drive Mode...................................................................................................................15632 Backup Mode.........................................................................................................................15632 Functions of Input / Output Components..............................................................................................15633 Diagnosis...............................................................................................................................15634 Electronic Diagnosis................................................................................................................15634 Check Trans Indicator...............................................................................................................15634 Diagnostic Check....................................................................................................................15634 “Check Trans” Check.................................................................................................................15635 Tech 2 OBD II Connection............................................................................................................15636 Transmission Data...................................................................................................................15641 OBD II Diagnostic Management System.................................................................................................15642 16 – Terminal Data Link Connector (DLC).............................................................................................15643 Malfunction Indicator Lamp (MIL)....................................................................................................15644 DTC Types...........................................................................................................................15644 Clear DTC...........................................................................................................................15645 DTC Check...........................................................................................................................15645 PCM Precaution......................................................................................................................15645 Information On PCM..................................................................................................................15645 Intermittent Conditions.............................................................................................................15646 Transmission and PCM Identification.................................................................................................15647 Diagnostic Trouble Code (DTC) Identification........................................................................................15648 DTC P0218 Transmission Fluid Over Temperature...........................................................................................15649 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................15651 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................15654 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................15657 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................15660 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................15663 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................15666 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................15669 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................15672 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................15675 DTC P0730 Gear Error Without Input Speed................................................................................................15677 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................15680 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................15682 DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................15684 DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................15686 DTC P0753 Shift Solenoid A Electrical...................................................................................................15688 DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................15691 DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................15693 DTC P0758 Shift Solenoid B Electrical...................................................................................................15695 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................15699 DTC P1860 TCC Solenoid Electrical.......................................................................................................15703 DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................15706 Circuit Diagram.........................................................................................................................15708 Parts Location..........................................................................................................................15710 Harness Connector Faces.................................................................................................................15711 7B MANUAL TRANSMISSION MUA 5C..............................................................................................................15713 Service Precaution......................................................................................................................15713 General Description.....................................................................................................................15714 Diagnosis...............................................................................................................................15716 Rear Oil Seal (4X2).....................................................................................................................15717 Disassembled View...................................................................................................................15717 Removal.............................................................................................................................15717 Installation........................................................................................................................15717 Transmission............................................................................................................................15718 Disassembled View...................................................................................................................15718 Removal.............................................................................................................................15719 Installation........................................................................................................................15723 Transmission Case.......................................................................................................................15728 Major Component (4X2)...............................................................................................................15728 Disassembly.........................................................................................................................15729 Reassembly..........................................................................................................................15730 Transmission Case and Transfer Case.....................................................................................................15733 Major Component (4X4)...............................................................................................................15733 Disassembly.........................................................................................................................15734 Reassembly..........................................................................................................................15737 Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin.............................................................15743 Disassembled View...................................................................................................................15743 Disassembly.........................................................................................................................15744 Inspection and Repair...............................................................................................................15745 Reassembly..........................................................................................................................15746 Reverse Gear and 5th Gear...............................................................................................................15747 Disassembled View...................................................................................................................15747 Disassembly.........................................................................................................................15748 Inspection and Repair...............................................................................................................15750 Reassembly..........................................................................................................................15750 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................15756 Disassmebled View...................................................................................................................15756 Disassembly.........................................................................................................................15757 Inspection and Repair...............................................................................................................15758 Reassembly..........................................................................................................................15761 Main Data and Specifications............................................................................................................15767 Special Tools (MUA).....................................................................................................................15771 7C CLUTCH..................................................................................................................................15773 Service Precaution......................................................................................................................15773 General Description.....................................................................................................................15774 Diagnosis...............................................................................................................................15779 Clutch Assembly (Y22SE).................................................................................................................15780 Clutch Assembly (Y22SE) and Associated Parts........................................................................................15780 Removal.............................................................................................................................15780 Inspection and Repair...............................................................................................................15781 Installation........................................................................................................................15785 Clutch Assembly (6VD1)..................................................................................................................15787 Clutch Assembly (6VD1) and Associated Parts.........................................................................................15787 Removal.............................................................................................................................15787 Inspection and Repair...............................................................................................................15789 Installation........................................................................................................................15793 Clutch Control..........................................................................................................................15795 Parts Location View.................................................................................................................15795 Removal.............................................................................................................................15796 Inspection and Repair...............................................................................................................15796 Installation........................................................................................................................15796 Master Cylinder.........................................................................................................................15799 Slave Cylinder..........................................................................................................................15800 Disassembled View...................................................................................................................15800 Disassembly.........................................................................................................................15800 Inspection and Repair...............................................................................................................15800 Reassembly..........................................................................................................................15801 Main Data and Specifications............................................................................................................15802 Special Tools...........................................................................................................................15805 Sec.8 BODY AND ACCESSORIES......................................................................................................................15806 8A LIGHTING SYSTEM..........................................................................................................................15806 Service Precaution......................................................................................................................15807 Headlight Bulb..........................................................................................................................15808 Headlight Assembly......................................................................................................................15808 Headlight Adjustment................................................................................................................15809 Fog Light Bulb..........................................................................................................................15811 Fog Light Assembly......................................................................................................................15812 Fog Light Adjustment................................................................................................................15812 Side Marker Light Bulb..................................................................................................................15812 Taillight Bulb..........................................................................................................................15813 License Plate Light Bulb (Bumper Type)..................................................................................................15813 License Plate Light Bulb (Tailgate Type)................................................................................................15814 Stoplight Bulb..........................................................................................................................15814 High Mounted Stoplight Assembly.........................................................................................................15815 High Mounted Stoplight Bulb.............................................................................................................15815 High Mounted Stoplight Assembly (Soft Top Model)........................................................................................15816 High Mounted Stoplight Bulb (Soft Top Model)............................................................................................15816 High Mounted Stoplight Assembly (Resin Top Model).......................................................................................15817 High Mounted Stoplight Bulb (Resin Top Model)...........................................................................................15817 Backup Light Bulb.......................................................................................................................15818 Front Turn Signal Light Bulb............................................................................................................15818 Rear Turn Signal Light Bulb.............................................................................................................15819 Dome Light Bulb (LWB)...................................................................................................................15819 Dome Light Bulb (SWB)...................................................................................................................15820 Courtesy Light Bulb.....................................................................................................................15820 Spotlight Bulb..........................................................................................................................15821 Luggage Room Light Bulb (LWB)...........................................................................................................15821 Luggage Room Light Bulb (Resin Top Model)...............................................................................................15822 HVAC Bezel Illumination Light Bulb......................................................................................................15822 Shift Lever Illumination Light Bulb (A/T)...............................................................................................15823 Vanity Mirror Illumination Light Bulb...................................................................................................15823 Starter Switch..........................................................................................................................15824 Lighting Switch (Combination Switch)....................................................................................................15824 Dimmer・Passing Switch (Combination Switch)..............................................................................................15824 Door Switch.............................................................................................................................15824 Rear Defogger Switch....................................................................................................................15825 Key Remind Switch (Starter Switch)......................................................................................................15825 Hazard Warning Light Switch.............................................................................................................15826 Stoplight Switch........................................................................................................................15826 Backup Light Switch (M/T)...............................................................................................................15827 Turn Signal Light Switch (Combination Switch)...........................................................................................15827 Illumination Controller.................................................................................................................15828 Light and Bulb Specifications (LWB).....................................................................................................15829 Light and Bulb Specifications (SWB).....................................................................................................15830 8B WIPER / WASHER SYSTEM....................................................................................................................15832 Service Precaution......................................................................................................................15832 Windshield Wiper/Washer System..........................................................................................................15833 General Description.....................................................................................................................15833 Windshield Wiper And Washer Switch......................................................................................................15833 Removal and Installation............................................................................................................15833 Windshield Wiper Motor..................................................................................................................15833 Removal.............................................................................................................................15833 Installation........................................................................................................................15833 Windshield Washer Motor.................................................................................................................15834 Removal.............................................................................................................................15834 Installation........................................................................................................................15834 Windshield Washer Spray Pattern.........................................................................................................15835 Windshield Wiper Linkage............................................................................................................15836 Windshield Wiper Linkage and Associated Parts.......................................................................................15836 Removal.............................................................................................................................15836 Installation........................................................................................................................15836 Windshield Wiper Arm/Blade..............................................................................................................15837 Removal.............................................................................................................................15837 Installation........................................................................................................................15837 Windshield Wiper Blade Rubber...........................................................................................................15838 Removal.............................................................................................................................15838 Installation........................................................................................................................15838 Rear Wiper/Washer System................................................................................................................15839 General Description.....................................................................................................................15839 Rear Wiper and Washer Switch............................................................................................................15839 Removal.............................................................................................................................15839 Installation........................................................................................................................15839 Rear Wiper Motor (LWB)..................................................................................................................15840 Removal.............................................................................................................................15840 Installation........................................................................................................................15840 Rear Wiper Motor (Resin Top Model)......................................................................................................15841 Removal.............................................................................................................................15841 Installation........................................................................................................................15841 Rear Washer Motor.......................................................................................................................15842 Removal.............................................................................................................................15842 Installation........................................................................................................................15842 Alarm and Relay Control Unit............................................................................................................15843 Removal.............................................................................................................................15843 Installation........................................................................................................................15843 Rear Wiper Arm/Blade (LWB)..............................................................................................................15843 Removal.............................................................................................................................15843 Installation........................................................................................................................15843 Rear Wiper Arm/Blade (Resin Top Model)..................................................................................................15844 Removal.............................................................................................................................15844 Installation........................................................................................................................15844 Rear Washer Nozzle......................................................................................................................15844 Removal.............................................................................................................................15844 Installation........................................................................................................................15844 Rear Washer Spray Pattern...........................................................................................................15844 Rear Washer Nozzle (Resin Top Model)....................................................................................................15845 Removal.............................................................................................................................15845 Installation........................................................................................................................15845 Rear Washer Spray Pattern...........................................................................................................15845 Rear Wiper Blade Rubber.................................................................................................................15846 Removal.............................................................................................................................15846 Installation........................................................................................................................15846 Main Data and Specifications............................................................................................................15847 8C ENTERTAINMENT............................................................................................................................15848 Service Precaution......................................................................................................................15848 Cigarette Lighter.......................................................................................................................15849 General Description.....................................................................................................................15849 Removal.............................................................................................................................15849 Installation........................................................................................................................15849 Digital Clock...........................................................................................................................15849 Removal.............................................................................................................................15849 Installation........................................................................................................................15849 Rod Type Antenna........................................................................................................................15850 Removal.............................................................................................................................15850 Installation........................................................................................................................15850 Accessory Socket........................................................................................................................15851 Front Accessory Socket..............................................................................................................15851 Rear Accessory Socket...............................................................................................................15851 Radio...................................................................................................................................15852 Removal.............................................................................................................................15852 Installation........................................................................................................................15852 Speaker.................................................................................................................................15853 Front Speaker.......................................................................................................................15853 Tweeter Assembly....................................................................................................................15853 Rear Door Speaker (LWB).............................................................................................................15853 Rear Speaker (LWB)..................................................................................................................15854 Rear Speaker (SWB)..................................................................................................................15854 Horn....................................................................................................................................15855 Removal.............................................................................................................................15855 Installation........................................................................................................................15855 8D WIRING SYSTEM............................................................................................................................15856 Fuse, Relay and Diode...................................................................................................................15857 Relay / Fuse Box Location...........................................................................................................15857 Relay / Fuse Box (Instrument Panel).................................................................................................15858 Relay / Fuse Box (L4 Engine Room)...................................................................................................15859 Relay / Fuse Box (V6 Engine Room)...................................................................................................15860 Circuit Diagram.........................................................................................................................15861 8E METER AND GAUGE..........................................................................................................................15892 Service Precaution......................................................................................................................15892 General Description.....................................................................................................................15892 Meter Assembly..........................................................................................................................15893 General Description.....................................................................................................................15893 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................15893 Table for Meter/Gauge Connector Terminal Connections................................................................................15895 Removal.............................................................................................................................15897 Installation........................................................................................................................15897 Warning Light Bulb and Indicator Light Bulb.............................................................................................15897 Removal.............................................................................................................................15897 Installation........................................................................................................................15897 A/T Shift Indicator Light Bulb..........................................................................................................15898 Removal.............................................................................................................................15898 Installation........................................................................................................................15899 Vehicle Speed Sensor....................................................................................................................15899 Removal.............................................................................................................................15899 Installation........................................................................................................................15899 Fuel Tank Unit..........................................................................................................................15900 Removal.............................................................................................................................15900 Installation........................................................................................................................15900 Main Data and Specifications............................................................................................................15901 8F BODY STRUCTURE...........................................................................................................................15902 Service Precaution......................................................................................................................15903 Frame...................................................................................................................................15903 General Description.....................................................................................................................15903 Frame Dimensions (LWB)..............................................................................................................15904 Frame Dimensions (SWB)..............................................................................................................15905 General Description (Bumper)............................................................................................................15906 Front Bumper............................................................................................................................15906 Parts Location......................................................................................................................15906 Removal.............................................................................................................................15907 Installation........................................................................................................................15907 Front Bumper Slider Bracket.............................................................................................................15908 Removal.............................................................................................................................15908 Installation........................................................................................................................15908 Rear Bumper.............................................................................................................................15909 Parts Location (Spare tire mounted tailgate model)..................................................................................15909 Removal.............................................................................................................................15910 Installation........................................................................................................................15910 Parts Location (Spare tire mounted under floor model)...............................................................................15912 Removal.............................................................................................................................15913 Installation........................................................................................................................15913 Rear Bumper Slider......................................................................................................................15914 Removal.............................................................................................................................15914 Installation........................................................................................................................15914 General Description (Sheet Metal).......................................................................................................15915 Engine Hood.............................................................................................................................15915 Parts Location......................................................................................................................15915 Removal.............................................................................................................................15916 Installation........................................................................................................................15916 Engine Hood Lock........................................................................................................................15918 Parts Location......................................................................................................................15918 Removal.............................................................................................................................15918 Installation........................................................................................................................15919 Radiator Grille.........................................................................................................................15920 Parts Location......................................................................................................................15920 Removal.............................................................................................................................15920 Installation........................................................................................................................15921 Front Fender Panel......................................................................................................................15922 Parts Location......................................................................................................................15922 Removal.............................................................................................................................15922 Installation........................................................................................................................15923 Body Mounting...........................................................................................................................15925 Parts Location......................................................................................................................15925 Tightening Torque...................................................................................................................15925 Body Dimension..........................................................................................................................15926 Front Section.......................................................................................................................15926 Room Section (SWB)..................................................................................................................15929 Room Section (LWB)..................................................................................................................15931 Rear Section (SWB)..................................................................................................................15933 Rear Section (LWB)..................................................................................................................15935 Side Body Section (Front side)......................................................................................................15937 Side Body Section (Rear side).......................................................................................................15939 General Description (Body)..............................................................................................................15941 Instrument Panel Assembly...............................................................................................................15941 Parts Location......................................................................................................................15941 Removal.............................................................................................................................15942 Installation........................................................................................................................15943 Front Door Assembly.....................................................................................................................15944 Parts Location......................................................................................................................15944 Removal.............................................................................................................................15944 Installation........................................................................................................................15945 Rear Door Assembly......................................................................................................................15946 Parts Location......................................................................................................................15946 Removal.............................................................................................................................15946 Installation........................................................................................................................15947 Front Window Regulator, Glass and Glass Run.............................................................................................15948 Parts Location......................................................................................................................15948 Removal.............................................................................................................................15949 Installation........................................................................................................................15951 Rear Window Regulator, Glass and Glass Run..............................................................................................15952 Parts Location......................................................................................................................15952 Removal.............................................................................................................................15953 Installation........................................................................................................................15955 Tailgate (LWB)..........................................................................................................................15956 Parts Location......................................................................................................................15956 Removal.............................................................................................................................15957 Installation........................................................................................................................15958 Tailgate (SWB)..........................................................................................................................15959 Parts Location......................................................................................................................15959 Removal.............................................................................................................................15960 Installation........................................................................................................................15960 Rear Hatchgate (LWB)....................................................................................................................15961 Parts Location......................................................................................................................15961 Removal.............................................................................................................................15962 Installation........................................................................................................................15962 Adjustment..............................................................................................................................15964 Tailgate Glass (Resin Top)..............................................................................................................15965 Parts Location......................................................................................................................15965 Removal.............................................................................................................................15966 Installation........................................................................................................................15966 Spare Tire Carrier......................................................................................................................15967 Parts Location......................................................................................................................15967 Removal.............................................................................................................................15967 Installation........................................................................................................................15967 Spare Tire Hanger.......................................................................................................................15968 Parts Location......................................................................................................................15968 Removal.............................................................................................................................15969 Installation........................................................................................................................15969 Windshield..............................................................................................................................15970 Parts Location......................................................................................................................15970 Removal.............................................................................................................................15971 Installation........................................................................................................................15971 Rear Quarter Glass (LWB)................................................................................................................15974 Parts Location......................................................................................................................15974 Removal.............................................................................................................................15974 Installation........................................................................................................................15975 Rear Quarter Glass (Resin Top)..........................................................................................................15976 Parts Location......................................................................................................................15976 Removal.............................................................................................................................15976 Installation........................................................................................................................15976 Side Window Glass (SWB).................................................................................................................15978 Parts Location......................................................................................................................15978 Removal.............................................................................................................................15978 Installation........................................................................................................................15978 Main Data and Specifications............................................................................................................15979 Special Tools...........................................................................................................................15982 8G SEATS....................................................................................................................................15983 Service Precaution......................................................................................................................15983 Front Seat Assembly.....................................................................................................................15984 Front Seat Assembly and Associated Parts............................................................................................15984 Removal.............................................................................................................................15984 Installation........................................................................................................................15986 Power Seat Assembly.....................................................................................................................15987 Power Seat Assembly and Associated Parts............................................................................................15987 Removal.............................................................................................................................15988 Installation........................................................................................................................15989 Rear Seat Assembly (LWB)................................................................................................................15990 Rear Seat Cushion Assembly and Associated Parts.....................................................................................15990 Removal.............................................................................................................................15991 Installation........................................................................................................................15991 Rear Seat Back Assembly and Associated Parts........................................................................................15992 Removal.............................................................................................................................15992 Installation........................................................................................................................15993 Rear Seat Assembly (SWB)................................................................................................................15994 Rear Seat Assembly and Associated Parts.............................................................................................15994 Removal.............................................................................................................................15995 Installation........................................................................................................................15995 Main Data and Specifications............................................................................................................15996 8H SECURITY AND LOCKS.......................................................................................................................15998 Service Precaution......................................................................................................................15998 Front Door Lock Assembly................................................................................................................15999 Front Door Lock Assembly and Associated Parts.......................................................................................15999 Removal.............................................................................................................................16000 Installation........................................................................................................................16001 Front Outside Handle....................................................................................................................16002 Front Outside Handle and Associated Parts...........................................................................................16002 Removal.............................................................................................................................16002 Installation........................................................................................................................16002 Rear Door Lock Assembly.................................................................................................................16003 Rear Door Lock Assembly and Associated Parts........................................................................................16003 Removal.............................................................................................................................16003 Installation........................................................................................................................16004 Rear Outside Handle.....................................................................................................................16005 Rear Outside Handle and Associated Parts............................................................................................16005 Removal.............................................................................................................................16005 Installation........................................................................................................................16005 Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................16006 Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................16006 Removal.............................................................................................................................16006 Installation........................................................................................................................16007 Tailgate Lock (SWB).....................................................................................................................16008 Tailgate Lock and Associated Parts..................................................................................................16008 Removal.............................................................................................................................16008 Installation........................................................................................................................16009 Key.....................................................................................................................................16010 Key Coding..........................................................................................................................16010 Key Styles..........................................................................................................................16010 Power Door Lock System..................................................................................................................16011 General Description.................................................................................................................16011 Door Lock Key Switch................................................................................................................16011 Front Door Lock Actuator............................................................................................................16011 Rear Door Lock Actuator.............................................................................................................16011 Tailgate Lock Actuator..............................................................................................................16011 Anti-Theft System.......................................................................................................................16011 General Description.................................................................................................................16011 Anti-Theft & Keyless Entry Control-ler..............................................................................................16011 Anti-Theft Indicator................................................................................................................16012 Anti-Theft Horn.....................................................................................................................16012 Engine Hood Switch..................................................................................................................16013 Anti-theft & Keyless Entry ControlUnit/Transmitter Replacement......................................................................16013 Keyless Entry System....................................................................................................................16014 ID Code Registration................................................................................................................16014 Main Data and Specifications............................................................................................................16018 8I SUNROOF/CONVERTIBLE TOP.................................................................................................................16019 Service Precaution......................................................................................................................16019 Sunroof Glass (LWB).....................................................................................................................16020 Sunroof Glass and Associated Parts..................................................................................................16020 Removal.............................................................................................................................16020 Installation........................................................................................................................16021 Sunroof Glass (SWB).....................................................................................................................16021 Sunroof Glass and Associated Parts..................................................................................................16021 Removal.............................................................................................................................16022 Installation........................................................................................................................16022 Sunroof Deflector (LWB).................................................................................................................16023 Removal.............................................................................................................................16023 Installation........................................................................................................................16023 Sunroof Deflector (SWB).................................................................................................................16024 Parts Location......................................................................................................................16024 Removal.............................................................................................................................16024 Installation........................................................................................................................16024 Sunshade (LWB)..........................................................................................................................16025 Disassembled View...................................................................................................................16025 Removal.............................................................................................................................16025 Installation........................................................................................................................16026 Sunroof Frame Complete Assembly (LWB)...................................................................................................16027 Sunroof Frame Complete Assembly and Associated Parts................................................................................16027 Removal.............................................................................................................................16027 Installation........................................................................................................................16028 Sunroof Switch..........................................................................................................................16028 Removal.............................................................................................................................16028 Installation........................................................................................................................16028 Sunroof Control Unit....................................................................................................................16029 Removal.............................................................................................................................16029 Installation........................................................................................................................16029 Safety Stop Switch......................................................................................................................16029 Removal.............................................................................................................................16029 Installation........................................................................................................................16029 Limit Switch............................................................................................................................16030 Removal.............................................................................................................................16030 Installation........................................................................................................................16030 Sunroof Motor...........................................................................................................................16030 Removal.............................................................................................................................16030 Installation........................................................................................................................16030 Soft Top Assembly.......................................................................................................................16031 Soft Top Assembly and Associated Parts..............................................................................................16031 Removal.............................................................................................................................16032 Installation........................................................................................................................16032 Resin Top Assembly......................................................................................................................16033 Resin Top Assembly and Associated Parts.............................................................................................16033 Removal.............................................................................................................................16033 Installation........................................................................................................................16034 Seat Belt Cross Bar Assembly............................................................................................................16035 Seat Belt Cross Bar Assembly and Associated Parts...................................................................................16035 Removal.............................................................................................................................16035 Installation........................................................................................................................16036 Main Data and Specifications............................................................................................................16037 8J EXTERIOR / INTERIOR TRIM.................................................................................................................16038 Service Precaution......................................................................................................................16039 Consoles................................................................................................................................16040 Consoles and Associated Parts.......................................................................................................16040 Removal.............................................................................................................................16040 Installation........................................................................................................................16040 Front Door Trim Panel...................................................................................................................16041 Front Door Trim Panel and Associated Parts..........................................................................................16041 Removal.............................................................................................................................16042 Installation........................................................................................................................16042 Rear Door Trim Panel....................................................................................................................16043 Rear Door Trim Panel and Associated Parts...........................................................................................16043 Removal.............................................................................................................................16044 Installation........................................................................................................................16044 Door Mirror Assembly....................................................................................................................16045 Removal.............................................................................................................................16045 Installation........................................................................................................................16045 Interior Trim Panels (LWB)..............................................................................................................16046 Interior Trim Panels and Associated Parts...........................................................................................16046 Removal.............................................................................................................................16046 Installation........................................................................................................................16048 Interior Trim Panels (SWB)..............................................................................................................16049 Interior Trim Panels and Associated Parts...........................................................................................16049 Removal.............................................................................................................................16049 Installation........................................................................................................................16050 Headlining (LWB)........................................................................................................................16051 Parts Location......................................................................................................................16051 Removal.............................................................................................................................16051 Installation........................................................................................................................16052 Headlining (SWB)........................................................................................................................16053 Parts Location......................................................................................................................16053 Removal.............................................................................................................................16054 Installation........................................................................................................................16055 Wheel Arch Protector (LWB)..............................................................................................................16056 Wheel Arch Protector and Associated Parts...........................................................................................16056 Removal.............................................................................................................................16056 Installation........................................................................................................................16056 Wheel Arch Protector (SWB)..............................................................................................................16057 Wheel Arch Protector and Associated Parts...........................................................................................16057 Removal.............................................................................................................................16057 Installation........................................................................................................................16057 Wheel Arch Molding (SWB)................................................................................................................16058 Wheel Arch Molding and Associated Parts.............................................................................................16058 Removal.............................................................................................................................16058 Installation........................................................................................................................16059 Wheel Arch Molding (LWB)................................................................................................................16060 Wheel Arch Molding and Associated Parts.............................................................................................16060 Removal.............................................................................................................................16060 Installation........................................................................................................................16061 Fuel Filler Door........................................................................................................................16061 Parts Location......................................................................................................................16061 Removal.............................................................................................................................16061 Installation........................................................................................................................16061 Roof Rail...............................................................................................................................16062 Parts Location......................................................................................................................16062 Removal.............................................................................................................................16062 Installation........................................................................................................................16062 License Plate Garnish...................................................................................................................16063 Parts Location......................................................................................................................16063 Removal.............................................................................................................................16063 Installation........................................................................................................................16064 Power Door Mirror System................................................................................................................16064 General Description.....................................................................................................................16064 Door Mirror Switch..................................................................................................................16064 Power Window System.....................................................................................................................16065 General Description.....................................................................................................................16065 Power Window Switch Driver Seat Side................................................................................................16065 Power Window Motor..................................................................................................................16066 Main Data and Specifications........................................................................................................16067 Sec.9 RESTRAINTS................................................................................................................................16068 9A SEAT BELT SYSTEM........................................................................................................................16068 Service Precaution......................................................................................................................16068 Front Seat Belt (LWB)...................................................................................................................16069 Front Seat Belt and Associated Parts................................................................................................16069 Removal.............................................................................................................................16069 Inspection..........................................................................................................................16070 Installation........................................................................................................................16070 Front Seat Belt (SWB)...................................................................................................................16071 Front Seat Belt and Associated Parts................................................................................................16071 Removal.............................................................................................................................16071 Inspection..........................................................................................................................16073 Installation........................................................................................................................16073 Rear Seat Belt (LWB)....................................................................................................................16074 Rear Seat Belt and Associated Parts.................................................................................................16074 Removal.............................................................................................................................16074 Inspection..........................................................................................................................16075 Installation........................................................................................................................16076 Rear Seat Belt (SWB)....................................................................................................................16077 Rear Seat Belt and Associated Parts.................................................................................................16077 Removal.............................................................................................................................16077 Inspection..........................................................................................................................16079 Installation........................................................................................................................16079 Front Seat Buckle Assembly..............................................................................................................16080 Removal.............................................................................................................................16080 Installation........................................................................................................................16080 Rear Center Seat Belt / Buckle Assembly.................................................................................................16081 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................16081 Removal.............................................................................................................................16081 Installation........................................................................................................................16081 Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................16082 Child Seat Tether Anchorage Bracket and Associated Parts............................................................................16082 Removal.............................................................................................................................16082 Installation........................................................................................................................16082 Child Seat Lower Anchorage Striker (LWB)................................................................................................16083 Child Seat Lower Anchorage Striker and Associated Parts.............................................................................16083 Removal.............................................................................................................................16083 Installation........................................................................................................................16084 Main Data and Specifications............................................................................................................16085 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).....................................................................................................16088 Service Precaution......................................................................................................................16088 General Description.....................................................................................................................16089 SRS Component and Wiring Location View..............................................................................................16091 Component Description...................................................................................................................16091 Definition..............................................................................................................................16094 Diagnosis...............................................................................................................................16095 SRS Connector Body Face Views...........................................................................................................16096 Repairs and Inspections Required After an Accident......................................................................................16096 On–Vehicle Service......................................................................................................................16097 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................16098 Special Tools...........................................................................................................................16113 Service Precaution......................................................................................................................16115 Sensing and Diagnostic Module (SDM).....................................................................................................16117 Service Precautions.................................................................................................................16117 Removal.............................................................................................................................16117 Installation........................................................................................................................16118 Driver Air Bag Assembly.................................................................................................................16119 Service Precautions.................................................................................................................16119 Removal.............................................................................................................................16119 Installation........................................................................................................................16119 Steering Wheel..........................................................................................................................16120 Service Precautions.................................................................................................................16120 Removal.............................................................................................................................16120 Installation........................................................................................................................16121 SRS Coil Assembly.......................................................................................................................16122 Service Precaution..................................................................................................................16122 Removal.............................................................................................................................16122 How to Disconnect the horn terminal.................................................................................................16124 How to Connect Horn Terminal........................................................................................................16124 Installation........................................................................................................................16125 Steering Column.........................................................................................................................16127 Service Precaution..................................................................................................................16127 Removal.............................................................................................................................16127 Installation........................................................................................................................16129 Passenger Air Bag Assembly..............................................................................................................16131 Service Precaution..................................................................................................................16131 Removal.............................................................................................................................16131 Installation........................................................................................................................16131 Main Data and Specifications............................................................................................................16132 SRS Air Bag System Inspection Standards For Repair......................................................................................16133 9J1 SRS CONTROL SYSTEM......................................................................................................................16134 Service Precaution......................................................................................................................16134 Diagnostic Information..................................................................................................................16135 Plotting Snapshot Graph.................................................................................................................16140 Parts For Electrical Circuit............................................................................................................16143 System Schematic........................................................................................................................16144 SRS Diagnostic System Check.............................................................................................................16144 Chart A SDM Integrity Check.............................................................................................................16147 Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................16149 Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................16151 DTC 15 Passenger Deployment Loop Resistance High........................................................................................16154 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................16157 DTC 17 Passenger Deployment Loop Open...................................................................................................16160 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................16162 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................16164 DTC 21 Driver Deployment Loop Resistance High...........................................................................................16166 DTC 22 Driver Deployment Loop Resistance Low............................................................................................16169 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................16172 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................16174 DTC 26 Driver Deployment Loop Open......................................................................................................16177 DTC 51 Deployment Event Commanded.......................................................................................................16180 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................16182 DTC 61 Warning Lamp Circuit Failure.....................................................................................................16184 DTC 71 Internal SDM Fault...............................................................................................................16186 Sec.10 CONTROL SYSTEM...........................................................................................................................16188 10A CRUISE CONTROL SYSTEM...................................................................................................................16188 Service Precaution......................................................................................................................16188 General Description.....................................................................................................................16188 Brake Switch............................................................................................................................16189 Removal and Installation............................................................................................................16189 Adjustment..........................................................................................................................16189 Clutch Switch...........................................................................................................................16190 Removal and Installation............................................................................................................16190 Adjustment..........................................................................................................................16190 Powertrain Control Module (PCM).........................................................................................................16190 Removal and Installation............................................................................................................16190 Mode Switch.............................................................................................................................16190 Removal and Installation............................................................................................................16190 Cruise Control Main Switch..............................................................................................................16191 Removal.............................................................................................................................16191 Installation........................................................................................................................16191 Cruise Control Switch (Combination Switch)..............................................................................................16191 Removal and Installation............................................................................................................16191 Diagnosis...............................................................................................................................16192 (UA) RODEO SPORT....................................................................................................................................16193 Sec.0 GENERAL INFORMATION.......................................................................................................................16195 0A General Information......................................................................................................................16195 General Repair Instruction..............................................................................................................16195 Illustration Arrows.....................................................................................................................16196 Identification..........................................................................................................................16197 Theft Prevention Standard...............................................................................................................16200 Lifting Instructions....................................................................................................................16205 Standard Bolts Torque Specifications....................................................................................................16207 Abbreviations Charts....................................................................................................................16208 Service Parts Identification Plate......................................................................................................16209 0B Maintenance and Lubrication..............................................................................................................16210 Maintenance Schedule List...............................................................................................................16210 Explanation of Complete Vehicle Maintenance Schedule....................................................................................16214 Recommended Fluids and Lubricants...................................................................................................16217 Lubricant Viscosity Chart...............................................................................................................16218 Recommended Liquid Gasket...........................................................................................................16220 Recommended Thread Locking Agents...................................................................................................16220 Maintenance Service Data................................................................................................................16221 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................16222 1A HVAC System..............................................................................................................................16222 Sec.2 STEERING..................................................................................................................................16224 2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................16224 Service Precaution......................................................................................................................16225 Diagnosis...............................................................................................................................16225 General Description.....................................................................................................................16231 Power Steering System Test..............................................................................................................16233 Maintenance.............................................................................................................................16234 Fluid Level.............................................................................................................................16234 Bleeding The Power Steering System......................................................................................................16234 Bleeding Procedure......................................................................................................................16234 Flushing The Power Steering System......................................................................................................16234 Steering Wheel Free Play Inspection.....................................................................................................16235 Front End Alignment Inspection and Adjustment...........................................................................................16235 Main Data and Specifications............................................................................................................16239 Special Tools.......................................................................................................................16240 Power Steering Unit.....................................................................................................................16241 Power Steering Unit and Associated Parts............................................................................................16241 Removal.............................................................................................................................16241 Installation (4×2 Model)............................................................................................................16242 Installation (4×4 Model)............................................................................................................16242 Power Steering Unit Disassembled View...............................................................................................16243 Disassembly.........................................................................................................................16243 Inspection and Repair...............................................................................................................16243 Reassembly..........................................................................................................................16243 Main Data and Specifications........................................................................................................16244 Special Tools...........................................................................................................................16244 Power Steering Pump.....................................................................................................................16245 Power Steering Pump and Associated Parts............................................................................................16245 Removal.............................................................................................................................16245 Installation........................................................................................................................16245 Power Steering Pump Disassembled View...............................................................................................16246 Disassembly.........................................................................................................................16246 Inspection and Repair...............................................................................................................16247 Reassembly..........................................................................................................................16247 Main Data and Specifications............................................................................................................16249 Transfer Gear Assembly..................................................................................................................16250 Transfer Gear Assembly and Associated Parts.........................................................................................16250 Removal.............................................................................................................................16250 Inspection and Repair...............................................................................................................16250 Installation........................................................................................................................16250 Supplemental Restraint System Steering Wheel & Column...................................................................................16251 Service Precaution..................................................................................................................16251 SRS Connectors......................................................................................................................16251 Inflator Module.........................................................................................................................16253 Inflator Module and Associated Parts................................................................................................16253 Removal.............................................................................................................................16253 Inspection and Repair...............................................................................................................16254 Installation........................................................................................................................16254 Steering Wheel..........................................................................................................................16255 Steering Wheel and Associated Parts.................................................................................................16255 Removal.............................................................................................................................16255 Installation........................................................................................................................16257 Combination Switch......................................................................................................................16258 Combination Switch and Associated Parts.............................................................................................16258 Removal.............................................................................................................................16258 Installation........................................................................................................................16260 Lock Cylinder...........................................................................................................................16262 Lock Cylinder and Associated Parts..................................................................................................16262 Removal.............................................................................................................................16262 Installation........................................................................................................................16264 System Inspection...................................................................................................................16265 Steering Column.........................................................................................................................16266 Steering Column and Associated Parts................................................................................................16266 Removal.............................................................................................................................16266 Installation........................................................................................................................16268 System Inspection...................................................................................................................16269 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................16270 Main Data and Specifications............................................................................................................16270 Special Tools.......................................................................................................................16270 Sec.3 SUSPENSION................................................................................................................................16272 3C FRONT SUSPENSION.........................................................................................................................16272 Service Precaution......................................................................................................................16272 General Description.....................................................................................................................16273 Diagnosis...............................................................................................................................16273 Shock Absorber..........................................................................................................................16276 Shock Absorber and Associated Parts.................................................................................................16276 Removal.............................................................................................................................16276 Inspection and Repair...............................................................................................................16276 Installation........................................................................................................................16276 Stabilizer Bar..........................................................................................................................16277 Stabilizer Bar and Associated Parts.................................................................................................16277 Removal.............................................................................................................................16277 Inspection and Repair...............................................................................................................16277 Installation........................................................................................................................16277 Torsion Bar.............................................................................................................................16278 Torsion Bar and Associated Parts....................................................................................................16278 Removal.............................................................................................................................16278 Inspection and Repair...............................................................................................................16279 Installation........................................................................................................................16279 Knuckle.................................................................................................................................16281 Knuckle and Associated Parts........................................................................................................16281 Removal.............................................................................................................................16281 Inspection and Repair...............................................................................................................16282 Installation........................................................................................................................16282 Upper Control Arm.......................................................................................................................16284 Upper Control Arm and Associated Parts..............................................................................................16284 Removal.............................................................................................................................16284 Inspection and Repair...............................................................................................................16285 Installation........................................................................................................................16285 Lower Control Arm.......................................................................................................................16287 Lower Control Arm and Associated Parts..............................................................................................16287 Removal.............................................................................................................................16287 Inspection and Repair...............................................................................................................16288 Installation........................................................................................................................16289 Upper Ball Joint........................................................................................................................16290 Upper Ball Joint and Associated Parts...............................................................................................16290 Removal.............................................................................................................................16290 Inspection and Repair...............................................................................................................16291 Installation........................................................................................................................16291 Lower Ball Joint........................................................................................................................16292 Lower Ball Joint and Associated Parts...............................................................................................16292 Removal.............................................................................................................................16292 Inspection and Repair...............................................................................................................16293 Installation........................................................................................................................16293 Main Data and Specifications............................................................................................................16294 Special Tools...........................................................................................................................16295 3D REAR SUSPENSION..........................................................................................................................16296 Service Precaution......................................................................................................................16296 General Description.....................................................................................................................16296 Diagnosis...............................................................................................................................16297 Coil Spring.............................................................................................................................16300 Coil Spring and Associated Parts....................................................................................................16300 Removal.............................................................................................................................16300 Inspection and Repair...............................................................................................................16301 Installation........................................................................................................................16301 Shock Absorber..........................................................................................................................16302 Shock Absorber and Associated Parts.................................................................................................16302 Removal.............................................................................................................................16302 Inspection and Repair...............................................................................................................16302 Installation........................................................................................................................16302 Trailing Link...........................................................................................................................16303 Trailing Link and Associated Parts..................................................................................................16303 Removal.............................................................................................................................16303 Inspection and Repair...............................................................................................................16303 Installation........................................................................................................................16304 Upper Link..............................................................................................................................16305 Upper Link and Associated Parts.....................................................................................................16305 Removal.............................................................................................................................16305 Inspection and Repair...............................................................................................................16305 Installation........................................................................................................................16306 Lateral Rod.............................................................................................................................16307 Lateral Rod and Associated Parts....................................................................................................16307 Removal.............................................................................................................................16307 Inspection and Repair...............................................................................................................16307 Installation........................................................................................................................16308 Stabilizer Bar..........................................................................................................................16309 Stabilizer Bar and Associated Parts.................................................................................................16309 Removal.............................................................................................................................16309 Inspection and Repair...............................................................................................................16309 Installation........................................................................................................................16310 Main Data and Specifications............................................................................................................16310 Special Tools...........................................................................................................................16312 3E Wheel and Tire System....................................................................................................................16271 3F FINTELLIGENT SUSPENSION CONTROL..........................................................................................................16313 Service Precaution......................................................................................................................16314 General Description.....................................................................................................................16314 PIN ASSIGNMENT TABLE................................................................................................................16316 System Components...................................................................................................................16316 Control Unit........................................................................................................................16316 Actuator............................................................................................................................16316 Adjustable Damping Force Shock Absorber.............................................................................................16316 Warning Lamp and Mode Lamp..........................................................................................................16316 Vertical G-Sensor...................................................................................................................16317 Lateral G-Sensor....................................................................................................................16317 Acronyms and Abbreviations..........................................................................................................16317 General Diagnosis.......................................................................................................................16317 General Information.................................................................................................................16317 Service Precautions.................................................................................................................16317 Computer System Service Precautions.................................................................................................16317 General Service Precautions.........................................................................................................16317 Parts Handling......................................................................................................................16317 FLASHING CODES......................................................................................................................16318 CLEAR DTC...........................................................................................................................16319 INTERMITTENT CONDITIONS.............................................................................................................16320 BULB CHECK..........................................................................................................................16320 DTC CHECK...........................................................................................................................16320 Basic Diagnosis Flow................................................................................................................16321 Circuit Diagram.....................................................................................................................16322 Parts Location......................................................................................................................16325 Connector List......................................................................................................................16326 Diagnostic Trouble Code (DTC) Identification........................................................................................16328 DTC2 Actuator Coil Over Current.........................................................................................................16329 Circuit Description.................................................................................................................16329 Diagnostic Aids.....................................................................................................................16329 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................16331 Circuit Description.................................................................................................................16331 Diagnostic Aids.....................................................................................................................16331 DTC4 G-Sensor Open Circuit or Short.....................................................................................................16334 Circuit Description.................................................................................................................16334 Diagnostic Aids.....................................................................................................................16334 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................16335 Circuit Description.................................................................................................................16335 Diagnostic Aids.....................................................................................................................16335 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................16337 Circuit Description.................................................................................................................16337 Diagnostic Aids.....................................................................................................................16337 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................16339 Circuit Description.................................................................................................................16339 Diagnostic Aids.....................................................................................................................16339 DTC9 Control Unit Abnormality.......................................................................................................16340 Control Unit............................................................................................................................16344 Control Unit and Associated Parts...................................................................................................16344 Removal.................................................................................................................................16344 Installation............................................................................................................................16345 Front Actuator..........................................................................................................................16346 Front Actuator and Associated Parts.................................................................................................16346 Removal.................................................................................................................................16347 View B..............................................................................................................................16347 Inspection and Repair...................................................................................................................16347 Installation............................................................................................................................16347 Rear Shock Absorber.....................................................................................................................16348 Rear Shock Absorber and Associated Parts............................................................................................16348 Removal.................................................................................................................................16349 Inspection and Repair...................................................................................................................16349 Installation............................................................................................................................16349 Sec.4 DRIVELINE/AXLE............................................................................................................................16351 4A1 DIFFERENTIAL (FRONT)....................................................................................................................16351 Main Data And Specifications............................................................................................................16352 4A2 DIFFERENTIAL (REAR).....................................................................................................................16353 Main Data And Specifications............................................................................................................16354 4B Driveline Control System................................................................................................................16350 4C Drive Shaft System......................................................................................................................16355 Service Precaution......................................................................................................................16356 Front Propeller Shaft...................................................................................................................16357 General Description.................................................................................................................16357 Diagnosis of Propeller Shaft and Universal Joint....................................................................................16359 Front Propeller Shaft and Associated Parts..........................................................................................16360 Removal.............................................................................................................................16360 Installation........................................................................................................................16360 Slip Joint Disassembly..............................................................................................................16361 Universal Joint Disassembly(Single Cardan Type).....................................................................................16362 Universal Joint Reassembly(Single Cardan Type)......................................................................................16364 Slip Joint Reassembly...............................................................................................................16366 Main Data And Specifications........................................................................................................16367 Rear Propeller Shaft....................................................................................................................16368 General Description.................................................................................................................16368 Diagnosis of Propeller Shaft and Universal Joint....................................................................................16370 Rear Propeller Shaft and Associated Parts...........................................................................................16371 Removal.............................................................................................................................16371 Installation........................................................................................................................16371 Slip Joint Disassembly (6VD1 Model Only)............................................................................................16372 Universal Joint Disassembly.........................................................................................................16373 Inspection..........................................................................................................................16375 Universal Joint Reassembly..........................................................................................................16376 Slip Joint Reassembly (6VD1 Model Only).............................................................................................16377 Main Data and Specifications........................................................................................................16378 4D Transfer Case...........................................................................................................................16350 Sec.5 BRAKE.....................................................................................................................................16379 5A Brake Control System.....................................................................................................................16379 5B Anti‐lock Brake System...................................................................................................................16379 5C Power‐assisted Brake System..............................................................................................................16379 5D Parking Brakes (4x4 Model)...............................................................................................................16379 5E Parking Brakes (4x2 Model)...............................................................................................................16379 Sec.6 ENGINE....................................................................................................................................16381 Y22SE 2.2L ENGINE...........................................................................................................................16381 6A Engine Mechanical...................................................................................................................16380 6B Engine Cooling......................................................................................................................16380 6C ENGINE FUEL (Y22SE 2.2L) For Short Wheel Base.......................................................................................16381 Service Precaution..................................................................................................................16381 General Description.................................................................................................................16382 Fuel Metering.......................................................................................................................16383 Fuel Filter.........................................................................................................................16384 Fuel Filter and Associated Parts................................................................................................16384 Removal.........................................................................................................................16384 Inspection......................................................................................................................16385 Installation....................................................................................................................16385 Inspection......................................................................................................................16385 In–Tank Fuel Filter.............................................................................................................16385 Fuel Pump Flow Test.............................................................................................................16385 Fuel Pump Relay.....................................................................................................................16386 General Description.............................................................................................................16386 Fuel Tank...........................................................................................................................16386 Fuel Tank and Associated Parts..................................................................................................16386 Removal.........................................................................................................................16387 Installation....................................................................................................................16387 Fuel Gauge Unit.....................................................................................................................16387 Removal and Installation........................................................................................................16387 Fuel Tube / Quick – Connector Fittings..............................................................................................16388 Precautions.....................................................................................................................16388 Cautions During Work............................................................................................................16388 Removal.........................................................................................................................16388 Reuse of Quick–Connector........................................................................................................16389 Assembling Advice...............................................................................................................16390 Fuel Filler Cap.....................................................................................................................16390 General Description.............................................................................................................16390 Inspection......................................................................................................................16390 Fuel Pump...........................................................................................................................16391 Fuel Pump and Associated Parts..................................................................................................16391 Removal.........................................................................................................................16391 Installation....................................................................................................................16392 Main Data and Specifications........................................................................................................16392 Special Tool....................................................................................................................16392 6D1 Engine Electrical...................................................................................................................16380 6D2 Ignition System.....................................................................................................................16380 6D3 Starting and Charging System........................................................................................................16380 6E Driveability and Emissions..........................................................................................................16380 6F Engine Exhaust......................................................................................................................16380 6G Engine Lubrication..................................................................................................................16380 6H Engine Speed Control System.........................................................................................................16380 6J Induction...........................................................................................................................16380 6VD1 3.2L ENGINE...........................................................................................................................16393 6A Engine Mechanical...................................................................................................................16380 6B Engine Cooling......................................................................................................................16380 6C ENGINE FUEL.........................................................................................................................16393 Service Precaution..................................................................................................................16393 General Description.................................................................................................................16394 Fuel Metering.......................................................................................................................16395 Fuel Filter.........................................................................................................................16396 Removal.........................................................................................................................16396 Inspection......................................................................................................................16396 Installation....................................................................................................................16397 Inspection......................................................................................................................16397 In‐Tank Fuel Filter.............................................................................................................16397 Fuel Pump Flow Test.............................................................................................................16397 Fuel Pump...........................................................................................................................16398 Fuel Pump and Associated Parts..................................................................................................16398 Removal.........................................................................................................................16398 Installation....................................................................................................................16399 Fuel Tube / Quick-Connector Fittings................................................................................................16400 Precautions.....................................................................................................................16400 Cautions During Work............................................................................................................16400 Removal.........................................................................................................................16400 Reuse of Quick–Connector........................................................................................................16401 Assembling Advice...............................................................................................................16402 Fuel Pump Relay.....................................................................................................................16402 General Description.............................................................................................................16402 Fuel Tank...........................................................................................................................16403 Fuel Tank and Associated Parts..................................................................................................16403 Removal.........................................................................................................................16403 Installation....................................................................................................................16404 Fuel Gauge Unit.....................................................................................................................16404 Removal and Installation........................................................................................................16404 Fuel Filler Cap.....................................................................................................................16404 General Description.............................................................................................................16404 Inspection......................................................................................................................16404 Main Data and Specifications........................................................................................................16405 Special Tool....................................................................................................................16405 6D1 Engine Electrical...................................................................................................................16380 6D2 Ignition System.....................................................................................................................16380 6D3 Starting and Charging System........................................................................................................16380 6E Driveability and Emissions..........................................................................................................16380 6F Engine Exhaust......................................................................................................................16380 6G Engine Lubrication..................................................................................................................16380 6H Engine Speed Control System.........................................................................................................16380 6J Induction...........................................................................................................................16380 Sec.7 TRANSMISSION..............................................................................................................................16406 7B Manual Transmission......................................................................................................................16406 7C Clutch...................................................................................................................................16406 Sec.8 BODY AND ACCESSORIES......................................................................................................................16407 8A Lighting System..........................................................................................................................16407 8B Wiper / Washer System....................................................................................................................16407 8C Entertainment............................................................................................................................16407 8D Wiring System............................................................................................................................16407 8E Meter and Gauge..........................................................................................................................16407 8F Body Structure...........................................................................................................................16407 8G Seats....................................................................................................................................16407 8H Security and Locks.......................................................................................................................16407 8I Sunroof / Convertible Top...............................................................................................................16407 8J Exterior / Interior Trim.................................................................................................................16407 Sec.9 RESTRAINTS................................................................................................................................16408 9A Seat Belt System........................................................................................................................16408 9J Supplemental Restraint System (Air Bag System) .........................................................................................16408 9J1 Restraint Control System................................................................................................................16408 Sec.10 CONTROL SYSTEM...........................................................................................................................16409 10A Cruise Control System...................................................................................................................16409 2002 MODEL.............................................................................................................................................. 2 (UP) AXIOM..........................................................................................................................................16410 Sec.0 GENERAL INFORMATION.....................................................................................................................16411 0A General Information......................................................................................................................16411 General Repair Instruction..............................................................................................................16411 Illustration Arrows.....................................................................................................................16412 Identification..........................................................................................................................16413 Theft Prevention Standard...............................................................................................................16415 Lifting Instructions....................................................................................................................16419 Standard Bolts Torque Specifications....................................................................................................16421 Abbreviations Charts....................................................................................................................16422 Service Parts Identification Plate......................................................................................................16423 0B Maintenance and Lubrication..............................................................................................................16424 Maintenance Schedule List...............................................................................................................16424 Explanation of Complete Vehicle Maintenance Schedule....................................................................................16428 Recommended Fluids and Lubricants...................................................................................................16431 Lubricant Viscosity Chart...............................................................................................................16432 Recommended Liquid Gasket...........................................................................................................16434 Recommended Thread Locking Agents...................................................................................................16434 Maintenance Service Data................................................................................................................16435 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)........................................................................................16436 1A HVAC SYSTEMS.............................................................................................................................16436 Service Precaution......................................................................................................................16438 Heating and Ventilation System..........................................................................................................16438 General Description.....................................................................................................................16438 Heater Unit.............................................................................................................................16441 Heater Unit and Associated Parts....................................................................................................16441 Removal.............................................................................................................................16441 Installation........................................................................................................................16441 Heater Core and / or Mode Door..........................................................................................................16442 Disassembled View...................................................................................................................16442 Removal.............................................................................................................................16443 Inspection..........................................................................................................................16443 Installation........................................................................................................................16443 Heater Mode Control Link Unit...........................................................................................................16444 Disassembled View...................................................................................................................16444 Removal.............................................................................................................................16444 Installation........................................................................................................................16445 Heater Temperature Control Link Unit....................................................................................................16446 Disassembled View...................................................................................................................16446 Removal.............................................................................................................................16446 Installation........................................................................................................................16446 Blower Assembly.........................................................................................................................16447 Blower Assembly and Associated Parts................................................................................................16447 Removal.............................................................................................................................16447 Installation........................................................................................................................16447 Blower Link Unit and / or Mode door.....................................................................................................16448 Disassembled View...................................................................................................................16448 Removal.............................................................................................................................16448 Installation........................................................................................................................16449 Blower Motor............................................................................................................................16450 Blower Motor and Associated Parts...................................................................................................16450 Removal.............................................................................................................................16450 Installation........................................................................................................................16450 Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................16451 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................16451 Removal.............................................................................................................................16451 Installation........................................................................................................................16452 Air Conditioning System.................................................................................................................16453 General Description.....................................................................................................................16453 Diagnosis...............................................................................................................................16459 Air Conditioning System.................................................................................................................16466 Individual Inspection...................................................................................................................16466 General Repair Procedure............................................................................................................16466 Leak Check..........................................................................................................................16468 Compressor Assembly.....................................................................................................................16473 Compressor Assembly and Associated Parts (6VE1).....................................................................................16473 Removal.............................................................................................................................16473 Installation........................................................................................................................16474 New Compressor Installation.........................................................................................................16474 Condenser Assembly......................................................................................................................16475 Condenser Assembly and Associated Parts.............................................................................................16475 Removal.............................................................................................................................16475 Installation........................................................................................................................16476 Condenser Fan Motor.....................................................................................................................16477 Condenser Fan Motor and Associated Parts............................................................................................16477 Removal.............................................................................................................................16477 Installation........................................................................................................................16477 Receiver / Drier........................................................................................................................16478 Receiver / Drier and Associated Parts...............................................................................................16478 Removal.............................................................................................................................16478 Installation........................................................................................................................16478 Pressure Switch.........................................................................................................................16479 Pressure Switch and Associated Parts................................................................................................16479 Removal.............................................................................................................................16479 Installation........................................................................................................................16479 Evaporator Assembly.....................................................................................................................16480 Evaporator Assembly and Associated Parts............................................................................................16480 Removal.............................................................................................................................16480 Installation........................................................................................................................16481 Duct Sensor, Evaporator Core and/or Expansion Valve.....................................................................................16482 Disassembled View...................................................................................................................16482 Removal.............................................................................................................................16482 Installation........................................................................................................................16483 Refrigerant Line........................................................................................................................16484 Refrigerant Line and Associated Parts...............................................................................................16484 Removal.............................................................................................................................16484 Installation........................................................................................................................16485 Main Data And Specifications............................................................................................................16486 Compressor..............................................................................................................................16488 Service Precaution..................................................................................................................16488 General Description.................................................................................................................16488 Diagnosis...........................................................................................................................16489 Magnetic Clutch Assembly (DKV-14G Type).................................................................................................16490 Parts Location View.................................................................................................................16490 Removal.............................................................................................................................16490 Inspection and Repair...............................................................................................................16492 Installation........................................................................................................................16492 Compressor Oil..........................................................................................................................16494 Oil Specification...................................................................................................................16494 Handling of Oil.....................................................................................................................16494 Compressor Oil Check................................................................................................................16494 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................16494 Checking and Adjusting for Compressor Replacement...................................................................................16495 Contamination of Compressor Oil.....................................................................................................16495 Oil Return Operation................................................................................................................16495 Replacement of Component Parts......................................................................................................16495 Main Data and Specifications............................................................................................................16496 Special Tools.......................................................................................................................16498 Automatic Air Conditioning System.......................................................................................................16499 General Description.................................................................................................................16499 Automatic Air Conditioner Parts Configuration.......................................................................................16499 Circuit Diagram.....................................................................................................................16500 Functions and Features..............................................................................................................16505 Automatic Air Conditioner Block Diagram.............................................................................................16506 Control Panel Layout................................................................................................................16507 Air Control Functions...............................................................................................................16508 Control Panel Switch Operation......................................................................................................16509 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System...................................16512 Overview of Automatic Control of Automatic Air Conditioner..........................................................................16516 Automatic Air Conditioning System...................................................................................................16517 Troubleshooting.........................................................................................................................16521 Troubleshooting, Its Overview and Procedures........................................................................................16521 Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................16522 Performance and Movement checklist for Automatic Air Conditioner Related Parts......................................................16524 Troubleshooting With Self-Diagnosis Function........................................................................................16526 Inspection By Failed Location...........................................................................................................16532 Inspection of the Sensors...........................................................................................................16532 Inspection of the Intake Actuator System............................................................................................16536 Inspection of the Mix Actuator System...............................................................................................16539 Inspection of the Mode Actuator System..............................................................................................16542 Inspection of the Fan Motor System..................................................................................................16545 Inspection of the Magnetic Clutch System............................................................................................16550 Individual Inspection...............................................................................................................16553 On-Vehicle Service......................................................................................................................16556 Power Transistor....................................................................................................................16556 Removal.............................................................................................................................16556 Installation........................................................................................................................16556 Automatic Heater/Air Conditioner Control Unit.......................................................................................16556 Removal.............................................................................................................................16556 Installation........................................................................................................................16556 In Car Sensor.......................................................................................................................16557 Removal.............................................................................................................................16557 Installation........................................................................................................................16557 Ambient Sensor......................................................................................................................16557 Removal.............................................................................................................................16557 Installation........................................................................................................................16557 Sun Sensor..........................................................................................................................16558 Removal.............................................................................................................................16558 Installation........................................................................................................................16558 Duct Sensor.........................................................................................................................16558 Removal.............................................................................................................................16558 Installation........................................................................................................................16558 Mode Actuator.......................................................................................................................16559 Removal.............................................................................................................................16559 Installation........................................................................................................................16559 Mix Actuator........................................................................................................................16559 Removal.............................................................................................................................16559 Installation........................................................................................................................16559 Intake Actuator.....................................................................................................................16560 Removal.............................................................................................................................16560 Installation........................................................................................................................16560 Sec.2 STEERING................................................................................................................................16561 2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................16561 Service Precaution......................................................................................................................16562 Diagnosis...............................................................................................................................16562 General Description.....................................................................................................................16568 Power Steering System Test..............................................................................................................16570 Maintenance.............................................................................................................................16571 Fluid Level.............................................................................................................................16571 Bleeding The Power Steering System......................................................................................................16571 Bleeding Procedure......................................................................................................................16571 Flushing The Power Steering System......................................................................................................16571 Steering Wheel Free Play Inspection.....................................................................................................16572 Front End Alignment Inspection and Adjustment...........................................................................................16572 Main Data and Specifications............................................................................................................16576 Special Tools...........................................................................................................................16577 Power Steering Unit.....................................................................................................................16578 Power Steering Unit and Associated Parts............................................................................................16578 Removal.............................................................................................................................16578 Installation (4×2 Model)............................................................................................................16579 Installation (4×4 Model)............................................................................................................16579 Power Steering Unit Disassembled View...............................................................................................16580 Disassembly.........................................................................................................................16581 Inspection and Repair...............................................................................................................16581 Reassembly..........................................................................................................................16581 Main Data and Specifications........................................................................................................16582 Special Tools...........................................................................................................................16582 Power Steering Pump.....................................................................................................................16583 Power Steering Pump and Associated Parts............................................................................................16583 Removal.............................................................................................................................16583 Installation........................................................................................................................16583 Power Steering Pump Disassembled View...............................................................................................16584 Disassembly.........................................................................................................................16584 Inspection and Repair...............................................................................................................16585 Reassembly..........................................................................................................................16585 Main Data and Specifications........................................................................................................16587 Transfer Gear Assembly..................................................................................................................16588 Transfer Gear Assembly and Associated Parts.........................................................................................16588 Removal.............................................................................................................................16588 Inspection and Repair...............................................................................................................16588 Installation........................................................................................................................16588 Supplemental Restraint System Steering Wheel & Column...................................................................................16589 Service Precaution..................................................................................................................16589 SRS Connectors......................................................................................................................16589 Inflator Module.........................................................................................................................16591 Inflator Module and Associated Parts................................................................................................16591 Removal.............................................................................................................................16591 Inspection and Repair...............................................................................................................16592 Installation........................................................................................................................16592 Steering Wheel..........................................................................................................................16593 Steering Wheel and Associated Parts.................................................................................................16593 Removal.............................................................................................................................16593 Installation........................................................................................................................16595 Combination Switch......................................................................................................................16596 Combination Switch and Associated Parts.............................................................................................16596 Removal.............................................................................................................................16596 Installation........................................................................................................................16598 Lock Cylinder...........................................................................................................................16600 Lock Cylinder and Associated Parts..................................................................................................16600 Removal.............................................................................................................................16600 Installation........................................................................................................................16602 System Inspection...................................................................................................................16603 Steering Column.........................................................................................................................16604 Steering Column and Associated Parts................................................................................................16604 Removal.............................................................................................................................16604 Inspection..........................................................................................................................16606 Installation........................................................................................................................16608 System Inspection.......................................................................................................................16609 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................16610 Main Data and Specifications........................................................................................................16610 Special Tools.......................................................................................................................16610 Sec.3 SUSPENSION..............................................................................................................................16611 3C FRONT SUSPENSION.........................................................................................................................16611 Service Precaution......................................................................................................................16611 General Description.....................................................................................................................16612 Diagnosis...............................................................................................................................16612 Shock Absorber..........................................................................................................................16615 Shock Absorber and Associated Parts.................................................................................................16615 Removal.............................................................................................................................16615 Inspection and Repair...............................................................................................................16615 Installation........................................................................................................................16615 Stabilizer Bar..........................................................................................................................16616 Stabilizer Bar and Associated Parts.................................................................................................16616 Removal.............................................................................................................................16616 Inspection and Repair...............................................................................................................16616 Installation........................................................................................................................16616 Torsion Bar.............................................................................................................................16617 Torsion Bar and Associated Parts....................................................................................................16617 Removal.............................................................................................................................16617 Inspection and Repair...............................................................................................................16618 Installation........................................................................................................................16618 Knuckle.................................................................................................................................16620 Knuckle and Associated Parts........................................................................................................16620 Removal.............................................................................................................................16620 Inspection and Repair...............................................................................................................16621 Installation........................................................................................................................16621 Upper Control Arm.......................................................................................................................16623 Upper Control Arm and Associated Parts..............................................................................................16623 Removal.............................................................................................................................16623 Inspection and Repair...............................................................................................................16624 Installation........................................................................................................................16624 Lower Control Arm.......................................................................................................................16626 Lower Control Arm and Associated Parts..............................................................................................16626 Removal.............................................................................................................................16626 Inspection and Repair...............................................................................................................16627 Installation........................................................................................................................16628 Upper Ball Joint........................................................................................................................16629 Upper Ball Joint and Associated Parts...............................................................................................16629 Removal.............................................................................................................................16629 Inspection and Repair...............................................................................................................16630 Installation........................................................................................................................16630 Lower Ball Joint........................................................................................................................16631 Lower Ball Joint and Associated Parts...............................................................................................16631 Removal.............................................................................................................................16631 Inspection and Repair...............................................................................................................16632 Installation........................................................................................................................16632 Main Data and Specifications............................................................................................................16633 Special Tools...........................................................................................................................16635 3D REAR SUSPENSION..........................................................................................................................16636 Service Precaution......................................................................................................................16636 General Description.....................................................................................................................16636 Diagnosis...............................................................................................................................16637 Coil Spring.............................................................................................................................16640 Coil Spring and Associated Parts....................................................................................................16640 Removal.............................................................................................................................16640 Inspection and Repair...............................................................................................................16641 Installation........................................................................................................................16641 Shock Absorber..........................................................................................................................16642 Shock Absorber and Associated Parts.................................................................................................16642 Removal.............................................................................................................................16642 Inspection and Repair...............................................................................................................16642 Installation........................................................................................................................16642 Trailing Link...........................................................................................................................16643 Trailing Link and Associated Parts..................................................................................................16643 Removal.............................................................................................................................16643 Inspection and Repair...............................................................................................................16643 Installation........................................................................................................................16644 Upper Link..............................................................................................................................16645 Upper Link and Associated Parts.....................................................................................................16645 Removal.............................................................................................................................16645 Inspection and Repair...............................................................................................................16645 Installation........................................................................................................................16646 Lateral Rod.............................................................................................................................16647 Lateral Rod and Associated Parts....................................................................................................16647 Removal.............................................................................................................................16647 Inspection and Repair...............................................................................................................16647 Installation........................................................................................................................16648 Stabilizer Bar..........................................................................................................................16649 Stabilizer Bar and Associated Parts.................................................................................................16649 Removal.............................................................................................................................16649 Inspection and Repair...............................................................................................................16649 Installation........................................................................................................................16650 Main Data and Specifications............................................................................................................16651 Special Tools...........................................................................................................................16653 3E WHEEL AND TIRE SYSTEM....................................................................................................................16672 Service Precaution......................................................................................................................16672 General Description.....................................................................................................................16673 Diagnosis...............................................................................................................................16674 Wheel...................................................................................................................................16682 Wheel and Associated Parts..........................................................................................................16682 Removal.............................................................................................................................16682 Installation........................................................................................................................16682 Tire....................................................................................................................................16683 Tire Replacement....................................................................................................................16683 General Balance Procedure...............................................................................................................16683 Balancing Wheel and Tire................................................................................................................16684 Main Data and Specifications............................................................................................................16685 3F INTELLIGENT SUSPENSION CONTROL...........................................................................................................16686 Service Precaution......................................................................................................................16687 General Description.....................................................................................................................16687 PIN ASSIGNMENT TABLE................................................................................................................16689 System Components...................................................................................................................16689 Control Unit........................................................................................................................16689 Actuator............................................................................................................................16689 Adjustable Damping Force Shock Absorber.............................................................................................16689 Warning Lamp........................................................................................................................16689 Vertical G-Sensor...................................................................................................................16690 Lateral G-Sensor....................................................................................................................16690 Acronyms and Abbreviations..........................................................................................................16690 General Diagnosis.......................................................................................................................16690 General Information.................................................................................................................16690 Service Precautions.................................................................................................................16690 Computer System Service Precautions.................................................................................................16690 General Service Precautions.........................................................................................................16690 Parts Handling......................................................................................................................16690 FLASHING CODES......................................................................................................................16691 CLEAR DTC...........................................................................................................................16692 INTERMITTENT CONDITIONS.............................................................................................................16693 BULB CHECK..........................................................................................................................16693 DTC CHECK...........................................................................................................................16693 Connector List......................................................................................................................16699 Diagnostic Trouble Code (DTC) Identification........................................................................................16701 DTC2 Actuator Coil Over Current.........................................................................................................16702 Circuit Description.................................................................................................................16702 Diagnostic Aids.....................................................................................................................16702 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................16704 Circuit Description.................................................................................................................16704 Diagnostic Aids.....................................................................................................................16704 DTC4 G-Sensor Open Circuit or Short.....................................................................................................16707 Circuit Description.................................................................................................................16707 Diagnostic Aids.....................................................................................................................16707 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................16708 Circuit Description.................................................................................................................16708 Diagnostic Aids.....................................................................................................................16708 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................16710 Circuit Description.................................................................................................................16710 Diagnostic Aids.....................................................................................................................16710 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................16712 Circuit Description.................................................................................................................16712 Diagnostic Aids.....................................................................................................................16712 DTC9 Control Unit Abnormality...........................................................................................................16713 Control Unit............................................................................................................................16717 Removal.................................................................................................................................16718 Installation............................................................................................................................16718 Front Actuator..........................................................................................................................16719 Removal.................................................................................................................................16720 Inspection and Repair...................................................................................................................16720 Installation............................................................................................................................16720 Rear Shock Absorber.....................................................................................................................16721 Rear Shock Absorber.....................................................................................................................16721 Removal.................................................................................................................................16722 Inspection and Repair...................................................................................................................16722 Installation............................................................................................................................16722 Sec.4 DRIVELINE/AXLE..........................................................................................................................16723 4A1 Differential (Front)....................................................................................................................16723 Service Precaution......................................................................................................................16723 Front Drive Axle........................................................................................................................16724 Diagnosis...............................................................................................................................16724 Pinion Shaft Oil Seal...................................................................................................................16725 Pinion Shaft Oil Seal and Associated Parts..........................................................................................16725 Removal.............................................................................................................................16725 Inspection and Repair...............................................................................................................16726 Installation........................................................................................................................16726 Front Drive Axle Assembly...............................................................................................................16727 Front Drive Axle Assembly and Associated Parts......................................................................................16727 Removal.............................................................................................................................16728 Installation........................................................................................................................16728 Differential Assembly...................................................................................................................16730 Disassembled View...................................................................................................................16730 Disassembly.........................................................................................................................16731 Reassembly..........................................................................................................................16733 Differential Cage Assembly..............................................................................................................16742 Disassembled View...................................................................................................................16742 Disassembly.........................................................................................................................16742 Inspection and Repair...............................................................................................................16743 Reassembly..........................................................................................................................16743 Main Data and Specifications........................................................................................................16745 Special Tools.......................................................................................................................16747 4A2 Differential (Rear).....................................................................................................................16749 Service Precaution......................................................................................................................16749 General Description.....................................................................................................................16750 Diagnosis...............................................................................................................................16751 Axle Housing............................................................................................................................16753 Axle Housing and Associated Parts...................................................................................................16753 Removal.............................................................................................................................16753 Installation........................................................................................................................16755 Axle Shaft, Oil Seal and Bearing........................................................................................................16755 Axle Shaft and Associated Parts.....................................................................................................16755 Removal.............................................................................................................................16756 Inspection..........................................................................................................................16756 Installation........................................................................................................................16756 Pinion Oil Seal.........................................................................................................................16758 Pinion Oil Seal and Associated Parts................................................................................................16758 Removal.............................................................................................................................16758 Inspection and Repair...............................................................................................................16759 Installation........................................................................................................................16759 Differential Assembly...................................................................................................................16761 Disassembled View...................................................................................................................16761 Inspecting the Axle Before Disassembly..............................................................................................16762 Disassembly.........................................................................................................................16762 Inspection and Repair...............................................................................................................16764 Reassembly..........................................................................................................................16764 Side Bearing Preload Adjustment.....................................................................................................16768 Pinion Installation.................................................................................................................16769 Determination of Backlash & Preload Shims...........................................................................................16770 Backlash Adjustment.................................................................................................................16771 Gear Tooth Pattern Check............................................................................................................16771 Adjustments Affecting Tooth Contact.................................................................................................16772 Differential Case Assembly..............................................................................................................16773 Disassembled View...................................................................................................................16773 Disassembly.........................................................................................................................16774 Inspection and Repair...............................................................................................................16774 Reassembly..........................................................................................................................16774 Limited Slip Differential Assembly......................................................................................................16775 Disassembled View...................................................................................................................16775 Disassembly.........................................................................................................................16775 Inspection and Repair...............................................................................................................16777 Reassembly..........................................................................................................................16777 Main Data And Specifications............................................................................................................16779 Special Tools...........................................................................................................................16780 4B1 DRIVELINE CONTROL SYSTEM................................................................................................................16782 Service Precaution......................................................................................................................16782 Shift On The Fly System.................................................................................................................16783 Outline of Shift on The Fly System......................................................................................................16783 Functions of Indicator Lamp.............................................................................................................16785 Shift On The Fly Electrical Equipment...................................................................................................16786 Axle Shaft Connection and Disconnection.................................................................................................16786 Shift On The Fly Controller.............................................................................................................16788 Shift On The Fly Controller and Associated Parts....................................................................................16788 Removal.............................................................................................................................16788 Installation........................................................................................................................16788 4B2 DRIVELINE CONTROL SYSTEM (TOD)..........................................................................................................16789 Service Precaution......................................................................................................................16789 General Description.....................................................................................................................16790 Transfer Position and Drive Mode....................................................................................................16790 TOD Control.........................................................................................................................16791 TOD Indicator Control...............................................................................................................16791 Abbreviations.......................................................................................................................16791 System Components.......................................................................................................................16792 Parts Location......................................................................................................................16792 Front and Rear Speed Sensors........................................................................................................16793 Electromagnetic Coil................................................................................................................16793 Multi Plate Disk Clutch Pack........................................................................................................16793 Mechanical Lock Sleeve..............................................................................................................16793 High-Low Planetary Gear Set.........................................................................................................16794 4H and 4L Switch....................................................................................................................16794 Transfer Connector (12-pin type)....................................................................................................16794 Transfer Connector (8-pin type).....................................................................................................16794 TOD Indicator Lamps (on the instrument panel).......................................................................................16795 Check Lamp..........................................................................................................................16795 TOD ECU.............................................................................................................................16796 High-Low Shift Motor................................................................................................................16797 Motor Position and Encoder Position Code............................................................................................16798 Encode Position Plate...............................................................................................................16798 Shift High Range and Low Range......................................................................................................16798 Functions of TOD Switch and Indicator Lamp..............................................................................................16799 TOD Switch and Indication of Drive Mode.............................................................................................16799 Check Lamp..........................................................................................................................16801 Diagnosis...............................................................................................................................16802 General Information Diagnosis.......................................................................................................16802 Self-diagnosis......................................................................................................................16802 Precautions on Diagnosis............................................................................................................16804 Basic Diagnostic Flow Chart.............................................................................................................16806 Parts Location..........................................................................................................................16807 Circuit Diagram.........................................................................................................................16808 Connector List..........................................................................................................................16812 Checking Failed Pin.....................................................................................................................16814 Connector Pin Assignment............................................................................................................16814 Reference...........................................................................................................................16816 Checking Failed TOD Control Unit Pin....................................................................................................16818 Tech 2 Scan Tool....................................................................................................................16820 Getting Started.....................................................................................................................16821 Operating Procedure.................................................................................................................16821 Diagnostic Trouble Codes................................................................................................................16823 Diagnosis from Trouble Codes............................................................................................................16824 Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................16855 Diagnosis from Symptom..................................................................................................................16890 4C DRIVE SHAFT SYSTEM.......................................................................................................................16907 Service Precaution......................................................................................................................16907 General Description.....................................................................................................................16908 Diagnosis...............................................................................................................................16908 Front Hub and Disc (2WD Model)..........................................................................................................16909 Disassembled View...................................................................................................................16909 Disassembly.........................................................................................................................16909 Inspection and Repair...............................................................................................................16910 Reassembly..........................................................................................................................16911 Front Hub and Disc (4WD Model)..........................................................................................................16914 Disassembled View...................................................................................................................16914 Disassembly.........................................................................................................................16914 Inspection and Repair...............................................................................................................16916 Reassembly..........................................................................................................................16916 Front Drive Shaft Joint.................................................................................................................16919 Front Drive Shaft Joints Replacement................................................................................................16919 Front Axle Drive Shaft..................................................................................................................16920 Front Axle Drive Shaft and Associated Parts.........................................................................................16920 Disassembly.........................................................................................................................16921 Inspection And Repair...............................................................................................................16922 Bushing Replacement.................................................................................................................16922 Reassembly..........................................................................................................................16923 Shift On The Fly System.................................................................................................................16925 Shift On The Fly System and Associated Parts........................................................................................16925 Disassembly.........................................................................................................................16926 Inspection And Repair...............................................................................................................16927 Reassembly..........................................................................................................................16929 Main Data and Specifications........................................................................................................16932 Special Tools.......................................................................................................................16934 Propeller Shaft.........................................................................................................................16935 General Description.................................................................................................................16935 Front Propeller Shaft...................................................................................................................16936 General Description.................................................................................................................16936 Front Propeller Shaft and Associated Parts..........................................................................................16937 Removal.............................................................................................................................16937 Installation........................................................................................................................16938 Main Data and Specifications........................................................................................................16941 Rear Propeller Shaft....................................................................................................................16942 Rear Propeller Shaft and Associated Parts...........................................................................................16942 Removal.............................................................................................................................16942 Installation........................................................................................................................16942 Slip Joint Disassembly..............................................................................................................16943 Universal Joint Disassembly.........................................................................................................16944 Inspection..........................................................................................................................16946 Universal Joint Reassembly..........................................................................................................16947 Slip Joint Reassembly...............................................................................................................16948 Main Data and Specifications........................................................................................................16949 4D2 TRANSFER CASE (TOD).....................................................................................................................16993 Service Precaution......................................................................................................................16993 General Description.....................................................................................................................16994 Removal and Installation of Tfansfer Case Assembly......................................................................................16995 Removal.............................................................................................................................16996 Installation........................................................................................................................16996 Transfer Rear Oil Seal..................................................................................................................16998 Removal.............................................................................................................................16998 Installation........................................................................................................................16998 TOD Control Unit........................................................................................................................17000 Removal.............................................................................................................................17000 Installation........................................................................................................................17000 Unit Repair.............................................................................................................................17001 Disassembly and Reassembly of Major Components......................................................................................17001 Disassembly.........................................................................................................................17002 Reassembly..........................................................................................................................17002 Transfer Cover Assembly.................................................................................................................17005 Disassembly.........................................................................................................................17005 Inspection and Repair...............................................................................................................17006 Reassembly..........................................................................................................................17007 Clutch Pack and Clutch Cam (Transfer Case Assembly).....................................................................................17008 Disassembly.........................................................................................................................17008 Reassembly..........................................................................................................................17010 Chain, Sprocket and Mechanical Lock (Transfer Case Assembly)............................................................................17012 Disassembly.........................................................................................................................17013 Reassembly..........................................................................................................................17014 Transfer Case Assembly..................................................................................................................17016 Disassembly.........................................................................................................................17016 Reassembly..........................................................................................................................17018 Inspection and Repair (Transfer Case Assembly)......................................................................................17020 Main Data and Specification.............................................................................................................17024 General Specification...............................................................................................................17024 Torque Specifications...............................................................................................................17025 Torque Specifications (Cont’d)......................................................................................................17026 Torque Specifications (Cont’d)......................................................................................................17027 Special Tools...........................................................................................................................17028 Sec.5 BRAKES..................................................................................................................................17029 5A Brake Control System....................................................................................................................17029 Service Precaution......................................................................................................................17030 General Description.....................................................................................................................17031 Functional Description..............................................................................................................17032 System Components...................................................................................................................17038 Electronic Hydraulic Control Unit (EHCU)............................................................................................17038 ABS Warning Light...................................................................................................................17038 Wheel Speed Sensor..................................................................................................................17038 G-Sensor............................................................................................................................17038 Normal and Anti-lock Braking........................................................................................................17038 Brake Pedal Travel..................................................................................................................17038 Acronyms and Abbreviations..........................................................................................................17039 General Diagnosis.......................................................................................................................17039 General Information.................................................................................................................17039 ABS Service Precautions.............................................................................................................17039 Computer System Service Precautions.................................................................................................17039 General Service Precautions.........................................................................................................17039 Note on Intermittents...............................................................................................................17039 Test Driving ABS Complaint Vehicles.................................................................................................17040 “ABS” Warning Light.................................................................................................................17040 Normal Operation....................................................................................................................17040 Tech 2 Scan Tool....................................................................................................................17041 DATA LIST...........................................................................................................................17044 ACTUATOR TEST.......................................................................................................................17045 Tech 2 Service Bleed................................................................................................................17049 Basic Diagnostic Flow Chart.........................................................................................................17050 Basic Inspection Procedure..........................................................................................................17051 EHCU Connector Pin-out Checks...........................................................................................................17052 Circuit Diagram.....................................................................................................................17053 Connector List......................................................................................................................17056 Part Location.......................................................................................................................17057 Symptom Diagnosis.......................................................................................................................17058 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................17058 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................17059 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................17059 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................17059 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................17060 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................17060 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................17061 Diagnostic Trouble Codes................................................................................................................17062 Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................17064 Diagnostic Trouble Codes (DTCs).....................................................................................................17065 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................17067 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)........................................17067 Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))...................................17068 Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))..................................................17068 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)).............................................17068 Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))..............................................17069 Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)).................................................17069 Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Sig........17070 Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................17070 Chart B-10 EHCU Valve Relay Failure (DTC 35 (Flash out) / C0265, C0266 (Serial communications)).....................................17071 Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))...........................17071 Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................17071 Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))...........................17072 Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications)).................................17072 Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications)).........................17072 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))..............................17073 Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications)).....................................17073 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)).....................................17074 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))...................................17075 Chart B-20 FL Speed Sensor Missing Signal (DTC 61 (Flash out) / C0226, C0227 (Serial communications))...............................17076 Chart B-21 FR Speed Sensor Missing Signal (DTC 62 (Flash out) / C0222, C0223 (Serial communications))...............................17077 Chart B-22 Rear Speed Sensor Missing Signal (DTC 63 (Flash out) / C0236, C0237 (Serial communications)).............................17078 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))..................17079 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)).......................................17080 Unit Inspection Procedure...............................................................................................................17081 Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................17081 Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................17082 Chart C-1-3 Rear Sensor Output Inspection Procedure.................................................................................17082 Chart TC-1 Sensor Output Inspection Procedure.......................................................................................17083 Special Tools...........................................................................................................................17084 5B ANTI-LOCK BRAKE SYSTEM..................................................................................................................17085 Service Precaution......................................................................................................................17085 Electronic Hydraulic Control Unit.......................................................................................................17086 Electronic Hydraulic Control Unit and Associated Parts..............................................................................17086 Removal.............................................................................................................................17086 Disassembled View...................................................................................................................17087 Disassembly.........................................................................................................................17087 Reassembly..........................................................................................................................17087 Installation........................................................................................................................17087 Front Wheel Speed Sensor................................................................................................................17088 Front Wheel Speed Sensor and Associated Parts.......................................................................................17088 Removal.............................................................................................................................17088 Inspection and Repair...............................................................................................................17088 Installation........................................................................................................................17088 Rear Wheel Speed Sensor.................................................................................................................17089 Removal.............................................................................................................................17089 Inspection and Repair...............................................................................................................17089 Installation........................................................................................................................17089 5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................17090 Service Precaution......................................................................................................................17091 General Description.....................................................................................................................17091 Diagnosis...............................................................................................................................17095 General Diagnosis.......................................................................................................................17096 Hydraulic Brakes........................................................................................................................17099 Filling Master Cylinder Reservoir...................................................................................................17099 Deterioration of Brake Fluid........................................................................................................17099 Leakage of Brake Fluid..............................................................................................................17099 Bleeding Brake Hydraulic System.....................................................................................................17099 Flushing Brake Hydraulic System.....................................................................................................17100 Brake Pipes and Hoses...............................................................................................................17100 Brake Hose Inspection...............................................................................................................17100 Front Caliper Brake Hose................................................................................................................17101 Front Caliper Brake Hose and Associated Parts.......................................................................................17101 Removal.............................................................................................................................17101 Installation........................................................................................................................17101 Rear Axle Brake Hose....................................................................................................................17102 Rear Axle Brake Hose and Associated Parts...........................................................................................17102 Removal.............................................................................................................................17102 Installation........................................................................................................................17102 Brake Pipe..............................................................................................................................17103 Removal.............................................................................................................................17103 Installation........................................................................................................................17103 P & B (Proportioning and Bypass) Valve..................................................................................................17104 P & B (Proportioning and Bypass) Valve Sectional View...............................................................................17104 Removal.............................................................................................................................17104 Installation........................................................................................................................17104 Main Data and Specifications............................................................................................................17105 Brake Pedal.............................................................................................................................17106 Checking Pedal Height...............................................................................................................17106 Checking Pedal Travel...............................................................................................................17106 Brake Pedal and Associated Parts....................................................................................................17107 Removal.............................................................................................................................17107 Installation........................................................................................................................17107 Stoplight Switch........................................................................................................................17108 Parts Location......................................................................................................................17108 Removal.............................................................................................................................17108 Installation........................................................................................................................17108 Main Data and Specifications............................................................................................................17109 Fluid Reservoir Tank....................................................................................................................17110 Fluid Reservoir Tank and Associated Parts...........................................................................................17110 Removal.............................................................................................................................17110 Installation........................................................................................................................17110 Master Cylinder Assembly................................................................................................................17111 Master Cylinder Assembly and Associated Parts...........................................................................................17111 Removal.............................................................................................................................17111 Inspection and Repair...............................................................................................................17111 Installation........................................................................................................................17112 Main Data and Specifications........................................................................................................17113 Special Tools.......................................................................................................................17113 Vacuum Booster Assembly.................................................................................................................17114 Vacuum Booster Assembly and Associated Parts........................................................................................17114 Removal.............................................................................................................................17114 Inspection and Repair...............................................................................................................17115 Installation........................................................................................................................17115 Exterior Components.....................................................................................................................17117 Exterior Components and Associated Parts............................................................................................17117 Removal.............................................................................................................................17117 Inspection and Repair...............................................................................................................17118 Installation........................................................................................................................17118 Vacuum Booster Overhaul.................................................................................................................17118 Vacuum Booster..........................................................................................................................17118 Main Data and Specifications............................................................................................................17119 Special Tools...........................................................................................................................17120 Front Disc Brake Pads...................................................................................................................17121 Front Disc Brake Pads Inspection....................................................................................................17121 Front Disc Brake Pads and Associated Parts..........................................................................................17121 Removal.............................................................................................................................17122 Installation........................................................................................................................17122 Front Disc Brake Rotor..................................................................................................................17124 Inspection..........................................................................................................................17124 Replacing Brake Rotors..............................................................................................................17124 Refinishing Brake Rotors............................................................................................................17124 Front Disc Brake Caliper Assembly.......................................................................................................17125 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................17125 Removal.............................................................................................................................17126 Installation........................................................................................................................17126 Front Disc Brake Caliper................................................................................................................17128 Front Disc Brake Caliper Disassembled View..........................................................................................17128 Disassembly.........................................................................................................................17128 Inspection and Repair...............................................................................................................17129 Reassembly..........................................................................................................................17129 Main Data and Specifications........................................................................................................17131 Rear Disc Brake Pads (4×4 Model)........................................................................................................17132 Brake Pads Inspection...............................................................................................................17132 Brake Pads and Associated Parts.....................................................................................................17132 Removal.............................................................................................................................17133 Installation........................................................................................................................17133 Rear Disc Brake Rotor (4×4 Model).......................................................................................................17135 Inspection..........................................................................................................................17135 Replacing Brake Rotors..............................................................................................................17135 Refinishing Brake Rotors............................................................................................................17135 Rear Drum (In Disc) Inside Diameter Check...........................................................................................17136 Rear Disc Brake Caliper Assembly (4×4 Model)............................................................................................17137 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................17137 Removal.............................................................................................................................17137 Installation........................................................................................................................17138 Rear Disc Brake Caliper (4×4 Model).....................................................................................................17139 Rear Disc Brake Caliper Disassembled View...........................................................................................17139 Disassembly.........................................................................................................................17140 Inspection and Repair...............................................................................................................17140 Reassembly..........................................................................................................................17140 Main Data and Specifications (4×4 Model)............................................................................................17142 Brake Lining............................................................................................................................17143 Brake Lining and Associated Parts...................................................................................................17143 Removal.............................................................................................................................17143 Brake Lining Inspection.............................................................................................................17144 Installation........................................................................................................................17144 Drum Brake Adjustment (4×2 Model)...................................................................................................17145 Servicing The Brake Drum............................................................................................................17145 Wheel Cylinder Assembly (4×2 Model).....................................................................................................17146 Wheel Cylinder Assembly and Associated Parts............................................................................................17146 Removal.............................................................................................................................17146 Installation........................................................................................................................17146 Disassembled View...................................................................................................................17147 Disassembly.........................................................................................................................17147 Inspection and Repair...............................................................................................................17147 Reassembly..........................................................................................................................17147 Main Data and Specifications........................................................................................................17149 5D1 PARKING BRAKE SYSTEM (4×4 Model)........................................................................................................17208 Service Precaution......................................................................................................................17208 General Description.....................................................................................................................17208 Operation...............................................................................................................................17209 Parking Brake Lever and Front Cable.....................................................................................................17210 Parking Brake Lever Assembly and Associated Parts...................................................................................17210 Removal.............................................................................................................................17210 Installation........................................................................................................................17210 Parking Brake Rear Cable................................................................................................................17211 Parking Brake Rear Cable and Associated Parts.......................................................................................17211 Removal.............................................................................................................................17212 Installation........................................................................................................................17212 Inspection and Repair...............................................................................................................17213 Parking Brake Lining Inspection.........................................................................................................17213 Main Data and Specifications............................................................................................................17214 5D2 PARKING BRAKE SYSTEM (4×2 Model)........................................................................................................17215 Service Precaution......................................................................................................................17215 General Description.....................................................................................................................17215 Parking Brake Lever.....................................................................................................................17216 Parking Brake Lever Assembly and Associated Parts...................................................................................17216 Removal.............................................................................................................................17216 Installation........................................................................................................................17216 Parking Brake Rear Cable................................................................................................................17217 Parking Brake Rear Cable and Associated Parts.......................................................................................17217 Removal.............................................................................................................................17218 Installation........................................................................................................................17218 Parking Brake Adjustment................................................................................................................17218 Main Data and Specifications............................................................................................................17219 Sec.6 ENGINE..................................................................................................................................17220 6A ENGINE MECHANICAL (6VE1 3.5L)...........................................................................................................17220 Service Precaution......................................................................................................................17221 General Description.....................................................................................................................17222 Engine Diagnosis........................................................................................................................17223 Cylinder Head Cover LH..................................................................................................................17238 Removal.............................................................................................................................17238 Installation........................................................................................................................17239 Cylinder Head Cover RH..................................................................................................................17240 Removal.............................................................................................................................17240 Installation........................................................................................................................17240 Common Chamber..........................................................................................................................17241 Removal.............................................................................................................................17241 Installation........................................................................................................................17241 Exhaust Manifold LH.....................................................................................................................17243 Removal.............................................................................................................................17243 Installation........................................................................................................................17243 Exhaust Manifold RH.....................................................................................................................17244 Removal.............................................................................................................................17244 Installation........................................................................................................................17244 Crankshaft Pulley.......................................................................................................................17245 Removal.............................................................................................................................17245 Installation........................................................................................................................17245 Timing Belt.............................................................................................................................17246 Removal.............................................................................................................................17246 Installation........................................................................................................................17247 Camshaft................................................................................................................................17251 Removal.............................................................................................................................17251 Installation........................................................................................................................17252 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................17256 Removal.............................................................................................................................17256 Installation........................................................................................................................17256 Piston, Piston Ring and Connecting Rod..................................................................................................17257 Removal.............................................................................................................................17257 Installation........................................................................................................................17258 Crankshaft and Main Bearings............................................................................................................17259 Removal.............................................................................................................................17259 Installation........................................................................................................................17260 Rear Oil Seal...........................................................................................................................17264 Removal.............................................................................................................................17264 Installation........................................................................................................................17264 Engine Assembly.........................................................................................................................17265 Removal.............................................................................................................................17265 Installation........................................................................................................................17266 Cylinder Head...........................................................................................................................17268 Cylinder Head and Associated Parts..................................................................................................17268 Disassembly.........................................................................................................................17269 Clean...............................................................................................................................17269 Inspection and Repair...............................................................................................................17269 Reassembly..........................................................................................................................17270 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................17272 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................17272 Disassembly.........................................................................................................................17272 Inspection and Repair...............................................................................................................17273 Reassembly..........................................................................................................................17276 Camshaft................................................................................................................................17279 Camshaft and Associated Parts.......................................................................................................17279 Disassembly.........................................................................................................................17279 Inspection and Repair...............................................................................................................17280 Reassembly..........................................................................................................................17282 Crankshaft..............................................................................................................................17286 Crankshaft and Associated Parts.....................................................................................................17286 Disassembly.........................................................................................................................17286 Inspection and Repair for Bearings..................................................................................................17287 Inspection and Repair for Crankshaft................................................................................................17289 Reassembly..........................................................................................................................17290 Piston and Connecting Rod...............................................................................................................17294 Piston, Connecting Rod and Associate Parts..........................................................................................17294 Disassembly.........................................................................................................................17294 Inspection and Repair...............................................................................................................17295 Reassembly..........................................................................................................................17299 Cylinder Block..........................................................................................................................17301 Cylinder Block and Associated Parts.................................................................................................17301 Disassembly.........................................................................................................................17301 Inspection and Repair...............................................................................................................17302 Reassembly..........................................................................................................................17303 Main Data and Specification.............................................................................................................17306 Special Tool............................................................................................................................17312 6B ENGINE COOLING (6VE1 3.5L)...............................................................................................................17314 Service Precaution......................................................................................................................17314 General Description.....................................................................................................................17315 Diagnosis...............................................................................................................................17317 Draining and Refilling Cooling System...................................................................................................17318 Water Pump..............................................................................................................................17319 Water Pump and Associated Parts.....................................................................................................17319 Removal.............................................................................................................................17319 Inspection..........................................................................................................................17319 Installation........................................................................................................................17319 Thermostat..............................................................................................................................17320 Thermostat and Associated Parts.....................................................................................................17320 Removal.............................................................................................................................17320 Inspection..........................................................................................................................17320 Installation........................................................................................................................17320 Radiator................................................................................................................................17321 Radiator and Associated Parts.......................................................................................................17321 Removal.............................................................................................................................17321 Inspection..........................................................................................................................17322 Installation........................................................................................................................17323 Drive Belt and Cooling Fan..............................................................................................................17324 Drive Belt and Associated Parts.....................................................................................................17324 Removal.............................................................................................................................17324 Inspection..........................................................................................................................17324 Installation........................................................................................................................17324 Main Data and Specifications............................................................................................................17325 Special Tool............................................................................................................................17326 6C ENGINE FUEL(6VE1 3.5L)...................................................................................................................17327 General Description.....................................................................................................................17328 General Description.....................................................................................................................17328 Fuel Metering...........................................................................................................................17329 Fuel Filter.............................................................................................................................17330 Removal.............................................................................................................................17330 Inspection..........................................................................................................................17330 Installation........................................................................................................................17331 Inspection..........................................................................................................................17331 In–Tank Fuel Filter.................................................................................................................17331 Fuel Pump Flow Test.................................................................................................................17331 Fuel Pump...............................................................................................................................17332 Fuel Pump and Associated Parts......................................................................................................17332 Removal.............................................................................................................................17332 Installation........................................................................................................................17333 Fuel Tube / Quick ‐ Connector Fittings..................................................................................................17334 Precautions.........................................................................................................................17334 Cautions During Work................................................................................................................17334 Removal.............................................................................................................................17334 Reuse of Quick‐Connector............................................................................................................17335 Assembling Advice...................................................................................................................17335 Fuel Pump Relay.........................................................................................................................17336 General Description.................................................................................................................17336 Fuel Tank...............................................................................................................................17336 Fuel Tank and Associated Parts......................................................................................................17336 Removal.............................................................................................................................17337 Installation........................................................................................................................17337 Fuel Gauge Unit.........................................................................................................................17338 Removal and Installation............................................................................................................17338 Fuel Filler Cap.........................................................................................................................17338 General Description.................................................................................................................17338 Inspection..........................................................................................................................17338 Main Data and Specifications............................................................................................................17339 Special Tool............................................................................................................................17339 6D1 ENGINE ELECTRICAL (6VE1 3.5L)...........................................................................................................17340 Service Precaution......................................................................................................................17340 Battery.................................................................................................................................17341 General Description.....................................................................................................................17341 Diagnosis...............................................................................................................................17341 Battery Charging....................................................................................................................17342 Jump Starting...........................................................................................................................17342 Battery Removal.........................................................................................................................17343 Battery Installation....................................................................................................................17343 Main Data and Specifications............................................................................................................17344 6D2 IGNITION SYSTEM (6VE1 3.5L).............................................................................................................17345 Service Precaution......................................................................................................................17345 General Description.....................................................................................................................17346 Diagnosis...............................................................................................................................17346 Ignition Coil...........................................................................................................................17347 Removal.............................................................................................................................17347 Inspection and Repair...............................................................................................................17347 Installation........................................................................................................................17347 Spark Plug..............................................................................................................................17349 Removal.............................................................................................................................17349 Inspection and Repair...............................................................................................................17349 Installation........................................................................................................................17349 Crankshaft Position Sensor..............................................................................................................17350 Removal.............................................................................................................................17350 Installation........................................................................................................................17350 Main Data and Specifications............................................................................................................17351 6D3 STARTING AND CHARGING SYSTEM............................................................................................................17352 Service Precaution......................................................................................................................17352 Starting System.........................................................................................................................17353 General Description.....................................................................................................................17353 Diagnosis...............................................................................................................................17355 Starter.................................................................................................................................17356 Removal.............................................................................................................................17356 Installation........................................................................................................................17356 Disassembled View...................................................................................................................17358 Disassembly.........................................................................................................................17359 Inspection and Repair...............................................................................................................17361 Reassembly..........................................................................................................................17364 Main Data and Specifications........................................................................................................17365 Charging System.........................................................................................................................17368 General Description.................................................................................................................17368 General On‐Vehicle Inspection.......................................................................................................17368 Generator...............................................................................................................................17369 Removal.............................................................................................................................17369 Inspection..........................................................................................................................17369 Installation........................................................................................................................17370 Disassembled View...................................................................................................................17370 Disassembly.........................................................................................................................17371 Inspection and Repair...............................................................................................................17372 Reassembly..........................................................................................................................17374 Bench Test..........................................................................................................................17375 Main Data and Specifications............................................................................................................17376 6E DRIVEABILITY AND EMISSIONS..............................................................................................................17377 Specifications..........................................................................................................................17382 Tightening Specifications...........................................................................................................17382 Diagrams and Schematics.................................................................................................................17383 PCM Wiring Diagram (1 of 7).........................................................................................................17383 PCM Wiring Diagram (2 of 7).........................................................................................................17384 PCM Wiring Diagram (3 of 7).........................................................................................................17385 PCM Wiring Diagram (4 of 7).........................................................................................................17386 PCM Wiring Diagram (5 of 7).........................................................................................................17387 PCM Wiring Diagram (6 of 7).........................................................................................................17388 PCM Wiring Diagram (7 of 7).........................................................................................................17389 PCM Pinouts.............................................................................................................................17390 PCM Pinout Table, 80-Way Blue Connector-Row “F1～20”.................................................................................17390 PCM Pinout Table, 80-Way Blue Connector-Row “F20～40”................................................................................17391 PCM Pinout Table, 80-Way Blue Connector-Row “F41～60”................................................................................17392 PCM Pinout Table, 80-Way Blue Connector-Row “F61～80”................................................................................17393 PCM Pinout Table, 80-Way Red Connector-Row “S21～40”.................................................................................17397 PCM Pinout Table, 80-Way Red Connector-Row “S41～60”.................................................................................17399 PCM Pinout Table, 80-Way Red Connector-Row “S61～80”.................................................................................17401 Component Locators..................................................................................................................17403 Undercarriage Component Locator.....................................................................................................17405 Fuse and Relay Panel (Underhood Electrical Center)..................................................................................17406 Sensors and Miscellaneous Component Locators........................................................................................17407 Diagnosis...............................................................................................................................17409 Strategy-Based Diagnostics..........................................................................................................17409 DTC Stored..........................................................................................................................17409 No DTC..............................................................................................................................17409 No Matching Symptom.................................................................................................................17409 Intermittents.......................................................................................................................17409 No Trouble Found....................................................................................................................17409 Verifying Vehicle Repair............................................................................................................17409 General Service Information.............................................................................................................17409 OBD II Serviceablity Issues.........................................................................................................17409 Emissions Control Information Label.................................................................................................17410 Visual / Physical Engine Compartment Inspection.....................................................................................17410 Basic Knowledge of Tools Required...................................................................................................17411 Serial Data Communications..............................................................................................................17411 Class 2 Serial Data Communications..................................................................................................17411 On-Board Diagnostic (OBD II)............................................................................................................17411 On-Board Diagnostic Tests...........................................................................................................17411 Comprehensive Component Monitor Diagnostic Operation................................................................................17411 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................17412 Common OBD II Terms.................................................................................................................17412 The Diagnostic Executive............................................................................................................17412 DTC Types...........................................................................................................................17413 Decimal/Binary/Hexadecimal Conversions..............................................................................................17415 Verifying Vehicle Repair............................................................................................................17415 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................17415 Tech 2..............................................................................................................................17416 Tech 2 Features.....................................................................................................................17417 Getting Started.....................................................................................................................17417 Operating Procedure (For Example)...................................................................................................17418 DTC Modes...........................................................................................................................17419 DTC Information Mode................................................................................................................17419 Miscellaneous Test..................................................................................................................17420 Lamps Test..........................................................................................................................17420 Relays Test.........................................................................................................................17422 EVAP Test...........................................................................................................................17423 Fuel System Test....................................................................................................................17424 Instruments Test....................................................................................................................17426 EGR Control Test....................................................................................................................17428 Variable Intake Manifold Solenoid Test..............................................................................................17428 Injector Balance Test...............................................................................................................17430 Plotting Snapshot Graph.................................................................................................................17430 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................17431 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................17432 Primary System-Based Diagnostic.........................................................................................................17433 Primary System-Based Diagnostic.....................................................................................................17433 Fuel Control Heated Oxygen Sensor...................................................................................................17433 HO2S Heater.........................................................................................................................17433 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................17433 Misfire Monitor Diagnostic Operation....................................................................................................17434 Misfire Monitor Diagnostic Operation................................................................................................17434 Misfire Counters....................................................................................................................17434 Fuel Trim System Monitor Diagnostic Operation...........................................................................................17435 Fuel Trim System Monitor Diagnostic Operation.......................................................................................17435 Fuel Trim Cell Diagnostic Weights...................................................................................................17435 On-Board Diagnostic (OBD II) System Check...............................................................................................17436 Circuit Description.................................................................................................................17436 Diagnostic Aids.....................................................................................................................17436 Test Description....................................................................................................................17436 A/C Clutch Control Circuit Diagnosis....................................................................................................17439 Circuit Description.................................................................................................................17439 Diagnostic Aids.....................................................................................................................17439 A/C Clutch Diagnosis................................................................................................................17440 Electronic Ignition System Diagnosis....................................................................................................17444 EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...............................................................................17444 Visual Check of The Evaporative Emission Canister.......................................................................................17444 Fuel Metering System Check..............................................................................................................17444 Fuel System Pressure Test...............................................................................................................17444 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..............................................................17444 Test Description....................................................................................................................17444 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)...........................................17445 Powertrain Control Module (PCM) Diagnosis...............................................................................................17449 Multiple PCM Information Sensor DTCs Set................................................................................................17449 Circuit Description.................................................................................................................17449 Diagnostic Aids.....................................................................................................................17449 Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................17452 Engine Tech 2 Data Definitions and Ranges...............................................................................................17452 Typical Scan Data Values................................................................................................................17454 Test Conditions.....................................................................................................................17454 No Malfunction Indicator Lamp (MIL).....................................................................................................17460 Circuit Description.................................................................................................................17460 Diagnostic Aids.....................................................................................................................17460 Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................................17463 Circuit description.................................................................................................................17463 Diagnostic Aids.....................................................................................................................17463 No Reduced Power Lamp (RPL).............................................................................................................17465 Circuit Description.................................................................................................................17465 Diagnostic Aids.....................................................................................................................17465 Test Description....................................................................................................................17465 Reduced Power Lamp (RPL) “ON” Steady....................................................................................................17469 Circuit Description.................................................................................................................17469 Diagnostic Aids.....................................................................................................................17469 Test Description....................................................................................................................17469 Starter Control System Check............................................................................................................17472 Circuit Description.................................................................................................................17472 Diagnostic Aids.....................................................................................................................17472 Engine Cranks But Will Not Run..........................................................................................................17476 Circuit Description.................................................................................................................17478 Diagnostic Aids.....................................................................................................................17478 Test Description....................................................................................................................17478 Fuel System Electrical Test.............................................................................................................17483 Circuit Description.................................................................................................................17484 Diagnostic Aids.....................................................................................................................17484 Test Description....................................................................................................................17484 Fuel Pressure Relief Procedure......................................................................................................17484 Electric Throttle Control (ETC) System Check............................................................................................17487 Circuit Description.................................................................................................................17488 Diagnostic Aids.....................................................................................................................17488 Test Description....................................................................................................................17488 Fuel System Diagnosis...................................................................................................................17491 Circuit Description.................................................................................................................17492 Test Description....................................................................................................................17492 Fuel Pressure Relief Procedure......................................................................................................17493 Exhaust Gas Recirculation (EGR) System Check............................................................................................17496 Circuit Description.................................................................................................................17496 Manifold Absolute Pressure (MAP) Output Check...........................................................................................17498 Circuit Description.................................................................................................................17498 Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................17500 Circuit Description.................................................................................................................17500 Diagnostic Aids.....................................................................................................................17500 PCM Diagnostic Trouble Codes............................................................................................................17503 Diagnostic Trouble Code (DTC) P0101 MAF System Performance..............................................................................17507 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency....................................................................17510 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...................................................................17513 Diagnostic Trouble Code (DTC) P0106 MAP System Performance..............................................................................17516 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage......................................................................17519 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.....................................................................17522 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage......................................................................17525 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.....................................................................17528 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage......................................................................17531 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.....................................................................17534 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control......................................................17537 Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient Temperature for Stable Operation.............................................17540 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1............................................................17542 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1...........................................................17545 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..................................................................17548 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..................................................17552 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.................................................................17555 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2............................................................17558 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2...........................................................17561 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...................................................17564 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.................................................................17567 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1............................................................17570 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1...........................................................17573 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..................................................................17576 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..................................................17580 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1............................................................17583 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2............................................................17586 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2...........................................................17589 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..................................................17592 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.................................................................17595 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1........................................................................17598 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1........................................................................17602 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2........................................................................17606 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2........................................................................17610 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit..........................................................................17614 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit..........................................................................17617 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit..........................................................................17620 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit..........................................................................17623 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit..........................................................................17626 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit..........................................................................17629 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.............................................................................17632 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected...........................................................................17636 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected...........................................................................17638 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected...........................................................................17640 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected...........................................................................17642 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected...........................................................................17644 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected...........................................................................17646 Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault........................................17648 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit........................................................................17651 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency....................................................................17654 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit..........................................................................17657 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit..........................................................................17660 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit..........................................................................17663 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit..........................................................................17666 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit..........................................................................17669 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit..........................................................................17672 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...............................................................................17675 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..............................................................................17678 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck......................................................................................17680 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage....................................................................................17685 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1....................................................................17688 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2....................................................................17691 Diagnostic Trouble Code (DTC) P0440 EVAP System.........................................................................................17694 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.....................................................................17697 Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.....................................................................17700 Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short....................................................................17702 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..............................................................17704 Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.....................................................................17707 Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short....................................................................17709 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage.......................................17711 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage......................................17714 Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak................................................................................17717 Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance.......................................................................17720 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit‐Low Voltage...............................................................17722 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit‐High Voltage..............................................................17725 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal......................................................................17727 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...............................................................................17729 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.....................................................................17732 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM....................................................................17735 Diagnostic Trouble Code (DTC) P0562 System Voltage Low..................................................................................17738 Diagnostic Trouble Code (DTC) P0563 System Voltage High.................................................................................17740 Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error....................................................................17742 Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error..................................................................17744 Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error..................................................................17746 Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error.....................................................................17748 Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal..............................................................................17750 Diagnostic Trouble Code (DTC) P0601 PCM Memory..........................................................................................17752 Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...............................................................................17754 Diagnostic Trouble Code (DTC) P0604 PCM RAM Error.......................................................................................17756 Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance............................................................................17758 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage........................................................17760 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage................................................................17762 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage........................................................17764 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.........................................................17767 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.........................................................17769 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage........................................................17771 Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Output Abnormal................................................17774 Diagnostic Trouble Code (DTC) P1125 ETC (Electric Throttle Control) Limit Performance Mode..............................................17777 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.........................................................17780 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1..........................................................17784 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.........................................................17788 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..................................................17792 Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).................................................17796 Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).................................................17798 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration................................................................17800 Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault......................................................17803 Diagnosis Trouble Code(DTC) P1221 TPS1- TPS2 Correlation(Circuit Performance)...........................................................17806 Diagnostic Trouble Code (DTC) P1271 APS 1-2 Correlation Error...........................................................................17809 Diagnostic Trouble Code (DTC) P1272 APS 2-3 Correlation Error...........................................................................17812 Diagnostic Trouble Code (DTC) P1273 APS 1-3 Correlation Error...........................................................................17815 Diagnostic Trouble Code (DTC) P1275 APS 1 Output Fault..................................................................................17818 Diagnostic Trouble Code (DTC) P1280 APS 2 Output Fault..................................................................................17820 Diagnostic Trouble Code (DTC) P1285 APS 3 Output Fault..................................................................................17822 Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode................................................................................17824 Diagnostic Trouble Code (DTC) P1295 ETC Power Management Mode...........................................................................17827 Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.....................................................................17831 Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis........................................................................17835 Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault.........................................................17838 Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault.........................................................17841 Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault...........................................17844 Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)................................17847 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed....................................................................................17850 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...................................................................17853 Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.........................................................................17856 Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..............................................................17860 Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..............................................................17863 Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.................................................................17866 Diagnostic Trouble Code (DTC) P1571 Brake Switch No Operation...........................................................................17869 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset................................................................................17871 Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.................................................................17872 Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.................................................................17874 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).................................................................17876 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module “A” Fault........................................................................17879 Symptom Diagnosis.......................................................................................................................17882 Default Matrix Table....................................................................................................................17911 On Vehicle Service Crankshaft Position (CKP) Sensor.....................................................................................17914 Engine Coolant Temperature (ECT) Sensor.................................................................................................17914 Heated Oxygen Sensor (HO2S).............................................................................................................17915 Intake Air Temperature (IAT) Sensor.....................................................................................................17918 ION Sensing Module......................................................................................................................17918 Mass Air Flow (MAF) Sensor..............................................................................................................17919 Manifold Absolute Pressure (MAP) Sensor.................................................................................................17920 Malfunction Indicator Lamp (MIL)........................................................................................................17921 Reduced Power Lamp......................................................................................................................17921 Powertrain Control Module(PCM)..........................................................................................................17921 Service Precaution......................................................................................................................17921 EEPROM..................................................................................................................................17923 Throttle Position (TP) Sensor...........................................................................................................17923 Vehicle Speed Sensor (VSS)..............................................................................................................17924 Air Cleaner/Air Filter..................................................................................................................17925 Common Chamber..........................................................................................................................17925 Accelerator Pedal Replacement...........................................................................................................17926 Accelerator Position Sensor Replacement.................................................................................................17927 Accelerator Position Sensor Adjustment..................................................................................................17927 Fuel Filler Cap.........................................................................................................................17928 Fuel Filter.............................................................................................................................17928 Fuel Gauge Unit.........................................................................................................................17929 Fuel Injectors..........................................................................................................................17930 Fuel Metering System....................................................................................................................17931 Fuel Pump Assembly......................................................................................................................17931 Fuel Pump Relay.........................................................................................................................17932 Fuel Rail Assembly......................................................................................................................17933 Fuel Tank...............................................................................................................................17934 Throttle Body (TB)......................................................................................................................17934 Electronic Ignition System..............................................................................................................17936 Catalytic Converter.....................................................................................................................17937 Air Conditioning Thermo Relay...........................................................................................................17937 EVAP Canister Hoses.....................................................................................................................17937 EVAP Canister...........................................................................................................................17938 EVAP Canister Vent Solenoid.............................................................................................................17938 Fuel Tank Pressure (Vapor Pressure) Sensor..............................................................................................17939 Fuel Tank Vent Valve (Vent Solenoid Valve)..............................................................................................17941 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................17941 Positive Crankcase Ventilation (PCV) Valve..............................................................................................17942 Wiring and Connectors...................................................................................................................17942 PCM Connectors and Terminals............................................................................................................17943 Wire Harness Repair: Twisted Shielded Cable.............................................................................................17943 Twisted Leads...........................................................................................................................17944 Weather-Pack Connector..................................................................................................................17945 Com-Pack III............................................................................................................................17946 Metri-Pack..............................................................................................................................17947 General Description (PCM and Sensors)...................................................................................................17948 General Description (Air Induction).....................................................................................................17953 General Description (Fuel Metering).....................................................................................................17954 General Description (Electronic Ignition System)........................................................................................17956 A/C Clutch Diagnosis....................................................................................................................17959 General Description (Evaporative (EVAP) Emission System)................................................................................17959 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................17964 General Description (Positive Crankcase Ventilation (PCV) System).......................................................................17965 Special Tools...........................................................................................................................17967 6F ENGINE EXHAUST (6VE1 3.5L)..............................................................................................................17969 Service Precaution......................................................................................................................17969 General Description.....................................................................................................................17970 Three Way Catalytic Converter RH and Forked Exhaust Pipe................................................................................17971 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts.......................................................17971 Removal.............................................................................................................................17971 Installation........................................................................................................................17971 Three Way Catalytic Converter LH and Forked Exhaust Pipe................................................................................17972 Removal.............................................................................................................................17972 Installation........................................................................................................................17972 Forked Exhaust Pipe.....................................................................................................................17973 Forked Exhaust Pipe and Associated Parts............................................................................................17973 Removal.............................................................................................................................17973 Installation........................................................................................................................17973 Exhaust Silencer........................................................................................................................17974 Exhaust Silencer and Associated Parts...............................................................................................17974 Removal.............................................................................................................................17974 Installation........................................................................................................................17974 Rear Exhaust pipe.......................................................................................................................17975 Rear Exhaust pipe and Associated Parts..............................................................................................17975 Removal.............................................................................................................................17975 Installation........................................................................................................................17975 Main Data and Specifications............................................................................................................17976 6G ENGINE LUBRICATION (6VE1 3.5L)..........................................................................................................17977 Service Precaution......................................................................................................................17977 General Description.....................................................................................................................17978 Oil Pump................................................................................................................................17979 Oil Pump and Associated Parts.......................................................................................................17979 Disassembly.........................................................................................................................17980 Inspection and Repair...............................................................................................................17980 Reassembly..........................................................................................................................17981 Oil Pan and Crankcase...................................................................................................................17983 Removal.............................................................................................................................17983 Installation........................................................................................................................17983 Oil Pump................................................................................................................................17985 Removal.............................................................................................................................17985 Installation........................................................................................................................17985 Oil Pump Oil Seal.......................................................................................................................17987 Removal.............................................................................................................................17987 Installation........................................................................................................................17987 Oil Filter..............................................................................................................................17988 Removal.............................................................................................................................17988 Installation........................................................................................................................17988 Main Data and Specification.............................................................................................................17989 6H ENGINE SPEED CONTROL SYSTEM.............................................................................................................17990 Service Precaution......................................................................................................................17990 Accelerator Pedal.......................................................................................................................17991 Accelerator Pedal and Associated Parts..............................................................................................17991 Removal.............................................................................................................................17991 Installation........................................................................................................................17991 6J INDUCTION (6VE1 3.5L)...................................................................................................................17992 Service Precaution......................................................................................................................17992 Air Cleaner Element.....................................................................................................................17993 Removal.............................................................................................................................17993 Inspection..........................................................................................................................17993 Installation........................................................................................................................17993 Sec.7 TRANSMISSION............................................................................................................................17994 7A AUTOMATIC TRANSMISSION (4L30‐E).........................................................................................................17994 Service Precaution......................................................................................................................17995 Construction............................................................................................................................17996 Range Reference Chart...................................................................................................................17997 Normal Operation Of 2002 4L30‐E Transmission............................................................................................17998 Diagnosis...............................................................................................................................17998 Driver Information......................................................................................................................17998 General Diagnosis Procedure.............................................................................................................18001 Preliminary Inspection Chart............................................................................................................18002 Checking Transmission Fluid Level and Condition.........................................................................................18003 Test Driving............................................................................................................................18004 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................18005 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................18006 Stall Test..............................................................................................................................18016 Line Pressure Test......................................................................................................................18016 Shift Speed Chart.......................................................................................................................18017 Lockup Speed Chart......................................................................................................................18019 Changing Transmission Fluid.............................................................................................................18020 Selector Lever..........................................................................................................................18020 Inspection..........................................................................................................................18020 Removal.............................................................................................................................18020 Installation........................................................................................................................18022 Select Cable............................................................................................................................18022 Removal.............................................................................................................................18022 Installation........................................................................................................................18025 Shift Lock Cable........................................................................................................................18027 Removal.............................................................................................................................18027 Installation........................................................................................................................18027 Mode Switch.............................................................................................................................18028 Removal.............................................................................................................................18028 Installation........................................................................................................................18029 Transmission Assembly...................................................................................................................18030 Transmission and Associated Parts...................................................................................................18030 Removal.............................................................................................................................18031 Installation........................................................................................................................18036 Solenoid (Main Case Valve Body).........................................................................................................18040 Removal.............................................................................................................................18040 Installation........................................................................................................................18040 Solenoid (Adapter Case Valve Body)......................................................................................................18041 Removal.............................................................................................................................18041 Installation........................................................................................................................18041 Valve Body Assembly (Main Case).........................................................................................................18042 Removal.............................................................................................................................18042 Installation........................................................................................................................18042 Valve Body Assembly (Adapter Case)......................................................................................................18043 Removal.............................................................................................................................18043 Installation........................................................................................................................18043 Powertrain Control Module (PCM).........................................................................................................18043 Removal.............................................................................................................................18043 Installation........................................................................................................................18043 Speed Sensor (Extension Assembly).......................................................................................................18044 Removal.............................................................................................................................18044 Installation........................................................................................................................18044 Transmission Oil Temperature Sensor (Main Case).........................................................................................18045 Removal.............................................................................................................................18045 Installation........................................................................................................................18045 Front Oil Seal (Converter Housing)......................................................................................................18046 Removal.............................................................................................................................18046 Installation........................................................................................................................18046 Rear Oil Seal (Extension Assembly)......................................................................................................18046 Removal.............................................................................................................................18046 Installation........................................................................................................................18046 Transmission (4L30‐E)...................................................................................................................18047 Disassembly.........................................................................................................................18047 Reassembly..........................................................................................................................18051 Converter Housing And Oil Pump Assembly.................................................................................................18061 Disassembled View...................................................................................................................18061 Disassembly.........................................................................................................................18061 Inspection And Repair...............................................................................................................18061 Reassembly..........................................................................................................................18061 Oil Pump................................................................................................................................18062 Disassembled View...................................................................................................................18062 Disassembly.........................................................................................................................18062 Inspection And Repair...............................................................................................................18063 Reassembly..........................................................................................................................18063 Main Case Valve Body....................................................................................................................18064 Disassembled View...................................................................................................................18064 Disassembly.........................................................................................................................18064 Inspection And Repair...............................................................................................................18065 Reassembly..........................................................................................................................18065 Adapter Case Valve Body.................................................................................................................18066 Disassembled View...................................................................................................................18066 Disassembly.........................................................................................................................18066 Inspection And Repair...............................................................................................................18066 Reassembly..........................................................................................................................18067 Third Clutch And Sprag Unit.............................................................................................................18068 Disassembled View...................................................................................................................18068 Disassembly.........................................................................................................................18068 Inspection And Repair...............................................................................................................18068 Reassembly..........................................................................................................................18069 Third Clutch............................................................................................................................18070 Disassembled View...................................................................................................................18070 Disassemble.........................................................................................................................18070 Inspection And Repair...............................................................................................................18070 Reassembly..........................................................................................................................18070 Sprag Unit..............................................................................................................................18072 Disassembled View...................................................................................................................18072 Disassembly.........................................................................................................................18072 Inspection And Repair...............................................................................................................18072 Reassembly..........................................................................................................................18072 Second Clutch...........................................................................................................................18073 Disassembled View...................................................................................................................18073 Disassembly.........................................................................................................................18073 Inspection And Repair...............................................................................................................18074 Reassembly..........................................................................................................................18074 3‐4 Accumulator Piston..................................................................................................................18075 Disassembled View...................................................................................................................18075 Disassembly.........................................................................................................................18075 Inspection And Repair...............................................................................................................18076 Reassembly..........................................................................................................................18076 Reverse Clutch Piston And Center Support................................................................................................18077 Disassembled View...................................................................................................................18077 Disassembly.........................................................................................................................18077 Inspection And Repair...............................................................................................................18078 Reassembly..........................................................................................................................18078 Overrun Clutch And Turbine Shaft........................................................................................................18079 Disassembled View...................................................................................................................18079 Disassembly.........................................................................................................................18080 Inspection And Repair...............................................................................................................18080 Reassembly..........................................................................................................................18080 Main Data And Specification.............................................................................................................18082 General Specifications..............................................................................................................18082 Torque Specifications...............................................................................................................18083 Special Tools...........................................................................................................................18086 4L30-E Parts List.......................................................................................................................18089 7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....................................................................................................18097 Service Precaution......................................................................................................................18098 General Description.....................................................................................................................18098 Electronic Control Diagram..........................................................................................................18099 Powertrain Control Module (PCM).....................................................................................................18100 Control System Diagram..............................................................................................................18101 Shift Control.......................................................................................................................18102 Band Apply Control..................................................................................................................18102 Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)..................................................18102 Line Pressure Control...............................................................................................................18102 On‐Board Diagnostic System..........................................................................................................18102 Fail Safe Mechanism.................................................................................................................18102 Torque Management Control...........................................................................................................18102 ATF Warning Control.................................................................................................................18102 Reverse Lock Out Control............................................................................................................18102 Downhill Control....................................................................................................................18102 Uphill Control......................................................................................................................18102 Shift Mode Control..................................................................................................................18103 Gear Shift Control..................................................................................................................18104 Winter Drive Mode...................................................................................................................18105 Backup Mode.........................................................................................................................18105 Functions of Input / Output Components..............................................................................................18106 Diagnosis...............................................................................................................................18107 Electronic Diagnosis................................................................................................................18107 Check Trans Indicator...............................................................................................................18107 Diagnostic Check....................................................................................................................18107 “Check Trans” Check.................................................................................................................18108 Tech 2 OBD II Connection............................................................................................................18109 Transmission Data...................................................................................................................18114 OBD II Diagnostic Management System.................................................................................................18115 16-Terminal Data Link Connector (DLC)...............................................................................................18116 Malfunction Indicator Lamp (MIL)....................................................................................................18117 DTC Types...........................................................................................................................18117 Clear DTC...........................................................................................................................18118 DTC Check...........................................................................................................................18118 PCM Precaution......................................................................................................................18118 Information On PCM..................................................................................................................18118 Intermittent Conditions.............................................................................................................18119 Transmission And PCM Identification.................................................................................................18119 Diagnostic Trouble Code (DTC) Identification........................................................................................18120 DTC P0218 Transmission Fluid Over Temperature...........................................................................................18121 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................18123 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................18126 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................18129 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................18132 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................18135 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................18138 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................18141 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................18144 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................18147 DTC P0730 Gear Error Without Input Speed................................................................................................18149 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................18152 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................18154 DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................18156 DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................18158 DTC P0753 Shift Solenoid A Electrical...................................................................................................18160 DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................18163 DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................18165 DTC P0758 Shift Solenoid B Electrical...................................................................................................18167 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................18171 DTC P1860 TCC PWM Solenoid Electrical...................................................................................................18175 DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................18178 Circuit Diagram.........................................................................................................................18180 Parts Location..........................................................................................................................18182 Harness Connector Faces.................................................................................................................18183 Transmission Fluid Temperature (TFT) Sensor Specifications..............................................................................18185 Sec.8 BODY AND ACCESSORIES....................................................................................................................18186 8A LIGHTING SYSTEM..........................................................................................................................18186 Service Precaution......................................................................................................................18187 Headlight Bulb..........................................................................................................................18188 Removal.............................................................................................................................18188 Installation........................................................................................................................18188 Headlight Assembly......................................................................................................................18189 Removal.............................................................................................................................18189 Installation........................................................................................................................18189 Headlight Adjustment................................................................................................................18189 Side Marker Light Bulb..................................................................................................................18191 Removal.............................................................................................................................18191 Installation........................................................................................................................18191 Taillight Bulb..........................................................................................................................18192 Removal.............................................................................................................................18192 Installation........................................................................................................................18192 License Plate Light Bulb................................................................................................................18193 Removal.............................................................................................................................18193 Installation........................................................................................................................18193 Stoplight Bulb..........................................................................................................................18193 Removal and Installation............................................................................................................18193 High Mounted Stoplight Assembly.........................................................................................................18194 Removal.............................................................................................................................18194 Installation........................................................................................................................18194 High Mounted Stoplight Bulb.............................................................................................................18194 Removal.............................................................................................................................18194 Installation........................................................................................................................18194 Backup Light Bulb.......................................................................................................................18195 Removal.............................................................................................................................18195 Installation........................................................................................................................18195 Front Turn Signal Light Bulb............................................................................................................18195 Removal and Installation............................................................................................................18195 Rear Turn Signal Light Bulb.............................................................................................................18196 Removal.............................................................................................................................18196 Installation........................................................................................................................18196 Dome Light Bulb.........................................................................................................................18196 Removal.............................................................................................................................18196 Installation........................................................................................................................18196 Map Light Bulb..........................................................................................................................18197 Removal.............................................................................................................................18197 Installation........................................................................................................................18197 Courtesy Light Bulb.....................................................................................................................18197 Removal.............................................................................................................................18197 Installation........................................................................................................................18197 Luggage Room Light Bulb.................................................................................................................18198 Removal.............................................................................................................................18198 Installation........................................................................................................................18198 Shift Lever Illumination Light Bulb (A/T)...............................................................................................18198 Removal.............................................................................................................................18198 Installation........................................................................................................................18198 Vanity Mirror Illumination Light Bulb...................................................................................................18199 Removal.............................................................................................................................18199 Installation........................................................................................................................18199 Switch Unit Assembly Illumination Light Bulb (Power/Winter & Intelligent Suspension Switch).............................................18199 Removal.............................................................................................................................18199 Installation........................................................................................................................18199 TOD Switch Illumination Light Bulb......................................................................................................18200 Removal.............................................................................................................................18200 Installation........................................................................................................................18200 Cruise Control Main Switch Illumination Light Bulb......................................................................................18200 Removal.............................................................................................................................18200 Installation........................................................................................................................18200 Rear Wiper and Washer Switch Illumination Light Bulb....................................................................................18201 Removal.............................................................................................................................18201 Installation........................................................................................................................18201 Seat Heater Switch Illumination Light Bulb..............................................................................................18201 Removal.............................................................................................................................18201 Installation........................................................................................................................18201 Starter Switch..........................................................................................................................18202 Removal and Installation............................................................................................................18202 Lighting Switch (Combination Switch)....................................................................................................18202 Removal and Installation............................................................................................................18202 Dimmer Passing Switch (Combination Switch)..............................................................................................18202 Removal and Installation............................................................................................................18202 Front Door Switch.......................................................................................................................18202 Removal.............................................................................................................................18202 Installation........................................................................................................................18202 Rear Door Switch........................................................................................................................18203 Removal.............................................................................................................................18203 Installation........................................................................................................................18203 Tailgate Lock Switch....................................................................................................................18203 Removal.............................................................................................................................18203 Installation........................................................................................................................18203 Key Remind Switch (Starter Switch)......................................................................................................18204 Removal and Installation............................................................................................................18204 Hazard Warning Light Switch.............................................................................................................18204 Removal.............................................................................................................................18204 Installation........................................................................................................................18204 Stoplight Switch........................................................................................................................18205 Removal and Installation............................................................................................................18205 Turn Signal Light Switch (Combination Switch)...........................................................................................18205 Removal and Installation............................................................................................................18205 Illumination Controller.................................................................................................................18205 Removal.............................................................................................................................18205 Installation........................................................................................................................18205 Main Data and Specifications............................................................................................................18206 8B WIPER / WASHER SYSTEM....................................................................................................................18208 Service Precaution......................................................................................................................18208 Windshield Wiper/Washer System..........................................................................................................18209 General Description.....................................................................................................................18209 Windshield Wiper And Washer Switch......................................................................................................18209 Removal and Installation............................................................................................................18209 Windshield Wiper Motor..................................................................................................................18209 Removal.............................................................................................................................18209 Installation........................................................................................................................18209 Windshield Washer Motor.................................................................................................................18210 Removal.............................................................................................................................18210 Installation........................................................................................................................18210 Windshield Washer Spray Pattern.........................................................................................................18211 Windshield Wiper Linkage................................................................................................................18212 Windshield Wiper Linkage and Associated Parts.......................................................................................18212 Removal.............................................................................................................................18212 Installation........................................................................................................................18212 Windshield Wiper Arm/Blade..............................................................................................................18213 Removal.............................................................................................................................18213 Installation........................................................................................................................18213 Windshield Wiper Blade Rubber...........................................................................................................18214 Removal.............................................................................................................................18214 Installation........................................................................................................................18214 Rear Wiper/Washer System................................................................................................................18215 General Description.................................................................................................................18215 Rear Wiper and Washer Switch............................................................................................................18215 Removal.............................................................................................................................18215 Installation........................................................................................................................18215 Rear Wiper Motor........................................................................................................................18216 Removal.............................................................................................................................18216 Installation........................................................................................................................18216 Rear Washer Motor.......................................................................................................................18217 Removal.............................................................................................................................18217 Installation........................................................................................................................18217 Alarm and Relay Control Unit............................................................................................................18218 Removal.............................................................................................................................18218 Installation........................................................................................................................18218 Rear Wiper Arm/Blade....................................................................................................................18218 Removal.............................................................................................................................18218 Installation........................................................................................................................18218 Rear Washer Nozzle......................................................................................................................18219 Removal.............................................................................................................................18219 Installation........................................................................................................................18219 Rear Washer Spray Pattern...........................................................................................................18219 Rear Wiper Blade Rubber.................................................................................................................18220 Removal.............................................................................................................................18220 Installation........................................................................................................................18220 Main Data and Specifications............................................................................................................18221 8C ENTERTAINMENT............................................................................................................................18222 Service Precaution......................................................................................................................18222 Cigarette Lighter.......................................................................................................................18223 General Description.....................................................................................................................18223 Removal.............................................................................................................................18223 Installation........................................................................................................................18223 Rod Type Antenna........................................................................................................................18224 Removal.............................................................................................................................18224 Installation........................................................................................................................18224 Accessory Socket........................................................................................................................18225 Front Accessory Socket..............................................................................................................18225 Removal.............................................................................................................................18225 Installation........................................................................................................................18225 Rear Accessory Socket...............................................................................................................18225 Removal.............................................................................................................................18225 Installation........................................................................................................................18225 Speaker.................................................................................................................................18227 Front Speaker.......................................................................................................................18227 Removal.............................................................................................................................18227 Installation........................................................................................................................18227 Front Tweeter Assembly..............................................................................................................18227 Removal.............................................................................................................................18227 Installation........................................................................................................................18227 Rear Door Speaker...................................................................................................................18227 Removal.............................................................................................................................18227 Installation........................................................................................................................18228 Rear Tweeter Assembly...............................................................................................................18228 Removal.............................................................................................................................18228 Installation........................................................................................................................18228 Horn....................................................................................................................................18229 Removal.............................................................................................................................18229 Installation........................................................................................................................18229 Display (MID)...........................................................................................................................18229 Removal.............................................................................................................................18229 Installation........................................................................................................................18229 MID Control Unit........................................................................................................................18230 Removal.............................................................................................................................18230 Installation........................................................................................................................18230 GPS Control Unit........................................................................................................................18231 Removal.............................................................................................................................18231 Installation........................................................................................................................18231 Self-Diagnosis..........................................................................................................................18232 Self-Diagnosis Flow Char-1..........................................................................................................18232 Self-Diagnosis Flow Char-2 (Audio)..................................................................................................18233 Self-Diagnosis Flow Char-3 (Display)................................................................................................18234 Self-Diagnosis Flow Char-4 (MID)....................................................................................................18235 Audio Self-Diagnosis................................................................................................................18236 Display Self-Diagnosis..............................................................................................................18237 MID Self-Diagnosis..................................................................................................................18238 Symptom Diagnosis.......................................................................................................................18239 MID Not Appears.....................................................................................................................18239 No COMPASS, CLOCK, FUEL CONSUMPTION, or SERVICE Display.............................................................................18240 No COMPASS Display..................................................................................................................18241 No SERVICE Display..................................................................................................................18241 Other Trouble Symptom...............................................................................................................18242 MID Circuit.........................................................................................................................18243 Harness Connector Faces.............................................................................................................18244 8D WIRING SYSTEM............................................................................................................................18245 Fuse, Relay and Diode...................................................................................................................18246 Relay / Fuse Box Location...........................................................................................................18246 Relay / Fuse Box (Instrument Panel).................................................................................................18247 Relay / Fuse Box (Engine Room)......................................................................................................18248 Circuit Diagram.........................................................................................................................18249 Fuse Block Circuit..................................................................................................................18249 Ground Location (Engine Room).......................................................................................................18250 Ground Location (Cabin).............................................................................................................18251 Starter and Generator...............................................................................................................18252 PCM-1...............................................................................................................................18253 PCM-2...............................................................................................................................18254 Headlight and Fog Light.............................................................................................................18255 Turn, Hazard, Stop, Back Up, Horn and A/T Shift Lock................................................................................18256 Dome Light, Luggage Room Light, Courtesy Light, Spot Light, and Warning Buzzer......................................................18257 Power Window and Door Lock..........................................................................................................18258 Alarm and Relay Control Unit........................................................................................................18259 Rear Wiper/Washer and Rear Defogger.................................................................................................18260 Audio, Clock, Cigarette Lighter and ACC Socket......................................................................................18261 MID.................................................................................................................................18262 Door Mirror.........................................................................................................................18263 Meter...............................................................................................................................18264 Anti-theft with Keyless Entry.......................................................................................................18265 Air Conditioning....................................................................................................................18266 ABS.................................................................................................................................18267 SRS–Air Bag.........................................................................................................................18268 Intelligent Suspension..............................................................................................................18269 T.O.D...............................................................................................................................18270 Sunroof.............................................................................................................................18271 Illumination Light..................................................................................................................18272 Windshield Wiper and Washer.........................................................................................................18273 Power Seat..........................................................................................................................18274 Seat Heater.........................................................................................................................18275 8E METER AND GAUGE..........................................................................................................................18276 Service Precaution......................................................................................................................18276 General Description.....................................................................................................................18276 Meter Assembly..........................................................................................................................18277 General Description.....................................................................................................................18277 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................18277 Table for Meter/Gauge Connector Terminal Connections................................................................................18279 Removal.............................................................................................................................18281 Installation........................................................................................................................18281 Warning Light Bulb and Indicator Light Bulb.........................................................................................18281 Removal.............................................................................................................................18281 Installation........................................................................................................................18281 A/T Shift Indicator Light Bulb..........................................................................................................18282 Removal.............................................................................................................................18282 Installation........................................................................................................................18283 Vehicle Speed Sensor....................................................................................................................18284 Removal.............................................................................................................................18284 Installation........................................................................................................................18284 Fuel Tank Unit..........................................................................................................................18284 Removal.............................................................................................................................18284 Main Data and Specifications............................................................................................................18285 8F BODY STRUCTURE...........................................................................................................................18286 Service Precaution......................................................................................................................18287 Frame...................................................................................................................................18287 General Description.....................................................................................................................18287 Frame Dimensions........................................................................................................................18288 General Description (Bumper)............................................................................................................18289 Front Bumper............................................................................................................................18289 Parts Location..........................................................................................................................18289 Removal.................................................................................................................................18290 Installation............................................................................................................................18291 Rear Bumper.............................................................................................................................18292 Parts Location..........................................................................................................................18292 Removal.................................................................................................................................18293 Installation............................................................................................................................18294 General Description (Sheet Metal).......................................................................................................18295 Engine Hood.............................................................................................................................18295 Parts Location..........................................................................................................................18295 Removal.................................................................................................................................18296 Installation............................................................................................................................18296 Engine Hood Lock........................................................................................................................18298 Parts Location..........................................................................................................................18298 Removal.................................................................................................................................18298 Installation............................................................................................................................18299 Front Fender Panel......................................................................................................................18300 Parts Location..........................................................................................................................18300 Removal.................................................................................................................................18301 Installation............................................................................................................................18301 Body Mounting...........................................................................................................................18303 Parts Location..........................................................................................................................18303 Tightening Torque.......................................................................................................................18303 Body Dimension..........................................................................................................................18304 Front Section...........................................................................................................................18304 Room Section (Front Side)...............................................................................................................18307 Room Section (Rear Side)................................................................................................................18309 Rear Section............................................................................................................................18311 Side Body Section (Front side)..........................................................................................................18313 Side Body Section (Rear side)...........................................................................................................18315 General Description (Body)..............................................................................................................18317 Instrument Panel Assembly...............................................................................................................18317 Parts Location..........................................................................................................................18317 Removal.................................................................................................................................18318 Installation............................................................................................................................18319 Front Door Assembly.....................................................................................................................18320 Parts Location..........................................................................................................................18320 Removal.................................................................................................................................18320 Installation............................................................................................................................18321 Rear Door Assembly......................................................................................................................18322 Parts Location..........................................................................................................................18322 Removal.................................................................................................................................18322 Installation............................................................................................................................18323 Front Window Regulator, Glass and Glass Run.............................................................................................18324 Parts Location..........................................................................................................................18324 Removal.................................................................................................................................18325 Installation............................................................................................................................18326 Rear Window Regulator, Glass and Glass Run..............................................................................................18327 Parts Location..........................................................................................................................18327 Removal.................................................................................................................................18328 Installation............................................................................................................................18330 Tailgate................................................................................................................................18331 Parts Location..........................................................................................................................18331 Removal.................................................................................................................................18332 Installation............................................................................................................................18333 Spare Tire Hanger.......................................................................................................................18334 Parts Location..........................................................................................................................18334 Removal.................................................................................................................................18335 Installation............................................................................................................................18335 Windshield..............................................................................................................................18336 Parts Location..........................................................................................................................18336 Removal.................................................................................................................................18336 Installation............................................................................................................................18337 Rear Quarter Glass......................................................................................................................18340 Parts Location..........................................................................................................................18340 Removal.................................................................................................................................18340 Installation............................................................................................................................18341 Tailgate Glass..........................................................................................................................18342 Parts Location..........................................................................................................................18342 Removal.................................................................................................................................18342 Installation............................................................................................................................18343 Main Data and Specifications............................................................................................................18344 8G SEATS....................................................................................................................................18348 Service Precaution......................................................................................................................18348 Front Seat Assembly.....................................................................................................................18349 Front Seat Assembly and Associated Parts............................................................................................18349 Removal.............................................................................................................................18349 Installation........................................................................................................................18350 Power Seat Assembly.....................................................................................................................18351 Power Seat Assembly and Associated Parts............................................................................................18351 Removal.............................................................................................................................18352 Installation........................................................................................................................18353 Rear Seat Assembly......................................................................................................................18354 Rear Seat Cushion Assembly and Associated Parts.....................................................................................18354 Removal.............................................................................................................................18355 Installation........................................................................................................................18355 Rear Seat Back Assembly and Associated Parts........................................................................................18356 Removal.............................................................................................................................18356 Installation........................................................................................................................18357 Main Data and Specifications............................................................................................................18358 8H SECURITY AND LOCKS.......................................................................................................................18360 Service Precaution......................................................................................................................18360 Front Door Lock Assembly................................................................................................................18361 Front Door Lock Assembly and Associated Parts.......................................................................................18361 Removal.............................................................................................................................18361 Installation........................................................................................................................18363 Front Outside Handle....................................................................................................................18364 Front Outside Handle and Associated Parts...........................................................................................18364 Removal.............................................................................................................................18364 Installation........................................................................................................................18364 Rear Door Lock Assembly.................................................................................................................18365 Rear Door Lock Assembly and Associated Parts........................................................................................18365 Removal.............................................................................................................................18365 Installation........................................................................................................................18367 Rear Outside Handle.....................................................................................................................18368 Rear Outside Handle and Associated Parts............................................................................................18368 Removal.............................................................................................................................18368 Installation........................................................................................................................18368 Tailgate Lock and Outside Handle........................................................................................................18369 Tailgate Lock, Outside Handle and Associated Parts..................................................................................18369 Removal.............................................................................................................................18369 Installation........................................................................................................................18370 Key.....................................................................................................................................18371 Key Coding..........................................................................................................................18371 Key Styles..........................................................................................................................18371 Power Door Lock System..................................................................................................................18372 General Description.................................................................................................................18372 Door Lock Key Switch................................................................................................................18372 Front Door Lock Actuator............................................................................................................18372 Rear Door Lock Actuator.............................................................................................................18372 Tailgate Lock Actuator..............................................................................................................18372 Anti-Theft System.......................................................................................................................18373 General Description.................................................................................................................18373 Anti‐Theft & Keyless Entry Control-ler..............................................................................................18373 Anti‐Theft Indicator................................................................................................................18373 Anti‐Theft Horn.....................................................................................................................18373 Engine Hood Switch..................................................................................................................18374 Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................18374 Keyless Entry System....................................................................................................................18375 ID Code Check.......................................................................................................................18377 Main Data and Specifications............................................................................................................18378 8I SUNROOF/CONVERTIBLE TOP.................................................................................................................18379 Service Precaution......................................................................................................................18379 Sunroof Glass...........................................................................................................................18380 Sunroof Glass and Associated Parts..................................................................................................18380 Removal.............................................................................................................................18380 Installation........................................................................................................................18381 Sunroof Deflector.......................................................................................................................18381 Removal.............................................................................................................................18381 Installation........................................................................................................................18381 Sunshade................................................................................................................................18382 Disassembled View...................................................................................................................18382 Removal.............................................................................................................................18382 Installation........................................................................................................................18383 Sunroof Frame Complete Assembly.........................................................................................................18384 Sunroof Frame Complete Assembly and Associated Parts................................................................................18384 Removal.............................................................................................................................18384 Installation........................................................................................................................18385 Sunroof Switch..........................................................................................................................18385 Removal.............................................................................................................................18385 Installation........................................................................................................................18385 Sunroof Control Unit....................................................................................................................18386 Removal.............................................................................................................................18386 Installation........................................................................................................................18386 Sunroof Motor...........................................................................................................................18386 Removal.............................................................................................................................18386 Installation........................................................................................................................18386 Main Data and Specifications............................................................................................................18387 8J EXTERIOR / INTERIOR TRIM.................................................................................................................18388 Service Precaution......................................................................................................................18389 Consoles................................................................................................................................18390 Consoles and Associated Parts.......................................................................................................18390 Removal.............................................................................................................................18390 Installation........................................................................................................................18391 Front Door Trim Panel...................................................................................................................18391 Front Door Trim Panel and Associated Parts..........................................................................................18391 Removal.............................................................................................................................18392 Installation........................................................................................................................18392 Rear Door Trim Panel....................................................................................................................18393 Rear Door Trim Panel and Associated Parts...........................................................................................18393 Removal.............................................................................................................................18394 Installation........................................................................................................................18394 Door Mirror Assembly....................................................................................................................18395 Removal.............................................................................................................................18395 Installation........................................................................................................................18395 Interior Mirror Assembly................................................................................................................18395 Removal.............................................................................................................................18395 Installation........................................................................................................................18395 Interior Trim Panels....................................................................................................................18396 Interior Trim Panels and Associated Parts...........................................................................................18396 Removal.............................................................................................................................18396 Installation........................................................................................................................18398 Headlining..............................................................................................................................18399 Parts Location......................................................................................................................18399 Removal.............................................................................................................................18399 Installation........................................................................................................................18400 Overhead Console........................................................................................................................18401 Parts Location (W/O Sunroof)........................................................................................................18401 Removal.............................................................................................................................18401 Installation........................................................................................................................18401 Parts Location (W/ Sunroof).........................................................................................................18402 Removal.............................................................................................................................18402 Installation........................................................................................................................18402 Wheel Arch Cover........................................................................................................................18403 Wheel Arch Cover and Associated Parts...............................................................................................18403 Removal.............................................................................................................................18403 Installation........................................................................................................................18403 Locker Cover............................................................................................................................18404 Locker Cover and Associated Parts...................................................................................................18404 Removal.............................................................................................................................18404 Installation........................................................................................................................18404 Fuel Filler Door........................................................................................................................18405 Parts Location......................................................................................................................18405 Removal.............................................................................................................................18405 Installation........................................................................................................................18405 Roof Moulding...........................................................................................................................18406 Parts Location......................................................................................................................18406 Removal.............................................................................................................................18406 Installation........................................................................................................................18406 Power Door Mirror System................................................................................................................18407 General Description.....................................................................................................................18407 Power Window System.................................................................................................................18408 General Description.....................................................................................................................18408 Power Window Switch Driver Seat Side................................................................................................18408 Power Window Motor..................................................................................................................18409 Main Data and Specifications............................................................................................................18410 Sec.9 RESTRAINTS..............................................................................................................................18411 9A SEAT BELT SYSTEM........................................................................................................................18411 Service Precaution......................................................................................................................18411 Front Seat Belt.........................................................................................................................18412 Front Seat Belt and Associated Parts................................................................................................18412 Removal.............................................................................................................................18412 Inspection..........................................................................................................................18413 Installation........................................................................................................................18414 Rear Seat Belt..........................................................................................................................18415 Rear Seat Belt and Associated Parts.................................................................................................18415 Removal.............................................................................................................................18415 Inspection..........................................................................................................................18416 Installation........................................................................................................................18416 Rear Center Seat Belt / Buckle Assembly.................................................................................................18418 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................18418 Removal.............................................................................................................................18418 Installation........................................................................................................................18418 Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................18419 Child Seat Tether Anchorage Bracket and Associated Parts............................................................................18419 Removal.............................................................................................................................18419 Installation........................................................................................................................18419 Child Seat Lower Anchorage Striker......................................................................................................18420 Child Seat Lower Anchorage Striker and Associated Parts.............................................................................18420 Removal.............................................................................................................................18420 Installation........................................................................................................................18421 Main Data and Specifications............................................................................................................18422 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS).....................................................................................................18424 Service Precaution......................................................................................................................18425 General Description.....................................................................................................................18425 Restraint Devices...................................................................................................................18425 System Description..................................................................................................................18426 SRS Component and Wiring Location View..............................................................................................18427 Component Description...................................................................................................................18427 SDM (Sensing and Diagnostic Module).................................................................................................18427 “Air Bag” Warning Lamp..............................................................................................................18428 SRS Coil Assembly...................................................................................................................18428 Air Bag Assemblies..................................................................................................................18428 Steering Column.....................................................................................................................18429 Knee Bolster........................................................................................................................18429 Definition..............................................................................................................................18429 Diagnosis...............................................................................................................................18430 Diagnostic Trouble Codes............................................................................................................18430 Scan Tool Diagnostics...............................................................................................................18430 SRS Connector Body Face Views...........................................................................................................18431 Repairs and Inspections Required After an Accident......................................................................................18431 Accident With Deployment ‐ Component Replacement and Inspections....................................................................18432 Accident With or Without Deployment-Component Inspection............................................................................18432 SDM Replacement Guidelines..........................................................................................................18432 Wiring Damage.......................................................................................................................18432 SRS Connector (Plastic Body And Terminal Metal Pin) Damage..........................................................................18432 SRS Wire Pigtail Damage.............................................................................................................18432 On‐Vehicle Service......................................................................................................................18432 Service Precautions.................................................................................................................18432 Disabling The SRS...................................................................................................................18432 Enabling The SRS....................................................................................................................18432 Handling / Installation / Diagnosis.................................................................................................18433 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................18433 Live (Undeployed) Air Bag Assembly..................................................................................................18433 Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................18434 Deployed Air Bag Assembly...........................................................................................................18434 Air Bag Assembly Scrapping Procedure................................................................................................18434 Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................18434 Deployment Outside Vehicle (Passenger Air Bag Assembly).............................................................................18436 Deployment Inside Vehicle (Vehicle Scrapping Procedure).............................................................................18438 Deployed Air Bag Assembly Handling..................................................................................................18441 Special Tools...........................................................................................................................18441 J‐41433 SRS Driver/Passenger Load Tool..............................................................................................18441 J-39200 DVM.........................................................................................................................18442 Scan Tool...........................................................................................................................18442 J‐35616‐A Connector Test Adapter Kit................................................................................................18442 J‐42986 SRS Deployment Tool.........................................................................................................18442 J‐42987 SRS Adapter For Load Tool...................................................................................................18443 J‐41497 SRS Deployment Fixture......................................................................................................18443 Tech 2 Scan Tool....................................................................................................................18444 DTC Modes...........................................................................................................................18447 Plottong Snapshot Graph.................................................................................................................18447 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................18448 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................18449 Service Precaution......................................................................................................................18450 Disabling The SRS...................................................................................................................18450 Enabling The SRS....................................................................................................................18450 Handling / Installation / Diagnosis.................................................................................................18450 Inspections Required After An Accident..............................................................................................18450 Sensing and Diagnostic Module (SDM).....................................................................................................18451 Service Precautions.................................................................................................................18451 Removal.............................................................................................................................18451 Installation........................................................................................................................18452 Driver Air Bag Assembly.................................................................................................................18452 Service Precautions.................................................................................................................18452 Removal.............................................................................................................................18452 Installation........................................................................................................................18453 Steering Wheel..........................................................................................................................18453 Service Precautions.................................................................................................................18453 Removal.............................................................................................................................18453 Installation........................................................................................................................18454 SRS Coil Assembly.......................................................................................................................18455 Service Precaution..................................................................................................................18455 Removal.............................................................................................................................18455 Installation........................................................................................................................18455 Steering Column.........................................................................................................................18457 Service Precaution..................................................................................................................18457 Removal.............................................................................................................................18457 Installation........................................................................................................................18458 Passenger Air Bag Assembly..............................................................................................................18459 Service Precaution..................................................................................................................18459 Removal.............................................................................................................................18459 Installation........................................................................................................................18459 9J1 SRS CONTROL SYSTEM......................................................................................................................18460 Service Precaution......................................................................................................................18460 Diagnostic Procedures...................................................................................................................18461 Diagnostic Codes....................................................................................................................18461 How To Read Trouble Codes...........................................................................................................18461 How To Clear Trouble Codes..........................................................................................................18461 Scan Tool Diagnostics...............................................................................................................18461 Basic Knowledge Required............................................................................................................18461 Basic Electrical Circuits...........................................................................................................18461 “Flash Code” Diagnostics............................................................................................................18462 System Schematic........................................................................................................................18462 SRS Diagnostic System Check.............................................................................................................18463 Circuit Description.................................................................................................................18463 Notes On System Check Chart:........................................................................................................18463 Diagnostic Aids:....................................................................................................................18463 Chart A SDM Integrity Check.............................................................................................................18465 Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................18467 Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................18469 DTC 15 Passenger Deployment Loop Resistance High........................................................................................18472 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................18475 DTC 17 Passenger Deployment Loop Open...................................................................................................18478 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................18480 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................18482 DTC 21 Driver Deployment Loop Resistance High...........................................................................................18484 DTC 22 Driver Deployment Loop Resistance Low............................................................................................18487 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................18490 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................18492 DTC 26 Driver Deployment Loop Open......................................................................................................18495 DTC 51 Deployment Event Commanded.......................................................................................................18498 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................18500 DTC 61 Warning Lamp Circuit Failure.....................................................................................................18502 DTC 71 Internal SDM Fault...............................................................................................................18504 Sec.10 CONTROL SYSTEM..........................................................................................................................18506 10A. CRUISE CONTROL SYSTEM..................................................................................................................18506 Service Precaution......................................................................................................................18506 General Description.....................................................................................................................18506 Brake Switch............................................................................................................................18507 Removal and Installation............................................................................................................18507 Adjustment..........................................................................................................................18507 Powertrain Control Module (PCM).........................................................................................................18508 Removal and Installation............................................................................................................18508 Mode Switch.............................................................................................................................18508 Removal and Installation............................................................................................................18508 Cruise Control Main Switch..............................................................................................................18508 Removal.............................................................................................................................18508 Installation........................................................................................................................18508 Cruise Control Switch (Combination Switch)..............................................................................................18508 Removal and Installation............................................................................................................18508 Diagnosis...............................................................................................................................18509 SECURITY AND LOCKS......................................................................................................................18360 (UX) TROOPER........................................................................................................................................18510 Sec.0 GENERAL INFORMATION.......................................................................................................................18511 0A GENERAL INFORMATION......................................................................................................................18511 General Repair Instruction..............................................................................................................18511 Illustration Arrows.....................................................................................................................18512 Identification..........................................................................................................................18513 Theft Prevention Standard...............................................................................................................18516 Lifting Instructions....................................................................................................................18522 Standard Bolts Torque Specifications....................................................................................................18524 Abbreviations Charts....................................................................................................................18525 Service Parts Identification Plate......................................................................................................18526 0B MAINTENANCE AND LUBRICATION..............................................................................................................18527 Maintenance Schedule List...............................................................................................................18527 Explanation of Complete Vehicle Maintenance Schedule....................................................................................18531 Recommended Fluids and Lubricants...................................................................................................18534 Lubricant Viscosity Chart...............................................................................................................18535 Recommended Liquid Gasket...........................................................................................................18537 Recommended Thread Locking Agents...................................................................................................18537 Maintenance Service Data................................................................................................................18538 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................18539 1A HVAC SYSTEMS.............................................................................................................................18539 Service Precaution......................................................................................................................18541 Heating and Ventilation System..........................................................................................................18541 General Description.....................................................................................................................18541 Wiring Diagram......................................................................................................................18546 Diagnosis...........................................................................................................................18547 Individual Inspection...............................................................................................................18550 Heater Unit.............................................................................................................................18552 Heater Unit and Associated Parts....................................................................................................18552 Removal.............................................................................................................................18553 Installation........................................................................................................................18553 Heater Core and / or Mode Door..........................................................................................................18554 Disassembled View...................................................................................................................18554 Removal.............................................................................................................................18554 Inspection..........................................................................................................................18555 Installation........................................................................................................................18555 Heater Mode Control Link Unit...........................................................................................................18556 Disassembled View...................................................................................................................18556 Removal.............................................................................................................................18556 Installation........................................................................................................................18557 Heater Temperature Control Link Unit....................................................................................................18557 Disassembled View...................................................................................................................18557 Removal.............................................................................................................................18557 Installation........................................................................................................................18557 Blower Assembly.........................................................................................................................18558 Blower Assembly and Associated Parts................................................................................................18558 Removal.............................................................................................................................18558 Installation........................................................................................................................18559 Blower Link Unit and / or Mode door.....................................................................................................18559 Disassembled View...................................................................................................................18559 Removal.............................................................................................................................18559 Installation........................................................................................................................18560 Blower Motor............................................................................................................................18561 Blower Motor and Associated Parts...................................................................................................18561 Removal.............................................................................................................................18561 Installation........................................................................................................................18561 Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................18562 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................18562 Removal.............................................................................................................................18562 Installation........................................................................................................................18563 Center and / or Drive Side Vent.........................................................................................................18563 Center Vent, Drive Side Vent and Associated Parts...................................................................................18563 Removal.............................................................................................................................18563 Installation........................................................................................................................18563 Control Lever Assembly and / or Control Cable...........................................................................................18564 Control Lever Assembly, Control Cable and Associated Parts..........................................................................18564 Removal.............................................................................................................................18564 Installation........................................................................................................................18566 Control Panel Illumination Bulb.........................................................................................................18567 Control Panel Illumination Bulb and Associated Parts................................................................................18567 Removal.............................................................................................................................18567 Installation........................................................................................................................18567 Resistor................................................................................................................................18568 Resistor and Associated Parts.......................................................................................................18568 Removal.............................................................................................................................18568 Installation........................................................................................................................18568 Air Conditioning System.................................................................................................................18569 General Description.................................................................................................................18569 Diagnosis...........................................................................................................................18577 Individual Inspection...............................................................................................................18585 General Repair Procedure............................................................................................................18586 Compressor Assembly.....................................................................................................................18594 Compressor Assembly and Associated Parts (6VE1).....................................................................................18594 Removal.............................................................................................................................18594 Installation........................................................................................................................18595 New Compressor Installation.........................................................................................................18595 Condenser Assembly......................................................................................................................18596 Condenser Assembly and Associated Parts.............................................................................................18596 Removal.............................................................................................................................18596 Installation........................................................................................................................18596 Receiver / Drier........................................................................................................................18597 Receiver / Drier and Associated Parts...............................................................................................18597 Removal.............................................................................................................................18597 Installation........................................................................................................................18597 Pressure Switch.........................................................................................................................18598 Pressure Switch and Associated Parts................................................................................................18598 Removal.............................................................................................................................18598 Installation........................................................................................................................18598 Evaporator Assembly.....................................................................................................................18599 Evaporator Assembly and Associated Parts............................................................................................18599 Removal.............................................................................................................................18599 Installation........................................................................................................................18600 Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................18600 Disassembled View...................................................................................................................18600 Removal.............................................................................................................................18601 Installation........................................................................................................................18601 Air Conditioning Switch and Illumination Bulb...........................................................................................18602 Air Conditioning Switch, Illumination Bulb and Associated Parts.....................................................................18602 Removal.............................................................................................................................18602 Installation........................................................................................................................18602 Refrigerant Line........................................................................................................................18603 Refrigerant Line and Associated Parts...............................................................................................18603 Removal.............................................................................................................................18603 Installation........................................................................................................................18604 Main Data And Specifications............................................................................................................18605 Compressor..............................................................................................................................18608 Service Precaution..................................................................................................................18608 General Description.................................................................................................................18608 Diagnosis...........................................................................................................................18609 Magnetic Clutch Assembly (DKV-14G Type).................................................................................................18610 Parts Location View.................................................................................................................18610 Removal.............................................................................................................................18610 Inspection and Repair...............................................................................................................18612 Installation........................................................................................................................18612 Compressor Oil..........................................................................................................................18614 Oil Specification...................................................................................................................18614 Handling of Oil.....................................................................................................................18614 Compressor Oil Check................................................................................................................18614 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................18614 Checking and Adjusting for Compressor Replacement...................................................................................18614 Contamination of Compressor Oil.....................................................................................................18615 Oil Return Operation................................................................................................................18615 Replacement of Component Parts......................................................................................................18615 Main Data and Specifications........................................................................................................18616 Special Tools.......................................................................................................................18618 Automatic Air Conditioning System.......................................................................................................18619 General Description.....................................................................................................................18619 Full Automatic Air Conditioner Parts Configuration..................................................................................18619 Refrigerant Line and Associated Parts...............................................................................................18620 Circuit Diagram.....................................................................................................................18621 Functions and Features..............................................................................................................18626 Automatic Air Conditioner Block Diagram.............................................................................................18627 Control Panel Layout................................................................................................................18628 Air Control Functions...............................................................................................................18629 Operation and Functions of Control Panel Switches...................................................................................18630 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System...................................18632 Overview of Automatic Control of Automatic Air Conditioner..........................................................................18636 Troubleshooting.........................................................................................................................18640 Troubleshooting, Its Overview and Procedures........................................................................................18640 Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................18641 Performance and Movement checklist for Automatic Air Conditioner Related Parts......................................................18643 Troubleshooting With Self-Diagnosis Function........................................................................................18645 Inspection By Failed Location...........................................................................................................18649 Inspection of the Sensors...........................................................................................................18649 Inspection of the Intake Actuator System............................................................................................18653 Inspection of the Mix Actuator System...............................................................................................18656 Inspection of the Mode Actuator System..............................................................................................18659 Inspection of the Fan Motor System..................................................................................................18662 Inspection of the Magnetic Clutch System............................................................................................18664 Condenser Fan Diagnosis.............................................................................................................18667 Individual Inspection...............................................................................................................18670 On-Vehicle Service......................................................................................................................18673 Power Transistor....................................................................................................................18673 Removal.............................................................................................................................18673 Installation........................................................................................................................18673 Automatic Heater/Air Conditioner Control Unit.......................................................................................18673 Removal.............................................................................................................................18673 Installation........................................................................................................................18673 In Car Sensor.......................................................................................................................18674 Removal.............................................................................................................................18674 Installation........................................................................................................................18674 Ambient Sensor......................................................................................................................18674 Removal.............................................................................................................................18674 Installation........................................................................................................................18674 Sun Sensor..........................................................................................................................18675 Removal.............................................................................................................................18675 Installation........................................................................................................................18675 Duct Sensor.........................................................................................................................18675 Removal.............................................................................................................................18675 Installation........................................................................................................................18675 Mode Actuator.......................................................................................................................18676 Removal.............................................................................................................................18676 Installation........................................................................................................................18676 Mix Actuator........................................................................................................................18676 Removal.............................................................................................................................18676 Installation........................................................................................................................18676 Intake Actuator.....................................................................................................................18677 Removal.............................................................................................................................18677 Installation........................................................................................................................18677 Sec.2 STEERING..................................................................................................................................18678 2A POWER ASSISTED SYSTEM....................................................................................................................18678 Service Precaution......................................................................................................................18679 General Description.....................................................................................................................18679 Diagnosis...............................................................................................................................18682 Power Steering System Test..............................................................................................................18688 Maintenance.............................................................................................................................18689 Fluid Level.............................................................................................................................18689 Bleeding The Power Steering System......................................................................................................18689 Bleeding Procedure......................................................................................................................18689 Flushing The Power Steering System......................................................................................................18689 Steering Wheel Free Play Adjustment.....................................................................................................18690 Front End Alignment Inspection and Adjustment...........................................................................................18690 Main Data and Specifications............................................................................................................18695 Special Tools...........................................................................................................................18696 Power Steering Gear.....................................................................................................................18697 Power Steering Gear and Associated Parts............................................................................................18697 Removal.............................................................................................................................18697 Installation........................................................................................................................18698 Steering Gear Disassembled View.....................................................................................................18699 Disassembly.........................................................................................................................18700 Inspection and Repair...............................................................................................................18701 Reassembly..........................................................................................................................18702 Main Data and Specifications........................................................................................................18704 Power Steering Pump.....................................................................................................................18705 Power Steering Pump and Associated Parts............................................................................................18705 Removal.............................................................................................................................18705 Installation........................................................................................................................18706 Power Steering Pump Disassembled View...............................................................................................18707 Disassembly.........................................................................................................................18707 Inspection and Repair...............................................................................................................18708 Reassembly..........................................................................................................................18709 1Main Data and Specifications.......................................................................................................18710 Center Track Rod Assembly...............................................................................................................18711 Center Track Rod Assembly and Associated Parts......................................................................................18711 Removal.............................................................................................................................18712 Inspection and Repair...............................................................................................................18712 Installation........................................................................................................................18712 Outer Track Rod Assembly................................................................................................................18713 Outer Track Rod Assembly and Associated Parts.......................................................................................18713 Removal.............................................................................................................................18714 Inspection and Repair...............................................................................................................18714 Installation........................................................................................................................18715 Relay Lever.............................................................................................................................18716 Relay Lever and Associated Parts....................................................................................................18716 Removal.............................................................................................................................18716 Installation........................................................................................................................18717 Steering Linkage and Associated Parts...................................................................................................18718 Main Data and Specifications........................................................................................................18718 Special Tools.......................................................................................................................18719 Supplemental Restraint System Steering Wheel & Column...................................................................................18720 Service Precaution..................................................................................................................18720 SRS Connectors......................................................................................................................18720 Inflator Module.........................................................................................................................18722 Inflator Module and Associated Parts................................................................................................18722 Removal.............................................................................................................................18722 Inspection and Repair...............................................................................................................18723 Installation........................................................................................................................18723 Steering Wheel..........................................................................................................................18724 Steering Wheel and Associated Parts.................................................................................................18724 Removal.............................................................................................................................18724 Installation........................................................................................................................18726 Combination Switch......................................................................................................................18727 Combination Switch and Associated Parts.............................................................................................18727 Removal.............................................................................................................................18727 Installation........................................................................................................................18729 Lock Cylinder...........................................................................................................................18731 Lock Cylinder and Associated Parts..................................................................................................18731 Removal.............................................................................................................................18731 Installation........................................................................................................................18733 System Inspection...................................................................................................................18734 Steering Column.........................................................................................................................18735 Steering Column and Associated Parts................................................................................................18735 Removal.............................................................................................................................18735 Inspection..........................................................................................................................18737 Installation........................................................................................................................18739 System Inspection...................................................................................................................18740 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................18741 Main Data and Specifications........................................................................................................18741 Special Tools.......................................................................................................................18742 Sec.3 SUSPENSION................................................................................................................................18743 3C FRONT SUSPENSION.........................................................................................................................18743 Service Precaution......................................................................................................................18743 General Description.....................................................................................................................18744 General Diagnosis.......................................................................................................................18745 Shock Absorber..........................................................................................................................18748 Shock Absorber and Associated Parts.................................................................................................18748 Removal.............................................................................................................................18748 Inspection and Repair...............................................................................................................18748 Installation........................................................................................................................18748 Stabilizer Bar..........................................................................................................................18749 Stabilizer Bar and Associated Parts.................................................................................................18749 Removal.............................................................................................................................18749 Inspection and Repair...............................................................................................................18749 Installation........................................................................................................................18749 Torsion Bar.............................................................................................................................18750 Torsion Bar and Associated Parts....................................................................................................18750 Removal.............................................................................................................................18750 Inspection and Repair...............................................................................................................18751 Installation........................................................................................................................18751 Knuckle.................................................................................................................................18753 Knuckle and Associated Parts........................................................................................................18753 Removal.............................................................................................................................18753 Inspection and Repair...............................................................................................................18754 Installation........................................................................................................................18754 Upper Control Arm.......................................................................................................................18756 Upper Control Arm and Associated Parts..............................................................................................18756 Removal.............................................................................................................................18756 Inspection and Repair...............................................................................................................18757 Installation........................................................................................................................18758 Lower Control Arm.......................................................................................................................18760 Lower Control Arm and Associated Parts..............................................................................................18760 Removal.............................................................................................................................18760 Inspection and Repair...............................................................................................................18761 Installation........................................................................................................................18762 Upper Ball Joint........................................................................................................................18763 Upper Ball Joint and Associated Parts...............................................................................................18763 Removal.............................................................................................................................18763 Inspection and Repair...............................................................................................................18764 Installation........................................................................................................................18764 Lower Ball Joint........................................................................................................................18765 Lower Ball Joint and Associated Parts...............................................................................................18765 Removal.............................................................................................................................18765 Inspection and Repair...............................................................................................................18766 Installation........................................................................................................................18766 Main Data and Specifications............................................................................................................18767 Special Tools...........................................................................................................................18768 3D REAR SUSPENSION..........................................................................................................................18769 Service Precaution......................................................................................................................18769 General Description.....................................................................................................................18770 Coil Spring.............................................................................................................................18771 Coil Spring and Associated Parts....................................................................................................18771 Removal.............................................................................................................................18771 Inspection and Repair...............................................................................................................18772 Installation........................................................................................................................18772 Shock Absorber..........................................................................................................................18773 Shock Absorber and Associated Parts.................................................................................................18773 Removal.............................................................................................................................18773 Inspection and Repair...............................................................................................................18773 Installation........................................................................................................................18773 Trailing Link...........................................................................................................................18774 Trailing Link and Associated Parts..................................................................................................18774 Removal.............................................................................................................................18774 Inspection and Repair...............................................................................................................18774 Installation........................................................................................................................18775 Center Link.............................................................................................................................18776 Center Link and Associated Parts....................................................................................................18776 Removal.............................................................................................................................18776 Inspection and Repair...............................................................................................................18776 Installation........................................................................................................................18777 Lateral Rod.............................................................................................................................18778 Lateral Rod and Associated Parts....................................................................................................18778 Removal.............................................................................................................................18778 Inspection and Repair...............................................................................................................18778 Installation........................................................................................................................18779 Stabilizer Bar..........................................................................................................................18780 Stabilizer Bar and Associated Parts.................................................................................................18780 Removal.............................................................................................................................18780 Inspection and Repair...............................................................................................................18780 Installation........................................................................................................................18781 Main Data and Specifications............................................................................................................18782 Special Tools...........................................................................................................................18784 3E WHEEL AND TIRE SYSTEM....................................................................................................................18785 Service Precaution......................................................................................................................18785 General Description.....................................................................................................................18786 Diagnosis...............................................................................................................................18787 Wheel...................................................................................................................................18793 Wheel and Associated Parts..........................................................................................................18793 Removal.............................................................................................................................18793 Installation........................................................................................................................18793 Tire....................................................................................................................................18794 Tire Replacement....................................................................................................................18794 General Balance Procedure...............................................................................................................18794 Balancing Wheel and Tire................................................................................................................18795 Main Data and Specifications............................................................................................................18796 Sec.4 DRIVELINE/AXLE............................................................................................................................18797 4A1 DIFFERENTIAL (FRONT)....................................................................................................................18797 Service Precaution......................................................................................................................18797 Front Drive Axle........................................................................................................................18798 Diagnosis...............................................................................................................................18798 Pinion Shaft Oil Seal...................................................................................................................18799 Pinion Shaft Oil Seal and Associated Parts..........................................................................................18799 Removal.............................................................................................................................18799 Inspection and Repair...............................................................................................................18800 Installation........................................................................................................................18800 Front Drive Axle Assembly...............................................................................................................18801 Front Drive Axle Assembly and Associated Parts......................................................................................18801 Removal.............................................................................................................................18801 Installation........................................................................................................................18803 Differential Assembly...................................................................................................................18805 Disassembled View...................................................................................................................18805 Disassembly.........................................................................................................................18806 Reassembly..........................................................................................................................18808 Differential Cage Assembly..............................................................................................................18817 Disassembled View...................................................................................................................18817 Disassembly.........................................................................................................................18817 Inspection and Repair...............................................................................................................18818 Reassembly..........................................................................................................................18819 Main Data and Specifications........................................................................................................18821 Special Tools.......................................................................................................................18823 4A2 DIFFERENTIAL (REAR).....................................................................................................................18825 Service Precaution......................................................................................................................18825 General Description.....................................................................................................................18827 Diagnosis...............................................................................................................................18828 Axle Housing............................................................................................................................18829 Axle Housing and Associated Parts...................................................................................................18829 Removal.............................................................................................................................18829 Oil Seal Replacement................................................................................................................18830 Installation........................................................................................................................18830 Axle Shaft..............................................................................................................................18831 Axle Shaft and Associated Parts.....................................................................................................18831 Removal.............................................................................................................................18831 Inspection and Repair...............................................................................................................18832 Oil Seal Replacement................................................................................................................18833 Installation........................................................................................................................18833 Pinion Oil Seal.........................................................................................................................18834 Pinion Oil Seal and Associated Parts................................................................................................18834 Removal.............................................................................................................................18834 Inspection and Repair...............................................................................................................18835 Installation........................................................................................................................18835 Differential Assembly...................................................................................................................18836 Differential Assembly and Associated Parts..........................................................................................18836 Removal.............................................................................................................................18836 Installation........................................................................................................................18837 Disassembled View...................................................................................................................18838 Disassembly.........................................................................................................................18839 Reassembly..........................................................................................................................18841 Differential Cage Assembly..............................................................................................................18848 Disassembled View...................................................................................................................18848 Disassembly.........................................................................................................................18849 Inspection and Repair...............................................................................................................18849 Reassembly..........................................................................................................................18850 Limited Slip Differential...............................................................................................................18852 Disassembled View...................................................................................................................18852 Disassembly.........................................................................................................................18853 Inspection and Repair...............................................................................................................18853 Reassembly..........................................................................................................................18855 Main Data and Specifications............................................................................................................18859 Special Tools...........................................................................................................................18860 4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY).............................................................................................18863 Service Precaution......................................................................................................................18863 Shift On The Fly System.................................................................................................................18864 Outline of Shift on The Fly System..................................................................................................18864 Functions of Indicator Lamp.........................................................................................................18868 Diagnosis...........................................................................................................................18869 Front Axle Diagnosis................................................................................................................18879 Shift On The Fly Vacuum Piping And Electric Equipment...................................................................................18881 Vacuum piping diagram...............................................................................................................18881 Inspection And Repair...............................................................................................................18882 4WD Control Unit........................................................................................................................18885 4WD Control Unit Associated Parts...................................................................................................18885 Removal.............................................................................................................................18886 Installation........................................................................................................................18886 4B2 DRIVELINE CONTROL SYSTEM (TOD)..........................................................................................................18887 Service Precaution......................................................................................................................18887 General Description.....................................................................................................................18888 System Components.......................................................................................................................18890 Parts Location......................................................................................................................18890 Functions of Indicator Lamp.............................................................................................................18894 Diagnosis...............................................................................................................................18898 Basic Diagnostic Flow Chart.............................................................................................................18902 Parts Location..........................................................................................................................18903 Circuit Diagram.........................................................................................................................18904 Connector List..........................................................................................................................18907 Checking Failed Pin.....................................................................................................................18909 Checking Failed TOD Control Unit Pin....................................................................................................18912 Diagnostic Trouble Codes................................................................................................................18917 Diagnosis from Trouble Codes............................................................................................................18918 Trouble Diagnosis Depending on The Status of TOD Indicator..............................................................................18942 Diagnosis from Symptom..................................................................................................................18971 4C DRIVE SHAFT SYSTEM.......................................................................................................................18981 Service Precaution......................................................................................................................18982 General Description.....................................................................................................................18982 Diagnosis...............................................................................................................................18983 Front Hub and Disc (2WD Model)..........................................................................................................18984 Disassembled View...................................................................................................................18984 Disassembly.........................................................................................................................18984 Inspection and Repair...............................................................................................................18986 Reassembly..........................................................................................................................18986 Main Data and Specifications........................................................................................................18989 Special Tools.......................................................................................................................18990 Front Hub and Disc (4WD Model)..........................................................................................................18991 Disassembled View...................................................................................................................18991 Disassembly.........................................................................................................................18991 Inspection and Repair...............................................................................................................18992 Reassembly..........................................................................................................................18992 Main Data and Specifications........................................................................................................18996 Special Tools.......................................................................................................................18997 Front Drive Shaft Joint.................................................................................................................18998 Front Drive Shaft Joints Replacement................................................................................................18998 Front Axle Drive Shaft..................................................................................................................18999 Front Axle Drive Shaft and Associated Parts.........................................................................................18999 Disassembly.........................................................................................................................19000 Inspection and Repair...............................................................................................................19001 Bushing Replacement.................................................................................................................19001 Reassembly..........................................................................................................................19002 Shift On The Fly System.................................................................................................................19004 Shift On The Fly System and Associated Parts........................................................................................19004 Disassembly.........................................................................................................................19004 Inspection and Repair...............................................................................................................19006 Main Data and Specifications........................................................................................................19011 Special Tools.......................................................................................................................19012 Front Propeller Shaft...................................................................................................................19013 General Description.................................................................................................................19013 Front Propeller Shaft and Associated Parts..........................................................................................19014 Removal.............................................................................................................................19014 Installation........................................................................................................................19015 Disassembly (Except TOD 4×4)........................................................................................................19016 Universal Joint Disassembly.........................................................................................................19017 Inspection and Repair...............................................................................................................19018 Universal Joint Reassembly..........................................................................................................19021 Reassembly (Except TOD 4×4).........................................................................................................19022 Main Data and Specifications........................................................................................................19023 Rear Propeller Shaft....................................................................................................................19024 General Description.................................................................................................................19024 Rear Propeller Shaft and Associated Parts...........................................................................................19024 Removal.............................................................................................................................19024 Installation........................................................................................................................19025 Disassembly.........................................................................................................................19026 Universal Joint Disassembly.........................................................................................................19027 Inspection and Repair...............................................................................................................19028 Universal Joint Reassembly..........................................................................................................19029 Reassembly..........................................................................................................................19030 Main Data and Specifications........................................................................................................19031 4D1 TRANSFER CASE (STANDARD TYPE)...........................................................................................................19032 Service Precaution......................................................................................................................19032 General Description.....................................................................................................................19033 Transfer Rear Oil Seal..................................................................................................................19035 Removal.............................................................................................................................19035 Installation........................................................................................................................19035 Transfer Case Assembly..................................................................................................................19037 Removal.............................................................................................................................19037 Installation........................................................................................................................19038 Transfer Rear Case Assembly.............................................................................................................19040 Removal.............................................................................................................................19040 Installation........................................................................................................................19041 Disassembly.........................................................................................................................19044 Inspection and Repair...............................................................................................................19045 Reassembly..........................................................................................................................19045 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)...........................................................................19047 Disassembled View...................................................................................................................19047 Disassembly.........................................................................................................................19048 Inspection and Repair...............................................................................................................19049 Reassembly..........................................................................................................................19049 Transfer Case Assembly..................................................................................................................19051 Disassembled View...................................................................................................................19051 Disassembly.........................................................................................................................19052 Inspection and Repair...............................................................................................................19054 Reassembly..........................................................................................................................19058 Main Data and Specifications............................................................................................................19064 Special Tools...........................................................................................................................19067 4D2 TRANSFER CASE (TOD).....................................................................................................................19068 Service Precaution......................................................................................................................19068 Transfer Case Assembly..................................................................................................................19069 Removal.............................................................................................................................19069 Installation........................................................................................................................19070 Transfer Rear Oil Seal..................................................................................................................19072 Transfer Rear Oil Seal and Associated Parts.........................................................................................19072 Removal.............................................................................................................................19072 Installation........................................................................................................................19072 TOD ECU.................................................................................................................................19074 Removal.............................................................................................................................19074 Installation........................................................................................................................19074 Unit Repair.............................................................................................................................19075 Inspection..........................................................................................................................19075 Transfer Case...........................................................................................................................19076 Disassembled View...................................................................................................................19076 Disassembly.........................................................................................................................19076 Reassembly..........................................................................................................................19077 Transfer Cover Assembly.................................................................................................................19079 Disassembled View...................................................................................................................19079 Disassembly.........................................................................................................................19079 Reassembly..........................................................................................................................19081 Transfer Case Assembly Clutch Pack and Clutch Cam.......................................................................................19083 Disassembled View...................................................................................................................19083 Disassembly.........................................................................................................................19083 Sprocket and Mechanical Lock............................................................................................................19085 Disassembled View...................................................................................................................19085 Disassembly.........................................................................................................................19085 Output Shafts and Shift Control Shaft...................................................................................................19087 Disassembled View...................................................................................................................19087 Disassembly.........................................................................................................................19088 Transfer Case...........................................................................................................................19090 Disassembled View...................................................................................................................19090 Disassembly.........................................................................................................................19091 Inspection and Repair...............................................................................................................19093 Transfer Case...........................................................................................................................19097 Disassembled View...................................................................................................................19097 Reassembly..........................................................................................................................19097 Output Shafts and Shift Control Shaft...................................................................................................19101 Disassembled View...................................................................................................................19101 Reassembly..........................................................................................................................19102 Sprocket and Mechanical Lock............................................................................................................19104 Disassembled View...................................................................................................................19104 Reassembly..........................................................................................................................19104 Clutch Pack and Clutch Cam..............................................................................................................19106 Disassembled View...................................................................................................................19106 Reassembly..........................................................................................................................19106 Main Data and Specifications............................................................................................................19108 Special Tools...........................................................................................................................19110 Sec.5 BRAKES....................................................................................................................................19111 5A BRAKE CONTROL SYSTEM.....................................................................................................................19111 Service Precaution......................................................................................................................19112 General Description.....................................................................................................................19113 System Components...................................................................................................................19113 Electronic Hydraulic Control Unit (EHCU)............................................................................................19113 ABS Warning Light...................................................................................................................19114 Wheel Speed Sensor..................................................................................................................19114 G-Sensor............................................................................................................................19114 Normal and Anti-lock Braking........................................................................................................19114 Brake Pedal Travel..................................................................................................................19114 Acronyms and Abbreviations..........................................................................................................19114 General Diagnosis.......................................................................................................................19115 General Information.................................................................................................................19115 ABS Service Precautions.............................................................................................................19115 Computer System Service Precautions.................................................................................................19115 General Service Precautions.........................................................................................................19115 Note on Intermittents...............................................................................................................19115 Test Driving ABS Complaint Vehicles.................................................................................................19115 “ABS” Warning Light.................................................................................................................19116 Normal Operation....................................................................................................................19116 Basic Diagnostic Flow Chart.........................................................................................................19116 Basic Inspection Procedure..........................................................................................................19117 Tech 2 Scan Tool....................................................................................................................19118 Getting Started.....................................................................................................................19119 Operating Procedure.................................................................................................................19119 Data List...............................................................................................................................19121 EHCU Connector Pin-out Checks...........................................................................................................19122 Circuit Diagram.....................................................................................................................19123 Connector List......................................................................................................................19126 Part Location.......................................................................................................................19128 Symptom Diagnosis.......................................................................................................................19129 Chart A–1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................19129 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................19130 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................19130 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................19131 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................19131 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking.................................................................19132 Diagnostic Trouble Codes................................................................................................................19133 Diagnosis By “ABS” Warning Light Illumination Pattern...................................................................................19134 Diagnostic Trouble Codes (DTCs).....................................................................................................19134 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated.......................19137 Chart B-2 EHCU Abnormality (DTC 14).................................................................................................19137 Chart B-3 Power Voltage Drop (DTC 15)...............................................................................................19138 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)...........................................................................19138 Chart B-5 G-Sensor Circuit (DTC 21).................................................................................................19138 Chart B-6 Abnormal Transmission Input (DTC 23)......................................................................................19139 Chart B-7 Transfer Monitor (DTC 24).................................................................................................19140 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32)..........................................................................19140 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35)..........................................................................19141 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41).........................................................................19141 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42)..............................................................................19141 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43).........................................................................19142 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44)..............................................................................19142 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45).......................................................................19142 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................19143 Chart B-16 FL Speed Sensor Disconnection (DTC 51)...................................................................................19143 Chart B-17 FR Speed Sensor Disconnection (DTC 52)...................................................................................19144 Chart B-18 RL Speed Sensor Disconnection (DTC 53)...................................................................................19144 Chart B-19 RR Speed Sensor Disconnection (DTC 54)...................................................................................19145 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)...................................................................................19146 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)...................................................................................19147 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)...................................................................................19148 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)...................................................................................19149 Chart B-24 Sensor Signal Input Abnormality (DTC 65).................................................................................19150 Sensor Signal Abnormality Criteria using TECH 2.....................................................................................19150 Unit Inspection Procedure...............................................................................................................19151 Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................19151 Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................19152 Chart C-1-3 RL Sensor Output Inspection Procedure...................................................................................19152 Chart C-1-4 RR Sensor Output Inspection Procedure...................................................................................19153 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2)..........................................................................19153 Chart C-2 Transmission Input Inspection Procedure...................................................................................19154 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2).....................................................................19155 Special Tools...........................................................................................................................19156 5B ANTI-LOCK BRAKE SYSTEM...................................................................................................................19157 Service Precaution......................................................................................................................19157 Electronic Hydraulic Control Unit.......................................................................................................19158 Electronic Hydraulic Control Unit and Associated Parts..............................................................................19158 Removal.............................................................................................................................19158 Installation........................................................................................................................19158 G-Sensor................................................................................................................................19159 Removal.............................................................................................................................19159 Inspection and Repair...............................................................................................................19159 Installation........................................................................................................................19159 Front Wheel Speed Sensor................................................................................................................19160 Front Wheel Speed Sensor and Associated Parts.......................................................................................19160 Removal.............................................................................................................................19160 Inspection and Repair...............................................................................................................19161 Installation........................................................................................................................19161 Rear Wheel Speed Sensor.................................................................................................................19162 Rear Wheel Speed Sensor and Associated Parts........................................................................................19162 Removal.............................................................................................................................19162 Inspection and Repair...............................................................................................................19162 Installation........................................................................................................................19162 5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................19163 Service Precaution......................................................................................................................19164 General Description.....................................................................................................................19164 Diagnosis...............................................................................................................................19167 General Diagnosis.......................................................................................................................19168 Hydraulic Brakes........................................................................................................................19171 Filling Master Cylinder Reservoir...................................................................................................19171 Deterioration of Brake Fluid........................................................................................................19171 Leakage of Brake Fluid..............................................................................................................19171 Bleeding Brake Hydraulic System.....................................................................................................19171 Flushing Brake Hydraulic System.....................................................................................................19172 Brake Pipes and Hoses...............................................................................................................19172 Brake Hose Inspection...............................................................................................................19172 Front / Rear Caliper Brake Hose.........................................................................................................19173 Front / Rear Caliper Brake Hose and Associated Parts................................................................................19173 Removal.............................................................................................................................19173 Installation........................................................................................................................19173 Rear Axle Brake Hose....................................................................................................................19174 Rear Axle Brake Hose and Associated Parts..........................................................................................19174 Removal.............................................................................................................................19174 Installation........................................................................................................................19174 Brake Pipe..............................................................................................................................19175 Removal.............................................................................................................................19175 Installation........................................................................................................................19175 P & B (Proportioning and Bypass) Valve..................................................................................................19176 Removal.............................................................................................................................19176 Installation........................................................................................................................19176 Main Data and Specifications............................................................................................................19177 Brake Pedal.............................................................................................................................19178 Checking Pedal Height...............................................................................................................19178 Checking Pedal Travel...............................................................................................................19178 Brake Pedal and Associated Parts....................................................................................................19179 Removal.............................................................................................................................19179 Installation........................................................................................................................19179 Stoplight Switch........................................................................................................................19180 Removal.............................................................................................................................19180 Installation........................................................................................................................19180 Main Data and Specifications............................................................................................................19181 Fluid Reservoir Tank....................................................................................................................19182 Fluid Reservoir Tank and Associated Parts...........................................................................................19182 Removal.............................................................................................................................19182 Installation........................................................................................................................19182 Master Cylinder Assembly................................................................................................................19183 Master Cylinder Assembly and Associated Parts.......................................................................................19183 Removal.............................................................................................................................19183 Inspection and Repair...............................................................................................................19183 Installation........................................................................................................................19184 Main Data and Specifications........................................................................................................19185 Special Tools.......................................................................................................................19186 Vacuum Booster Assembly.................................................................................................................19187 Vacuum Booster Assembly and Associated Parts........................................................................................19187 Removal.............................................................................................................................19187 Inspection and Repair...............................................................................................................19187 Installation........................................................................................................................19188 Exterior Components.....................................................................................................................19190 Exterior Components and Associated Parts............................................................................................19190 Removal.............................................................................................................................19190 Inspection and Repair...............................................................................................................19191 Installation........................................................................................................................19191 Vacuum Booster Overhaul.................................................................................................................19191 Vacuum Booster......................................................................................................................19191 Main Data and Specifications............................................................................................................19192 Special Tools...........................................................................................................................19193 Front Disc Brake Pads...................................................................................................................19194 Front Disc Brake Pads Inspection....................................................................................................19194 Front Disc Brake Pads and Associated Parts..........................................................................................19194 Removal.............................................................................................................................19195 Installation........................................................................................................................19195 Front Disc Brake Rotor..................................................................................................................19197 Inspection..........................................................................................................................19197 Replacing Brake Rotors..............................................................................................................19197 Refinishing Brake Rotors............................................................................................................19197 Front Disc Brake Caliper Assembly.......................................................................................................19199 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................19199 Removal.............................................................................................................................19199 Installation........................................................................................................................19200 Front Disc Brake Caliper................................................................................................................19202 Front Disc Brake Caliper Disassembled View..........................................................................................19202 Disassembly.........................................................................................................................19202 Inspection and Repair...............................................................................................................19203 Reassembly..........................................................................................................................19203 Main Data and Specifications........................................................................................................19205 Rear Disc Brake Pads....................................................................................................................19206 Brake Pads Inspection...............................................................................................................19206 Brake Pads and Associated Parts.....................................................................................................19206 Removal.............................................................................................................................19207 Installation........................................................................................................................19207 Rear Disc Brake Rotor...................................................................................................................19209 Inspection..........................................................................................................................19209 Replacing Brake Rotors..............................................................................................................19209 Refinishing Brake Rotors............................................................................................................19209 Rear Drum (In Disc) Inside Diameter Check...........................................................................................19210 Rear Disc Brake Caliper Assembly........................................................................................................19211 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................19211 Removal.............................................................................................................................19211 Installation........................................................................................................................19212 Rear Disc Brake Caliper.................................................................................................................19214 Rear Disc Brake Caliper Disassembled View...........................................................................................19214 Disassembly.........................................................................................................................19214 Inspection and Repair...............................................................................................................19215 Reassembly..........................................................................................................................19215 Main Data and Specifications........................................................................................................19217 5D PARKING BRAKE SYSTEM.....................................................................................................................19218 Service Precaution......................................................................................................................19218 General Description.....................................................................................................................19218 Operation...............................................................................................................................19219 Parking Brake Lever and Front Cable.....................................................................................................19220 Parking Brake Lever, Front Cable and Associated Parts...............................................................................19220 Removal.............................................................................................................................19220 Installation........................................................................................................................19221 Parking Brake Rear Cable................................................................................................................19222 Parking Brake Rear Cable and Associated Parts.......................................................................................19222 Removal.............................................................................................................................19222 Installation........................................................................................................................19223 Inspection and Repair...............................................................................................................19224 Parking Brake Adjustment................................................................................................................19224 Main Data and Specifications............................................................................................................19225 Sec.6 ENGINE....................................................................................................................................19226 6A ENGINE MECHANICAL........................................................................................................................19226 Service Precaution......................................................................................................................19227 General Description.....................................................................................................................19228 Engine Diagnosis........................................................................................................................19229 Cylinder Head Cover LH..................................................................................................................19244 Removal.............................................................................................................................19244 Installation........................................................................................................................19245 Cylinder Head Cover RH..................................................................................................................19246 Removal.............................................................................................................................19246 Installation........................................................................................................................19246 Common Chamber..........................................................................................................................19247 Removal.............................................................................................................................19247 Installation........................................................................................................................19247 Exhaust Manifold LH.....................................................................................................................19249 Removal.............................................................................................................................19249 Installation........................................................................................................................19249 Exhaust Manifold RH.....................................................................................................................19250 Removal.............................................................................................................................19250 Installation........................................................................................................................19250 Crankshaft Pulley.......................................................................................................................19251 Removal.............................................................................................................................19251 Installation........................................................................................................................19251 Timing Belt.............................................................................................................................19252 Removal.............................................................................................................................19252 Installation........................................................................................................................19253 Camshaft................................................................................................................................19257 Removal.............................................................................................................................19257 Installation........................................................................................................................19257 Cylinder Head...........................................................................................................................19260 Removal.............................................................................................................................19260 Installation........................................................................................................................19260 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................19262 Removal.............................................................................................................................19262 Installation........................................................................................................................19262 Piston, Piston Ring and Connecting Rod..................................................................................................19263 Removal.............................................................................................................................19263 Installation........................................................................................................................19264 Crankshaft and Main Bearings............................................................................................................19265 Removal.............................................................................................................................19265 Installation........................................................................................................................19266 Rear Oil Seal...........................................................................................................................19270 Removal.............................................................................................................................19270 Installation........................................................................................................................19270 Engine Assembly.........................................................................................................................19271 Removal.............................................................................................................................19271 Installation........................................................................................................................19272 Cylinder Head...........................................................................................................................19274 Cylinder Head and Associated Parts..................................................................................................19274 Disassembly.........................................................................................................................19275 Clean...............................................................................................................................19275 Inspection and Repair...............................................................................................................19275 Reassembly..........................................................................................................................19276 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................19278 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................19278 Disassembly.........................................................................................................................19278 Inspection and Repair...............................................................................................................19279 Reassembly..........................................................................................................................19282 Valve Clearance Adjustments.............................................................................................................19283 Camshaft................................................................................................................................19285 Camshaft and Associated Parts.......................................................................................................19285 Disassembly.........................................................................................................................19285 Inspection and Repair...............................................................................................................19286 Reassembly..........................................................................................................................19288 Crankshaft..............................................................................................................................19291 Crankshaft and Associated Parts.....................................................................................................19291 Disassembly.........................................................................................................................19292 Inspection and Repair...............................................................................................................19292 Inspection and Repair...............................................................................................................19293 Reassembly..........................................................................................................................19295 Piston and Connecting Rod...............................................................................................................19299 Piston, Connecting Rod and Associate Parts..........................................................................................19299 Disassembly.........................................................................................................................19299 Inspection and Repair...............................................................................................................19300 Reassembly..........................................................................................................................19304 Cylinder Block..........................................................................................................................19306 Cylinder Block and Associated Parts.................................................................................................19306 Disassembly.........................................................................................................................19306 Inspection and Repair...............................................................................................................19307 Reassembly..........................................................................................................................19308 Main Data and Specification.............................................................................................................19311 Special Tool............................................................................................................................19317 6B ENGINE COOLING...........................................................................................................................19319 Service Precaution......................................................................................................................19319 General Description.....................................................................................................................19320 Diagnosis...............................................................................................................................19323 Draining and Refilling Cooling System...................................................................................................19324 Water Pump..............................................................................................................................19325 Water Pump and Associated Parts.....................................................................................................19325 Removal.............................................................................................................................19325 Inspection..........................................................................................................................19325 Installation........................................................................................................................19325 Thermostat..............................................................................................................................19326 Thermostat and Associated Parts.....................................................................................................19326 Removal.............................................................................................................................19326 Inspection..........................................................................................................................19326 Installation........................................................................................................................19326 Radiator................................................................................................................................19327 Radiator and Associated Parts.......................................................................................................19327 Removal.............................................................................................................................19327 Inspection..........................................................................................................................19328 Installation........................................................................................................................19329 Drive Belt and Cooling Fan..............................................................................................................19330 Drive Belt and Associated Parts.....................................................................................................19330 Inspection..........................................................................................................................19330 Installation........................................................................................................................19330 Main Data and Specifications............................................................................................................19331 Special Tool............................................................................................................................19332 6C ENGINE FUEL..............................................................................................................................19333 Service Precaution......................................................................................................................19333 General Description.....................................................................................................................19334 Fuel Metering...........................................................................................................................19335 Fuel Filter.............................................................................................................................19336 Fuel Filter and Associated Parts....................................................................................................19336 Removal.............................................................................................................................19336 Inspection..........................................................................................................................19336 Installation........................................................................................................................19336 Inspection..........................................................................................................................19337 In–Tank Fuel Filter.................................................................................................................19337 Fuel Pump Flow Test.................................................................................................................19337 Fuel Pump...............................................................................................................................19338 Fuel Pump and Associated Parts......................................................................................................19338 Removal.............................................................................................................................19338 Installation........................................................................................................................19338 Fuel Pump Relay.........................................................................................................................19338 General Description.....................................................................................................................19338 Fuel Tank...............................................................................................................................19339 Fuel Tank and Associated Parts......................................................................................................19339 Removal.............................................................................................................................19339 Installation........................................................................................................................19339 Fuel Tube / Quick – Connect Fittings....................................................................................................19340 Precautions.........................................................................................................................19340 Cautions During Work................................................................................................................19340 Removal.............................................................................................................................19340 Reuse of Quick–Connector................................................................................................................19341 Assembling Advice.......................................................................................................................19342 Fuel Gauge Unit.........................................................................................................................19343 Fuel Gauge Unit and Associated Parts................................................................................................19343 Removal.............................................................................................................................19343 Installation........................................................................................................................19343 Fuel Filler Cap.........................................................................................................................19344 General Description.....................................................................................................................19344 Inspection..........................................................................................................................19344 Main Data and Specifications............................................................................................................19345 6D1 ENGINE ELECTRICAL.......................................................................................................................19346 Battery.................................................................................................................................19346 General Description.................................................................................................................19346 Diagnosis...........................................................................................................................19346 Battery Charging....................................................................................................................19347 Jump Starting.......................................................................................................................19347 Battery Removal.....................................................................................................................19348 Battery Installation................................................................................................................19348 Main Data and Specifications........................................................................................................19349 6D2 IGNITION SYSTEM.........................................................................................................................19350 Service Precaution......................................................................................................................19350 General Description.....................................................................................................................19351 Diagnosis...............................................................................................................................19351 Ignition Coil...........................................................................................................................19352 Removal.............................................................................................................................19352 Inspection and Repair...............................................................................................................19352 Installation........................................................................................................................19352 Spark Plug..............................................................................................................................19354 Removal.............................................................................................................................19354 Inspection and Repair...............................................................................................................19354 Installation........................................................................................................................19354 Crankshaft Position Sensor..............................................................................................................19355 Removal.............................................................................................................................19355 Installation........................................................................................................................19355 Main Data and Specifications............................................................................................................19356 6D3 STARTING AND CHARGING SYSTEM............................................................................................................19357 Service Precaution......................................................................................................................19357 Starting System.........................................................................................................................19358 General Description.....................................................................................................................19358 Diagnosis...............................................................................................................................19360 Starter.................................................................................................................................19361 Removal.............................................................................................................................19361 Installation........................................................................................................................19361 Disassembled View...................................................................................................................19362 Disassembly.........................................................................................................................19363 Inspection and Repair...............................................................................................................19365 Reassembly..........................................................................................................................19369 Main Data and Specifications........................................................................................................19371 Charging System.........................................................................................................................19374 General Description.....................................................................................................................19374 General On–Vehicle Inspection...........................................................................................................19374 Generator...............................................................................................................................19375 Removal.............................................................................................................................19375 Inspection..........................................................................................................................19375 Installation........................................................................................................................19375 Disassembled View...................................................................................................................19376 Disassembly.........................................................................................................................19377 Inspection and Repair...............................................................................................................19379 Reassembly..........................................................................................................................19381 Bench Test..........................................................................................................................19381 Main Data and Specifications............................................................................................................19382 6E TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS...........................................................................................19383 Specifications..........................................................................................................................19388 Tightening Specifications...........................................................................................................19388 Diagrams and Schematics.................................................................................................................19389 PCM Wiring Diagram (1 of 8).........................................................................................................19389 PCM Wiring Diagram (2 of 8).........................................................................................................19390 PCM Wiring Diagram (3 of 8).........................................................................................................19391 PCM Wiring Diagram (4 of 8).........................................................................................................19392 PCM Wiring Diagram (5 of 8).........................................................................................................19393 PCM Wiring Diagram (6 of 8).........................................................................................................19394 PCM Wiring Diagram (7 of 8).........................................................................................................19395 PCM Wiring Diagram (8 of 8).........................................................................................................19396 PCM Pinouts.............................................................................................................................19397 PCM Pinout Table, 80-Way Blue Connector – Row “F1 ~ 20”.............................................................................19397 PCM Pinout Table, 80-Way Blue Connector – Row “F20 ~ 40”............................................................................19398 PCM Pinout Table, 80-Way Blue Connector – Row “F41 ~ 60”............................................................................19400 PCM Pinout Table, 80-Way Blue Connector – Row “F61 ~ 80”............................................................................19402 PCM Pinout Table, 80-Way Red Connector – Row “S1 ~ 20”..............................................................................19404 PCM Pinout Table, 80-Way Red Connector – Row “S21 ~ 40”.............................................................................19406 PCM Pinout Table, 80-Way Red Connector – Row “S41 ~ 60”.............................................................................19408 PCM Pinout Table, 80-Way Red Connector – Row “S61 ~ 80”.............................................................................19410 Component Locators..................................................................................................................19412 Undercarriage Component Locator.....................................................................................................19414 Fuse and Relay Panel (Underhood Electrical Center)..................................................................................19415 Sensors and Miscellaneous Component Locators........................................................................................19416 Diagnosis...............................................................................................................................19418 Strategy-Based Diagnostics..........................................................................................................19418 DTC Stored..........................................................................................................................19418 No DTC..............................................................................................................................19418 No Matching Symptom.................................................................................................................19418 Intermittents.......................................................................................................................19418 No Trouble Found....................................................................................................................19418 Verifying Vehicle Repair............................................................................................................19418 General Service Information.............................................................................................................19418 OBD II Serviceablity Issues.........................................................................................................19418 Visual / Physical Engine Compartment Inspection.....................................................................................19419 Basic Knowledge of Tools Required...................................................................................................19419 Serial Data Communications..............................................................................................................19420 Class 2 Serial Data Communications..................................................................................................19420 On-Board Diagnostic (OBD II)............................................................................................................19420 On-Board Diagnostic Tests...........................................................................................................19420 Comprehensive Component Monitor Diagnostic Operation................................................................................19420 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................19421 Common OBD II Terms.................................................................................................................19421 The Diagnostic Executive............................................................................................................19421 DTC Types...........................................................................................................................19422 Decimal/Binary/Hexadecimal Conversions..............................................................................................19423 Verifying Vehicle Repair............................................................................................................19424 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................19424 Tech 2..............................................................................................................................19425 Tech 2 Features.....................................................................................................................19426 Getting Started.....................................................................................................................19426 Operating Procedure (For Example)...................................................................................................19427 DTC Modes...........................................................................................................................19428 DTC Information Mode................................................................................................................19428 Miscellaneous Test..................................................................................................................19429 Lamps Test..........................................................................................................................19429 Relays Test.........................................................................................................................19431 EVAP Test...........................................................................................................................19432 Fuel System Test....................................................................................................................19433 Instruments Test....................................................................................................................19435 EGR Control Test....................................................................................................................19437 Variable Intake Manifold Solenoid Test..............................................................................................19437 Injector Balance Test...............................................................................................................19439 Plotting Snapshot Graph.................................................................................................................19439 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................19440 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................19441 Primary System-Based Diagnostic.........................................................................................................19442 Primary System-Based Diagnostic.....................................................................................................19442 Fuel Control Heated Oxygen Sensor...................................................................................................19442 HO2S Heater.........................................................................................................................19442 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................19442 Misfire Monitor Diagnostic Operation....................................................................................................19443 Misfire Monitor Diagnostic Operation................................................................................................19443 Misfire Counters....................................................................................................................19443 Fuel Trim System Monitor Diagnostic Operation...........................................................................................19444 Fuel Trim System Monitor Diagnostic Operation.......................................................................................19444 Fuel Trim Cell Diagnostic Weights...................................................................................................19444 On-Board Diagnostic (OBD II) System Check...............................................................................................19445 Circuit Description.................................................................................................................19445 Diagnostic Aids.....................................................................................................................19445 Test Description....................................................................................................................19445 A/C Clutch Control Circuit Diagnosis....................................................................................................19448 Circuit Description.................................................................................................................19448 Diagnostic Aids.....................................................................................................................19448 A/C Clutch Diagnosis................................................................................................................19449 Electronic Ignition System Diagnosis....................................................................................................19453 EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...............................................................................19453 Visual Check of The Evaporative Emission Canister.......................................................................................19453 Fuel Metering System Check..............................................................................................................19453 Fuel System Pressure Test...............................................................................................................19453 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..............................................................19453 Test Description....................................................................................................................19453 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)...........................................19454 Powertrain Control Module (PCM) Diagnosis...............................................................................................19458 Multiple PCM Information Sensor DTCs Set................................................................................................19458 Circuit Description.................................................................................................................19458 Diagnostic Aids.....................................................................................................................19458 Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................19461 Engine Tech 2 Data Definitions and Ranges...............................................................................................19461 Typical Scan Data Values................................................................................................................19463 Test Conditions.....................................................................................................................19463 No Malfunction Indicator Lamp (MIL).....................................................................................................19469 Circuit Description.................................................................................................................19469 Diagnostic Aids.....................................................................................................................19469 Malfunction Indicator Lamp (MIL) “ON” Steady............................................................................................19472 Circuit description.................................................................................................................19472 Diagnostic Aids.....................................................................................................................19472 No Reduced Power Lamp (RPL).............................................................................................................19474 Circuit Description.................................................................................................................19474 Diagnostic Aids.....................................................................................................................19474 Reduced Power Lamp (RPL) “ON” Steady....................................................................................................19477 Circuit description.................................................................................................................19477 Diagnostic Aids.....................................................................................................................19477 Engine Cranks But Will Not Run..........................................................................................................19479 Circuit Description.................................................................................................................19481 Diagnostic Aids.....................................................................................................................19481 Test Description....................................................................................................................19481 Fuel System Electrical Test.............................................................................................................19486 Circuit Description.................................................................................................................19487 Diagnostic Aids.....................................................................................................................19487 Test Description....................................................................................................................19487 Fuel Pressure Relief Procedure......................................................................................................19487 Electric Throttle Control (ETC) System Check............................................................................................19490 Circuit Description.................................................................................................................19491 Diagnostic Aids.....................................................................................................................19491 Test Description....................................................................................................................19491 Fuel System Diagnosis...................................................................................................................19494 Circuit Description.................................................................................................................19495 Test Description....................................................................................................................19495 Fuel Pressure Relief Procedure......................................................................................................19496 Exhaust Gas Recirculation (EGR) System Check............................................................................................19499 Circuit Description.................................................................................................................19499 Manifold Absolute Pressure (MAP) Output Check...........................................................................................19501 Circuit Description.................................................................................................................19501 Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................19503 Circuit Description.................................................................................................................19503 Diagnostic Aids.....................................................................................................................19503 PCM Diagnostic Trouble Codes............................................................................................................19506 DTC P0101 MAF System Performance........................................................................................................19510 DTC P0102 MAF Sensor Circuit Low Frequency..............................................................................................19513 DTC P0103 MAF Sensor Circuit High Frequency.............................................................................................19516 DTC P0106 MAP System Performance........................................................................................................19518 DTC P0107 MAP Sensor Circuit Low Voltage................................................................................................19521 DTC P0108 MAP Sensor Circuit High Voltage...............................................................................................19524 DTC P0112 IAT Sensor Circuit Low Voltage................................................................................................19527 DTC P0113 IAT Sensor Circuit High Voltage...............................................................................................19530 DTC P0117 ECT Sensor Circuit Low Voltage................................................................................................19533 DTC P0118 ECT Sensor Circuit High Voltage...............................................................................................19536 DTC P0125 ECT Excessive Time to Closed Loop Fuel Control................................................................................19539 DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1......................................................................................19542 DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.....................................................................................19545 DTC P0133 HO2S Slow Response Bank 1 Sensor 1............................................................................................19548 DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1............................................................................19552 DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1...........................................................................................19555 DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2......................................................................................19558 DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.....................................................................................19561 DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................................................19564 DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2...........................................................................................19567 DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1......................................................................................19570 DTC P0152 HO2S Circuit High Voltage Bank 2 Sensor 1.....................................................................................19573 DTC P0153 HO2S Slow Response Bank 2 Sensor 1............................................................................................19576 DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1............................................................................19580 DTC P0155 HO2S Heater Circuit Open Bank 2 Sensor 1......................................................................................19583 DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2......................................................................................19586 DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.....................................................................................19589 DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2............................................................................19592 DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2...........................................................................................19595 DTC P0171 Fuel Trim System Lean Bank 1..................................................................................................19598 DTC P0172 Fuel Trim System Rich Bank 1..................................................................................................19602 DTC P0174 Fuel Trim System Lean Bank 2..................................................................................................19606 DTC P0175 Fuel Trim System Rich Bank 2..................................................................................................19610 DTC P0201 Injector 1 Control Circuit....................................................................................................19614 DTC P0202 Injector 2 Control Circuit....................................................................................................19617 DTC P0203 Injector 3 Control Circuit....................................................................................................19620 DTC P0204 Injector 4 Control Circuit....................................................................................................19623 DTC P0205 Injector 5 Control Circuit....................................................................................................19626 DTC P0206 Injector 6 Control Circuit....................................................................................................19629 DTC P0300 Engine Misfire Detected.......................................................................................................19632 DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault..................................................................19636 DTC P0336 58X Reference Signal Circuit..................................................................................................19639 DTC P0337 CKP Sensor Circuit Low Frequency..............................................................................................19642 DTC P0351 Ignition 1 Control Circuit....................................................................................................19645 DTC P0352 Ignition 2 Control Circuit....................................................................................................19648 DTC P0353 Ignition 3 Control Circuit....................................................................................................19651 DTC P0354 Ignition 4 Control Circuit....................................................................................................19654 DTC P0355 Ignition 5 Control Circuit....................................................................................................19657 DTC P0356 Ignition 6 Control Circuit....................................................................................................19660 DTC P0401 EGR Flow Insufficient.........................................................................................................19663 DTC P0402 EGR Pintle Crank Error........................................................................................................19666 DTC P0404 EGR Open Stuck................................................................................................................19668 DTC P0405 EGR Low Voltage...............................................................................................................19670 DTC P0406 EGR High Voltage..............................................................................................................19673 DTC P0420 TWC System Low Efficiency Bank 1..............................................................................................19676 DTC P0430 TWC System Low Efficiency Bank 2..............................................................................................19679 DTC P0440 EVAP System...................................................................................................................19682 DTC P0442 EVAP System Small Leak Detected...............................................................................................19685 DTC P0444 EVAP Purge Control Circuit Open...............................................................................................19688 DTC P0445 EVAP Purge Control Circuit Short..............................................................................................19690 DTC P0446 EVAP Canister Vent Control Malfunction........................................................................................19692 DTC P0447 EVAP Vent Solenoid Circuit Open...............................................................................................19695 DTC P0448 EVAP Vent solenoid Circuit Short..............................................................................................19697 DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage.................................................................19699 DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage................................................................19702 DTC P0456 EVAP Very Small Leak..........................................................................................................19705 DTC P0461 Fuel Level Sensor Performance.................................................................................................19708 DTC P0462 Fuel Level Sensor Circuit‐Low Voltage.........................................................................................19710 DTC P0463 Fuel Level Sensor Circuit‐High Voltage........................................................................................19713 DTC P0464 Fuel Level Sensor Noisy Signal................................................................................................19715 DTC P0502 VSS Circuit Low Input.........................................................................................................19717 DTC P0506 Idle Air Control System Low RPM...............................................................................................19720 DTC P0507 Idle Air Control System High RPM..............................................................................................19723 DTC P0562 System Voltage Low............................................................................................................19726 DTC P0563 System Voltage High...........................................................................................................19728 DTC P0565 Cruise Main Switch Circuit Error..............................................................................................19730 DTC P0566 Cruise Cancel Switch Circuit Error............................................................................................19732 DTC P0567 Cruise Resume Switch Circuit Error............................................................................................19734 DTC P0568 Cruise Set Switch Circuit Error...............................................................................................19736 DTC P0571 No Brake Switch Signal........................................................................................................19738 DTC P0601 PCM Memory....................................................................................................................19740 DTC P0602 PCM Programming Error.........................................................................................................19742 DTC P0604 PCM RAM Error.................................................................................................................19744 DTC P0606 PCM Internal Performance......................................................................................................19746 DTC P0660 VIM Solenoid Circuit Open.....................................................................................................19748 DTC P0662 VIM Solenoid Circuit Short....................................................................................................19750 DTC P1106 MAP Sensor Circuit Intermittent High Voltage..................................................................................19752 DTC P1107 MAP Circuit Intermittent Low Voltage..........................................................................................19754 DTC P1111 IAT Sensor Circuit Intermittent High Voltage..................................................................................19756 DTC P1112 IAT Sensor Circuit Intermittent Low Voltage...................................................................................19759 DTC P1114 ECT Sensor Circuit Intermittent Low Voltage...................................................................................19761 DTC P1115 ECT Sensor Circuit Intermittent High Voltage..................................................................................19763 DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault...........................................................................19766 DTC P1125 ETC (Electric throttle control) Limit Performance Mode........................................................................19769 DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1...................................................................................19772 DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1....................................................................................19776 DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1...................................................................................19780 DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1............................................................................19784 DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)...........................................................................19788 DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)...........................................................................19790 DTC P1171 Fuel System Lean During Acceleration..........................................................................................19792 DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault................................................................................19795 DTC P1221 TPS1 ‐ TPS2 correlation(Circuit Performance)..................................................................................19798 DTC P1271 APS 1‐ 2 Correlation Error....................................................................................................19801 DTC P1272 APS 2 ‐ 3 Correlation Error...................................................................................................19804 DTC P1273 APS 1 ‐ 3 Correlation Error...................................................................................................19807 DTC P1275 APS 1 Circuit Fault...........................................................................................................19810 DTC P1280 APS 2 Circuit Fault...........................................................................................................19812 DTC P1285 APS 3 Circuit Fault...........................................................................................................19814 DTC P1290 ETC Forced Idle Mode..........................................................................................................19816 DTC P1295 Power Management Mode.........................................................................................................19818 DTC P1299 ETC Forced Engine Shutdown Mode...............................................................................................19820 DTC P1310 ION Sensing Module Diagnosis..................................................................................................19822 DTC P1311 ION Sensing Module SEC Line 1 Circuit Fault...................................................................................19825 DTC P1312 ION Sensing Module SEC Line 2 Circuit Fault...................................................................................19828 DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault.....................................................................19831 DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)..........................................................19834 DTC P1404 EGR Stuck Closed..............................................................................................................19837 DTC P1441 EVAP System Flow During Non-Purge.............................................................................................19840 DTC P1514 TPS - MAF Correlation Error...................................................................................................19843 DTC P1515 Command - Actual TPS Correlation Error........................................................................................19847 DTC P1516 Command - Actual TPS Correlation Error........................................................................................19850 DTC P1523 Actuator Control Return Performance...........................................................................................19853 DTC P1574 Brake Switch No Operation.....................................................................................................19856 DTC P1635 Reference Voltage # 1 Circuit Fault...........................................................................................19858 DTC P1636 PCM RAM Stack.................................................................................................................19860 DTC P1639 Reference Voltage # 2 Circuit Fault...........................................................................................19861 DTC P1640 Driver-1-Output Circuit Fault (ODM)...........................................................................................19863 DTC P1650 Quad Driver Module “A” Fault..................................................................................................19865 Symptom Diagnosis.......................................................................................................................19868 Default Matrix Table....................................................................................................................19897 On Vehicle Service Crankshaft Position (CKP) Sensor.....................................................................................19900 Engine Coolant Temperature (ECT) Sensor.................................................................................................19900 Heated Oxygen Sensor (HO2S).............................................................................................................19901 Intake Air Temperature (IAT) Sensor.....................................................................................................19904 ION Sensing Module......................................................................................................................19904 Mass Air Flow (MAF) Sensor..............................................................................................................19905 Manifold Absolute Pressure (MAP) Sensor.................................................................................................19906 Malfunction Indicator Lamp (MIL)........................................................................................................19907 Reduced Power Lamp......................................................................................................................19907 Powertrain Control Module (PCM).........................................................................................................19907 Service Precaution..................................................................................................................19907 Removal Procedure...................................................................................................................19907 Installation Procedure..............................................................................................................19908 EEPROM..................................................................................................................................19909 Throttle Position (TP) Sensor...........................................................................................................19909 Vehicle Speed Sensor (VSS)..............................................................................................................19910 Air Cleaner/Air Filter..................................................................................................................19911 Common Chamber..........................................................................................................................19911 Accelerator Pedal Replacement...........................................................................................................19912 Accelerator Position Sensor Replacement.................................................................................................19913 Accelerator Position Sensor Adjustment..................................................................................................19913 Fuel Filler Cap.........................................................................................................................19914 Fuel Filter.............................................................................................................................19914 Fuel Gauge Unit.........................................................................................................................19916 Fuel Injectors..........................................................................................................................19916 Fuel Metering System....................................................................................................................19917 Fuel Pump Assembly......................................................................................................................19918 Fuel Pump Relay.........................................................................................................................19918 Fuel Rail Assembly......................................................................................................................19919 Fuel Tank...............................................................................................................................19920 Throttle Body (TB)......................................................................................................................19920 Electronic Ignition System..............................................................................................................19922 Catalytic Converter.....................................................................................................................19923 Air Conditioning Thermo Relay...........................................................................................................19923 EVAP Canister Hoses.....................................................................................................................19923 EVAP Canister...........................................................................................................................19924 EVAP Canister Vent Solenoid.............................................................................................................19925 Fuel Tank Pressure (Vapor Pressure) Sensor..............................................................................................19926 EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)................................................................................19927 Fuel Tank Vent Valve (Vent Solenoid Valve)..............................................................................................19927 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................19927 Positive Crankcase Ventilation (PCV) Valve..............................................................................................19928 Wiring and Connectors...................................................................................................................19929 PCM Connectors and Terminals............................................................................................................19930 Wire Harness Repair: Twisted Shielded Cable.............................................................................................19930 Twisted Leads...........................................................................................................................19931 Weather-Pack Connector..................................................................................................................19932 Com-Pack III............................................................................................................................19933 Metri-Pack..............................................................................................................................19934 General Description (PCM and Sensors)...................................................................................................19935 58X Reference PCM Input.............................................................................................................19935 A/C Request Signal..................................................................................................................19935 Crankshaft Position (CKP) Sensor....................................................................................................19935 Engine Coolant Temperature (ECT) Sensor.............................................................................................19935 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................19935 Fuel Control Heated Oxygen Sensors..................................................................................................19935 Catalyst Monitor Heated Oxygen Sensors..............................................................................................19936 Intake Air Temperature (IAT) Sensor.................................................................................................19936 Linear Exhaust Gas Recirculation (EGR) Control......................................................................................19937 Mass Air Flow (MAF) Sensor..........................................................................................................19937 Manifold Absolute Pressure (MAP) Sensor.............................................................................................19937 Powertrain Control Module (PCM).....................................................................................................19938 PCM Function........................................................................................................................19938 PCM Components......................................................................................................................19938 PCM Voltage Description.............................................................................................................19938 PCM Input/Outputs...................................................................................................................19938 PCM Service Precautions.............................................................................................................19939 Reprogramming The PCM...............................................................................................................19939 Throttle Position (TP) Sensor.......................................................................................................19939 Transmission Fluid Temperature (TFT) Sensor.........................................................................................19939 Transmission Range Switch (Mode Switch).............................................................................................19939 Vehicle Speed Sensor (VSS)..........................................................................................................19939 Use of Circuit Testing Tools........................................................................................................19939 Aftermarket Electrical and Vacuum Equipment.........................................................................................19940 Electrostatic Discharge Damage......................................................................................................19940 General Description (Air Induction).....................................................................................................19940 Air Induction System................................................................................................................19940 General Description (Fuel Metering).....................................................................................................19941 Acceleration Mode...................................................................................................................19941 Battery Voltage Correction Mode.....................................................................................................19941 Clear Flood Mode....................................................................................................................19941 Deceleration Mode...................................................................................................................19941 Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................19941 Fuel Cutoff Mode....................................................................................................................19941 Fuel Injector.......................................................................................................................19941 Fuel Metering System Components.....................................................................................................19941 Fuel Metering System Purpose........................................................................................................19941 Fuel Pressure Regulator.............................................................................................................19942 Fuel Pump Electrical Circuit........................................................................................................19942 Fuel Rail...........................................................................................................................19942 Run Mode............................................................................................................................19942 Starting Mode.......................................................................................................................19942 Throttle Body Unit..................................................................................................................19943 General Description (Electronic Ignition System)........................................................................................19943 Crankshaft Position (CKP) Sensor....................................................................................................19943 Electronic Ignition.................................................................................................................19943 Ignition Coils......................................................................................................................19943 Ignition Control....................................................................................................................19943 Ignition Control PCM Output.........................................................................................................19944 Powertrain Control Module (PCM).....................................................................................................19944 Spark Plug..........................................................................................................................19945 A/C Clutch Diagnosis....................................................................................................................19946 A/C Clutch Circuit Operation........................................................................................................19946 A/C Clutch Circuit Purpose..........................................................................................................19946 A/C Request Signal..................................................................................................................19946 General Description (Evaporative (EVAP) Emission System)................................................................................19947 EVAP Emission Control System Purpose................................................................................................19947 EVAP Emission Control System Operation..............................................................................................19947 Enhanced Evaporative Emission Control System........................................................................................19947 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................19950 EGR Purpose.........................................................................................................................19950 Linear EGR Valve....................................................................................................................19951 Linear EGR Control..................................................................................................................19951 Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................19951 EGR Pintle Position Sensor..........................................................................................................19951 General Description (Positive Crankcase Ventilation (PCV) System).......................................................................19951 Crankcase Ventilation System Purpose................................................................................................19951 Crankcase Ventilation System Operation..............................................................................................19951 Special Tools...........................................................................................................................19953 6F ENGINE EXHAUST...........................................................................................................................19955 General Description.....................................................................................................................19956 Front Exhaust Pipe......................................................................................................................19957 Front Exhaust Pipe and Associated Parts.............................................................................................19957 Removal.............................................................................................................................19957 Installation........................................................................................................................19957 Three Way Catalytic Converter LH........................................................................................................19958 Removal.............................................................................................................................19958 Installation........................................................................................................................19958 Three Way Catalytic Converter RH........................................................................................................19959 Removal.............................................................................................................................19959 Installation........................................................................................................................19959 Exhaust Silencer........................................................................................................................19960 Exhaust Silencer and Associated Parts...............................................................................................19960 Removal.............................................................................................................................19960 Installation........................................................................................................................19960 Rear Exhaust pipe.......................................................................................................................19961 Rear Exhaust pipe and Associated Parts..............................................................................................19961 Removal.............................................................................................................................19961 Installation........................................................................................................................19961 Main Data and Specifications............................................................................................................19962 6G ENGINE LUBRICATION.......................................................................................................................19963 Service Precaution......................................................................................................................19963 General Description.....................................................................................................................19964 Oil Pump................................................................................................................................19965 Oil Pump and Associated Parts.......................................................................................................19965 Disassembly.........................................................................................................................19965 Inspection and Repair...............................................................................................................19966 Reassembly..........................................................................................................................19967 Oil Pan and Crankcase...................................................................................................................19969 Removal.............................................................................................................................19969 Installation........................................................................................................................19969 Oil Pump................................................................................................................................19972 Removal.............................................................................................................................19972 Installation........................................................................................................................19972 Oil Pump Oil Seal.......................................................................................................................19974 Removal.............................................................................................................................19974 Installation........................................................................................................................19974 Oil Filter..............................................................................................................................19975 Removal.............................................................................................................................19975 Installation........................................................................................................................19975 Main Data and Specification.............................................................................................................19976 6H ENGINE SPEED CONTROL SYSTEM..............................................................................................................19977 Service Precaution......................................................................................................................19977 Accelerator Pedal.......................................................................................................................19978 Accelerator Pedal and Associated Parts..............................................................................................19978 Removal.............................................................................................................................19978 Installation........................................................................................................................19978 6J INDUCTION................................................................................................................................19979 Service Precaution......................................................................................................................19979 Air Cleaner Element.....................................................................................................................19980 Removal.............................................................................................................................19980 Inspection..........................................................................................................................19980 Installation........................................................................................................................19980 Sec.7 TRANSMISSION..............................................................................................................................19981 7A AUTOMATIC TRANSMISSION (4L30‐E)..........................................................................................................19981 Service Precaution......................................................................................................................19983 Construction............................................................................................................................19983 Range Reference Chart...................................................................................................................19984 Normal Operation Of 2000 4L30‐E Transmission............................................................................................19985 Diagnosis...............................................................................................................................19985 Driver Information......................................................................................................................19985 General Diagnosis Procedure.............................................................................................................19988 Preliminary Inspection Chart............................................................................................................19989 Checking Transmission Fluid Level and Condition.........................................................................................19990 Test Driving............................................................................................................................19991 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................19992 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................19993 Stall Test..............................................................................................................................20003 Line Pressure Test......................................................................................................................20003 Shift Speed Chart.......................................................................................................................20004 Lockup Speed Chart......................................................................................................................20006 Changing Transmission Fluid.............................................................................................................20007 Selector Lever..........................................................................................................................20007 Inspection..........................................................................................................................20007 Removal.............................................................................................................................20007 Installation........................................................................................................................20008 Mode Switch.............................................................................................................................20009 Removal.............................................................................................................................20009 Installation........................................................................................................................20009 Transmission (With Transfer Case / Extension Assembly)..................................................................................20011 Transmission And Associated Parts...................................................................................................20011 Removal.............................................................................................................................20012 Installation........................................................................................................................20013 Solenoid (Main Case Valve Body).........................................................................................................20018 Removal.............................................................................................................................20018 Installation........................................................................................................................20018 Solenoid (Adapter Case Valve Body)......................................................................................................20019 Removal.............................................................................................................................20019 Installation........................................................................................................................20019 Valve Body Assembly (Main Case).........................................................................................................20020 Removal.............................................................................................................................20020 Installation........................................................................................................................20020 Valve Body Assembly (Adapter Case)......................................................................................................20021 Removal.............................................................................................................................20021 Installation........................................................................................................................20021 Powertrain Control Module (PCM).........................................................................................................20021 Removal.............................................................................................................................20021 Installation........................................................................................................................20021 Speed Sensor (Extension Housing)........................................................................................................20022 Removal.............................................................................................................................20022 Installation........................................................................................................................20022 Transmission Oil Temperature Sensor (Main Case).........................................................................................20022 Removal.............................................................................................................................20022 Installation........................................................................................................................20022 Front Oil Seal (Converter Housing)......................................................................................................20023 Removal.............................................................................................................................20023 Installation........................................................................................................................20023 Rear Oil Seal (Extension Housing).......................................................................................................20023 Removal.............................................................................................................................20023 Installation........................................................................................................................20024 Transmission (4L30–E)...................................................................................................................20024 Disassembly.........................................................................................................................20024 Reassembly..........................................................................................................................20028 Converter Housing And Oil Pump Assembly.................................................................................................20038 Disassembled View...................................................................................................................20038 Disassembly.........................................................................................................................20038 Inspection And Repair...............................................................................................................20038 Reassembly..........................................................................................................................20038 Oil Pump................................................................................................................................20039 Disassembled View...................................................................................................................20039 Disassembly.........................................................................................................................20039 Inspection And Repair...............................................................................................................20040 Reassembly..........................................................................................................................20040 Main Case Valve Body....................................................................................................................20041 Disassembled View...................................................................................................................20041 Disassembly.........................................................................................................................20041 Inspection And Repair...............................................................................................................20042 Reassembly..........................................................................................................................20042 Adapter Case Valve Body.................................................................................................................20043 Disassembled View...................................................................................................................20043 Disassembly.........................................................................................................................20043 Inspection And Repair...............................................................................................................20043 Reassembly..........................................................................................................................20043 Third Clutch And Sprag Unit.............................................................................................................20045 Disassembled View...................................................................................................................20045 Disassembly.........................................................................................................................20045 Inspection And Repair...............................................................................................................20045 Reassembly..........................................................................................................................20046 Third Clutch............................................................................................................................20047 Disassembled View...................................................................................................................20047 Disassemble.........................................................................................................................20047 Inspection And Repair...............................................................................................................20047 Reassembly..........................................................................................................................20047 Sprag Unit..............................................................................................................................20049 Disassembled View...................................................................................................................20049 Disassembly.........................................................................................................................20049 Inspection And Repair...............................................................................................................20049 Reassembly..........................................................................................................................20049 Second Clutch...........................................................................................................................20050 Disassembled View...................................................................................................................20050 Disassembly.........................................................................................................................20050 Inspection And Repair...............................................................................................................20051 Reassembly..........................................................................................................................20051 3–4 Accumulator Piston..................................................................................................................20052 Disassembled View...................................................................................................................20052 Disassembly.........................................................................................................................20052 Inspection And Repair...............................................................................................................20053 Reassembly..........................................................................................................................20053 Reverse Clutch Piston And Center Support................................................................................................20054 Disassembled View...................................................................................................................20054 Disassembly.........................................................................................................................20054 Inspection And Repair...............................................................................................................20055 Reassembly..........................................................................................................................20055 Overrun Clutch And Turbine Shaft........................................................................................................20056 Disassembled View...................................................................................................................20056 Disassembly.........................................................................................................................20057 Inspection And Repair...............................................................................................................20057 Reassembly..........................................................................................................................20057 Main Data And Specification.............................................................................................................20059 Special Tools...........................................................................................................................20063 4L30–E Parts List.......................................................................................................................20066 Extension Housing Assembly Oil Seal.....................................................................................................20074 Extension Housing Assembly Rear Oil Seal and Associated Parts.......................................................................20074 Removal.............................................................................................................................20074 Installation........................................................................................................................20074 Extension Housing Assembly..............................................................................................................20076 Extension Housing Assembly and Associated Parts.....................................................................................20076 Removal.............................................................................................................................20077 Installation........................................................................................................................20077 Extension Housing Assembly..............................................................................................................20079 Extension Housing Assembly and Associated Parts.....................................................................................20079 Removal.............................................................................................................................20080 Installation........................................................................................................................20080 Extension Housing Assembly..........................................................................................................20082 Disassembly.........................................................................................................................20083 Reassembly..........................................................................................................................20083 Inspection and Repair...............................................................................................................20084 Main Data and Specifications............................................................................................................20085 Special Tools...........................................................................................................................20086 7A1 TRANSMISSION CONTROL SYSTEM (4L30‐E)....................................................................................................20087 Service Precaution......................................................................................................................20088 General Description.....................................................................................................................20088 Electronic Control Diagram..........................................................................................................20089 Powertrain Control Module (PCM).....................................................................................................20090 Control System Diagram..............................................................................................................20091 Shift Control.......................................................................................................................20092 Band Apply Control..................................................................................................................20092 Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)..................................................20092 Line Pressure Control...............................................................................................................20092 On–Board Diagnostic System..........................................................................................................20092 Fail Safe Mechanism.................................................................................................................20092 Torque Management Control...........................................................................................................20092 ATF Warning Control.................................................................................................................20092 ABS Control.........................................................................................................................20092 Reverse Lock Out Control............................................................................................................20092 Downhill Control....................................................................................................................20092 Uphill Control......................................................................................................................20092 Shift Mode Control..................................................................................................................20093 Gear Shift Control..................................................................................................................20094 Winter Drive Mode...................................................................................................................20095 Backup Mode.........................................................................................................................20095 Functions of Input / Output Components..............................................................................................20096 Diagnosis...............................................................................................................................20097 Electronic Diagnosis................................................................................................................20097 Check Trans Indicator...............................................................................................................20097 Diagnostic Check....................................................................................................................20097 “Check Trans” Check.................................................................................................................20098 Tech 2 OBD II Connection............................................................................................................20099 Transmission Data...................................................................................................................20104 OBD II Diagnostic Management System.................................................................................................20105 16 – Terminal Data Link Connector (DLC).............................................................................................20106 Malfunction Indicator Lamp (MIL)....................................................................................................20107 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................20107 Clear DTC...........................................................................................................................20107 DTC Check...........................................................................................................................20108 PCM Precaution......................................................................................................................20108 Information On PCM..................................................................................................................20108 Intermittent Conditions.............................................................................................................20108 Transmission And PCM Identification.................................................................................................20109 Isuzu Trooper.......................................................................................................................20109 Diagnostic Trouble Code (DTC) Identification........................................................................................20110 DTC P0218 Transmission Fluid Over Temperature...........................................................................................20111 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................20113 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................20116 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................20119 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................20122 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................20125 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................20128 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................20131 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................20134 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................20137 DTC P0730 Gear Error Without Input Speed................................................................................................20139 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................20142 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................20144 DTC P0751 Shift Solenoid A Performance (Stuck OFF)......................................................................................20146 DTC P0752 Shift Solenoid A Performance (Stuck ON).......................................................................................20148 DTC P0753 Shift Solenoid A Electrical...................................................................................................20150 DTC P0756 Shift Solenoid B Performance (Stuck OFF)......................................................................................20153 DTC P0757 Shift Solenoid B Performance (Stuck ON).......................................................................................20155 DTC P0758 Shift Solenoid B Electrical...................................................................................................20157 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................20161 DTC P1860 TCC PWM Solenoid Electrical...................................................................................................20165 DTC P1870 Transmission Component Slipping (TCC Stuck OFF)...............................................................................20168 Connector List..........................................................................................................................20170 7B MANUAL TRANSMISSION......................................................................................................................20172 Service Precaution......................................................................................................................20172 General Description.....................................................................................................................20173 Diagnosis...............................................................................................................................20174 Manual Transmission Assembly............................................................................................................20175 Removal.............................................................................................................................20175 Installation........................................................................................................................20179 Disassembled View...................................................................................................................20184 Disassembly.........................................................................................................................20187 Inspection..........................................................................................................................20205 Reassembly..........................................................................................................................20207 Main Data and Specifications............................................................................................................20233 Special Tools...........................................................................................................................20235 7C CLUTCH...................................................................................................................................20237 Service Precaution......................................................................................................................20237 General Description.....................................................................................................................20238 Diagnosis...............................................................................................................................20242 Clutch Assembly.........................................................................................................................20243 Clutch Assembly and Associated Parts................................................................................................20243 Removal.............................................................................................................................20243 Inspection and Repair...............................................................................................................20244 Installation........................................................................................................................20248 Clutch Control..........................................................................................................................20251 Clutch Control Parts................................................................................................................20251 Removal.............................................................................................................................20251 Inspection and Repair...............................................................................................................20251 Installation........................................................................................................................20252 Adjustment..........................................................................................................................20252 Master Cylinder.........................................................................................................................20255 Inspection and Repair...............................................................................................................20255 Slave Cylinder..........................................................................................................................20256 Disassembled View...................................................................................................................20256 Disassembly.........................................................................................................................20256 Inspection and Repair...............................................................................................................20256 Reassembly..........................................................................................................................20257 Main Data and Specifications............................................................................................................20258 Special Tools...........................................................................................................................20260 Sec.8 BODY AND ACCESSORIES......................................................................................................................20261 8A LIGHTING SYSTEM..........................................................................................................................20261 Service Precaution......................................................................................................................20262 Headlight Bulb..........................................................................................................................20262 Removal.............................................................................................................................20262 Installation........................................................................................................................20262 Headlight...............................................................................................................................20263 Headlight and Associated Parts......................................................................................................20263 Removal.............................................................................................................................20263 Installation........................................................................................................................20263 Headlight Adjustment................................................................................................................20263 Fog Light Bulb..........................................................................................................................20264 Removal.............................................................................................................................20264 Installation........................................................................................................................20264 Fog Light Assembly......................................................................................................................20265 Removal.............................................................................................................................20265 Installation........................................................................................................................20265 Fog Light Adjustment................................................................................................................20265 Front Side Marker Light Bulb............................................................................................................20265 Removal.............................................................................................................................20265 Installation........................................................................................................................20265 Parking Light Bulb......................................................................................................................20266 Removal and Installation............................................................................................................20266 Taillight Bulb..........................................................................................................................20266 Removal.............................................................................................................................20266 Installation........................................................................................................................20266 License Plate Light Bulb................................................................................................................20267 Removal.............................................................................................................................20267 Installation........................................................................................................................20267 Stoplight Bulb..........................................................................................................................20267 Removal and Installation............................................................................................................20267 High Mount Stoplight....................................................................................................................20268 Removal.............................................................................................................................20268 Installation........................................................................................................................20268 Front Turn Signal Light Bulb............................................................................................................20268 Removal.............................................................................................................................20268 Installation........................................................................................................................20268 Rear Turn Signal Light Bulb.............................................................................................................20269 Removal.............................................................................................................................20269 Installation........................................................................................................................20269 Cornering Light Bulb....................................................................................................................20269 Removal.............................................................................................................................20269 Installation........................................................................................................................20269 Backup Light Bulb.......................................................................................................................20270 Removal.............................................................................................................................20270 Installation........................................................................................................................20270 Dome Light Bulb.........................................................................................................................20270 Removal.............................................................................................................................20270 Installation........................................................................................................................20270 Luggage Room Light Bulb.................................................................................................................20271 Removal.............................................................................................................................20271 Installation........................................................................................................................20271 Courtesy Light Bulb.....................................................................................................................20271 Removal.............................................................................................................................20271 Installation........................................................................................................................20271 Map Light Switch/Bulb...................................................................................................................20272 Removal.............................................................................................................................20272 Installation........................................................................................................................20272 Ashtray Illumination Bulb...............................................................................................................20272 Removal.............................................................................................................................20272 Installation........................................................................................................................20272 Glove Box Illumination Bulb.............................................................................................................20273 Removal.............................................................................................................................20273 Installation........................................................................................................................20273 Vanity Mirror Illumination Bulb.........................................................................................................20273 Removal.............................................................................................................................20273 Installation........................................................................................................................20273 Starter Switch..........................................................................................................................20274 Removal.............................................................................................................................20274 Installation........................................................................................................................20274 Lighting Switch (Combination Switch)....................................................................................................20275 Removal.............................................................................................................................20275 Installation........................................................................................................................20275 Fog Light Switch........................................................................................................................20276 Removal.............................................................................................................................20276 Installation........................................................................................................................20276 Stoplight Switch (W/O Cruise Control)...................................................................................................20277 Removal.............................................................................................................................20277 Installation........................................................................................................................20277 Brake Switch (W/Cruise Control).........................................................................................................20278 Removal.............................................................................................................................20278 Installation........................................................................................................................20278 Turn Signal Switch/Cornering Light Switch (Combination Switch)..........................................................................20278 Removal and Installation............................................................................................................20278 Hazard Warning Switch...................................................................................................................20279 Removal.............................................................................................................................20279 Installation........................................................................................................................20279 Tailgate Switch.........................................................................................................................20280 Removal.............................................................................................................................20280 Installation........................................................................................................................20280 Door Switch.............................................................................................................................20280 Removal.............................................................................................................................20280 Installation........................................................................................................................20280 Rear Defogger Switch....................................................................................................................20281 Removal.............................................................................................................................20281 Installation........................................................................................................................20281 Seat Heater Switch......................................................................................................................20282 Removal.............................................................................................................................20282 Installation........................................................................................................................20282 Key Remind Switch (Starter Switch)......................................................................................................20282 Removal and Installation............................................................................................................20282 Illumination Controller.................................................................................................................20283 Removal.............................................................................................................................20283 Installation........................................................................................................................20283 Main Data and Specifications............................................................................................................20284 8B WIPER / WASHER SYSTEM....................................................................................................................20286 Service Precaution......................................................................................................................20286 Windshield Wiper/Washer System..........................................................................................................20287 General Description.....................................................................................................................20287 Windshield Wiper And Washer Switch......................................................................................................20287 Removal and Installation............................................................................................................20287 Windshield Wiper Motor..................................................................................................................20287 Removal.............................................................................................................................20287 Installation........................................................................................................................20287 Windshield Washer Motor.................................................................................................................20288 Removal.............................................................................................................................20288 Installation........................................................................................................................20288 Windshield Wiper Linkage................................................................................................................20289 Windshield Wiper Linkage and Associated Parts.......................................................................................20289 Removal.............................................................................................................................20289 Installation........................................................................................................................20289 Windshield Wiper Arm/Blade..............................................................................................................20290 Removal.............................................................................................................................20290 Installation........................................................................................................................20290 Windshield Wiper Blade Rubber...........................................................................................................20291 Removal.............................................................................................................................20291 Installation........................................................................................................................20291 Rear Wiper/Washer System................................................................................................................20292 General Description.....................................................................................................................20292 Rear Wiper and Washer Switch............................................................................................................20292 Removal.............................................................................................................................20292 Installation........................................................................................................................20292 Rear Wiper Motor........................................................................................................................20293 Removal.............................................................................................................................20293 Installation........................................................................................................................20293 Alarm & Relay Control Unit..............................................................................................................20294 Removal.............................................................................................................................20294 Installation........................................................................................................................20294 Rear Washer Motor.......................................................................................................................20294 Removal.............................................................................................................................20294 Installation........................................................................................................................20294 Rear Wiper Arm/Blade....................................................................................................................20295 Removal.............................................................................................................................20295 Installation........................................................................................................................20295 Rear Washer Nozzle......................................................................................................................20295 Removal.............................................................................................................................20295 Installation........................................................................................................................20295 Rear Washer Nozzle Angle Adjustment.................................................................................................20295 Rear Wiper Blade Rubber.................................................................................................................20296 Removal and Installation............................................................................................................20296 Main Data and Specifications............................................................................................................20296 8C ENTERTAINMENT............................................................................................................................20297 Service Precaution......................................................................................................................20297 Cigarette Lighter.......................................................................................................................20298 General Description.....................................................................................................................20298 Removal.............................................................................................................................20298 Installation........................................................................................................................20298 Digital Clock and Outside Temp..........................................................................................................20299 Removal.............................................................................................................................20299 Installation........................................................................................................................20299 Front ACC Socket........................................................................................................................20300 Removal.............................................................................................................................20300 Installation........................................................................................................................20300 Rear ACC Socket.........................................................................................................................20300 Removal.............................................................................................................................20300 Installation........................................................................................................................20300 Rod Type Antenna........................................................................................................................20301 Removal.............................................................................................................................20301 Installation........................................................................................................................20301 Diversity Glass Antenna.................................................................................................................20302 Glass Antenna System Parts Location.................................................................................................20302 Glass Antenna Pattern...................................................................................................................20303 Glass Antenna Amplifier Removal.....................................................................................................20303 Glass Antenna Amplifier Installation................................................................................................20303 Radio...................................................................................................................................20304 Removal.............................................................................................................................20304 Installation........................................................................................................................20304 Front Speaker...........................................................................................................................20305 Removal.............................................................................................................................20305 Installation........................................................................................................................20305 Tweeter Assembly........................................................................................................................20305 Removal.............................................................................................................................20305 Installation........................................................................................................................20305 Rear Speaker............................................................................................................................20306 Removal.............................................................................................................................20306 Installation........................................................................................................................20306 8D WIRING SYSTEM............................................................................................................................20307 Fuse, Relay and Diode...................................................................................................................20308 Relay and Fuse Box / Fuse Box Location..............................................................................................20308 Relay & Fuse Box....................................................................................................................20309 Fuse Box............................................................................................................................20310 Circuit Diagram.........................................................................................................................20311 8E METER AND GAUGE..........................................................................................................................20344 Service Precaution......................................................................................................................20344 General Description.....................................................................................................................20344 Meter Assembly..........................................................................................................................20345 General Description.....................................................................................................................20345 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................20345 Table for Meter/Gauge Connector Terminal Connections................................................................................20349 Removal.............................................................................................................................20353 Installation........................................................................................................................20353 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb.............................................20353 Removal.............................................................................................................................20353 Installation........................................................................................................................20353 Vehicle Speed Sensor....................................................................................................................20354 Removal.............................................................................................................................20354 Installation........................................................................................................................20354 Fuel Tank Unit..........................................................................................................................20354 Removal.............................................................................................................................20354 Installation........................................................................................................................20354 Multi Meter.............................................................................................................................20355 Removal.............................................................................................................................20355 Installation........................................................................................................................20355 Ambient Sensor..........................................................................................................................20355 Removal.............................................................................................................................20355 Installation........................................................................................................................20355 Main Data and Specifications............................................................................................................20356 8F BODY STRUCTURE...........................................................................................................................20357 Service Precaution......................................................................................................................20359 Frame...................................................................................................................................20359 Frame Dimensions....................................................................................................................20360 General Description.................................................................................................................20361 Front Bumper............................................................................................................................20361 Parts Location......................................................................................................................20361 Removal.............................................................................................................................20362 Installation........................................................................................................................20362 Front Bumper Slider Bracket.............................................................................................................20362 Removal.............................................................................................................................20362 Installation........................................................................................................................20362 Rear Bumper.............................................................................................................................20363 Parts Location......................................................................................................................20363 Removal.............................................................................................................................20364 Installation........................................................................................................................20364 Rear Bumper Slider......................................................................................................................20365 Removal.............................................................................................................................20365 Installation........................................................................................................................20365 General Description.....................................................................................................................20366 Cowl Cover..............................................................................................................................20366 Parts Location......................................................................................................................20366 Removal.............................................................................................................................20367 Installation........................................................................................................................20367 Engine Hood.............................................................................................................................20367 Removal.............................................................................................................................20367 Installation........................................................................................................................20367 Engine Hood Hinge.......................................................................................................................20368 Parts Location......................................................................................................................20368 Removal.............................................................................................................................20368 Installation........................................................................................................................20368 Engine Hood Lock........................................................................................................................20369 Parts Location......................................................................................................................20369 Removal.............................................................................................................................20369 Installation........................................................................................................................20370 Radiator Grille And Front End Lower Panel...............................................................................................20370 Parts Location......................................................................................................................20370 Removal.............................................................................................................................20371 Installation........................................................................................................................20371 Front Fender Panel......................................................................................................................20372 Parts Location......................................................................................................................20372 Removal.............................................................................................................................20372 Installation........................................................................................................................20373 Body Mounting...........................................................................................................................20374 Parts Location......................................................................................................................20374 Removal (No.1 – No. 2)..............................................................................................................20374 Removal (No. 3 — No. 6).............................................................................................................20375 Installation........................................................................................................................20376 General Description.....................................................................................................................20377 Body Dimension..........................................................................................................................20378 Instrument Panel Assembly...............................................................................................................20396 Parts Location......................................................................................................................20396 Removal.............................................................................................................................20397 Installation........................................................................................................................20401 Cross Beam Assembly.....................................................................................................................20402 Parts Location......................................................................................................................20402 Removal.............................................................................................................................20402 Installation........................................................................................................................20403 Front Door Assembly.....................................................................................................................20404 Parts Location......................................................................................................................20404 Removal.............................................................................................................................20404 Installation........................................................................................................................20404 Rear Door Assembly......................................................................................................................20405 Parts Location......................................................................................................................20405 Removal.............................................................................................................................20405 Installation........................................................................................................................20406 Door Strikers...........................................................................................................................20406 Adjustment..........................................................................................................................20406 Door Check Arm Assembly (Front & Rear)..................................................................................................20407 Parts Location......................................................................................................................20407 Removal.............................................................................................................................20407 Installation........................................................................................................................20408 Front Window Regulator, Glass And Glass Run.............................................................................................20408 Parts Location......................................................................................................................20408 Removal.............................................................................................................................20408 Installation........................................................................................................................20410 Rear Window Regulator And Glass.........................................................................................................20411 Parts Location......................................................................................................................20411 Removal.............................................................................................................................20411 Installation........................................................................................................................20412 Rear Door Fixed Glass And Glass Run.....................................................................................................20413 Parts Location......................................................................................................................20413 Removal.............................................................................................................................20413 Installation........................................................................................................................20414 Front Door Sash Moulding................................................................................................................20415 Parts Location......................................................................................................................20415 Removal.............................................................................................................................20415 Installation........................................................................................................................20415 Rear Door Moulding......................................................................................................................20416 Parts Location......................................................................................................................20416 Removal.............................................................................................................................20416 Installation........................................................................................................................20416 Front Door Waist Seal...................................................................................................................20417 Parts Location......................................................................................................................20417 Removal.............................................................................................................................20417 Installation........................................................................................................................20417 Rear Door Waist Seal....................................................................................................................20418 Parts Location......................................................................................................................20418 Removal and Installation............................................................................................................20418 Front Door Weatherstrip.................................................................................................................20419 Parts Location......................................................................................................................20419 Removal.............................................................................................................................20419 Installation........................................................................................................................20420 Rear Door Weatherstrip..................................................................................................................20421 Parts Location......................................................................................................................20421 Removal and Installation............................................................................................................20421 Front Door Seal Finisher................................................................................................................20422 Parts Location......................................................................................................................20422 Removal.............................................................................................................................20422 Installation........................................................................................................................20422 Rear Door Seal Finisher.................................................................................................................20423 Parts Location......................................................................................................................20423 Removal.............................................................................................................................20423 Installation........................................................................................................................20423 Tailgate Assembly (LH)..................................................................................................................20424 Parts Location......................................................................................................................20424 Removal.............................................................................................................................20424 Installation........................................................................................................................20425 Tailgate Assembly (RH)..................................................................................................................20426 Parts Location......................................................................................................................20426 Removal.............................................................................................................................20426 Installation........................................................................................................................20427 Tailgate Strikers.......................................................................................................................20428 Adjustment..........................................................................................................................20428 Tailgate Stopper Assembly...............................................................................................................20428 Parts Location......................................................................................................................20428 Removal.............................................................................................................................20428 Installation........................................................................................................................20428 Tailgate Dove-Tail......................................................................................................................20429 Parts Location......................................................................................................................20429 Removal.............................................................................................................................20429 Installation........................................................................................................................20429 Tailgate Dove-Tail Striker..............................................................................................................20430 Adjustment..........................................................................................................................20430 Tailgate Frame Cover (LH)...............................................................................................................20431 Parts Location......................................................................................................................20431 Removal.............................................................................................................................20431 Installation........................................................................................................................20431 Tailgate Frame Cover (RH)...............................................................................................................20432 Removal.............................................................................................................................20432 Installation........................................................................................................................20432 Tailgate Sash Trim Cover................................................................................................................20433 Parts Location......................................................................................................................20433 Removal.............................................................................................................................20433 Installation........................................................................................................................20433 Tailgate Outer Weatherstrip.............................................................................................................20434 Parts Location......................................................................................................................20434 Removal.............................................................................................................................20434 Installation........................................................................................................................20434 Tailgate Center Weatherstrip............................................................................................................20435 Parts Location......................................................................................................................20435 Removal.............................................................................................................................20435 Installation........................................................................................................................20435 Tailgate Main Weatherstrip..............................................................................................................20436 Parts Location......................................................................................................................20436 Removal.............................................................................................................................20436 Installation........................................................................................................................20436 Spare Tire Carrier......................................................................................................................20437 Parts Location......................................................................................................................20437 Removal.............................................................................................................................20437 Installation........................................................................................................................20437 Headlining..............................................................................................................................20438 Parts Location......................................................................................................................20438 Removal.............................................................................................................................20438 Installation........................................................................................................................20439 Rear Air Deflector......................................................................................................................20440 Parts Location......................................................................................................................20440 Removal.............................................................................................................................20440 Installation........................................................................................................................20440 Roof Moulding...........................................................................................................................20442 Parts Location......................................................................................................................20442 Removal.............................................................................................................................20442 Installation........................................................................................................................20443 Windshield..............................................................................................................................20444 Parts Location......................................................................................................................20444 Removal.............................................................................................................................20444 Installation........................................................................................................................20445 Rear Quarter Side Glass.................................................................................................................20449 Parts Location......................................................................................................................20449 Removal.............................................................................................................................20449 Installation........................................................................................................................20449 Tailgate Glass..........................................................................................................................20451 Parts Location......................................................................................................................20451 Removal.............................................................................................................................20451 Installation........................................................................................................................20452 Main Data and Specifications............................................................................................................20453 Special Tools...........................................................................................................................20463 8G SEATS....................................................................................................................................20464 Service Precaution......................................................................................................................20464 Front Seat Assembly.....................................................................................................................20465 Front Seat Assembly and Associated Parts............................................................................................20465 Removal.............................................................................................................................20465 Installation........................................................................................................................20465 Disassembled View...................................................................................................................20466 Disassembly.........................................................................................................................20467 Reassembly..........................................................................................................................20468 Power Seat Assembly.....................................................................................................................20469 General Description.....................................................................................................................20469 Disassembled View...................................................................................................................20469 Disassembly.........................................................................................................................20470 Reassembly..........................................................................................................................20472 Power Seat Switch.......................................................................................................................20472 Removal.............................................................................................................................20472 Installation........................................................................................................................20472 Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor.......................................................................20473 Parts Location......................................................................................................................20473 Removal and Installation............................................................................................................20473 Seat Heater System......................................................................................................................20474 General Description.....................................................................................................................20474 Seat Heater Switch Removal and Installation.........................................................................................20474 Heat Unit Parts Location............................................................................................................20474 Heat Unit Removal and Installation..................................................................................................20474 Rear Seat Assembly......................................................................................................................20475 Rear Seat Assembly and Associated Parts.............................................................................................20475 Removal.............................................................................................................................20475 Installation........................................................................................................................20475 Disassembled View (Split Type)......................................................................................................20476 Disassembly (Split Type)............................................................................................................20477 Reassembly (Split Type).............................................................................................................20478 Disassembled View (Bench Type)......................................................................................................20479 Disassembly (Bench Type)............................................................................................................20480 Reassembly (Bench Type).............................................................................................................20481 Main Data and Specifications............................................................................................................20481 8H SECURITY AND LOCKS.......................................................................................................................20483 Service Precaution......................................................................................................................20484 Front Door Lock Assembly................................................................................................................20484 Front Door Lock Assembly and Associated Parts.......................................................................................20484 Removal.............................................................................................................................20485 Installation........................................................................................................................20485 Front Outside Handle and Door Lock Cylinder.............................................................................................20486 Front Outside Handle, Door Lock Cylinder and Associated Parts.......................................................................20486 Removal.............................................................................................................................20486 Installation........................................................................................................................20487 Rear Door Lock Assembly.................................................................................................................20489 Rear Door Lock Assembly and Associated Parts........................................................................................20489 Removal.............................................................................................................................20489 Installation........................................................................................................................20490 Rear Outside Handle.....................................................................................................................20491 Rear Outside Handle and Associated Parts............................................................................................20491 Removal.............................................................................................................................20491 Installation........................................................................................................................20492 Rear Door Inside Lock Knob Link.........................................................................................................20492 Removal.............................................................................................................................20492 Installation........................................................................................................................20492 Door Inside Lock Knob...................................................................................................................20493 Removal.............................................................................................................................20493 Installation........................................................................................................................20493 Door Inside Handle......................................................................................................................20493 Removal and Installation............................................................................................................20493 Tailgate Lock Assembly (LH).............................................................................................................20494 Tailgate Lock Assembly (LH) and Associated Parts....................................................................................20494 Removal.............................................................................................................................20494 Installation........................................................................................................................20495 Tailgate Lock Assembly (RH).............................................................................................................20496 Tailgate Lock Assembly (RH) and Associated Parts....................................................................................20496 Removal.............................................................................................................................20496 Installation........................................................................................................................20497 Tailgate Inside Lock Knob...............................................................................................................20497 Removal.............................................................................................................................20497 Installation........................................................................................................................20497 Tailgate Outside Handle and/or Tailgate Lock Cylinder...................................................................................20498 Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts..........................................................20498 Removal.............................................................................................................................20498 Installation........................................................................................................................20499 Key.....................................................................................................................................20500 Key Coding..........................................................................................................................20500 Key Styles..........................................................................................................................20500 Power Door Lock System..................................................................................................................20501 General Description.....................................................................................................................20501 Front Door Lock Actuator Removal....................................................................................................20501 Front Door Lock Actuator Installation...............................................................................................20501 Rear Door Lock Actuator Removal.....................................................................................................20501 Rear Door Lock Actuator Installation................................................................................................20502 Tailgate Lock Actuator Removal......................................................................................................20502 Tailgate Lock Actuator Installation.................................................................................................20502 Anti-theft System.......................................................................................................................20503 General Description.....................................................................................................................20503 Anti-theft & Keyless Entry Control Unit Removal.....................................................................................20503 Anti-theft & Keyless Entry Control Unit Installation................................................................................20503 Anti-theft Indicator Removal........................................................................................................20503 Anti-theft Indicator Installation...................................................................................................20504 Anti-theft Horn Removal.............................................................................................................20504 Anti-Theft Horn Installation........................................................................................................20504 Engine Hood Switch Removal..........................................................................................................20504 Engine Hood Switch Installation.....................................................................................................20504 Keyless Entry System....................................................................................................................20505 ID Code Registration................................................................................................................20505 Anti‐theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................20507 Main Data and Specifications............................................................................................................20508 8I SUN ROOF/CONVERTIBLE TOP.................................................................................................................20509 Service Precaution......................................................................................................................20509 Sun Roof Glass..........................................................................................................................20510 Sun Roof Glass and Associated Parts.................................................................................................20510 Removal.............................................................................................................................20510 Installation........................................................................................................................20511 Sun Roof Deflector......................................................................................................................20512 Removal.............................................................................................................................20512 Installation........................................................................................................................20512 Sunshade................................................................................................................................20512 Disassembled View...................................................................................................................20512 Removal.............................................................................................................................20513 Installation........................................................................................................................20513 Sun Roof Frame Complete Assembly........................................................................................................20514 Sun Roof Frame Complete Assembly and Associated Parts...............................................................................20514 Removal.............................................................................................................................20514 Installation........................................................................................................................20515 Disassembled View...................................................................................................................20515 Disassembly.........................................................................................................................20515 Reassembly..........................................................................................................................20516 Sun Roof Drain Hose (Front Side)........................................................................................................20517 Sun Roof Drain Hose (Front Side) and Associated Parts...............................................................................20517 Removal.............................................................................................................................20517 Installation........................................................................................................................20517 Sun Roof Drain Hose (Rear Side).........................................................................................................20518 Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................20518 Removal.............................................................................................................................20518 Installation........................................................................................................................20518 Sun Roof Switch.........................................................................................................................20519 General Description.....................................................................................................................20519 Removal.............................................................................................................................20519 Installation........................................................................................................................20519 Sun Roof Motor..........................................................................................................................20520 Removal.............................................................................................................................20520 Installation........................................................................................................................20520 Main Data and Specifications............................................................................................................20521 8J EXTERIOR / INTERIOR TRIM.................................................................................................................20522 Service Precaution......................................................................................................................20523 Dash Side Trim Panel....................................................................................................................20524 Removal.............................................................................................................................20524 Installation........................................................................................................................20524 Assist Grip.............................................................................................................................20524 Parts Location......................................................................................................................20524 Removal and Installation............................................................................................................20524 Consoles................................................................................................................................20525 Consoles and Associated Parts.......................................................................................................20525 Removal.............................................................................................................................20525 Installation........................................................................................................................20526 Front Door Trim Panel...................................................................................................................20527 Front Door Trim Panel and Associated Parts..........................................................................................20527 Removal.............................................................................................................................20527 Installation........................................................................................................................20530 Rear Door Trim Panel....................................................................................................................20531 Rear Door Trim Panel and Associated Parts...........................................................................................20531 Removal.............................................................................................................................20531 Installation........................................................................................................................20532 Door Wood Panel Assembly................................................................................................................20534 Door Wood Panel Assembly and Associated Parts.......................................................................................20534 Removal.............................................................................................................................20534 Installation........................................................................................................................20534 Door Mirror.............................................................................................................................20535 Door Mirror and Associated Parts....................................................................................................20535 Removal.............................................................................................................................20535 Installation........................................................................................................................20535 Luggage Side and Quarter Upper Trim Cover...............................................................................................20536 Luggage Side, Quarter Upper Trim Cover and Associated Parts.........................................................................20536 Removal.............................................................................................................................20536 Installation........................................................................................................................20538 Center Pillar and Roof Side Trim Cover..................................................................................................20539 Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................20539 Removal.............................................................................................................................20539 Installation........................................................................................................................20540 Front Pillar Trim Cover.................................................................................................................20541 Front Pillar Trim Cover and Associated Parts.......................................................................................20541 Removal.............................................................................................................................20541 Installation........................................................................................................................20541 Center Pillar Assist Grip...............................................................................................................20542 Parts Location......................................................................................................................20542 Removal and Installation............................................................................................................20542 Assist Grip.............................................................................................................................20542 Parts Location......................................................................................................................20542 Removal and Installation............................................................................................................20542 Fuel Filler Lid Opener Cable............................................................................................................20543 Fuel Filler Lid Opener Cable and Associated Parts...................................................................................20543 Removal.............................................................................................................................20543 Installation........................................................................................................................20544 Fuel Filler Door........................................................................................................................20544 Parts Location......................................................................................................................20544 Removal.............................................................................................................................20544 Installation........................................................................................................................20544 Rocker Protector (Without Wheel Opening Extension)......................................................................................20545 Rocker Protector (Without Wheel Opening Extension) and Associated Parts.............................................................20545 Removal.............................................................................................................................20545 Installation........................................................................................................................20545 Wheel Opening Extension and Rocker Protector Assembly...................................................................................20546 Wheel Opening Extension, Rocker Protector Assembly and Associated Parts.............................................................20546 Removal.............................................................................................................................20546 Installation........................................................................................................................20547 Mud Flaps (With Wheel Opening Extension)................................................................................................20548 Mud Flaps (With Wheel Opening Extension) and Associated Parts.......................................................................20548 Removal.............................................................................................................................20548 Installation........................................................................................................................20548 Ventilation Assembly....................................................................................................................20549 Ventilation Assembly and Associated Parts...........................................................................................20549 Removal.............................................................................................................................20549 Installation........................................................................................................................20549 Tailgate Trim Panel (LH)................................................................................................................20550 Tailgate Trim Panel (LH) and Associated Parts.......................................................................................20550 Removal.............................................................................................................................20550 Installation........................................................................................................................20550 Tailgate Trim Panel (RH)................................................................................................................20551 Parts Location......................................................................................................................20551 Removal.............................................................................................................................20551 Installation........................................................................................................................20551 Luggage Floor Box.......................................................................................................................20552 Luggage Floor Box and Associated Parts..............................................................................................20552 Remove..............................................................................................................................20552 Installation........................................................................................................................20552 Rope Hook Set...........................................................................................................................20552 Rope Hook Set and Associated Parts..................................................................................................20552 Removal.............................................................................................................................20552 Installation........................................................................................................................20552 Power Door Mirror System................................................................................................................20553 General Description.....................................................................................................................20553 Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................20553 Installation........................................................................................................................20553 Power Door Mirror.......................................................................................................................20554 General Description.................................................................................................................20554 Removal and Installation............................................................................................................20554 Power Window System.....................................................................................................................20555 General Description.....................................................................................................................20555 Power Window Switch Removal and Installation........................................................................................20555 Power Window Motor Removal and Installation.........................................................................................20556 Main Data and Specifications............................................................................................................20557 Sec.9 RESTRAINTS................................................................................................................................20558 9A SEAT BELT SYSTEM.........................................................................................................................20558 Service Precaution......................................................................................................................20558 Seat Belt...............................................................................................................................20559 Front Seat Belt and Associated Parts................................................................................................20559 Removal.............................................................................................................................20559 Inspection..........................................................................................................................20559 Installation........................................................................................................................20560 Rear Seat Belt and Associated Parts.................................................................................................20560 Removal.............................................................................................................................20561 Inspection..........................................................................................................................20561 Installation........................................................................................................................20561 Front Seat Buckle Assembly..............................................................................................................20561 Removal.............................................................................................................................20561 Installation........................................................................................................................20561 Rear Center Seat Belt / Buckle Assembly.................................................................................................20562 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................20562 Removal.............................................................................................................................20562 Installation........................................................................................................................20562 Rear Seat Lock Assembly.................................................................................................................20563 Removal.............................................................................................................................20563 Installation........................................................................................................................20563 Rear Seat Lock Assembly (Bench Type)....................................................................................................20563 Removal.............................................................................................................................20563 Installation........................................................................................................................20563 Rear Seat Strikers......................................................................................................................20564 Removal.............................................................................................................................20564 Installation........................................................................................................................20564 Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................20564 General Description.....................................................................................................................20564 Child Seat Tether Anchor Bracket and Associated Parts...............................................................................20564 Installation........................................................................................................................20564 Main Data and Specifications............................................................................................................20565 9J SUPPLEMENTAL RESTRAINT SYSTEM............................................................................................................20566 Service Precaution......................................................................................................................20566 General Description.....................................................................................................................20567 SRS Component And Wiring Location View..................................................................................................20569 Component Description...................................................................................................................20569 Definitions.............................................................................................................................20572 Diagnosis...............................................................................................................................20573 SRS Connector Body Face Views...........................................................................................................20574 Repairs And Inspections Required After An Accident......................................................................................20574 On–Vehicle Service......................................................................................................................20575 Air Bag Assembly Handling / Shipping / Scrapping.......................................................................................20576 Special Tools...........................................................................................................................20585 Service Precautions for SRS Component Service...........................................................................................20589 SRS Connectors..........................................................................................................................20590 Sensing And Diagnostic Module (SDM).....................................................................................................20592 Service Precautions.................................................................................................................20592 Removal.............................................................................................................................20592 Installation........................................................................................................................20592 Driver Air Bag Assembly.................................................................................................................20594 Service Precautions.................................................................................................................20594 Removal.............................................................................................................................20594 Installation........................................................................................................................20595 Steering Wheel..........................................................................................................................20596 Service Precautions.................................................................................................................20596 Removal.............................................................................................................................20596 Installation........................................................................................................................20597 SRS Coil Assembly.......................................................................................................................20599 Service Precautions.................................................................................................................20599 Removal.............................................................................................................................20599 Installation........................................................................................................................20600 Steering Column.........................................................................................................................20602 Service Precautions.................................................................................................................20602 Removal.............................................................................................................................20602 Installation........................................................................................................................20604 Passenger Air Bag Assembly..............................................................................................................20606 Service Precautions.................................................................................................................20606 Removal.............................................................................................................................20606 Installation........................................................................................................................20607 Main Data and Specifications............................................................................................................20607 9J1 RESTRAINT CONTROL SYSTEM................................................................................................................20608 Service Precaution......................................................................................................................20608 Diagnostic Information..................................................................................................................20609 System Schematic........................................................................................................................20611 SRS Diagnostic System Check.............................................................................................................20611 Chart A SDM Integrity Check.............................................................................................................20613 Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................20615 Chart C “AIR BAG” Warning Lamp Does Not Come “ON” Steady (1/2)..........................................................................20617 DTC 15 Passenger Deployment Loop Resistance High........................................................................................20620 DTC 16 Passenger Deployment loop Resistance Low.........................................................................................20622 DTC 17 Passenger Deployment Loop Open...................................................................................................20624 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................20626 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................20628 DTC 21 Driver Deployment Loop Resistance High...........................................................................................20630 DTC 22 Driver Deployment Loop Resistance Low............................................................................................20633 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................20635 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................20637 DTC 26 Driver Deployment Loop Open......................................................................................................20639 DTC 51 Deployment Event Commanded.......................................................................................................20641 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................20643 DTC 61 Warning Lamp Circuit Failure.....................................................................................................20645 DTC 71 Internal SDM Fault...............................................................................................................20647 Sec.10 CONTROL SYSTEM...........................................................................................................................20649 10A CRUISE CONTROL SYSTEM...................................................................................................................20649 Service Precaution......................................................................................................................20649 General Description.....................................................................................................................20649 Brake Switch............................................................................................................................20650 Removal.............................................................................................................................20650 Installation........................................................................................................................20650 Adjustment..........................................................................................................................20651 Clutch Switch...........................................................................................................................20651 Removal and Installation............................................................................................................20651 Adjustment..........................................................................................................................20651 Starter Switch..........................................................................................................................20652 Removal.............................................................................................................................20652 Installation........................................................................................................................20652 Cruise Control Main Switch..............................................................................................................20653 Removal.............................................................................................................................20653 Installation........................................................................................................................20653 Cruise Control Switch (Combination Switch)..............................................................................................20653 Removal and Installation............................................................................................................20653 Powertrain Control Module (PCM).........................................................................................................20653 Removal and Installation............................................................................................................20653 Mode Switch.............................................................................................................................20653 Removal and Installation............................................................................................................20653 Diagnosis...............................................................................................................................20654 Diagnostic trouble cade.............................................................................................................20654 (UE) RODEO..........................................................................................................................................20655 Sec.0 GENERAL INFORMATION.......................................................................................................................20656 0A General Information......................................................................................................................20656 General Repair Instruction..............................................................................................................20656 Illustration Arrows.....................................................................................................................20657 Identification..........................................................................................................................20659 Theft Prevention Standard...............................................................................................................20662 Lifting Instructions....................................................................................................................20667 Standard Bolts Torque Specifications....................................................................................................20669 Abbreviations Charts....................................................................................................................20670 Service Parts Identification Plate......................................................................................................20672 0B Maintenance and Lubrication..............................................................................................................20673 Maintenance Schedule List...............................................................................................................20673 Explanation of Complete Vehicle Maintenance Schedule....................................................................................20677 Recommended Fluids and Lubricants...................................................................................................20680 Lubricant Viscosity Chart...............................................................................................................20681 Recommended Liquid Gasket...........................................................................................................20683 Recommended Thread Locking Agents...................................................................................................20683 Maintenance Service Data................................................................................................................20684 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................20685 1A HVAC SYSTEMS.............................................................................................................................20685 Service Precaution......................................................................................................................20686 Heating and Ventilation System..........................................................................................................20686 General Description.....................................................................................................................20686 Wiring Diagram..........................................................................................................................20690 Diagnosis...............................................................................................................................20691 Individual Inspection...................................................................................................................20695 Heater Unit.............................................................................................................................20697 Heater Unit and Associated Parts....................................................................................................20697 Removal.............................................................................................................................20697 Installation........................................................................................................................20698 Heater Core and / or Mode Door..........................................................................................................20698 Disassembled View...................................................................................................................20698 Removal.............................................................................................................................20699 Inspection..........................................................................................................................20699 Installation........................................................................................................................20699 Heater Mode Control Link Unit...........................................................................................................20700 Disassembled View...................................................................................................................20700 Removal.............................................................................................................................20700 Installation........................................................................................................................20701 Heater Temperature Control Link Unit....................................................................................................20701 Disassembled View...................................................................................................................20701 Removal.............................................................................................................................20701 Installation........................................................................................................................20702 Blower Assembly.........................................................................................................................20702 Blower Assembly and Associated Parts................................................................................................20702 Removal.............................................................................................................................20703 Installation........................................................................................................................20703 Blower Link Unit and / or Mode door.....................................................................................................20703 Disassembled View...................................................................................................................20703 Removal.............................................................................................................................20703 Installation........................................................................................................................20704 Blower Motor............................................................................................................................20705 Blower Motor and Associated Parts...................................................................................................20705 Removal.............................................................................................................................20705 Installation........................................................................................................................20705 Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................20706 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................20706 Removal.............................................................................................................................20706 Installation........................................................................................................................20707 Control Lever Assembly and / or Control Cable...........................................................................................20707 Control Lever Assembly, Control Cable and Associated Parts..........................................................................20707 Removal.............................................................................................................................20708 Installation........................................................................................................................20709 Control Panel Illumination Bulb.........................................................................................................20710 Control Panel Illumination Bulb and Associated Parts................................................................................20710 Removal.............................................................................................................................20710 Installation........................................................................................................................20710 Resistor................................................................................................................................20710 Resistor and Associated Parts.......................................................................................................20710 Removal.............................................................................................................................20710 Installation........................................................................................................................20710 Air Conditioning System.................................................................................................................20711 General Description.....................................................................................................................20711 Diagnosis...............................................................................................................................20721 Air Source Select Lever Diagnosis.......................................................................................................20731 Air Conditioning System.................................................................................................................20734 Individual Inspection...............................................................................................................20734 General Repair Procedure............................................................................................................20735 Leak Check..........................................................................................................................20737 Compressor Assembly.....................................................................................................................20742 Compressor Assembly and Associated Parts (6VD1).....................................................................................20742 Removal.............................................................................................................................20742 Installation........................................................................................................................20743 New Compressor Installation.........................................................................................................20743 Compressor Assembly.....................................................................................................................20744 Compressor Assembly and Associated Parts (X22SE)....................................................................................20744 Removal.............................................................................................................................20744 Installation........................................................................................................................20745 New Compressor Installation.........................................................................................................20745 Condenser Assembly......................................................................................................................20746 Condenser Assembly and Associated Parts.............................................................................................20746 Removal.............................................................................................................................20746 Installation........................................................................................................................20746 Condenser Fan Motor.....................................................................................................................20747 Condenser Fan Motor and Associated Parts............................................................................................20747 Removal.............................................................................................................................20747 Installation........................................................................................................................20747 Receiver / Drier........................................................................................................................20748 Receiver / Drier and Associated Parts...............................................................................................20748 Removal.............................................................................................................................20748 Installation........................................................................................................................20748 Pressure Switch.........................................................................................................................20749 Pressure Switch and Associated Parts................................................................................................20749 Removal.............................................................................................................................20749 Installation........................................................................................................................20749 Evaporator Assembly.....................................................................................................................20750 Evaporator Assembly and Associated Parts............................................................................................20750 Removal.............................................................................................................................20750 Installation........................................................................................................................20751 Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................20752 Disassembled View...................................................................................................................20752 Removal.............................................................................................................................20752 Installation........................................................................................................................20753 Refrigerant Line........................................................................................................................20754 Refrigerant Line and Associated Parts...............................................................................................20754 Removal.............................................................................................................................20754 Installation........................................................................................................................20755 Main Data And Specifications............................................................................................................20756 Compressor..............................................................................................................................20759 Service Precaution..................................................................................................................20759 General Description.....................................................................................................................20759 Diagnosis...............................................................................................................................20760 Magnetic Clutch Assembly (DKV-14G Type).................................................................................................20761 Parts Location View.................................................................................................................20761 Removal.............................................................................................................................20761 Inspection and Repair...............................................................................................................20763 Installation........................................................................................................................20763 Compressor Oil..........................................................................................................................20765 Oil Specification...................................................................................................................20765 Handling of Oil.....................................................................................................................20765 Compressor Oil Check................................................................................................................20765 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................20765 Checking and Adjusting for Compressor Replacement...................................................................................20766 Contamination of Compressor Oil.....................................................................................................20766 Oil Return Operation................................................................................................................20766 Replacement of Component Parts......................................................................................................20766 Main Data and Specifications............................................................................................................20767 Special Tools...........................................................................................................................20769 Sec.2 STEERING..................................................................................................................................20770 2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................20770 Service Precaution......................................................................................................................20771 Diagnosis...........................................................................................................................20771 General Description.................................................................................................................20777 Power Steering System Test..........................................................................................................20779 Maintenance.........................................................................................................................20780 Fluid Level.........................................................................................................................20780 Bleeding The Power Steering System..................................................................................................20780 Bleeding Procedure..................................................................................................................20780 Flushing The Power Steering System..................................................................................................20780 Steering Wheel Free Play Inspection.................................................................................................20781 Front End Alignment Inspection and Adjustment.......................................................................................20781 Main Data and Specifications........................................................................................................20785 Special Tools.......................................................................................................................20786 Power Steering Unit.....................................................................................................................20787 Power Steering Unit and Associated Parts............................................................................................20787 Removal.............................................................................................................................20787 Installation (4x2 Model)............................................................................................................20788 Installation (4x4 Model)............................................................................................................20788 Power Steering Unit Disassembled View...............................................................................................20789 Disassembly.........................................................................................................................20790 Inspection and Repair...............................................................................................................20790 Reassembly..........................................................................................................................20790 Main Data and Specifications........................................................................................................20790 Special Tools.......................................................................................................................20791 Power Steering Pump.....................................................................................................................20792 Power Steering Pump and Associated Parts............................................................................................20792 Removal.............................................................................................................................20792 Installation........................................................................................................................20792 Power Steering Pump Disassembled View...............................................................................................20793 Disassembly.........................................................................................................................20793 Inspection and Repair...............................................................................................................20794 Reassembly..........................................................................................................................20794 Main Data and Specifications........................................................................................................20796 Transfer Gear Assembly..................................................................................................................20797 Transfer Gear Assembly and Associated Parts.........................................................................................20797 Removal.............................................................................................................................20797 Inspection and Repair...............................................................................................................20797 Installation........................................................................................................................20797 Supplemental Restraint System Steering Wheel & Column...................................................................................20798 Service Precaution..................................................................................................................20798 SRS Connectors......................................................................................................................20798 Inflator Module.........................................................................................................................20800 Inflator Module and Associated Parts................................................................................................20800 Removal.............................................................................................................................20800 Inspection and Repair...............................................................................................................20801 Installation........................................................................................................................20801 Steering Wheel..........................................................................................................................20802 Steering Wheel and Associated Parts.................................................................................................20802 Removal.............................................................................................................................20802 Installation........................................................................................................................20804 Combination Switch......................................................................................................................20805 Combination Switch and Associated Parts.............................................................................................20805 Removal.............................................................................................................................20805 Installation........................................................................................................................20807 Lock Cylinder...........................................................................................................................20809 Lock Cylinder and Associated Parts..................................................................................................20809 Removal.............................................................................................................................20809 Installation........................................................................................................................20811 System Inspection...................................................................................................................20812 Steering Column.........................................................................................................................20813 Steering Column and Associated Parts................................................................................................20813 Removal.............................................................................................................................20813 Insepction..........................................................................................................................20815 Installation........................................................................................................................20817 System Inspection...................................................................................................................20818 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................20819 Main Data and Specifications............................................................................................................20819 Special Tools.......................................................................................................................20819 Sec.3 SUSPENSION................................................................................................................................20820 3C FRONT SUSPENSION.........................................................................................................................20820 Service Precaution......................................................................................................................20820 General Description.................................................................................................................20821 Diagnosis...........................................................................................................................20821 Shock Absorber..........................................................................................................................20825 Shock Absorber and Associated Parts.................................................................................................20825 Removal.............................................................................................................................20825 Inspection and Repair...............................................................................................................20825 Installation........................................................................................................................20825 Stabilizer Bar..........................................................................................................................20826 Stabilizer Bar and Associated Parts.................................................................................................20826 Removal.............................................................................................................................20826 Inspection and Repair...............................................................................................................20826 Installation........................................................................................................................20826 Torsion Bar.............................................................................................................................20827 Torsion Bar and Associated Parts....................................................................................................20827 Removal.............................................................................................................................20827 Inspection and Repair...............................................................................................................20828 Installation........................................................................................................................20828 Knuckle.................................................................................................................................20830 Knuckle and Associated Parts........................................................................................................20830 Removal.............................................................................................................................20830 Inspection and Repair...............................................................................................................20831 Installation........................................................................................................................20831 Upper Control Arm.......................................................................................................................20832 Upper Control Arm and Associated Parts..............................................................................................20832 Removal.............................................................................................................................20832 Inspection and Repair...............................................................................................................20833 Installation........................................................................................................................20833 Lower Control Arm.......................................................................................................................20835 Lower Control Arm and Associated Parts..............................................................................................20835 Removal.............................................................................................................................20835 Inspection and Repair...............................................................................................................20836 Installation........................................................................................................................20837 Upper Ball Joint........................................................................................................................20838 Upper Ball Joint and Associated Parts...............................................................................................20838 Removal.............................................................................................................................20838 Inspection and Repair...............................................................................................................20839 Installation........................................................................................................................20839 Lower Ball Joint........................................................................................................................20840 Lower Ball Joint and Associated Parts...............................................................................................20840 Removal.............................................................................................................................20840 Inspection and Repair...............................................................................................................20841 Installation........................................................................................................................20841 Main Data and Specifications............................................................................................................20842 Special Tools.......................................................................................................................20844 3D REAR SUSPENSION..........................................................................................................................20845 Service Precaution......................................................................................................................20845 General Description.................................................................................................................20845 Diagnosis...........................................................................................................................20846 Coil Spring.............................................................................................................................20849 Coil Spring and Associated Parts....................................................................................................20849 Removal.............................................................................................................................20849 Inspection and Repair...............................................................................................................20850 Installation........................................................................................................................20850 Shock Absorber..........................................................................................................................20851 Shock Absorber and Associated Parts.................................................................................................20851 Removal.............................................................................................................................20851 Inspection and Repair...............................................................................................................20851 Installation........................................................................................................................20851 Trailing Link...........................................................................................................................20852 Trailing Link and Associated Parts..................................................................................................20852 Removal.............................................................................................................................20852 Inspection and Repair...............................................................................................................20852 Installation........................................................................................................................20853 Upper Link..............................................................................................................................20854 Upper Link and Associated Parts.....................................................................................................20854 Removal.............................................................................................................................20854 Inspection and Repair...............................................................................................................20854 Installation........................................................................................................................20855 Lateral Rod.............................................................................................................................20856 Lateral Rod and Associated Parts....................................................................................................20856 Removal.............................................................................................................................20856 Inspection and Repair...............................................................................................................20856 Installation........................................................................................................................20857 Stabilizer Bar..........................................................................................................................20858 Stabilizer Bar and Associated Parts.................................................................................................20858 Removal.............................................................................................................................20858 Inspection and Repair...............................................................................................................20858 Installation........................................................................................................................20859 Main Data and Specifications............................................................................................................20860 Special Tools...........................................................................................................................20862 3E WHEEL AND TIRE SYSTEM....................................................................................................................20863 Service Precaution......................................................................................................................20863 General Description.................................................................................................................20864 Diagnosis...........................................................................................................................20865 Wheel...................................................................................................................................20873 Wheel and Associated Parts..........................................................................................................20873 Removal.............................................................................................................................20873 Installation........................................................................................................................20873 Tire....................................................................................................................................20874 Tire Replacement....................................................................................................................20874 General Balance Procedure...........................................................................................................20874 Balancing Wheel and Tire............................................................................................................20875 Main Data and Specifications............................................................................................................20876 3F INTELLIGENT SUSPENSION CONTROL...........................................................................................................20877 Service Precaution......................................................................................................................20877 General Description.................................................................................................................20877 General Diagnosis...................................................................................................................20880 DTC2 Actuator Coil Over Current.....................................................................................................20892 DTC3 Actuator Coil/Position Sensor Open Circuit or Short............................................................................20894 DTC4 G-Sensor Open Circuit or Short.................................................................................................20897 DTC5 Vehicle Speed Sensor Open Circuit or Short.....................................................................................20898 DTC6 Stop Lamp Switch Open Circuit or Short.........................................................................................20900 DTC7 Engine Speed Signal Open Circuit or Short......................................................................................20902 Control Unit............................................................................................................................20907 Removal.............................................................................................................................20907 Installation........................................................................................................................20908 Front Actuator..........................................................................................................................20909 Removal.............................................................................................................................20910 Inspection and Repair...............................................................................................................20910 Installation........................................................................................................................20910 Rear Shock Absorber.....................................................................................................................20911 Removal.............................................................................................................................20912 Inspection and Repair...............................................................................................................20912 Installation........................................................................................................................20912 Sec.4 DRIVELINE/AXLE............................................................................................................................20913 4A1 DIFFERENTIAL (FRONT)....................................................................................................................20913 Service Precaution......................................................................................................................20913 Front Drive Axle....................................................................................................................20914 Diagnosis...........................................................................................................................20914 Pinion Shaft Oil Seal...................................................................................................................20915 Pinion Shaft Oil Seal and Associated Parts..........................................................................................20915 Removal.............................................................................................................................20915 Inspection and Repair...............................................................................................................20916 Installation........................................................................................................................20916 Front Drive Axle Assembly...............................................................................................................20917 Front Drive Axle Assembly and Associated Parts......................................................................................20917 Removal.............................................................................................................................20918 Installation........................................................................................................................20918 Differential Assembly...................................................................................................................20920 Disassembled View...................................................................................................................20920 Disassembly.........................................................................................................................20921 Reassembly..........................................................................................................................20923 Differential Cage Assembly..............................................................................................................20931 Disassembled View...................................................................................................................20931 Disassembly.........................................................................................................................20931 Inspection and Repair...............................................................................................................20932 Reassembly..........................................................................................................................20932 Main Data and Specifications............................................................................................................20934 Special Tools.......................................................................................................................20937 4A2 Differential (Rear).....................................................................................................................20939 Service Precaution......................................................................................................................20939 General Description.....................................................................................................................20940 Diagnosis...............................................................................................................................20941 Axle Housing............................................................................................................................20943 Axle Housing and Associated Parts...................................................................................................20943 Removal.............................................................................................................................20943 Installation........................................................................................................................20945 Axle Shaft, Oil Seal and Bearing........................................................................................................20945 Axle Shaft and Associated Parts.....................................................................................................20945 Removal.............................................................................................................................20946 Inspection..........................................................................................................................20946 Installation........................................................................................................................20946 Pinion Oil Seal.........................................................................................................................20948 Pinion Oil Seal and Associated Parts................................................................................................20948 Removal.............................................................................................................................20948 Inspection and Repair...............................................................................................................20949 Installation........................................................................................................................20949 Differential Assembly...................................................................................................................20951 Disassembled View...................................................................................................................20951 Inspecting the Axle Before Disassembly..............................................................................................20952 Disassembly.........................................................................................................................20952 Inspection and Repair...............................................................................................................20954 Reassembly..........................................................................................................................20955 Side Bearing Preload Adjustment.....................................................................................................20959 Pinion Installation.................................................................................................................20960 Determination of Backlash & Preload Shims...........................................................................................20961 Backlash Adjustment.................................................................................................................20962 Gear Tooth Pattern Check............................................................................................................20963 Adjustments Affecting Tooth Contact.................................................................................................20964 Differential Case Assembly..............................................................................................................20964 Disassembled View...................................................................................................................20964 Disassembly.........................................................................................................................20965 Inspection and Repair...............................................................................................................20965 Reassembly..........................................................................................................................20965 Limited Slip Differential Assembly......................................................................................................20966 Disassembled View...................................................................................................................20966 Disassembly.........................................................................................................................20966 Inspection and Repair...............................................................................................................20968 Reassembly..........................................................................................................................20968 Main Data And Specifications............................................................................................................20970 Special Tools.......................................................................................................................20972 4B DRIVELINE CONTROL SYSTEM.................................................................................................................20974 Service Precaution......................................................................................................................20974 Shift On The Fly System.................................................................................................................20975 Outline of Shift on The Fly System..................................................................................................20975 Functions of Indicator Lamp.........................................................................................................20979 Diagnosis...........................................................................................................................20980 Shift On The Fly Electrical Equipment...................................................................................................20990 Axle Shaft Connection and Disconnection.............................................................................................20990 Actuator Assembly...................................................................................................................20990 4WD Control Unit........................................................................................................................20993 4WD Control Unit Associated Parts...................................................................................................20993 Removal.............................................................................................................................20993 Installation........................................................................................................................20994 Shift On The Fly Controller.............................................................................................................20994 Shift On The Fly Controller and Associated Parts....................................................................................20994 Removal.............................................................................................................................20994 Installation........................................................................................................................20994 4C DRIVE SHAFT SYSTEM.......................................................................................................................20995 Service Precaution......................................................................................................................20995 General Description.................................................................................................................20996 Diagnosis...........................................................................................................................20996 Front Hub and Disc (2WD Model)..........................................................................................................20997 Disassembled View...................................................................................................................20997 Disassembly.........................................................................................................................20997 Inspection..........................................................................................................................20998 Reassembly..........................................................................................................................20999 Front Hub and Disc (4WD Model)..........................................................................................................21000 Disassembled View...................................................................................................................21000 Disassembly.........................................................................................................................21000 Inspection..........................................................................................................................21001 Reassembly..........................................................................................................................21002 Front Drive Shaft Joint.................................................................................................................21003 Front Drive Shaft Joints Replacement................................................................................................21003 Front Axle Drive Shaft..................................................................................................................21004 Front Axle Drive Shaft and Associated Parts.........................................................................................21004 Disassembly.........................................................................................................................21005 Inspection And Repair...............................................................................................................21006 Bushing Replacement.................................................................................................................21006 Reassembly..........................................................................................................................21007 Shift On The Fly System.................................................................................................................21010 Shift On The Fly System and Associated Parts........................................................................................21010 Disassembly.........................................................................................................................21011 Inspection And Repair...............................................................................................................21012 Reassembly..........................................................................................................................21014 Main Data and Specifications............................................................................................................21017 Special Tools.......................................................................................................................21019 Propeller Shaft.........................................................................................................................21020 General Description.................................................................................................................21020 Universal Joint.....................................................................................................................21021 Diagnosis of Propeller Shaft and Universal Joint....................................................................................21022 Front Propeller Shaft...................................................................................................................21023 Front Propeller Shaft and Associated Parts..........................................................................................21023 Removal.............................................................................................................................21023 Installation........................................................................................................................21023 Disassembly.........................................................................................................................21024 Universal Joint Disassembly.........................................................................................................21025 Inspection and Repair...............................................................................................................21026 Universal Joint Reassembly..........................................................................................................21027 Reassembly..........................................................................................................................21028 Main Data and Specifications........................................................................................................21029 Rear Propeller Shaft....................................................................................................................21030 Rear Propeller Shaft and Associated Parts...........................................................................................21030 Removal.............................................................................................................................21030 Installation........................................................................................................................21030 Slip Joint Disassembly..............................................................................................................21031 Universal Joint Disassembly.........................................................................................................21032 Inspection..........................................................................................................................21034 Universal Joint Reassembly..........................................................................................................21035 Slip Joint Reassembly...............................................................................................................21036 Main Data and Specifications............................................................................................................21037 4D TRANSFER CASE............................................................................................................................21038 Service Precaution...................................................................................................................... 0 General Description................................................................................................................. 0 Transfer Rear Oil Seal.................................................................................................................. 0 Transfer Rear Oil Seal and Associated Parts......................................................................................... 0 Removal............................................................................................................................. 0 Installation........................................................................................................................ 0 Transfer Case Assembly (A/T)............................................................................................................ 0 Transfer Case Assembly (A/T) and Associated Parts................................................................................... 0 Removal............................................................................................................................. 0 Installation........................................................................................................................ 0 Transfer Rear Case Assembly (A/T)....................................................................................................... 0 Transfer Rear Case Assembly (A/T) and Associated Parts.............................................................................. 0 Removal............................................................................................................................. 0 Installation........................................................................................................................ 0 Transfer Rear Cover Assembly........................................................................................................ 0 Disassembly......................................................................................................................... 0 Inspection and Repair 262RW021..................................................................................................... 0 Reassembly.......................................................................................................................... 0 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 0 Disassembled View................................................................................................................... 0 Disassembly......................................................................................................................... 0 Inspection and Repair............................................................................................................... 0 Reassembly.......................................................................................................................... 0 Transfer Case Assembly.................................................................................................................. 0 Disassembled View................................................................................................................... 0 Disassembly......................................................................................................................... 0 Inspection and Repair............................................................................................................... 0 Reassembly.......................................................................................................................... 0 Main Data and Specifications............................................................................................................ 0 Special Tools....................................................................................................................... 0 Sec.5 BRAKES....................................................................................................................................21078 5A Brake Control System.....................................................................................................................21078 Service Precaution......................................................................................................................21079 General Description.....................................................................................................................21080 Functional Description..............................................................................................................21081 System Components...................................................................................................................21087 Electronic Hydraulic Control Unit (EHCU)............................................................................................21087 ABS Warning Light...................................................................................................................21087 Wheel Speed Sensor..................................................................................................................21087 G-Sensor............................................................................................................................21087 Normal and Anti-lock Braking........................................................................................................21087 Brake Pedal Travel..................................................................................................................21088 Acronyms and Abbreviations..........................................................................................................21088 General Diagnosis.......................................................................................................................21088 General Information.................................................................................................................21088 ABS Service Precautions.............................................................................................................21088 Computer System Service Precautions.................................................................................................21088 General Service Precautions.........................................................................................................21089 Note on Intermittents...............................................................................................................21089 Test Driving ABS Complaint Vehicles.................................................................................................21089 “ABS” Warning Light.................................................................................................................21089 Normal Operation....................................................................................................................21089 Tech 2 Scan Tool....................................................................................................................21090 DATA LIST...........................................................................................................................21093 ACTUATOR TEST.......................................................................................................................21094 Tech 2 Service Bleed................................................................................................................21098 Basic Diagnostic Flow Chart.........................................................................................................21099 Basic Inspection Procedure..........................................................................................................21100 EHCU Connector Pin-out Checks...........................................................................................................21101 Circuit Diagram.....................................................................................................................21102 Connector List......................................................................................................................21105 Part Location.......................................................................................................................21107 Symptom Diagnosis.......................................................................................................................21108 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................21108 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................21109 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................21109 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................21109 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................21110 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................21110 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................21111 Diagnostic Trouble Codes............................................................................................................21112 Diagnosis By “ABS” Warning Light Illumination Pattern...............................................................................21114 Diagnostic Trouble Codes (DTCs).....................................................................................................21115 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................21117 Chart B-2 CPU Error.................................................................................................................21117 Chart B-3 Low or High Ignition Voltage..............................................................................................21118 Chart B-4 Excessive Dump Time.......................................................................................................21118 Chart B-5 Excessive Isolation Time..................................................................................................21118 Chart B-6 G-Sensor Output Failure...................................................................................................21119 Chart B-7 Brake Switch Failure......................................................................................................21119 Chart B-8 2WD Controller in 4WD Vehicle Controller, 4WD State Input Signal Failure..................................................21120 Chart B-9 Pump Motor Failure........................................................................................................21120 Chart B-10 EHCU Valve Relay Failure.................................................................................................21121 Chart B-11 FL Isolation Solenoid Coil Failure.......................................................................................21121 Chart B-12 FL Dump Solenoid Coil Failure............................................................................................21121 Chart B-13 FR Isolation Solenoid Coil Failure.......................................................................................21122 Chart B-14 FR Dump Solenoid Coil Failure............................................................................................21122 Chart B-15 Rear Isolation Solenoid Coil Failure.....................................................................................21122 Chart B-16 Rear Dump Solenoid Coil Failure..........................................................................................21123 Chart B-17 FL Speed Sensor Open or Shorted..........................................................................................21123 Chart B-18 FR Speed Sensor Open or Shorted..........................................................................................21124 Chart B-19 Rear Speed Sensor Open or Shorted........................................................................................21125 Chart B-20 FL Speed Sensor Missing Signal...........................................................................................21126 Chart B-21 FR Speed Sensor Missing Signal...........................................................................................21127 Chart B-22 Rear Speed Sensor Missing Signal.........................................................................................21128 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal.......................................................................21129 Chart B-24 Wheel Speed Input Abnormality............................................................................................21130 Unit Inspection Procedure...........................................................................................................21131 Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................21131 Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................21132 Chart C-1-3 Rear Sensor Output Inspection Procedure.................................................................................21132 Chart TC-1 Sensor Output Inspection Procedure.......................................................................................21133 Special Tools...........................................................................................................................21134 5B ANTI-LOCK BRAKE SYSTEM...................................................................................................................21135 Service Precaution......................................................................................................................21135 Electronic Hydraulic Control Unit.......................................................................................................21136 Electronic Hydraulic Control Unit and Associated Parts..............................................................................21136 Removal.............................................................................................................................21136 Disassembled View...................................................................................................................21137 Disassembly.........................................................................................................................21137 Reassembly..........................................................................................................................21137 Installation........................................................................................................................21137 Front Wheel Speed Sensor................................................................................................................21138 Front Wheel Speed Sensor and Associated Parts.......................................................................................21138 Removal.............................................................................................................................21138 Inspection and Repair...............................................................................................................21138 Installation........................................................................................................................21139 Rear Wheel Speed Sensor.................................................................................................................21139 Removal.............................................................................................................................21139 Inspection and Repair...............................................................................................................21139 Installation........................................................................................................................21139 5C POWER-ASSISTED BRAKE SYSTEM..............................................................................................................21140 Service Precaution......................................................................................................................21141 General Description.....................................................................................................................21141 Diagnosis...............................................................................................................................21145 General Diagnosis.......................................................................................................................21146 Hydraulic Brakes........................................................................................................................21149 Filling Master Cylinder Reservoir...................................................................................................21149 Deterioration of Brake Fluid........................................................................................................21149 Leakage of Brake Fluid..............................................................................................................21149 Bleeding Brake Hydraulic System.....................................................................................................21149 Flushing Brake Hydraulic System.....................................................................................................21150 Brake Pipes and Hoses...............................................................................................................21150 Brake Hose Inspection...............................................................................................................21151 Front Caliper Brake Hose................................................................................................................21151 Front Caliper Brake Hose and Associated Parts.......................................................................................21151 Removal.............................................................................................................................21151 Installation........................................................................................................................21151 Rear Axle Brake Hose....................................................................................................................21152 Rear Axle Brake Hose and Associated Parts...........................................................................................21152 Removal.............................................................................................................................21152 Installation........................................................................................................................21152 Brake Pipe..............................................................................................................................21153 Removal.............................................................................................................................21153 Installation........................................................................................................................21153 P & B (Proportioning and Bypass) Valve..................................................................................................21154 P & B (Proportioning and Bypass) Valve Sectional View...............................................................................21154 Removal.............................................................................................................................21154 Installation........................................................................................................................21154 Main Data and Specifications........................................................................................................21155 Brake Pedal.............................................................................................................................21156 Checking Pedal Height...............................................................................................................21156 Checking Pedal Travel...............................................................................................................21156 Brake Pedal and Associated Parts....................................................................................................21157 Removal.............................................................................................................................21157 Installation........................................................................................................................21157 Stoplight Switch........................................................................................................................21158 Parts Location......................................................................................................................21158 Removal.............................................................................................................................21158 Installation........................................................................................................................21158 Main Data and Specifications........................................................................................................21159 Master Cylinder Assembly................................................................................................................21160 Master Cylinder Assembly and Associated Parts.......................................................................................21160 Removal.............................................................................................................................21160 Inspection..........................................................................................................................21160 Master Cylinder Assembly................................................................................................................21161 Master Cylinder Assembly Desassembled View..........................................................................................21161 Desassembly.........................................................................................................................21161 Inspection..........................................................................................................................21161 Reassembly..........................................................................................................................21162 Installation........................................................................................................................21162 Main Data and Specifications............................................................................................................21163 Vacuum Booster Assembly.................................................................................................................21164 Vacuum Booster Assembly and Associated Parts........................................................................................21164 Removal.............................................................................................................................21164 Inspection and Repair...............................................................................................................21165 Exterior Components.....................................................................................................................21166 Exterior Components and Associated Parts............................................................................................21166 Removal.............................................................................................................................21166 Inspection and Repair...............................................................................................................21167 Installation........................................................................................................................21167 Vacuum Booster Overhaul.................................................................................................................21167 Vacuum Booster......................................................................................................................21167 Main Data and Specifications........................................................................................................21168 Front Disc Brake Pads...................................................................................................................21169 Front Disc Brake Pads Inspection....................................................................................................21169 Front Disc Brake Pads and Associated Parts..........................................................................................21169 Removal.............................................................................................................................21170 Installation........................................................................................................................21170 Front Disc Brake Rotor..................................................................................................................21172 Inspection..........................................................................................................................21172 Replacing Brake Rotors..............................................................................................................21172 Refinishing Brake Rotors............................................................................................................21172 Front Disc Brake Caliper Assembly.......................................................................................................21174 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................21174 Removal.............................................................................................................................21174 Installation........................................................................................................................21175 Front Disc Brake Caliper................................................................................................................21177 Front Disc Brake Caliper Disassembled View..........................................................................................21177 Disassembly.........................................................................................................................21177 Inspection and Repair...............................................................................................................21178 Reassembly..........................................................................................................................21178 Main Data and Specifications........................................................................................................21179 Rear Disc Brake Pads (4x4 Model)........................................................................................................21180 Brake Pads Inspection...............................................................................................................21180 Brake Pads and Associated Parts.....................................................................................................21180 Removal.............................................................................................................................21181 Installation........................................................................................................................21181 Rear Disc Brake Rotor (4x4 Model).......................................................................................................21183 Inspection..........................................................................................................................21183 Replacing Brake Rotors..............................................................................................................21183 Refinishing Brake Rotors............................................................................................................21183 Rear Drum (In Disc) Inside Diameter Check...........................................................................................21184 Rear Disc Brake Caliper Assembly (4x4 Model)............................................................................................21185 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................21185 Removal.............................................................................................................................21185 Installation........................................................................................................................21186 Rear Disc Brake Caliper (4x4 Model).....................................................................................................21187 Rear Disc Brake Caliper Disassembled View...........................................................................................21187 Disassembly.........................................................................................................................21188 Inspection and Repair...............................................................................................................21188 Reassembly..........................................................................................................................21188 Main Data and Specifications (4x4 Model)............................................................................................21190 Brake Lining............................................................................................................................21191 Brake Lining and Associated Parts...................................................................................................21191 Removal.............................................................................................................................21191 Brake Lining Inspection.............................................................................................................21192 Installation........................................................................................................................21192 Drum Brake Adjustment (4x2 Model)...................................................................................................21193 Servicing The Brake Drum............................................................................................................21193 Wheel Cylinder Assembly (4x2 Model).....................................................................................................21194 Wheel Cylinder Assembly and Associated Parts........................................................................................21194 Removal.............................................................................................................................21194 Installation........................................................................................................................21194 Disassembled View...................................................................................................................21195 Disassembly.........................................................................................................................21195 Inspection and Repair...............................................................................................................21195 Reassembly..........................................................................................................................21195 Main Data and Specifications............................................................................................................21197 5D1 PARKING BRAKE SYSTEM (4x4 Model)........................................................................................................21198 Service Precaution......................................................................................................................21198 General Description.....................................................................................................................21198 Operation...............................................................................................................................21199 Parking Brake Lever and Front Cable.....................................................................................................21200 Parking Brake Lever Assembly and Associated Parts...................................................................................21200 Removal.............................................................................................................................21200 Installation........................................................................................................................21200 Parking Brake Rear Cable................................................................................................................21201 Parking Brake Rear Cable and Associated Parts.......................................................................................21201 Removal.............................................................................................................................21202 Installation........................................................................................................................21202 Inspection and Repair...............................................................................................................21203 Parking Brake Adjustment................................................................................................................21203 Main Data and Specifications............................................................................................................21204 5D2 PARKING BRAKE SYSTEM (4x2 Model)........................................................................................................21205 Service Precaution......................................................................................................................21205 General Description.....................................................................................................................21205 Parking Brake Lever.....................................................................................................................21206 Parking Brake Lever Assembly and Associated Parts...................................................................................21206 Removal.............................................................................................................................21206 Installation........................................................................................................................21206 Parking Brake Rear Cable................................................................................................................21207 Parking Brake Rear Cable and Associated Parts.......................................................................................21207 Removal.............................................................................................................................21208 Installation........................................................................................................................21208 Parking Brake Adjustment............................................................................................................21208 Main Data and Specifications............................................................................................................21209 Sec.6 ENGINE....................................................................................................................................21210 Y22SE 2.2L ENGINE..........................................................................................................................21210 6A ENGINE MECHANICAL....................................................................................................................21210 Service Precaution..................................................................................................................21211 General Description.................................................................................................................21211 Engine Diagnosis....................................................................................................................21212 Cylinder Head Cover.................................................................................................................21225 Cylinder Head Cover and Associated Parts........................................................................................21225 Removal.........................................................................................................................21225 Installation....................................................................................................................21226 Exhaust Manifold....................................................................................................................21228 Removal.........................................................................................................................21228 Installation....................................................................................................................21228 Crankshaft Pulley...................................................................................................................21229 Removal.........................................................................................................................21229 Installation....................................................................................................................21229 Intake Manifold.....................................................................................................................21230 Removal.........................................................................................................................21230 Installation....................................................................................................................21231 Cylinder Head Assembly..............................................................................................................21233 Removal.........................................................................................................................21233 Installation....................................................................................................................21235 Timing Belt.........................................................................................................................21238 Removal.........................................................................................................................21238 Installation....................................................................................................................21238 Camshaft............................................................................................................................21244 Camshaft and Associated Parts...................................................................................................21244 Removal.........................................................................................................................21244 Installation....................................................................................................................21245 Engine Assembly.....................................................................................................................21248 Removal.........................................................................................................................21248 Installation....................................................................................................................21250 Cylinder Head.......................................................................................................................21252 Cylinder Head and Associated Parts..............................................................................................21252 Disassembly.....................................................................................................................21252 Inspection and Repair...........................................................................................................21253 Reassembly......................................................................................................................21254 Valve Spring, Valve, Valve Guide....................................................................................................21255 Valve Spring, Valve, Valve Guide and Associated Parts...........................................................................21255 Disassembly.....................................................................................................................21256 Inspection and Repair...........................................................................................................21256 Reassembly......................................................................................................................21257 Crankshaft..........................................................................................................................21258 Crankshaft and Associated Parts.................................................................................................21258 Disassembly.....................................................................................................................21258 Inspection and Repair for Bearing...............................................................................................21259 Inspection and Repair for Crankshaft............................................................................................21260 Reassembly......................................................................................................................21261 Piston and Connecting Rod...........................................................................................................21264 Piston, Connecting Rod and Associate Parts......................................................................................21264 Disassembly.....................................................................................................................21264 Inspection and Repair...........................................................................................................21265 Reassembly......................................................................................................................21267 Cylinder Block......................................................................................................................21269 Cylinder Block and Associated Parts.............................................................................................21269 Disassembly.....................................................................................................................21269 Inspection and Repair...........................................................................................................21270 Reassembly......................................................................................................................21270 Balance Unit Assembly...............................................................................................................21272 Balance Unit Assembly and Associated Parts......................................................................................21272 Disassembly.....................................................................................................................21272 Adjustment......................................................................................................................21273 Reassembly......................................................................................................................21275 Main Data and Specifications........................................................................................................21276 Special Tools.......................................................................................................................21282 6B ENGINE COOLING.......................................................................................................................21283 Service Precaution..................................................................................................................21283 General Description.................................................................................................................21284 Diagnosis...........................................................................................................................21286 Draining and Refilling Cooling......................................................................................................21286 Water Pump..........................................................................................................................21287 Water Pump and Associated Parts.................................................................................................21287 Removal.........................................................................................................................21287 Inspection......................................................................................................................21287 Installation....................................................................................................................21287 Thermostat..........................................................................................................................21288 Removal.........................................................................................................................21288 Inspection......................................................................................................................21288 Installation....................................................................................................................21288 Radiator............................................................................................................................21289 Radiator and Associated Parts...................................................................................................21289 Removal.........................................................................................................................21290 Inspection......................................................................................................................21291 Installation....................................................................................................................21292 Main Data and Specifications........................................................................................................21293 Special Tool........................................................................................................................21294 6C ENGINE FUEL (Y22SE 2.2L) For Long Wheel Base.........................................................................................21295 Service Precaution..................................................................................................................21295 General Description.............................................................................................................21296 Fuel Metering...................................................................................................................21297 Fuel Filter.........................................................................................................................21298 Fuel Filter and Associated Parts................................................................................................21298 Removal.........................................................................................................................21298 Inspection......................................................................................................................21299 Installation....................................................................................................................21299 Inspection......................................................................................................................21299 In–Tank Fuel Filter.............................................................................................................21299 Fuel Pump Flow Test.............................................................................................................21299 Fuel Pump...........................................................................................................................21300 Fuel Pump and Associated Parts..................................................................................................21300 Removal.........................................................................................................................21300 Installation....................................................................................................................21301 Fuel Tube / Quick – Connector Fittings..............................................................................................21301 Precautions.....................................................................................................................21301 Cautions During Work............................................................................................................21301 Removal.........................................................................................................................21301 Reuse of Quick–Connector........................................................................................................21302 Assembling Advice...............................................................................................................21302 Fuel Pump Relay.....................................................................................................................21302 General Description.............................................................................................................21302 Fuel Tank...........................................................................................................................21303 Fuel Tank and Associated Parts..................................................................................................21303 Removal.........................................................................................................................21303 Installation....................................................................................................................21303 Fuel Gage Unit......................................................................................................................21304 Removal and Installation........................................................................................................21304 Fuel Filler Cap.....................................................................................................................21304 General Description.............................................................................................................21304 Inspection......................................................................................................................21304 Main Data and Specifications........................................................................................................21305 Special Tool....................................................................................................................21305 6D1 ENGINE ELECTRICAL...................................................................................................................21306 Service Precaution..................................................................................................................21306 Battery.............................................................................................................................21307 General Description.................................................................................................................21307 Diagnosis...........................................................................................................................21307 Battery Charging................................................................................................................21308 Jump Starting...................................................................................................................21308 Battery Removal.................................................................................................................21309 Battery Installation............................................................................................................21309 Main Data and Specifications....................................................................................................21310 6D2 IGNITION SYSTEM.....................................................................................................................21311 Service Precaution..................................................................................................................21311 General Description.................................................................................................................21312 Diagnosis...........................................................................................................................21312 Ignition Module.....................................................................................................................21313 Removal.........................................................................................................................21313 Installation....................................................................................................................21313 Spark Plug..........................................................................................................................21314 Removal.........................................................................................................................21314 Inspection and Repair...........................................................................................................21314 Installation....................................................................................................................21314 Crankshaft Position Sensor..........................................................................................................21315 Removal.........................................................................................................................21315 Installation....................................................................................................................21315 Main Data and Specifications........................................................................................................21316 6D3 STARTING AND CHARGING SYSTEM........................................................................................................21317 Service Precaution..................................................................................................................21317 Starting System.....................................................................................................................21318 General Description.................................................................................................................21318 Diagnosis...........................................................................................................................21318 Starter.............................................................................................................................21319 Removal.........................................................................................................................21319 Installation....................................................................................................................21319 Disassembled View...............................................................................................................21320 Inspection and Repair...........................................................................................................21321 Characteristic Test.............................................................................................................21322 Charging System.....................................................................................................................21323 General Description.............................................................................................................21323 General On–Vehicle Inspection...................................................................................................21323 Generator...........................................................................................................................21324 Removal.........................................................................................................................21324 Inspection......................................................................................................................21324 Installation....................................................................................................................21325 Disassembled View...............................................................................................................21326 Disassembly.....................................................................................................................21327 Inspection and Repair...........................................................................................................21328 Reassembly......................................................................................................................21329 Main Data and Specifications....................................................................................................21330 6E1 RODEO 2.2L ENGINE DRIVEABILITY AND EMISSIONS........................................................................................21331 SPECIFICATIONS......................................................................................................................21336 DIAGRAMS AND SCHEMATICS.............................................................................................................21337 PCM PINOUTS.........................................................................................................................21350 COMPONENT LOCATOR...............................................................................................................21356 Undercarriage Component Locator Table...........................................................................................21358 Fuse And Relay Panel (Underhood Electrical Center)..............................................................................21359 DIAGNOSIS Strategy-Based Diagnostics................................................................................................21360 Strategy-Based Diagnostics......................................................................................................21360 DTC Stored......................................................................................................................21360 No DTC..........................................................................................................................21360 No Matching Symptom.............................................................................................................21360 Intermittents...................................................................................................................21360 No Trouble Found................................................................................................................21360 Verifying Vehicle Repair........................................................................................................21360 GENERAL SERVICE INFORMATION.........................................................................................................21361 OBD II Serviceability Issues....................................................................................................21361 Emissions Control Information Label.............................................................................................21361 Maintenance Schedule............................................................................................................21362 Visual/Physical Engine Compartment Inspection...................................................................................21362 Basic Knowledge Of Tools Required...............................................................................................21362 SERIAL DATA COMMUNICATIONS..........................................................................................................21362 Class II Serial Data Communications.............................................................................................21362 ON-BOARDDIAGNOSTIC (OBD II).........................................................................................................21362 O-Board Diagnostic Tests........................................................................................................21362 Comprehensive Component Monitor Diagnostic Operation............................................................................21362 System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................21363 Common OBD II Terms.............................................................................................................21363 The Diagnostic Executive........................................................................................................21364 DTC Types.......................................................................................................................21365 Decimal/Binary/Hexadecimal Conversions..........................................................................................21366 Verifying Vehicle Repair........................................................................................................21366 Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool.......................................................................21366 Tech 2 Features.................................................................................................................21368 Getting Started.................................................................................................................21368 Operating Procedure (Example)...................................................................................................21369 DTC Modes.......................................................................................................................21370 DTC Information Mode............................................................................................................21370 Miscellaneous Test..............................................................................................................21371 Lamps Test......................................................................................................................21371 Relays Test.....................................................................................................................21372 EVAP Test.......................................................................................................................21374 Idle Air Control System Test....................................................................................................21375 Fuel System Test................................................................................................................21377 EGR Control Test................................................................................................................21378 Injector Balance Test...........................................................................................................21379 Plotting Snapshot Graph.............................................................................................................21380 System Check at Tech 2..............................................................................................................21381 General Description.............................................................................................................21381 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................21385 Flow Chart for Snapshot Replay (Plotting Graph).................................................................................21386 PRIMARY SYSTE-BASED DIAGNOSTICS.....................................................................................................21387 Primary System-Based Diagnostics................................................................................................21387 Fuel Control Heated Oxygen Sensors..............................................................................................21387 HO2S Heater.....................................................................................................................21387 Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation.................................................................21387 MISFIRE MONITOR following conditions: DIAGNOSTIC OPERATION..........................................................................21388 Misfire Monitor Diagnostic Operation............................................................................................21388 Misfire Counters................................................................................................................21388 FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION.......................................................................................21389 Fuel Trim System Monitor Diagnostic Operation...................................................................................21389 Fuel Trim Cell Diagnostic Weights...............................................................................................21389 ON‐BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK...........................................................................................21390 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS................................................................................................21393 ELECTRONIC IGNITION SYSTEM DIAGNOSIS................................................................................................21396 EVAP CANISTER PURGE SOLENOID........................................................................................................21396 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER...................................................................................21396 IDLE AIR CONTROL (IAC) VALVE........................................................................................................21396 FUEL SYSTEM PRESSURE TEST...........................................................................................................21396 FUEL METERING SYSTEM CHECK..........................................................................................................21397 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE..........................................................21397 POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS...........................................................................................21402 MULTIPLE PCM INFORMATION SENSOR DTCs SET............................................................................................21403 EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS...........................................................................................21406 ENGINE Tech 2 DATA DEFINITIONS AND RANGES...........................................................................................21406 TYPICAL SCAN DATA VALUES............................................................................................................21409 NO MALFUNCTION INDICATOR LAMP (MIL).................................................................................................21413 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY..........................................................................................21416 ENGINE CRANKS BUT WILL NOT RUN......................................................................................................21418 FUEL SYSTEM ELECTRICAL TEST.........................................................................................................21424 FUEL SYSTEM DIAGNOSIS...............................................................................................................21427 IDLE AIR CONTROL (IAC) SYSTEM CHECK.................................................................................................21432 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK........................................................................................21435 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK.......................................................................................21437 EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK....................................................................21439 Upshift Lamp System Check (Manual Transmission Only)................................................................................21442 PCM DIAGNOSTIC TROUBLE CODES........................................................................................................21445 (DTC) P0106 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT/RANGE PERFORMANCE PROBLEM......................................................21448 (DTC) P0107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT LOW INPUT...............................................................21451 (DTC) P0108 MANIFOLD ABSOLUTE PRESSURE (MAP) CIRCUIT HIGH INPUT.....................................................................21454 (DTC) P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT...................................................................21457 (DTC) P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT..................................................................21460 (DTC) P0117 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT LOW INPUT...............................................................21463 (DTC) P0118 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT HIGH INPUT..............................................................21466 (DTC) P0121 THROTTLE POSITION (TP) SENSOR CIRCUIT RANGE/PERFORMANCE PROBLEM.........................................................21469 (DTC) P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT..........................................................................21472 (DTC) P0123 THROTTLE POSITION (TP) SENSOR CIRCUIT HIGH INPUT........................................................................21475 (DTC) P0125 INSUFFICIENT COOLANT TEM-PERATURE FOR CLOSED LOOP FUEL CONTROL..........................................................21478 (DTC) P0128 Thermostat Insufficient temperrature for Stable Opreation...............................................................21481 (DTC) P0131 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 1).........................................................................21483 (DTC) P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 1)........................................................................21486 (DTC) P0133 O2 SENSOR CIRCUIT SLOW RESPONSE (BANK 1 SENSOR 1).......................................................................21489 (DTC) P0134 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 1)................................................................21492 (DTC) P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1)..................................................................21495 (DTC) P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2).........................................................................21498 (DTC) P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)........................................................................21501 (DTC) P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)................................................................21504 (DTC) P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)..................................................................21507 (DTC) P0171 SYSTEM TOO LEAN (BANK 1)................................................................................................21510 (DTC) P0172 SYSTEM TOO RICH (BANK 1)................................................................................................21514 (DTC) P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1...............................................................................21518 (DTC) P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2...............................................................................21521 (DTC) P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3...............................................................................21524 (DTC) P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4...............................................................................21527 (DTC) P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21530 (DTC) P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21534 (DTC) P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21538 (DTC) P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21542 (DTC) P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED...............................................................................21546 (DTC) P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION...................................................................................21550 (DTC) P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT.....................................................................................21553 (DTC) P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE..............................................................21556 (DTC) P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT......................................................................21558 (DTC) P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE................................................................21561 (DTC) P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT........................................................................21564 (DTC) P0351 IGNITION COIL ”A” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................21567 (DTC) P0352 IGNITION COIL ”B” PRIMARY/ SECONDARY CIRCUIT MALFUNCTION................................................................21569 (DTC) P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED..............................................................21571 (DTC) P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED.................................................................21574 (DTC) P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE...............................................................21576 (DTC) P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW......................................................................21580 (DTC) P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH.....................................................................21583 (DTC) P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD..............................................................................21587 (DTC) P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION..................................................................21590 (DTC) P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED..........................................................21595 (DTC) P0456 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VERY SMALL LEAK DETECTED.....................................................21599 (DTC) P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION......................................21603 (DTC) P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION.............................................21606 (DTC) P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION......................................21610 (DTC) P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE.............................................................................21613 (DTC) P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT.....................................................................................21615 (DTC) P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT....................................................................................21617 (DTC) P0464 Fuel Level Sensor Noisy Signal..........................................................................................21619 (DTC) P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION...............................................................................21621 (DTC) P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION...............................................................................21624 (DTC) P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT............................................................................21627 (DTC) P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED.............................................................................21629 (DTC) P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED............................................................................21632 (DTC) P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.......................................................................21635 (DTC) P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT......................................................................21638 (DTC) P0562 SYSTEM VOLTAGE LOW......................................................................................................21641 (DTC) P0563 SYSTEM VOLTAGE HIGH.....................................................................................................21643 (DTC) P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR..........................................................................21645 (DTC) P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................21647 (DTC) P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................21649 (DTC) P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...................................................21651 (DTC) P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE....................................................21654 (DTC) P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................21656 (DTC) P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................21658 (DTC) P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.........................................................21661 (DTC) P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..........................................................21663 (DTC) P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)......................................................................21665 (DTC) P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).......................................................................21668 (DTC) P1171 FUEL SYSTEM LEAN DURING ACCELERATION....................................................................................21671 (DTC) P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED...........................................................21674 (DTC) P1380 ABS ROUGH ROAD SYSTEM FAULT.............................................................................................21677 (DTC) P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT................................................................................21679 (DTC) P1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE............................................................................21682 (DTC) P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NO-PURGE.................................................................21685 (DTC) P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION........................................................................21688 (DTC) P1618 Serial Peripheral Interface (SPI) PCM Interprocessor Communication Error................................................21691 (DTC) P1625 PCM Unexpected Reset....................................................................................................21692 (DTC) P1627 PCM A/D CONVERSION MALFUNCTION..........................................................................................21694 (DTC) P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION............................................................................21696 SYMPTOM DIAGNOSIS...................................................................................................................21698 DEFAULT MATRIX TABLE................................................................................................................21721 Camshaft Position (CMP) Sensor......................................................................................................21724 Removal Procedure...............................................................................................................21724 Installation Procedure..........................................................................................................21724 Crankshaft Position (CKP) Sensor....................................................................................................21725 Removal Procedure...............................................................................................................21725 Installation Procedure..........................................................................................................21726 EEPROM..............................................................................................................................21727 EEPROM..........................................................................................................................21727 EEPROM Programming..............................................................................................................21727 Engine Coolant Temperature (ECT) Sensor.............................................................................................21727 Removal Procedure...............................................................................................................21727 Installation Procedure..........................................................................................................21728 Heated Oxygen Sensor (HO2S).........................................................................................................21728 Removal Procedure...............................................................................................................21728 Inspection Procedure............................................................................................................21728 Installation Procedure..........................................................................................................21729 Intake Air Temperature (IAT) Sensor.................................................................................................21729 Removal Procedure...............................................................................................................21729 Installation Procedure..........................................................................................................21730 Manifold Absolute Pressure (MAP) Sensor.............................................................................................21730 Removal Procedure...............................................................................................................21730 Installation Procedure..........................................................................................................21730 Malfunction Indicator Lamp (MIL)....................................................................................................21731 Malfunction Indicator Lamp (MIL)................................................................................................21731 Powertrain Control Module (PCM).....................................................................................................21731 Electrostatic Discharge (ESD) Damage............................................................................................21731 Removal Procedure...............................................................................................................21731 Installation Procedure..........................................................................................................21733 Throttle Position (TP) Sensor.......................................................................................................21734 Removal Procedure...............................................................................................................21734 Function Check..................................................................................................................21734 Installation Procedure..........................................................................................................21734 Vehicle Speed Sensor (VSS)..........................................................................................................21735 Removal Procedure...............................................................................................................21735 Inspection Procedure............................................................................................................21735 Installation Procedure..........................................................................................................21735 Air Filter..........................................................................................................................21736 Removal Procedure...............................................................................................................21736 Installation Procedure..........................................................................................................21736 Idle Air Control (IAC) Valve........................................................................................................21737 Removal Procedure...............................................................................................................21737 Cleaning and Inspection Procedure...............................................................................................21737 Measurement Procedure...........................................................................................................21738 Installation Procedure..........................................................................................................21738 Intake Air Duct.....................................................................................................................21738 Removal Procedure...............................................................................................................21738 Installation Procedure..........................................................................................................21739 Knock Sensor........................................................................................................................21740 Removal Procedure...............................................................................................................21740 Installation Procedure..........................................................................................................21740 Oil Pressure Switch.................................................................................................................21741 Removal Procedure...............................................................................................................21741 Installation Procedure..........................................................................................................21741 FUEL METERING SYSTEM Accelerator Cable Assembly.....................................................................................21741 Removal Procedure...............................................................................................................21741 Inspection Procedure............................................................................................................21742 Installation Procedure..........................................................................................................21742 Accelerator Cable Adjustment....................................................................................................21743 Accelerator Pedal Replacement.......................................................................................................21743 Removal Procedure...............................................................................................................21743 Installation Procedure..........................................................................................................21743 Fuel Filler Cap.....................................................................................................................21744 Fuel Filler Cap.....................................................................................................................21744 Inspection Procedure............................................................................................................21744 Fuel Filter.........................................................................................................................21744 Removal Procedure...............................................................................................................21744 Inspection Procedure............................................................................................................21745 Installation Procedure..........................................................................................................21745 Fuel Injectors......................................................................................................................21746 Removal Procedure...............................................................................................................21746 Inspection Procedure............................................................................................................21746 Installation Procedure..........................................................................................................21746 Fuel Pressure Regulator.............................................................................................................21747 Removal Procedure...............................................................................................................21747 Installation Procedure..........................................................................................................21748 Fuel Pressure Relief Procedure..................................................................................................21748 Fuel Pump Assembly..................................................................................................................21749 Removal Procedure...............................................................................................................21749 Inspection Procedure............................................................................................................21750 Installation Procedure..........................................................................................................21750 Fuel Pump Relay.....................................................................................................................21751 Removal Procedure...............................................................................................................21751 Installation Procedure..........................................................................................................21751 Fuel Rail Assembly..................................................................................................................21751 Removal Procedure...............................................................................................................21751 Installation Procedure..........................................................................................................21752 Fuel Tank...........................................................................................................................21753 Removal Procedure...............................................................................................................21753 Installation Procedure..........................................................................................................21753 Throttle body (TB)..................................................................................................................21754 Removal Procedure...............................................................................................................21754 Inspection Procedure............................................................................................................21754 Installation Procedure..........................................................................................................21755 ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)............................................................................21756 Removal Procedure...............................................................................................................21756 Installation Procedure..........................................................................................................21756 Ignition Coil.......................................................................................................................21756 Removal Procedure...............................................................................................................21756 Installation Procedure..........................................................................................................21756 Spark Plugs.........................................................................................................................21757 Removal Procedure...............................................................................................................21757 Inspection Procedure............................................................................................................21757 Installation Procedure..........................................................................................................21758 Spark Plug Cables...................................................................................................................21758 Spark Plug Cables...................................................................................................................21758 Inspection Procedure............................................................................................................21758 EMISSIONS Catalytic Converter.......................................................................................................21759 Catalytic Converter.............................................................................................................21759 Air Conditioning Relay..............................................................................................................21759 Removal Procedure...............................................................................................................21759 Installation Procedure..........................................................................................................21759 Ignition Timing Adjustment..........................................................................................................21759 Ignition Timing Adjustment......................................................................................................21759 EVAP Canister Hoses.................................................................................................................21759 EVAP Canister Hoses.............................................................................................................21759 EVAP Canister.......................................................................................................................21759 Removal Procedure...............................................................................................................21759 Inspection Procedure............................................................................................................21759 Installation Procedure..........................................................................................................21759 EVAP Canister Vent Solenoid.........................................................................................................21760 Removal Procedure...............................................................................................................21760 Installation Procedure..........................................................................................................21760 EVAP Canister Purge Valve Solenoid..................................................................................................21760 Removal Procedure...............................................................................................................21760 Installation Procedure..........................................................................................................21761 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................21761 Removal Procedure...............................................................................................................21761 Inspection Procedure............................................................................................................21761 Installation Procedure..........................................................................................................21762 Wiring and Connectors...............................................................................................................21763 Wiring Harness Service..........................................................................................................21763 PCM Connectors And Terminals........................................................................................................21763 Removal Procedure...............................................................................................................21763 Installation Procedure..........................................................................................................21763 Connectors And Terminals............................................................................................................21763 Connectors And Terminals........................................................................................................21763 Wire Harness Repair: Twisted Shielded Cable.........................................................................................21763 Removal Procedure...............................................................................................................21763 Installation Procedure..........................................................................................................21764 Twisted Leads.......................................................................................................................21764 Removal Procedure...............................................................................................................21764 Installation Procedure..........................................................................................................21764 Weathe-Pack Connector...............................................................................................................21765 Tools Required..................................................................................................................21765 Removal Procedure...............................................................................................................21765 Installation Procedure..........................................................................................................21766 Com-Pack III........................................................................................................................21766 Com-Pack III....................................................................................................................21766 Metri-Pack..........................................................................................................................21767 Tools Required..................................................................................................................21767 Removal Procedure...............................................................................................................21767 Installation Procedure..........................................................................................................21767 GENERAL DESCRIPTION-PCM AND SENSORS.................................................................................................21767 GENERAL DESCRIPTION-AIRINDUCTION....................................................................................................21775 GENERAL DESCRIPTION-FUELMETERING....................................................................................................21775 GENERAL DESCRIPTION-ELECTRONIC IGNITION SYSTEM......................................................................................21778 A/C CLUTCH DIAGNOSIS................................................................................................................21782 GENERAL DESCRIPTION-EVAPORATIVE EMISSION (EVAP)SYSTEM...............................................................................21782 GENERAL DESCRIPTION-EXHAUST GAS RECIRCULATION(EGR) SYSTEM...........................................................................21784 GENERAL DESCRIPTION-POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM.....................................................................21785 SPECIAL TOOLS.......................................................................................................................21786 6F ENGINE EXHAUST.......................................................................................................................21788 Service Precaution..................................................................................................................21788 General Description.................................................................................................................21789 Front Exhaust Pipe..................................................................................................................21790 Front Exhaust Pipe and Associated Parts.........................................................................................21790 Removal.........................................................................................................................21790 Installation....................................................................................................................21790 Exhaust Silencer....................................................................................................................21791 Exhaust Silencer and Associated Parts...........................................................................................21791 Removal.........................................................................................................................21791 Installation....................................................................................................................21791 Rear Exhaust pipe...................................................................................................................21792 Rear Exhaust pipe and Associated Parts..........................................................................................21792 Removal.........................................................................................................................21792 Installation....................................................................................................................21792 Main Data and Specifications........................................................................................................21793 6G ENGINE LUBRICATION...................................................................................................................21794 Service Precaution..................................................................................................................21794 General Description.................................................................................................................21795 Oil Pump............................................................................................................................21796 Oil Pump and Associated Parts...................................................................................................21796 Disassembly.....................................................................................................................21797 Inspection and Repair...........................................................................................................21797 Reassembly......................................................................................................................21797 6H ENGINE SPEED CONTROL SYSTEM..........................................................................................................21798 Service Precaution..................................................................................................................21798 Accelerator Pedal Control Cable.....................................................................................................21799 Removal.........................................................................................................................21799 Inspection......................................................................................................................21799 Installation....................................................................................................................21799 Adjustment......................................................................................................................21799 Accelerator Pedal...................................................................................................................21800 Accelerator Pedal and Associated Parts..........................................................................................21800 Removal.........................................................................................................................21800 Installation....................................................................................................................21800 6J INDUCTION............................................................................................................................21801 Service Precaution..................................................................................................................21801 Air Cleaner Filter..................................................................................................................21802 Removal.........................................................................................................................21802 Inspection......................................................................................................................21802 Installation....................................................................................................................21802 6VD1 3.2L ENGINE..........................................................................................................................21803 6A ENGINE MECHANICAL....................................................................................................................21803 Service Precaution..................................................................................................................21804 General Description.................................................................................................................21805 Engine Diagnosis....................................................................................................................21806 Cylinder Head Cover LH..............................................................................................................21821 Removal.........................................................................................................................21821 Installation....................................................................................................................21822 Cylinder Head Cover RH..............................................................................................................21823 Removal.........................................................................................................................21823 Installation....................................................................................................................21823 Common Chamber......................................................................................................................21824 Removal.........................................................................................................................21824 Installation....................................................................................................................21824 Exhaust Manifold LH.................................................................................................................21826 Removal.........................................................................................................................21826 Installation....................................................................................................................21826 Exhaust Manifold RH.................................................................................................................21827 Removal.........................................................................................................................21827 Installation....................................................................................................................21827 Crankshaft Pulley...................................................................................................................21828 Removal.........................................................................................................................21828 Installation....................................................................................................................21828 Timing Belt.........................................................................................................................21829 Removal.........................................................................................................................21829 Installation....................................................................................................................21830 Camshaft............................................................................................................................21833 Removal.........................................................................................................................21833 Installation....................................................................................................................21834 Cylinder Head.......................................................................................................................21836 Removal.........................................................................................................................21836 Installation....................................................................................................................21836 Valve Stem Oil Controller , Valve Spring and Valve Guide............................................................................21838 Removal.........................................................................................................................21838 Installation....................................................................................................................21838 Piston, Piston Ring and Connecting Rod..............................................................................................21839 Removal.........................................................................................................................21839 Installation....................................................................................................................21840 Crankshaft and Main Bearings........................................................................................................21841 Removal.........................................................................................................................21841 Installation....................................................................................................................21842 Rear Oil Seal.......................................................................................................................21846 Removal.........................................................................................................................21846 Installation....................................................................................................................21846 Engine Assembly.....................................................................................................................21847 Removal.........................................................................................................................21847 Installation....................................................................................................................21848 Cylinder Head.......................................................................................................................21850 Cylinder Head and Associated Parts..............................................................................................21850 Disassembly.....................................................................................................................21850 Clean...........................................................................................................................21851 Inspection and Repair...........................................................................................................21851 Reassembly......................................................................................................................21852 Valve Spring, Oil Controller, Valve, Valve Guide....................................................................................21854 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...........................................................21854 Disassembly.....................................................................................................................21854 Inspection and Repair...........................................................................................................21855 Reassembly......................................................................................................................21858 Camshaft............................................................................................................................21861 Camshaft and Associated Parts...................................................................................................21861 Disassembly.....................................................................................................................21861 Inspection and Repair...........................................................................................................21862 Reassembly......................................................................................................................21864 Crankshaft..........................................................................................................................21867 Crankshaft and Associated Parts.................................................................................................21867 Disassembly.....................................................................................................................21867 Inspection and Repair for Bearings..............................................................................................21868 Inspection and Repair for Crankshaft............................................................................................21870 Reassembly......................................................................................................................21871 Piston and Connecting Rod...........................................................................................................21875 Piston, Connecting Rod and Associate Parts......................................................................................21875 Disassembly.....................................................................................................................21875 Inspection and Repair...........................................................................................................21876 Reassembly......................................................................................................................21880 Cylinder Block......................................................................................................................21882 Cylinder Block and Associated Parts.............................................................................................21882 Disassembly.....................................................................................................................21882 Inspection and Repair...........................................................................................................21883 Reassembly......................................................................................................................21884 Main Data and Specification.........................................................................................................21887 Special Tool........................................................................................................................21893 6B ENGINE COOLING.......................................................................................................................21895 Service Precaution..................................................................................................................21895 General Description.................................................................................................................21896 Diagnosis...........................................................................................................................21898 Draining and Refilling Cooling System...............................................................................................21899 Water Pump..........................................................................................................................21900 Water Pump and Associated Parts.................................................................................................21900 Removal.........................................................................................................................21900 Inspection......................................................................................................................21900 Installation....................................................................................................................21900 Thermostat..........................................................................................................................21901 Thermostat and Associated Parts.................................................................................................21901 Removal.........................................................................................................................21901 Inspection......................................................................................................................21901 Installation....................................................................................................................21901 Radiator............................................................................................................................21902 Radiator and Associated Parts...................................................................................................21902 Removal.........................................................................................................................21902 Inspection......................................................................................................................21903 Installation....................................................................................................................21904 Drive Belt and Cooling Fan..........................................................................................................21905 Drive Belt and Associated Parts.................................................................................................21905 Removal.........................................................................................................................21905 Inspection......................................................................................................................21905 Installation....................................................................................................................21905 Main Data and Specifications........................................................................................................21906 Special Tool........................................................................................................................21907 6C ENGINE FUEL FOR LONG WHEEL BASE......................................................................................................21908 Service Precaution..................................................................................................................21908 General Description.............................................................................................................21909 Fuel Metering...................................................................................................................21910 Fuel Filter.........................................................................................................................21911 Removal.........................................................................................................................21911 Inspection......................................................................................................................21911 Installation....................................................................................................................21912 Inspection......................................................................................................................21912 In–Tank Fuel Filter.............................................................................................................21912 Fuel Pump Flow Test.............................................................................................................21912 Fuel Pump...........................................................................................................................21913 Fuel Pump and Associated Parts..................................................................................................21913 Removal.........................................................................................................................21913 Installation....................................................................................................................21914 Fuel Tube / Quick – Connector Fittings..............................................................................................21914 Precautions.....................................................................................................................21914 Cautions During Work............................................................................................................21914 Removal.........................................................................................................................21914 Reuse of Quick–Connector........................................................................................................21915 Assembling Advice...............................................................................................................21915 Fuel Pump Relay.....................................................................................................................21916 General Description.............................................................................................................21916 Fuel Tank...........................................................................................................................21916 Fuel Tank and Associated Parts..................................................................................................21916 Removal.........................................................................................................................21916 Installation....................................................................................................................21917 Fuel Gauge Unit.....................................................................................................................21917 Removal and Installation........................................................................................................21917 Fuel Filler Cap.....................................................................................................................21917 General Description.............................................................................................................21917 Inspection......................................................................................................................21917 Main Data and Specifications........................................................................................................21918 Special Tool....................................................................................................................21918 6D1 ENGINE ELECTRICAL...................................................................................................................21919 Service Precaution..................................................................................................................21919 Battery.............................................................................................................................21920 General Description.................................................................................................................21920 Diagnosis...........................................................................................................................21920 Battery Charging....................................................................................................................21921 Jump Starting.......................................................................................................................21921 Battery Removal.....................................................................................................................21922 Battery Installation................................................................................................................21922 Main Data and Specifications........................................................................................................21923 6D2 IGNITION SYSTEM.....................................................................................................................21924 Service Precaution..................................................................................................................21924 General Description.................................................................................................................21925 Diagnosis...........................................................................................................................21925 Ignition Coil.......................................................................................................................21926 Removal.........................................................................................................................21926 Inspection and Repair...........................................................................................................21926 Installation....................................................................................................................21926 Spark Plug..........................................................................................................................21928 Removal.........................................................................................................................21928 Inspection and Repair...........................................................................................................21928 Installation....................................................................................................................21928 Crankshaft Position Sensor..........................................................................................................21929 Removal.........................................................................................................................21929 Installation....................................................................................................................21929 Main Data and Specifications........................................................................................................21930 6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)............................................................................................21931 Service Precaution..................................................................................................................21931 Starting System.....................................................................................................................21932 General Description.............................................................................................................21932 Diagnosis.......................................................................................................................21934 Starter.............................................................................................................................21935 Removal.........................................................................................................................21935 Installation....................................................................................................................21935 Disassembled View...............................................................................................................21937 Disassembly.....................................................................................................................21938 Inspection and Repair...........................................................................................................21940 Reassembly......................................................................................................................21943 Main Data and Specifications........................................................................................................21944 Charging System.....................................................................................................................21947 General Description.............................................................................................................21947 General On–Vehicle Inspection...................................................................................................21947 Generator...........................................................................................................................21948 Removal.........................................................................................................................21948 Inspection......................................................................................................................21948 Installation....................................................................................................................21949 Disassembled View...............................................................................................................21949 Disassembly.....................................................................................................................21950 Inspection and Repair...........................................................................................................21951 Reassembly......................................................................................................................21953 Bench Test......................................................................................................................21954 Main Data and Specifications........................................................................................................21955 6E2 DRIVEABILITY AND EMISSIONS..........................................................................................................21956 Specifications......................................................................................................................21961 Tightening Specifications.......................................................................................................21961 Diagrams and Schematics.............................................................................................................21962 PCM Wiring Diagram (1 of 7).....................................................................................................21962 PCM Wiring Diagram (2 of 7).....................................................................................................21963 PCM Wiring Diagram (3 of 7).....................................................................................................21964 PCM Wiring Diagram (4 of 7).....................................................................................................21965 PCM Wiring Diagram (5 of 7).....................................................................................................21966 PCM Wiring Diagram (6 of 7).....................................................................................................21967 PCM Wiring Diagram (7 of 7).....................................................................................................21968 PCM Pinouts.........................................................................................................................21969 PCM Pinout Table, 80-Way Blue Connector - Row "F1～20"...........................................................................21969 PCM Pinout Table, 80-Way Blue Connector - Row "F20～40"..........................................................................21970 PCM Pinout Table, 80-Way Blue Connector - Row "F41～60"..........................................................................21971 PCM Pinout Table, 80-Way Blue Connector - Row "F61～80"..........................................................................21972 PCM Pinout Table, 80-Way Red Connector - Row "S1～20"............................................................................21974 PCM Pinout Table, 80-Way Red Connector - Row "S21～40"...........................................................................21976 PCM Pinout Table, 80-Way Red Connector - Row "S41～60"...........................................................................21978 PCM Pinout Table, 80-Way Red Connector - Row "S61～80"...........................................................................21980 Component Locators..............................................................................................................21982 Undercarriage Component Locator.................................................................................................21984 Fuse and Relay Panel (Underhood Electrical Center)..............................................................................21985 Sensors and Miscellaneous Component Locators....................................................................................21986 Diagnosis...........................................................................................................................21988 Strategy-Based Diagnostics......................................................................................................21988 DTC Stored......................................................................................................................21988 No DTC..........................................................................................................................21988 No Matching Symptom.............................................................................................................21988 Intermittents...................................................................................................................21988 No Trouble Found................................................................................................................21988 Verifying Vehicle Repair........................................................................................................21988 General Service Information.........................................................................................................21988 OBD II Serviceablity Issues.....................................................................................................21988 Emissions Control Information Label.............................................................................................21989 Visual / Physical Engine Compartment Inspection.................................................................................21989 Basic Knowledge of Tools Required...............................................................................................21990 Serial Data Communications..........................................................................................................21990 Class 2 Serial Data Communications..............................................................................................21990 On-Board Diagnostic (OBD II)........................................................................................................21990 On-Board Diagnostic Tests.......................................................................................................21990 Comprehensive Component Monitor Diagnostic Operation............................................................................21990 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...............................21991 Common OBD II Terms.............................................................................................................21991 The Diagnostic Executive........................................................................................................21991 DTC Types.......................................................................................................................21992 Decimal/Binary/Hexadecimal Conversions..........................................................................................21994 Verifying Vehicle Repair........................................................................................................21994 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.....................................................................21994 Tech 2..........................................................................................................................21995 Tech 2 Features.................................................................................................................21996 Getting Started.................................................................................................................21996 Operating Procedure (For Example)...............................................................................................21997 DTC Modes.......................................................................................................................21998 DTC Information Mode............................................................................................................21998 Miscellaneous Test..............................................................................................................21999 Lamps Test......................................................................................................................21999 Relays Test.....................................................................................................................22001 EVAP Test.......................................................................................................................22002 Fuel System Test................................................................................................................22003 Instruments Test................................................................................................................22005 EGR Control Test................................................................................................................22007 Injector Balance Test...........................................................................................................22009 Plotting Snapshot Graph.............................................................................................................22009 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)..................................................22010 Flow Chart for Snapshot Replay (Plotting Graph).................................................................................22011 Primary System-Based Diagnostic.....................................................................................................22012 Primary System-Based Diagnostic.................................................................................................22012 Fuel Control Heated Oxygen Sensor...............................................................................................22012 HO2S Heater.....................................................................................................................22012 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.................................................................22012 Misfire Monitor Diagnostic Operation................................................................................................22013 Misfire Monitor Diagnostic Operation............................................................................................22013 Misfire Counters................................................................................................................22013 Fuel Trim System Monitor Diagnostic Operation.......................................................................................22014 Fuel Trim System Monitor Diagnostic Operation...................................................................................22014 Fuel Trim Cell Diagnostic Weights...............................................................................................22014 On-Board Diagnostic (OBD II) System Check...........................................................................................22015 Circuit Description.............................................................................................................22015 Diagnostic Aids.................................................................................................................22015 Test Description................................................................................................................22015 A/C Clutch Control Circuit Diagnosis................................................................................................22018 Circuit Description.............................................................................................................22018 Diagnostic Aids.................................................................................................................22018 A/C Clutch Diagnosis............................................................................................................22019 Test Description................................................................................................................22019 Electronic Ignition System Diagnosis................................................................................................22023 EVAP Canister Purge Solenoid and EVAP Vent Solenoid Valve...........................................................................22023 Visual Check of The Evaporative Emission Canister...................................................................................22023 Fuel Metering System Check..........................................................................................................22023 Fuel System Pressure Test...........................................................................................................22023 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..........................................................22023 Test Description................................................................................................................22023 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11).......................................22024 Powertrain Control Module (PCM) Diagnosis...........................................................................................22028 Multiple PCM Information Sensor DTCs Set............................................................................................22028 Circuit Description.............................................................................................................22028 Diagnostic Aids.................................................................................................................22028 Exhaust Gas Recirculation (EGR) Diagnosis...........................................................................................22031 Engine Tech 2 Data Definitions and Ranges...........................................................................................22031 Typical Scan Data Values............................................................................................................22033 Test Conditions.................................................................................................................22033 No Malfunction Indicator Lamp (MIL).................................................................................................22039 Circuit Description.............................................................................................................22039 Diagnostic Aids.................................................................................................................22039 Test Description................................................................................................................22039 Malfunction Indicator Lamp (MIL) "ON" Steady........................................................................................22042 Circuit description.............................................................................................................22042 Diagnostic Aids.................................................................................................................22042 Test Description................................................................................................................22042 No Reduced Power Lamp (RPL).........................................................................................................22044 Circuit Description.............................................................................................................22044 Diagnostic Aids.................................................................................................................22044 Test Description................................................................................................................22044 Reduced Power Lamp (RPL) "ON" Steady................................................................................................22048 Circuit Description.............................................................................................................22048 Diagnostic Aids.................................................................................................................22048 Test Description................................................................................................................22048 Starter Control System Check........................................................................................................22051 Circuit Description.............................................................................................................22051 Diagnostic Aids.................................................................................................................22051 Test Description................................................................................................................22051 Engine Cranks But Will Not Run......................................................................................................22055 Circuit Description.............................................................................................................22057 Diagnostic Aids.................................................................................................................22057 Test Description................................................................................................................22057 Fuel System Electrical Test.........................................................................................................22062 Circuit Description.............................................................................................................22063 Diagnostic Aids.................................................................................................................22063 Test Description................................................................................................................22063 Fuel Pressure Relief Procedure..................................................................................................22063 Fuel Gauge Installation.........................................................................................................22063 Electric Throttle Control (ETC) System Check........................................................................................22066 Circuit Description.............................................................................................................22067 Diagnostic Aids.................................................................................................................22067 Test Description................................................................................................................22067 Fuel System Diagnosis...............................................................................................................22070 Circuit Description.............................................................................................................22071 Test Description................................................................................................................22071 Fuel Pressure Relief Procedure..................................................................................................22072 Fuel Gauge Installation.........................................................................................................22072 Exhaust Gas Recirculation (EGR) System Check........................................................................................22075 Circuit Description.............................................................................................................22075 Diagnostic Aids.................................................................................................................22075 Manifold Absolute Pressure (MAP) Output Check.......................................................................................22077 Circuit Description.............................................................................................................22077 Test Description................................................................................................................22077 Evaporative (EVAP) Emissions Canister Purge Valve Check.............................................................................22079 Circuit Description.............................................................................................................22079 Diagnostic Aids.................................................................................................................22079 Test Description................................................................................................................22079 PCM Diagnostic Trouble Codes........................................................................................................22082 Diagnostic Trouble Code (DTC) P0101 MAF System Performance..........................................................................22086 Diagnostic Trouble Code (DTC) P0102 MAF Sensor Circuit Low Frequency................................................................22089 Diagnostic Trouble Code (DTC) P0103 MAF Sensor Circuit High Frequency...............................................................22092 Diagnostic Trouble Code (DTC) P0106 MAP System Performance..........................................................................22095 Diagnostic Trouble Code (DTC) P0107 MAP Sensor Circuit Low Voltage..................................................................22098 Diagnostic Trouble Code (DTC) P0108 MAP Sensor Circuit High Voltage.................................................................22101 Diagnostic Trouble Code (DTC) P0112 IAT Sensor Circuit Low Voltage..................................................................22104 Diagnostic Trouble Code (DTC) P0113 IAT Sensor Circuit High Voltage.................................................................22107 Diagnostic Trouble Code (DTC) P0117 ECT Sensor Circuit Low Voltage..................................................................22110 Diagnostic Trouble Code (DTC) P0118 ECT Sensor Circuit High Voltage.................................................................22113 Diagnostic Trouble Code (DTC) P0125 ECT Excessive Time to Closed Loop Fuel Control..................................................22116 Diagnostic Trouble Code(DTC) P0128 Thermostat Insufficient Temperature for Stable Operation.........................................22119 Diagnostic Trouble Code (DTC) P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1........................................................22121 Diagnostic Trouble Code (DTC) P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.......................................................22124 Diagnostic Trouble Code (DTC) P0133 HO2S Slow Response Bank 1 Sensor 1..............................................................22127 Diagnostic Trouble Code (DTC) P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1..............................................22131 Diagnostic Trouble Code (DTC) P0135 HO2S Heater Circuit Bank 1 Sensor 1.............................................................22134 Diagnostic Trouble Code (DTC) P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2........................................................22137 Diagnostic Trouble Code (DTC) P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.......................................................22140 Diagnostic Trouble Code(DTC) P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2...............................................22143 Diagnostic Trouble Code (DTC) P0141 HO2S Heater Circuit Bank 1 Sensor 2.............................................................22146 Diagnostic Trouble Code (DTC) P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1........................................................22149 Diagnostic Trouble Code (DTC) P0152 HO2S Circuit High Voltage Bank 2 Sensor 1.......................................................22152 Diagnostic Trouble Code (DTC) P0153 HO2S Slow Response Bank 2 Sensor 1..............................................................22155 Diagnostic Trouble Code (DTC) P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1..............................................22159 Diagnostic Trouble Code (DTC) P0155 HO2S Heater Circuit Open Bank 2 Sensor 1........................................................22162 Diagnostic Trouble Code (DTC) P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2........................................................22165 Diagnostic Trouble Code (DTC) P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.......................................................22168 Diagnostic Trouble Code (DTC) P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2..............................................22171 Diagnostic Trouble Code (DTC) P0161 HO2S Heater Circuit Bank 2 Sensor 2.............................................................22174 Diagnostic Trouble Code (DTC) P0171 Fuel Trim System Lean Bank 1....................................................................22177 Diagnostic Trouble Code (DTC) P0172 Fuel Trim System Rich Bank 1....................................................................22181 Diagnostic Trouble Code (DTC) P0174 Fuel Trim System Lean Bank 2....................................................................22185 Diagnostic Trouble Code (DTC) P0175 Fuel Trim System Rich Bank 2....................................................................22189 Diagnostic Trouble Code (DTC) P0201 Injector 1 Control Circuit......................................................................22193 Diagnostic Trouble Code (DTC) P0202 Injector 2 Control Circuit......................................................................22196 Diagnostic Trouble Code (DTC) P0203 Injector 3 Control Circuit......................................................................22199 Diagnostic Trouble Code (DTC) P0204 Injector 4 Control Circuit......................................................................22202 Diagnostic Trouble Code (DTC) P0205 Injector 5 Control Circuit......................................................................22205 Diagnostic Trouble Code (DTC) P0206 Injector 6 Control Circuit......................................................................22208 Diagnostic Trouble Code (DTC) P0300 Engine Misfire Detected.........................................................................22211 Diagnostic Trouble Code (DTC) P0301 Cylinder Misfire Detected.......................................................................22215 Diagnostic Trouble Code (DTC) P0302 Cylinder Misfire Detected.......................................................................22217 Diagnostic Trouble Code (DTC) P0303 Cylinder Misfire Detected.......................................................................22219 Diagnostic Trouble Code (DTC) P0304 Cylinder Misfire Detected.......................................................................22221 Diagnostic Trouble Code (DTC) P0305 Cylinder Misfire Detected.......................................................................22223 Diagnostic Trouble Code (DTC) P0306 Cylinder Misfire Detected.......................................................................22225 Diagnostic Trouble Code (DTC) P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault....................................22227 Diagnostic Trouble Code (DTC) P0336 58X Reference Signal Circuit....................................................................22230 Diagnostic Trouble Code (DTC) P0337 CKP Sensor Circuit Low Frequency................................................................22233 Diagnostic Trouble Code (DTC) P0351 Ignition 1 Control Circuit......................................................................22236 Diagnostic Trouble Code (DTC) P0352 Ignition 2 Control Circuit......................................................................22239 Diagnostic Trouble Code (DTC) P0353 Ignition 3 Control Circuit......................................................................22242 Diagnostic Trouble Code (DTC) P0354 Ignition 4 Control Circuit......................................................................22245 Diagnostic Trouble Code (DTC) P0355 Ignition 5 Control Circuit......................................................................22248 Diagnostic Trouble Code (DTC) P0356 Ignition 6 Control Circuit......................................................................22251 Diagnostic Trouble Code (DTC) P0401 EGR Flow Insufficient...........................................................................22254 Diagnostic Trouble Code (DTC) P0402 EGR Pintle Crank Error..........................................................................22257 Diagnostic Trouble Code (DTC) P0404 EGR Open Stuck..................................................................................22259 Diagnostic Trouble Code (DTC) P0405 EGR Low Voltage.................................................................................22261 Diagnostic Trouble Code (DTC) P0406 EGR High Voltage................................................................................22264 Diagnostic Trouble Code (DTC) P0420 TWC System Low Efficiency Bank 1................................................................22267 Diagnostic Trouble Code (DTC) P0430 TWC System Low Efficiency Bank 2................................................................22270 Diagnostic Trouble Code (DTC) P0440 EVAP System.....................................................................................22273 Diagnostic Trouble Code (DTC) P0442 EVAP System Small Leak Detected.................................................................22276 Diagnostic Trouble Code (DTC) P0444 EVAP Purge Control Circuit Open.................................................................22279 Diagnostic Trouble Code (DTC) P0445 EVAP Purge Control Circuit Short................................................................22281 Diagnostic Trouble Code (DTC) P0446 EVAP Canister Vent Control Malfunction..........................................................22283 Diagnostic Trouble Code (DTC) P0447 EVAP Vent Solenoid Circuit Open.................................................................22286 Diagnostic Trouble Code (DTC) P0448 EVAP Vent solenoid Circuit Short................................................................22288 Diagnostic Trouble Code (DTC) P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage...................................22290 Diagnostic Trouble Code (DTC) P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage..................................22293 Diagnostic Trouble Code (DTC) P0456 EVAP Very Small Leak............................................................................22296 Diagnostic Trouble Code (DTC) P0461 Fuel Level Sensor Performance...................................................................22299 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Circuit-Low Voltage...........................................................22301 Diagnostic Trouble Code (DTC) P0463 Fuel Level Sensor Circuit-High Voltage..........................................................22304 Diagnostic Trouble Code (DTC) P0462 Fuel Level Sensor Noisy Signal..................................................................22306 Diagnostic Trouble Code (DTC) P0502 VSS Circuit Low Input...........................................................................22308 Diagnostic Trouble Code (DTC) P0506 Idle Air Control System Low RPM.................................................................22311 Diagnostic Trouble Code (DTC) P0507 Idle Air Control System High RPM................................................................22314 Diagnostic Trouble Code (DTC) P0562 System Voltage Low..............................................................................22317 Diagnostic Trouble Code (DTC) P0563 System Voltage High.............................................................................22319 Diagnostic Trouble Code (DTC) P0565 Cruise Main Switch Circuit Error................................................................22321 Diagnostic Trouble Code (DTC) P0566 Cruise Cancel Switch Circuit Error..............................................................22323 Diagnostic Trouble Code (DTC) P0567 Cruise Resume Switch Circuit Error..............................................................22325 Diagnostic Trouble Code (DTC) P0568 Cruise Set Switch Circuit Error.................................................................22327 Diagnostic Trouble Code (DTC) P0571 No Brake Switch Signal..........................................................................22329 Diagnostic Trouble Code (DTC) P0601 PCM Memory......................................................................................22331 Diagnostic Trouble Code (DTC) P0602 PCM Programming Error...........................................................................22333 Diagnostic Trouble Code (DTC) P0604 PCM RAM Error...................................................................................22335 Diagnostic Trouble Code (DTC) P0606 PCM Internal Performance........................................................................22337 Diagnostic Trouble Code (DTC) P1106 MAP Sensor Circuit Intermittent High Voltage....................................................22339 Diagnostic Trouble Code (DTC) P1107 MAP Circuit Intermittent Low Voltage............................................................22341 Diagnostic Trouble Code (DTC) P1111 IAT Sensor Circuit Intermittent High Voltage....................................................22343 Diagnostic Trouble Code (DTC) P1112 IAT Sensor Circuit Intermittent Low Voltage.....................................................22346 Diagnostic Trouble Code (DTC) P1114 ECT Sensor Circuit Intermittent Low Voltage.....................................................22348 Diagnostic Trouble Code (DTC) P1115 ECT Sensor Circuit Intermittent High Voltage....................................................22350 Diagnostic Trouble Code(DTC) P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault..............................................22353 Diagnostic Trouble Code (DTC) P1125 ETC (Electric throttle control) Limit Performance Mode..........................................22356 Diagnostic Trouble Code (DTC) P1133 HO2S Insufficient Switching Bank 1 Sensor 1.....................................................22359 Diagnostic Trouble Code (DTC) P1134 HO2S Transition Time Ratio Bank 1 Sensor 1......................................................22363 Diagnostic Trouble Code (DTC) P1153 HO2S Insufficient Switching Bank 2 Sensor 1.....................................................22367 Diagnostic Trouble Code (DTC) P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1..............................................22371 Diagnostic Trouble Code (DTC) P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1).............................................22375 Diagnostic Trouble Code (DTC) P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2).............................................22377 Diagnostic Trouble Code (DTC) P1171 Fuel System Lean During Acceleration............................................................22379 Diagnostic Trouble Code (DTC) P1220 Throttle Position Senser2 (TPS2) Circuit Fault..................................................22382 Diagnosis Truble Code(DTC) P1221 TPS1 - TPS2 correlation(Circuit Performance).......................................................22385 Diagnostic Trouble Code (DTC) P1271 APS 1・2 Correlation Error.......................................................................22388 Diagnostic Trouble Code (DTC) P1272 APS 2 - 3 Correlation Error.....................................................................22391 Diagnostic Trouble Code (DTC) P1273 APS 1 - 3 Correlation Error.....................................................................22394 Diagnostic Trouble Code (DTC) P1275 APS 1 Circuit Fault.............................................................................22397 Diagnostic Trouble Code (DTC) P1280 APS 2 Circuit Fault.............................................................................22399 Diagnostic Trouble Code (DTC) P1285 APS 3 Circuit Fault.............................................................................22401 Diagnostic Trouble Code (DTC) P1290 ETC Forced Idle Mode............................................................................22403 Diagnostic Trouble Code (DTC) P1295 Power Management Mode...........................................................................22405 Diagnostic Trouble Code (DTC) P1299 ETC Forced Engine Shutdown Mode.................................................................22407 Diagnostic Trouble Code (DTC) P1310 ION Sensing Module Diagnosis....................................................................22409 Diagnostic Trouble Code (DTC) P1311 ION Sensing Module SEC Line 1 Circuit Fault.....................................................22412 Diagnostic Trouble Code (DTC) P1312 ION Sensing Module SEC Line 2 Circuit Fault.....................................................22415 Diagnostic Trouble Code (DTC) P1326 ION Sensing Module Combustion Quality Input Circuit Fault.......................................22418 Diagnostic Trouble Code (DTC) P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)............................22421 Diagnostic Trouble Code (DTC) P1404 EGR Stuck Closed................................................................................22424 Diagnostic Trouble Code (DTC) P1441 EVAP System Flow During Non-Purge...............................................................22427 Diagnostic Trouble Code (DTC) P1514 TPS - MAF Correlation Error.....................................................................22430 Diagnostic Trouble Code (DTC) P1515 Command - Actual TPS Correlation Error..........................................................22434 Diagnostic Trouble Code (DTC) P1516 Command - Actual TPS Correlation Error..........................................................22437 Diagnostic Trouble Code (DTC) P1523 Actuator Control Return Performance.............................................................22440 Diagnostic Trouble Code (DTC) P1571 Brake Switch No Operation.......................................................................22443 Diagnostic Trouble Code (DTC) P1625 PCM Unexpected Reset............................................................................22445 Diagnostic Trouble Code (DTC) P1635 Reference Voltage # 1 Circuit Fault.............................................................22446 Diagnostic Trouble Code (DTC) P1639 Reference Voltage # 2 Circuit Fault.............................................................22448 Diagnostic Trouble Code (DTC) P1640 Driver-1-Output Circuit Fault (ODM).............................................................22450 Diagnostic Trouble Code (DTC) P1650 Quad Driver Module "A" Fault....................................................................22452 Symptom Diagnosis...................................................................................................................22455 Default Matrix Table................................................................................................................22484 Default Matrix Table............................................................................................................22484 On Vehicle Service Crankshaft Position (CKP) Sensor.............................................................................22487 Engine Coolant Temperature (ECT) Sensor.............................................................................................22487 Heated Oxygen Sensor (HO2S).........................................................................................................22488 Intake Air Temperature (IAT) Sensor.................................................................................................22491 ION Sensing Module..................................................................................................................22491 Mass Air Flow (MAF) Sensor..........................................................................................................22492 Manifold Absolute Pressure (MAP) Sensor.............................................................................................22493 Malfunction Indicator Lamp (MIL)....................................................................................................22494 Reduced Power Lamp..................................................................................................................22494 Powertrain Control Module (PCM).....................................................................................................22494 EEPROM..............................................................................................................................22496 Throttle Position (TP) Sensor.......................................................................................................22496 Vehicle Speed Sensor (VSS)..........................................................................................................22497 Air Cleaner/Air Filter..............................................................................................................22498 Common Chamber......................................................................................................................22498 Accelerator Pedal Replacement.......................................................................................................22499 Accelerator Position Sensor Replacement.............................................................................................22500 Accelerator Position Sensor Adjustment..............................................................................................22500 Fuel Filler Cap.....................................................................................................................22501 Fuel Filter.........................................................................................................................22501 Fuel Gauge Unit.....................................................................................................................22502 Fuel Injectors......................................................................................................................22503 Fuel Metering System................................................................................................................22504 Fuel Pump Assembly..................................................................................................................22504 Fuel Pump Relay.....................................................................................................................22505 Fuel Rail Assembly..................................................................................................................22506 Fuel Tank...........................................................................................................................22507 Throttle Body (TB)..................................................................................................................22507 Electronic Ignition System..........................................................................................................22509 Catalytic Converter.................................................................................................................22510 Air Conditioning Thermo Relay.......................................................................................................22510 EVAP Canister Hoses.................................................................................................................22510 EVAP Canister.......................................................................................................................22511 EVAP Canister Vent Solenoid.........................................................................................................22511 Fuel Tank Pressure (Vapor Pressure) Sensor..........................................................................................22512 EVAP Canister Purge Solenoid (Purge Duty Solenoid Valve)............................................................................22513 Fuel Tank Vent Valve (Vent Solenoid Valve)..........................................................................................22514 Linear Exhaust Gas Recirculation (EGR) Valve........................................................................................22514 Positive Crankcase Ventilation (PCV) Valve..........................................................................................22515 Wiring and Connectors...............................................................................................................22515 PCM Connectors and Terminals........................................................................................................22516 Wire Harness Repair: Twisted Shielded Cable.........................................................................................22516 Twisted Leads.......................................................................................................................22517 Weather-Pack Connector..............................................................................................................22518 Com-Pack III........................................................................................................................22519 Metri-Pack..........................................................................................................................22520 General Description (PCM and Sensors)...............................................................................................22521 General Description (Air Induction).................................................................................................22526 General Description (Fuel Metering).................................................................................................22527 General Description (Electronic Ignition System)....................................................................................22529 A/C Clutch Diagnosis................................................................................................................22532 General Description (Evaporative (EVAP) Emission System)............................................................................22532 General Description (Exhaust Gas Recirculation (EGR) System)........................................................................22537 General Description (Positive Crankcase Ventilation (PCV) System)...................................................................22538 Special Tools.......................................................................................................................22540 6F ENGINE EXHAUST.......................................................................................................................22542 Service Precaution..................................................................................................................22542 General Description.................................................................................................................22543 Three Way Catalytic Converter RH and Forked Exhaust Pipe............................................................................22544 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts...................................................22544 Removal.........................................................................................................................22544 Installation....................................................................................................................22544 Three Way Catalytic Converter LH and Forked Exhaust Pipe............................................................................22545 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts...................................................22545 Removal.........................................................................................................................22545 Installation....................................................................................................................22545 Forked Exhaust Pipe.................................................................................................................22546 Forked Exhaust Pipe and Associated Parts........................................................................................22546 Removal.........................................................................................................................22546 Installation....................................................................................................................22546 Exhaust Silencer....................................................................................................................22547 Exhaust Silencer and Associated Parts...........................................................................................22547 Removal.........................................................................................................................22547 Installation....................................................................................................................22547 Rear Exhaust pipe...................................................................................................................22548 Rear Exhaust pipe and Associated Parts..........................................................................................22548 Removal.........................................................................................................................22548 Installation....................................................................................................................22548 Main Data and Specifications........................................................................................................22549 6G ENGINE LUBRICATION...................................................................................................................22550 Service Precaution..................................................................................................................22550 General Description.................................................................................................................22551 Oil Pump............................................................................................................................22552 Oil Pump and Associated Parts...................................................................................................22552 Disassembly.....................................................................................................................22553 Inspection and Repair...........................................................................................................22553 Reassembly......................................................................................................................22554 Oil Pan and Crankcase...............................................................................................................22556 Removal.........................................................................................................................22556 Installation....................................................................................................................22556 Oil Pump............................................................................................................................22558 Removal.........................................................................................................................22558 Installation....................................................................................................................22558 Oil Pump Oil Seal...................................................................................................................22560 Removal.........................................................................................................................22560 Installation....................................................................................................................22560 Oil Filter..........................................................................................................................22561 Removal.........................................................................................................................22561 Installation....................................................................................................................22561 Main Data and Specification.........................................................................................................22562 6H ENGINE SPEED CONTROL SYSTEM..........................................................................................................22563 Service Precaution..................................................................................................................22563 Accelerator Pedal...................................................................................................................22564 Accelerator Pedal and Associated Parts..........................................................................................22564 Removal.........................................................................................................................22564 Installation....................................................................................................................22564 6J INDUCTION............................................................................................................................22565 Service Precaution..................................................................................................................22565 Air Cleaner Element.................................................................................................................22566 Removal.........................................................................................................................22566 Inspection......................................................................................................................22566 Installation....................................................................................................................22566 Sec.7 TRANSMISSION..............................................................................................................................22567 7A AUTOMATIC TRANSMISSION...................................................................................................................22567 Service Precaution......................................................................................................................22568 Construction............................................................................................................................22569 Range Reference Chart...................................................................................................................22570 Normal Operation of 2001 4L30–E Transmission............................................................................................22571 Diagnosis...............................................................................................................................22571 Driver Information......................................................................................................................22571 General Diagnosis Procedure.............................................................................................................22574 Preliminary Inspection Chart............................................................................................................22575 Checking Transmission Fluid Level and Condition.........................................................................................22576 Test Driving............................................................................................................................22577 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................22578 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................22579 Stall Test..............................................................................................................................22588 Line Pressure Test......................................................................................................................22589 Shift Speed Chart (V6)..................................................................................................................22591 Lockup Speed Chart (V6).................................................................................................................22592 Shift Speed Chart (HEC).................................................................................................................22593 Lockup Speed Chart (HEC)................................................................................................................22594 Changing Transmission Fluid.............................................................................................................22595 Selector Lever..........................................................................................................................22595 Inspection..........................................................................................................................22595 Removal.............................................................................................................................22595 Installation........................................................................................................................22597 Select Cable............................................................................................................................22597 Removal.............................................................................................................................22597 Installation........................................................................................................................22600 Shift Lock Cable........................................................................................................................22602 Removal.............................................................................................................................22602 Installation........................................................................................................................22602 Mode Switch.............................................................................................................................22603 Removal.............................................................................................................................22603 Installation........................................................................................................................22604 Transmission Assembly...................................................................................................................22605 Transmission and Associated Parts...................................................................................................22605 Removal.............................................................................................................................22607 Installation........................................................................................................................22614 Solenoid (Main Case Valve Body).........................................................................................................22621 Removal.............................................................................................................................22621 Installation........................................................................................................................22621 Solenoid (Adapter Case Valve Body)......................................................................................................22622 Removal.............................................................................................................................22622 Installation........................................................................................................................22622 Valve Body Assembly (Main Case).........................................................................................................22623 Removal.............................................................................................................................22623 Installation........................................................................................................................22623 Valve Body Assembly (Adapter Case)......................................................................................................22624 Removal.............................................................................................................................22624 Installation........................................................................................................................22624 Powertrain Control Module (PCM) (V6)....................................................................................................22625 Removal.............................................................................................................................22625 Installation........................................................................................................................22625 Powertrain Control Module (PCM) (HEC)...................................................................................................22626 Removal.............................................................................................................................22626 Installation........................................................................................................................22626 Speed Sensor (Extension Assembly).......................................................................................................22627 Removal.............................................................................................................................22627 Installation........................................................................................................................22627 Transmission Oil Temperature Sensor (Main Case) (V6)....................................................................................22628 Removal.............................................................................................................................22628 Installation........................................................................................................................22628 Transmission Oil Temperature Sensor (Adapter Case) (HEC)................................................................................22629 Removal.............................................................................................................................22629 Installation........................................................................................................................22629 Front Oil Seal (Converter Housing)......................................................................................................22630 Removal.............................................................................................................................22630 Installation........................................................................................................................22630 Rear Oil Seal (Extension Assembly)......................................................................................................22631 Removal.............................................................................................................................22631 Installation........................................................................................................................22631 Transmission (4L30–E)...................................................................................................................22632 Disassembly.........................................................................................................................22632 Reassembly..........................................................................................................................22637 Converter Housing and Oil Pump Assembly.................................................................................................22648 Disassembled View...................................................................................................................22648 Disassembly.........................................................................................................................22648 Inspection and Repair...............................................................................................................22648 Reassembly..........................................................................................................................22648 Oil Pump................................................................................................................................22649 Disassembled View...................................................................................................................22649 Disassembly.........................................................................................................................22649 Inspection and Repair...............................................................................................................22649 Reassembly..........................................................................................................................22649 Main Case Valve Body....................................................................................................................22650 Disassembled View...................................................................................................................22650 Disassembly.........................................................................................................................22651 Inspection and Repair...............................................................................................................22651 Reassembly..........................................................................................................................22651 Adapter Case Valve Body.................................................................................................................22652 Disassembled View...................................................................................................................22652 Disassembly.........................................................................................................................22652 Inspection and Repair...............................................................................................................22652 Reassembly..........................................................................................................................22652 Third Clutch and Sprag Unit.............................................................................................................22653 Disassembled View...................................................................................................................22653 Disassembly.........................................................................................................................22653 Inspection and Repair...............................................................................................................22654 Reassembly..........................................................................................................................22654 Third Clutch............................................................................................................................22654 Disassembled View...................................................................................................................22654 Disassemble.........................................................................................................................22655 Inspection and Repair...............................................................................................................22655 Reassembly..........................................................................................................................22655 Sprag Unit..............................................................................................................................22656 Disassembled View...................................................................................................................22656 Disassembly.........................................................................................................................22656 Inspection and Repair...............................................................................................................22656 Reassembly..........................................................................................................................22656 Second Clutch...........................................................................................................................22657 Disassembled View...................................................................................................................22657 Disassembly.........................................................................................................................22657 Inspection and Repair...............................................................................................................22658 Reassembly..........................................................................................................................22658 3–4 Accumulator Piston..................................................................................................................22659 Disassembled View...................................................................................................................22659 Disassembly.........................................................................................................................22659 Inspection and Repair...............................................................................................................22660 Reassembly..........................................................................................................................22660 Reverse Clutch Piston and Center Support................................................................................................22661 Disassembled View...................................................................................................................22661 Disassembly.........................................................................................................................22662 Inspection and Repair...............................................................................................................22662 Reassembly..........................................................................................................................22662 Overrun Clutch and Turbine Shaft........................................................................................................22663 Disassembled View...................................................................................................................22663 Disassembly.........................................................................................................................22664 Inspection and Repair...............................................................................................................22664 Reassembly..........................................................................................................................22664 Main Data and Specification.............................................................................................................22666 General Specifications..............................................................................................................22666 Torque Specifications...............................................................................................................22667 Special Tools...........................................................................................................................22672 4L30–E Parts List.......................................................................................................................22675 7A1 TRANSMISSION CONTROL SYSTEM.............................................................................................................22682 Service Precaution......................................................................................................................22683 General Description.....................................................................................................................22683 Electronic Control Diagram..........................................................................................................22684 Powertrain Control Module (PCM).....................................................................................................22685 Control System Diagram..............................................................................................................22686 Shift Control.......................................................................................................................22687 Band Apply Control..................................................................................................................22687 Torque Converter Clutch Control.....................................................................................................22687 Line Pressure Control...............................................................................................................22687 On–Board Diagnostic System..........................................................................................................22687 Fail–Safe Mechanism.................................................................................................................22687 Torque Management Control...........................................................................................................22687 ATF Warning Control.................................................................................................................22687 Reverse Lock Out Control............................................................................................................22687 Downhill Control....................................................................................................................22687 Uphill Control......................................................................................................................22687 Shift Mode Control..................................................................................................................22688 Gear Shift Control..................................................................................................................22689 Winter Drive Mode...................................................................................................................22690 Backup Mode.........................................................................................................................22690 Functions of Input / Output Components..............................................................................................22691 Diagnosis...............................................................................................................................22692 Electronic Diagnosis................................................................................................................22692 Check Trans Indicator...............................................................................................................22692 Diagnostic Check....................................................................................................................22692 “Check Trans” Check.................................................................................................................22693 Tech 2 OBD II Connection............................................................................................................22694 Transmission Data...................................................................................................................22699 OBD II Diagnostic Management System.................................................................................................22700 16 – Terminal Data Link Connector (DLC).............................................................................................22701 Malfunction Indicator Lamp (MIL)....................................................................................................22702 DTC Types...........................................................................................................................22702 Clear DTC...........................................................................................................................22703 DTC Check...........................................................................................................................22703 PCM Precaution......................................................................................................................22703 Information On PCM..................................................................................................................22703 Intermittent Conditions.............................................................................................................22704 Transmission and PCM Identification.................................................................................................22705 Diagnostic Trouble Code (DTC) Identification........................................................................................22706 DTC P0218 Transmission Fluid Over Temperature...........................................................................................22707 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................22709 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................22712 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................22715 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................22718 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................22721 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................22724 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................22727 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................22730 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................22733 DTC P0730 Gear Error Without Input Speed................................................................................................22735 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................22738 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................22740 DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................22742 DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................22744 DTC P0753 Shift Solenoid A Electrical...................................................................................................22746 DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................22749 DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................22751 DTC P0758 Shift Solenoid B Electrical...................................................................................................22753 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................22757 DTC P1860 TCC Solenoid Electrical.......................................................................................................22761 DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................22764 Circuit Diagram.........................................................................................................................22766 Parts Location..........................................................................................................................22768 Harness Connector Faces.................................................................................................................22769 7B MANUAL TRANSMISSION MUA 5C...............................................................................................................22771 Service Precaution......................................................................................................................22771 General Description.....................................................................................................................22772 Diagnosis...............................................................................................................................22774 Rear Oil Seal (4X2).....................................................................................................................22775 Disassembled View...................................................................................................................22775 Removal.............................................................................................................................22775 Installation........................................................................................................................22775 Transmission............................................................................................................................22776 Disassembled View...................................................................................................................22776 Removal.............................................................................................................................22777 Installation........................................................................................................................22781 Transmission Case.......................................................................................................................22786 Major Component (4X2)...............................................................................................................22786 Disassembly.........................................................................................................................22787 Reassembly..........................................................................................................................22788 Transmission Case and Transfer Case.....................................................................................................22791 Major Component (4X4)...............................................................................................................22791 Disassembly.........................................................................................................................22792 Reassembly..........................................................................................................................22795 Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin.............................................................22801 Disassembled View...................................................................................................................22801 Disassembly.........................................................................................................................22802 Inspection and Repair...............................................................................................................22803 Reassembly..........................................................................................................................22804 Reverse Gear and 5th Gear...............................................................................................................22805 Disassembled View...................................................................................................................22805 Disassembly.........................................................................................................................22806 Inspection and Repair...............................................................................................................22808 Reassembly..........................................................................................................................22808 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................22814 Disassmebled View...................................................................................................................22814 Disassembly.........................................................................................................................22815 Inspection and Repair...............................................................................................................22816 Reassembly..........................................................................................................................22819 Main Data and Specifications............................................................................................................22825 Special Tools (MUA).....................................................................................................................22829 7C CLUTCH...................................................................................................................................22831 Service Precaution......................................................................................................................22831 General Description.....................................................................................................................22832 Diagnosis...............................................................................................................................22837 Clutch Assembly (Y22SE).................................................................................................................22838 Clutch Assembly (Y22SE) and Associated Parts........................................................................................22838 Removal.............................................................................................................................22838 Inspection and Repair...............................................................................................................22839 Installation........................................................................................................................22843 Clutch Assembly (6VD1)..................................................................................................................22845 Clutch Assembly (6VD1) and Associated Parts.........................................................................................22845 Removal.............................................................................................................................22845 Inspection and Repair...............................................................................................................22847 Installation........................................................................................................................22851 Clutch Control..........................................................................................................................22853 Parts Location View.................................................................................................................22853 Removal.............................................................................................................................22854 Inspection and Repair...............................................................................................................22854 Installation........................................................................................................................22854 Master Cylinder.........................................................................................................................22857 Slave Cylinder..........................................................................................................................22858 Disassembled View...................................................................................................................22858 Disassembly.........................................................................................................................22858 Inspection and Repair...............................................................................................................22858 Reassembly..........................................................................................................................22859 Main Data and Specifications............................................................................................................22860 Special Tools...........................................................................................................................22863 Sec.8 BODY AND ACCESSORIES......................................................................................................................22864 8A LIGHTING SYSTEM..........................................................................................................................22864 Service Precaution......................................................................................................................22865 Headlight Bulb..........................................................................................................................22866 Headlight Assembly......................................................................................................................22866 Headlight Adjustment................................................................................................................22867 Fog Light Bulb..........................................................................................................................22869 Fog Light Assembly......................................................................................................................22870 Fog Light Adjustment................................................................................................................22870 Side Marker Light Bulb..................................................................................................................22870 Taillight Bulb..........................................................................................................................22871 License Plate Light Bulb (Bumper Type)..................................................................................................22871 License Plate Light Bulb (Tailgate Type)................................................................................................22872 Stoplight Bulb..........................................................................................................................22872 High Mounted Stoplight Assembly.........................................................................................................22873 High Mounted Stoplight Bulb.............................................................................................................22873 High Mounted Stoplight Assembly (Soft Top Model)........................................................................................22874 High Mounted Stoplight Bulb (Soft Top Model)............................................................................................22874 High Mounted Stoplight Assembly (Resin Top Model).......................................................................................22875 High Mounted Stoplight Bulb (Resin Top Model)...........................................................................................22875 Backup Light Bulb.......................................................................................................................22876 Front Turn Signal Light Bulb............................................................................................................22876 Rear Turn Signal Light Bulb.............................................................................................................22877 Dome Light Bulb (LWB)...................................................................................................................22877 Dome Light Bulb (SWB)...................................................................................................................22878 Courtesy Light Bulb.....................................................................................................................22878 Spotlight Bulb..........................................................................................................................22879 Luggage Room Light Bulb (LWB)...........................................................................................................22879 Luggage Room Light Bulb (Resin Top Model)...............................................................................................22880 HVAC Bezel Illumination Light Bulb......................................................................................................22880 Shift Lever Illumination Light Bulb (A/T)...............................................................................................22881 Vanity Mirror Illumination Light Bulb...................................................................................................22881 Starter Switch..........................................................................................................................22882 Lighting Switch (Combination Switch)....................................................................................................22882 Dimmer・Passing Switch (Combination Switch)..............................................................................................22882 Door Switch.............................................................................................................................22882 Rear Defogger Switch....................................................................................................................22883 Key Remind Switch (Starter Switch)......................................................................................................22883 Hazard Warning Light Switch.............................................................................................................22884 Stoplight Switch........................................................................................................................22884 Backup Light Switch (M/T)...............................................................................................................22885 Turn Signal Light Switch (Combination Switch)...........................................................................................22885 Illumination Controller.................................................................................................................22886 Light and Bulb Specifications (LWB).....................................................................................................22887 Light and Bulb Specifications (SWB).....................................................................................................22888 8B WIPER / WASHER SYSTEM....................................................................................................................22890 Service Precaution......................................................................................................................22890 Windshield Wiper/Washer System..........................................................................................................22891 General Description.................................................................................................................22891 Windshield Wiper And Washer Switch......................................................................................................22891 Removal and Installation............................................................................................................22891 Windshield Wiper Motor..................................................................................................................22891 Removal.............................................................................................................................22891 Installation........................................................................................................................22891 Windshield Washer Motor.................................................................................................................22892 Removal.............................................................................................................................22892 Installation........................................................................................................................22892 Windshield Washer Spray Pattern.........................................................................................................22893 Windshield Wiper Linkage................................................................................................................22894 Windshield Wiper Linkage and Associated Parts.......................................................................................22894 Removal.............................................................................................................................22894 Installation........................................................................................................................22894 Windshield Wiper Arm/Blade..............................................................................................................22895 Removal.............................................................................................................................22895 Installation........................................................................................................................22895 Windshield Wiper Blade Rubber...........................................................................................................22896 Removal.............................................................................................................................22896 Installation........................................................................................................................22896 Rear Wiper/Washer System................................................................................................................22897 General Description.................................................................................................................22897 Rear Wiper and Washer Switch............................................................................................................22897 Removal.............................................................................................................................22897 Installation........................................................................................................................22897 Rear Wiper Motor (LWB)..................................................................................................................22898 Removal.............................................................................................................................22898 Installation........................................................................................................................22898 Rear Wiper Motor (Resin Top Model)......................................................................................................22899 Removal.............................................................................................................................22899 Installation........................................................................................................................22899 Rear Washer Motor.......................................................................................................................22900 Removal.............................................................................................................................22900 Installation........................................................................................................................22900 Alarm and Relay Control Unit............................................................................................................22901 Removal.............................................................................................................................22901 Installation........................................................................................................................22901 Rear Wiper Arm/Blade (LWB)..............................................................................................................22901 Removal.............................................................................................................................22901 Installation........................................................................................................................22901 Rear Wiper Arm/Blade (Resin Top Model)..................................................................................................22902 Removal.............................................................................................................................22902 Installation........................................................................................................................22902 Rear Washer Nozzle......................................................................................................................22902 Removal.............................................................................................................................22902 Installation........................................................................................................................22902 Rear Washer Spray Pattern...........................................................................................................22902 Rear Washer Nozzle (Resin Top Model)....................................................................................................22903 Removal.............................................................................................................................22903 Installation........................................................................................................................22903 Rear Washer Spray Pattern...........................................................................................................22903 Rear Wiper Blade Rubber (Spare Tire Storage-Tailgate Mounted)...........................................................................22904 Removal.............................................................................................................................22904 Installation........................................................................................................................22904 Rear Wiper Blade Rubber (Spare Tire Storage-Under Floor)................................................................................22905 Removal.............................................................................................................................22905 Installation........................................................................................................................22905 Main Data and Specifications............................................................................................................22906 8C ENTERTAINMENT............................................................................................................................22907 Service Precaution......................................................................................................................22907 Cigarette Lighter.......................................................................................................................22908 General Description.................................................................................................................22908 Removal.............................................................................................................................22908 Installation........................................................................................................................22908 Digital Clock...........................................................................................................................22908 Removal.............................................................................................................................22908 Installation........................................................................................................................22908 Rod Type Antenna........................................................................................................................22909 Removal.............................................................................................................................22909 Installation........................................................................................................................22909 Accessory Socket........................................................................................................................22910 Front Accessory Socket..............................................................................................................22910 Rear Accessory Socket...............................................................................................................22910 Radio...................................................................................................................................22911 Removal.............................................................................................................................22911 Installation........................................................................................................................22911 Amplifier...............................................................................................................................22912 Removal.............................................................................................................................22912 Installation........................................................................................................................22912 Speaker.................................................................................................................................22913 Front Speaker.......................................................................................................................22913 Tweeter Assembly....................................................................................................................22913 Rear Door Speaker (LWB).............................................................................................................22913 Rear Speaker (LWB)..................................................................................................................22914 Rear Speaker (SWB)..................................................................................................................22914 Horn....................................................................................................................................22915 Removal.............................................................................................................................22915 Installation........................................................................................................................22915 8D WIRING SYSTEM............................................................................................................................22916 Fuse, Relay and Diode...................................................................................................................22917 Relay / Fuse Box Location...........................................................................................................22917 Relay / Fuse Box (Instrument Panel).................................................................................................22918 Relay / Fuse Box (L4 Engine Room)...................................................................................................22919 Relay / Fuse Box (V6 Engine Room)...................................................................................................22920 Circuit Diagram.........................................................................................................................22921 Fuse Block Circuit-1 (L4)...........................................................................................................22921 Fuse Block Circuit-2 (V6)...........................................................................................................22922 Earth Location (Engine Room)........................................................................................................22923 Earth Location (Cabin)..............................................................................................................22924 Starter and Generator (L4)..........................................................................................................22925 Starter and Generator (V6)..........................................................................................................22926 ECM (L4)............................................................................................................................22927 PCM (V6)-1..........................................................................................................................22928 PCM (V6)-2..........................................................................................................................22929 Headlight and Fog Light.............................................................................................................22930 TURN, HAZARD, STOP, Back Up, Horn and A/T Shift Lock................................................................................22931 Room, Luggage, Courtesy, Spot, Warning Buzzer (LWB).................................................................................22932 Room, Luggage, Courtesy, Spot, Warning Buzzer (SWB).................................................................................22933 Power Window and Door Lock..........................................................................................................22934 Alarmer Unit........................................................................................................................22935 Rear Wiper/Washer, Rear Defogger and Mirror Defogger................................................................................22936 Audio, Clock, Cigarette Lighter and ACC Socket (W/O AMP)............................................................................22937 Audio, Clock, Cigarette Lighter and ACC Socket (W/AMP)..............................................................................22938 Door Mirror.........................................................................................................................22939 Meter (L4)..........................................................................................................................22940 Meter (V6)-1........................................................................................................................22941 Meter (V6)-2........................................................................................................................22942 Anti-theft with Keyless Entry (LWB).................................................................................................22943 Anti-theft with Keyless Entry (L4 SWB)..............................................................................................22944 Anti-theft with Keyless Entry (V6 SWB)..............................................................................................22945 Air Conditioning....................................................................................................................22946 ABS.................................................................................................................................22947 SRS-Air Bag.........................................................................................................................22948 Intelligent Suspension..............................................................................................................22949 Shift on the Fly....................................................................................................................22950 Sunroof.............................................................................................................................22951 Illumination Light..................................................................................................................22952 FRT Wiper...........................................................................................................................22953 Power Seat..........................................................................................................................22954 8E METER AND GAUGE..........................................................................................................................22955 Service Precaution......................................................................................................................22955 General Description.................................................................................................................22955 Meter Assembly..........................................................................................................................22956 General Description.................................................................................................................22956 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................22956 Table for Meter/Gauge Connector Terminal Connections................................................................................22958 Removal.............................................................................................................................22960 Installation........................................................................................................................22960 Warning Light Bulb and Indicator Light Bulb.............................................................................................22960 Removal.............................................................................................................................22960 Installation........................................................................................................................22960 A/T Shift Indicator Light Bulb..........................................................................................................22961 Removal.............................................................................................................................22961 Installation........................................................................................................................22962 Vehicle Speed Sensor....................................................................................................................22962 Removal.............................................................................................................................22962 Installation........................................................................................................................22962 Fuel Tank Unit..........................................................................................................................22963 Main Data and Specifications............................................................................................................22964 8F BODY STRUCTURE...........................................................................................................................22965 Service Precaution......................................................................................................................22966 Frame...................................................................................................................................22966 General Description.................................................................................................................22966 Frame Dimensions (LWB)..............................................................................................................22967 Frame Dimensions (SWB)..............................................................................................................22968 General Description (Bumper)........................................................................................................22969 Front Bumper............................................................................................................................22969 Parts Location......................................................................................................................22969 Removal.............................................................................................................................22970 Installation........................................................................................................................22970 Front Bumper Slider Bracket.............................................................................................................22971 Removal.............................................................................................................................22971 Installation........................................................................................................................22971 Rear Bumper.............................................................................................................................22972 Parts Location (Spare tire mounted tailgate model)..................................................................................22972 Removal.............................................................................................................................22973 Installation........................................................................................................................22973 Parts Location (Spare tire mounted under floor model)...............................................................................22975 Removal.............................................................................................................................22976 Installation........................................................................................................................22976 Rear Bumper Slider......................................................................................................................22977 Removal.............................................................................................................................22977 Installation........................................................................................................................22977 General Description (Sheet Metal)...................................................................................................22978 Engine Hood.............................................................................................................................22978 Parts Location......................................................................................................................22978 Removal.............................................................................................................................22979 Installation........................................................................................................................22979 Engine Hood Lock........................................................................................................................22981 Parts Location......................................................................................................................22981 Removal.............................................................................................................................22981 Installation........................................................................................................................22982 Radiator Grille.........................................................................................................................22983 Parts Location......................................................................................................................22983 Removal.............................................................................................................................22983 Installation........................................................................................................................22984 Front Fender Panel......................................................................................................................22985 Parts Location......................................................................................................................22985 Removal.............................................................................................................................22985 Installation........................................................................................................................22986 Body Mounting...........................................................................................................................22988 Parts Location......................................................................................................................22988 Tightening Torque...................................................................................................................22988 Body Dimension..........................................................................................................................22989 Front Section.......................................................................................................................22989 Room Section (SWB)..................................................................................................................22992 Room Section (LWB)..................................................................................................................22994 Rear Section (SWB)..................................................................................................................22996 Rear Section (LWB)..................................................................................................................22998 Side Body Section (Front side)......................................................................................................23000 Side Body Section (Rear side).......................................................................................................23002 General Description (Body)..........................................................................................................23004 Instrument Panel Assembly...............................................................................................................23004 Parts Location......................................................................................................................23004 Removal.............................................................................................................................23005 Installation........................................................................................................................23006 Front Door Assembly.....................................................................................................................23007 Parts Location......................................................................................................................23007 Removal.............................................................................................................................23007 Installation........................................................................................................................23008 Rear Door Assembly......................................................................................................................23009 Parts Location......................................................................................................................23009 Removal.............................................................................................................................23009 Installation........................................................................................................................23010 Front Window Regulator, Glass and Glass Run.............................................................................................23011 Parts Location......................................................................................................................23011 Removal.............................................................................................................................23012 Installation........................................................................................................................23014 Rear Window Regulator, Glass and Glass Run..............................................................................................23015 Parts Location......................................................................................................................23015 Removal.............................................................................................................................23016 Installation........................................................................................................................23018 Tailgate (LWB)..........................................................................................................................23019 Parts Location......................................................................................................................23019 Removal.............................................................................................................................23020 Installation........................................................................................................................23021 Tailgate (SWB)..........................................................................................................................23022 Parts Location......................................................................................................................23022 Removal.............................................................................................................................23023 Installation........................................................................................................................23023 Rear Hatchgate (LWB)....................................................................................................................23024 Parts Location......................................................................................................................23024 Removal.............................................................................................................................23025 Installation........................................................................................................................23025 Adjustment..........................................................................................................................23027 Tailgate Glass (Resin Top)..............................................................................................................23028 Parts Location......................................................................................................................23028 Removal.............................................................................................................................23029 Installation........................................................................................................................23029 Spare Tire Carrier......................................................................................................................23030 Parts Location......................................................................................................................23030 Removal.............................................................................................................................23030 Installation........................................................................................................................23030 Spare Tire Hanger.......................................................................................................................23031 Parts Location......................................................................................................................23031 Removal.............................................................................................................................23032 Installation........................................................................................................................23032 Windshield..............................................................................................................................23033 Parts Location......................................................................................................................23033 Removal.............................................................................................................................23034 Installation........................................................................................................................23034 Rear Quarter Glass (LWB)................................................................................................................23037 Parts Location......................................................................................................................23037 Removal.............................................................................................................................23037 Installation........................................................................................................................23038 Rear Quarter Glass (Resin Top)..........................................................................................................23039 Parts Location......................................................................................................................23039 Removal.............................................................................................................................23039 Installation........................................................................................................................23039 Side Window Glass (SWB).................................................................................................................23041 Parts Location......................................................................................................................23041 Removal.............................................................................................................................23041 Installation........................................................................................................................23041 Main Data and Specifications............................................................................................................23042 Special Tools...........................................................................................................................23045 8G SEATS....................................................................................................................................23046 Service Precaution......................................................................................................................23046 Front Seat Assembly.....................................................................................................................23047 Front Seat Assembly and Associated Parts............................................................................................23047 Removal.............................................................................................................................23047 Installation........................................................................................................................23048 Power Seat Assembly.....................................................................................................................23050 Power Seat Assembly and Associated Parts............................................................................................23050 Removal.............................................................................................................................23051 Installation........................................................................................................................23052 Rear Seat Assembly (LWB)................................................................................................................23053 Rear Seat Cushion Assembly and Associated Parts.....................................................................................23053 Removal.............................................................................................................................23054 Installation........................................................................................................................23054 Rear Seat Back Assembly and Associated Parts........................................................................................23055 Removal.............................................................................................................................23055 Installation........................................................................................................................23056 Rear Seat Assembly (SWB)................................................................................................................23057 Rear Seat Assembly and Associated Parts.............................................................................................23057 Removal.............................................................................................................................23058 Installation........................................................................................................................23058 Main Data and Specifications............................................................................................................23059 8H SECURITY AND LOCKS.......................................................................................................................23061 Service Precaution......................................................................................................................23061 Front Door Lock Assembly................................................................................................................23062 Front Door Lock Assembly and Associated Parts.......................................................................................23062 Removal.............................................................................................................................23063 Installation........................................................................................................................23064 Front Outside Handle....................................................................................................................23065 Front Outside Handle and Associated Parts...........................................................................................23065 Removal.............................................................................................................................23065 Installation........................................................................................................................23065 Rear Door Lock Assembly.................................................................................................................23066 Rear Door Lock Assembly and Associated Parts........................................................................................23066 Removal.............................................................................................................................23066 Installation........................................................................................................................23067 Rear Outside Handle.....................................................................................................................23068 Rear Outside Handle and Associated Parts............................................................................................23068 Removal.............................................................................................................................23068 Installation........................................................................................................................23068 Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................23069 Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................23069 Removal.............................................................................................................................23069 Installation........................................................................................................................23070 Tailgate Lock (SWB).....................................................................................................................23071 Tailgate Lock and Associated Parts..................................................................................................23071 Removal.............................................................................................................................23071 Installation........................................................................................................................23072 Key.....................................................................................................................................23073 Key Coding..........................................................................................................................23073 Key Styles..........................................................................................................................23073 Power Door Lock System..................................................................................................................23074 General Description.................................................................................................................23074 Door Lock Key Switch................................................................................................................23074 Front Door Lock Actuator............................................................................................................23074 Rear Door Lock Actuator.............................................................................................................23074 Tailgate Lock Actuator..............................................................................................................23074 Anti-Theft System.......................................................................................................................23074 General Description.................................................................................................................23074 Anti-Theft & Keyless Entry Controller...............................................................................................23074 Anti–Theft Indicator................................................................................................................23075 Anti–Theft Horn.....................................................................................................................23075 Engine Hood Switch..................................................................................................................23076 Anti–theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................23076 Keyless Entry System....................................................................................................................23077 ID Code Registration................................................................................................................23077 Main Data and Specifications............................................................................................................23081 8I SUNROOF/CONVERTIBLE TOP.................................................................................................................23082 Service Precaution......................................................................................................................23082 Sunroof Glass (LWB).....................................................................................................................23083 Sunroof Glass and Associated Parts..................................................................................................23083 Removal.............................................................................................................................23083 Installation........................................................................................................................23084 Sunroof Glass (SWB).....................................................................................................................23084 Sunroof Glass and Associated Parts..................................................................................................23084 Removal.............................................................................................................................23085 Installation........................................................................................................................23085 Sunroof Deflector (LWB).................................................................................................................23086 Removal.............................................................................................................................23086 Installation........................................................................................................................23086 Sunroof Deflector (SWB).................................................................................................................23087 Parts Location......................................................................................................................23087 Removal.............................................................................................................................23087 Installation........................................................................................................................23087 Sunshade (LWB)..........................................................................................................................23088 Disassembled View...................................................................................................................23088 Removal.............................................................................................................................23088 Installation........................................................................................................................23089 Sunroof Frame Complete Assembly (LWB)...................................................................................................23090 Sunroof Frame Complete Assembly and Associated Parts................................................................................23090 Removal.............................................................................................................................23090 Installation........................................................................................................................23091 Sunroof Switch..........................................................................................................................23091 Removal.............................................................................................................................23091 Installation........................................................................................................................23091 Sunroof Control Unit....................................................................................................................23092 Removal.............................................................................................................................23092 Installation........................................................................................................................23092 Sunroof Motor...........................................................................................................................23092 Removal.............................................................................................................................23092 Installation........................................................................................................................23092 Soft Top Assembly.......................................................................................................................23093 Soft Top Assembly and Associated Parts..............................................................................................23093 Removal.............................................................................................................................23094 Installation........................................................................................................................23094 Resin Top Assembly......................................................................................................................23095 Resin Top Assembly and Associated Parts.............................................................................................23095 Removal.............................................................................................................................23095 Installation........................................................................................................................23096 Seat Belt Cross Bar Assembly............................................................................................................23097 Seat Belt Cross Bar Assembly and Associated Parts...................................................................................23097 Removal.............................................................................................................................23097 Installation........................................................................................................................23098 Main Data and Specifications............................................................................................................23099 8J EXTERIOR / INTERIOR TRIM.................................................................................................................23100 Service Precaution......................................................................................................................23101 Consoles................................................................................................................................23102 Consoles and Associated Parts.......................................................................................................23102 Removal.............................................................................................................................23102 Installation........................................................................................................................23102 Front Door Trim Panel...................................................................................................................23103 Front Door Trim Panel and Associated Parts..........................................................................................23103 Removal.............................................................................................................................23104 Installation........................................................................................................................23104 Rear Door Trim Panel....................................................................................................................23105 Rear Door Trim Panel and Associated Parts...........................................................................................23105 Removal.............................................................................................................................23106 Installation........................................................................................................................23106 Door Mirror Assembly....................................................................................................................23107 Removal.............................................................................................................................23107 Installation........................................................................................................................23107 Interior Trim Panels (LWB)..............................................................................................................23108 Interior Trim Panels and Associated Parts...........................................................................................23108 Removal.............................................................................................................................23108 Installation........................................................................................................................23110 Interior Trim Panels (SWB)..............................................................................................................23111 Interior Trim Panels and Associated Parts...........................................................................................23111 Removal.............................................................................................................................23111 Installation........................................................................................................................23112 Headlining (LWB)........................................................................................................................23113 Parts Location......................................................................................................................23113 Removal.............................................................................................................................23113 Installation........................................................................................................................23114 Headlining (SWB)........................................................................................................................23115 Parts Location......................................................................................................................23115 Removal.............................................................................................................................23116 Installation........................................................................................................................23117 Wheel Arch Protector (LWB)..............................................................................................................23118 Wheel Arch Protector and Associated Parts...........................................................................................23118 Removal.............................................................................................................................23118 Installation........................................................................................................................23118 Wheel Arch Protector (SWB)..............................................................................................................23119 Wheel Arch Protector and Associated Parts...........................................................................................23119 Removal.............................................................................................................................23119 Installation........................................................................................................................23119 Wheel Arch Molding (SWB)................................................................................................................23120 Wheel Arch Molding and Associated Parts.............................................................................................23120 Removal.............................................................................................................................23120 Installation........................................................................................................................23121 Wheel Arch Molding (LWB)................................................................................................................23122 Wheel Arch Molding and Associated Parts.............................................................................................23122 Removal.............................................................................................................................23122 Installation........................................................................................................................23123 Fuel Filler Door........................................................................................................................23123 Parts Location......................................................................................................................23123 Removal.............................................................................................................................23123 Installation........................................................................................................................23123 Roof Rail...............................................................................................................................23124 Parts Location......................................................................................................................23124 Removal.............................................................................................................................23124 Installation........................................................................................................................23124 License Plate Garnish...................................................................................................................23125 Parts Location......................................................................................................................23125 Removal.............................................................................................................................23125 Installation........................................................................................................................23126 Power Door Mirror System................................................................................................................23126 General Description.................................................................................................................23126 Door Mirror Switch..................................................................................................................23126 Power Window System.....................................................................................................................23127 General Description.................................................................................................................23127 Power Window Switch Driver Seat Side................................................................................................23127 Power Window Motor..................................................................................................................23128 Main Data and Specifications............................................................................................................23129 Sec.9 RESTRAINTS................................................................................................................................23130 9A SEAT BELT SYSTEM.........................................................................................................................23130 Service Precaution......................................................................................................................23130 Front Seat Belt (LWB)...................................................................................................................23131 Front Seat Belt and Associated Parts................................................................................................23131 Removal.............................................................................................................................23131 Inspection..........................................................................................................................23132 Installation........................................................................................................................23132 Front Seat Belt (SWB)...................................................................................................................23133 Front Seat Belt and Associated Parts................................................................................................23133 Removal.............................................................................................................................23133 Inspection..........................................................................................................................23135 Installation........................................................................................................................23135 Rear Seat Belt (LWB)....................................................................................................................23136 Rear Seat Belt and Associated Parts.................................................................................................23136 Removal.............................................................................................................................23136 Inspection..........................................................................................................................23137 Installation........................................................................................................................23138 Rear Seat Belt (SWB)....................................................................................................................23139 Rear Seat Belt and Associated Parts.................................................................................................23139 Removal.............................................................................................................................23139 Inspection..........................................................................................................................23141 Installation........................................................................................................................23141 Front Seat Buckle Assembly..............................................................................................................23142 Removal.............................................................................................................................23142 Installation........................................................................................................................23142 Rear Center Seat Belt / Buckle Assembly.................................................................................................23143 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................23143 Removal.............................................................................................................................23143 Installation........................................................................................................................23143 Child Seat Tether Anchorage Bracket (Child Restraint)...................................................................................23144 Child Seat Tether Anchorage Bracket and Associated Parts............................................................................23144 Removal.............................................................................................................................23144 Installation........................................................................................................................23144 Child Seat Lower Anchorage Striker (LWB)................................................................................................23145 Child Seat Lower Anchorage Striker and Associated Parts.............................................................................23145 Removal.............................................................................................................................23145 Installation........................................................................................................................23146 Main Data and Specifications............................................................................................................23147 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)......................................................................................................23150 Service Precaution......................................................................................................................23150 General Description.....................................................................................................................23151 SRS Component and Wiring Location View..............................................................................................23153 Component Description...................................................................................................................23153 Definition..............................................................................................................................23156 Diagnosis...............................................................................................................................23157 SRS Connector Body Face Views...........................................................................................................23158 Repairs and Inspections Required After an Accident......................................................................................23158 On–Vehicle Service......................................................................................................................23159 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................23160 Special Tools...........................................................................................................................23175 Service Precaution......................................................................................................................23177 Sensing and Diagnostic Module (SDM).....................................................................................................23179 Service Precautions.................................................................................................................23179 Removal.............................................................................................................................23179 Installation........................................................................................................................23180 Driver Air Bag Assembly.................................................................................................................23181 Service Precautions.................................................................................................................23181 Removal.............................................................................................................................23181 Installation........................................................................................................................23181 Steering Wheel..........................................................................................................................23182 Service Precautions.................................................................................................................23182 Removal.............................................................................................................................23182 Installation........................................................................................................................23183 SRS Coil Assembly.......................................................................................................................23184 Service Precaution..................................................................................................................23184 Removal.............................................................................................................................23184 How to Disconnect the horn terminal.................................................................................................23186 How to Connect Horn Terminal........................................................................................................23186 Installation........................................................................................................................23187 Steering Column.........................................................................................................................23189 Service Precaution..................................................................................................................23189 Removal.............................................................................................................................23189 Installation........................................................................................................................23191 Passenger Air Bag Assembly..............................................................................................................23193 Service Precaution..................................................................................................................23193 Removal.............................................................................................................................23193 Installation........................................................................................................................23193 Main Data and Specifications............................................................................................................23194 SRS Air Bag System Inspection Standards For Repair......................................................................................23195 9J1 SRS CONTROL SYSTEM......................................................................................................................23196 Service Precaution......................................................................................................................23196 Diagnostic Information..................................................................................................................23197 Plotting Snapshot Graph.................................................................................................................23202 Parts For Electrical Circuit............................................................................................................23205 System Schematic........................................................................................................................23206 SRS Diagnostic System Check.............................................................................................................23206 Chart A SDM Integrity Check.............................................................................................................23209 Chart B “AIR BAG” Warning Lamp Comes “ON” Steady........................................................................................23211 Chart C “AIR BAG” Warning Lamp Does Not Comes “ON” Steady...............................................................................23213 DTC 15 Passenger Deployment Loop Resistance High........................................................................................23216 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................23219 DTC 17 Passenger Deployment Loop Open...................................................................................................23222 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................23224 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................23226 DTC 21 Driver Deployment Loop Resistance High...........................................................................................23228 DTC 22 Driver Deployment Loop Resistance Low............................................................................................23231 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................23234 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................23236 DTC 26 Driver Deployment Loop Open......................................................................................................23239 DTC 51 Deployment Event Commanded.......................................................................................................23242 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................23244 DTC 61 Warning Lamp Circuit Failure.....................................................................................................23246 DTC 71 Internal SDM Fault...............................................................................................................23248 Sec.10 CONTROL SYSTEM...........................................................................................................................23250 10A CRUISE CONTROL SYSTEM...................................................................................................................23250 Service Precaution......................................................................................................................23250 General Description.....................................................................................................................23250 Brake Switch............................................................................................................................23251 Removal and Installation............................................................................................................23251 Adjustment..........................................................................................................................23251 Clutch Switch...........................................................................................................................23252 Removal and Installation............................................................................................................23252 Adjustment..........................................................................................................................23252 Powertrain Control Module (PCM).........................................................................................................23252 Removal and Installation............................................................................................................23252 Mode Switch.............................................................................................................................23252 Removal and Installation............................................................................................................23252 Cruise Control Main Switch..............................................................................................................23253 Removal.............................................................................................................................23253 Installation........................................................................................................................23253 Cruise Control Switch (Combination Switch)..............................................................................................23253 Removal and Installation............................................................................................................23253 Diagnosis...............................................................................................................................23254 (UA) RODEO SPORT....................................................................................................................................23255 Sec.0 GENRAL INFORMATION........................................................................................................................23256 0A General Information......................................................................................................................23256 0B Maintenance and Lubrication..............................................................................................................23256 Sec.1 HEATING, VENTILATION AND AIR CONDITIONING.................................................................................................23257 1A HVAC System..............................................................................................................................23257 Sec.2 STEERING..................................................................................................................................23258 2A POWER-ASSISTED STEERING SYSTEM...........................................................................................................23258 Service Precaution......................................................................................................................23259 Diagnosis...........................................................................................................................23259 General Description.................................................................................................................23265 Power Steering System Test..........................................................................................................23267 Maintenance.........................................................................................................................23268 Fluid Level.........................................................................................................................23268 Bleeding The Power Steering System..................................................................................................23268 Bleeding Procedure..................................................................................................................23268 Flushing The Power Steering System..................................................................................................23268 Steering Wheel Free Play Inspection.................................................................................................23269 Front End Alignment Inspection and Adjustment.......................................................................................23269 Main Data and Specifications........................................................................................................23273 Special Tools.......................................................................................................................23274 Power Steering Unit.....................................................................................................................23275 Power Steering Unit and Associated Parts............................................................................................23275 Removal.............................................................................................................................23275 Installation (4x2 Model)............................................................................................................23276 Installation (4x4 Model)............................................................................................................23276 Power Steering Unit Disassembled View...............................................................................................23277 Disassembly.........................................................................................................................23277 Inspection and Repair...............................................................................................................23278 Reassembly..........................................................................................................................23278 Main Data and Specifications........................................................................................................23278 Special Tools.......................................................................................................................23279 Power Steering Pump.....................................................................................................................23280 Power Steering Pump and Associated Parts............................................................................................23280 Removal.............................................................................................................................23280 Installation........................................................................................................................23280 Power Steering Pump Disassembled View...............................................................................................23281 Disassembly.........................................................................................................................23281 Inspection and Repair...............................................................................................................23282 Reassembly..........................................................................................................................23282 Main Data and Specifications........................................................................................................23284 Transfer Gear Assembly..................................................................................................................23285 Transfer Gear Assembly and Associated Parts.........................................................................................23285 Removal.............................................................................................................................23285 Inspection and Repair...............................................................................................................23285 Installation........................................................................................................................23285 Supplemental Restraint System Steering Wheel & Column...................................................................................23286 Service Precaution..................................................................................................................23286 SRS Connectors......................................................................................................................23286 Inflator Module.........................................................................................................................23288 Inflator Module and Associated Parts................................................................................................23288 Removal.............................................................................................................................23288 Inspection and Repair...............................................................................................................23289 Installation........................................................................................................................23289 Steering Wheel..........................................................................................................................23290 Steering Wheel and Associated Parts.................................................................................................23290 Removal.............................................................................................................................23290 Installation........................................................................................................................23292 Combination Switch......................................................................................................................23293 Combination Switch and Associated Parts.............................................................................................23293 Removal.............................................................................................................................23293 Installation........................................................................................................................23295 Lock Cylinder...........................................................................................................................23297 Lock Cylinder and Associated Parts..................................................................................................23297 Removal.............................................................................................................................23297 Installation........................................................................................................................23299 System Inspection...................................................................................................................23300 Steering Column.........................................................................................................................23301 Steering Column and Associated Parts................................................................................................23301 Removal.............................................................................................................................23301 Installation........................................................................................................................23303 System Inspection...................................................................................................................23304 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................23305 Main Data and Specifications............................................................................................................23305 Special Tools.......................................................................................................................23305 Sec.3 SUSPENSION................................................................................................................................23306 3C FRONT SUSPENSION.........................................................................................................................23306 Service Precaution......................................................................................................................23306 General Description.................................................................................................................23307 Diagnosis...........................................................................................................................23307 Shock Absorber..........................................................................................................................23311 Shock Absorber and Associated Parts.................................................................................................23311 Removal.............................................................................................................................23311 Inspection and Repair...............................................................................................................23311 Installation........................................................................................................................23311 Stabilizer Bar..........................................................................................................................23312 Stabilizer Bar and Associated Parts.................................................................................................23312 Removal.............................................................................................................................23312 Inspection and Repair...............................................................................................................23312 Installation........................................................................................................................23312 Torsion Bar.............................................................................................................................23313 Torsion Bar and Associated Parts....................................................................................................23313 Removal.............................................................................................................................23313 Inspection and Repair...............................................................................................................23314 Installation........................................................................................................................23314 Knuckle.................................................................................................................................23316 Knuckle and Associated Parts........................................................................................................23316 Removal.............................................................................................................................23316 Inspection and Repair...............................................................................................................23317 Installation........................................................................................................................23317 Upper Control Arm.......................................................................................................................23318 Upper Control Arm and Associated Parts..............................................................................................23318 Removal.............................................................................................................................23318 Inspection and Repair...............................................................................................................23319 Installation........................................................................................................................23319 Lower Control Arm.......................................................................................................................23321 Lower Control Arm and Associated Parts..............................................................................................23321 Removal.............................................................................................................................23321 Inspection and Repair...............................................................................................................23322 Installation........................................................................................................................23323 Upper Ball Joint........................................................................................................................23324 Upper Ball Joint and Associated Parts...............................................................................................23324 Removal.............................................................................................................................23324 Inspection and Repair...............................................................................................................23325 Installation........................................................................................................................23325 Lower Ball Joint........................................................................................................................23326 Lower Ball Joint and Associated Parts...............................................................................................23326 Removal.............................................................................................................................23326 Inspection and Repair...............................................................................................................23327 Installation........................................................................................................................23327 Main Data and Specifications............................................................................................................23328 Special Tools.......................................................................................................................23329 3D REAR SUSPENSION..........................................................................................................................23330 Service Precaution......................................................................................................................23330 General Description.................................................................................................................23330 Diagnosis...........................................................................................................................23331 Coil Spring.............................................................................................................................23334 Coil Spring and Associated Parts....................................................................................................23334 Removal.............................................................................................................................23334 Inspection and Repair...............................................................................................................23335 Installation........................................................................................................................23335 Shock Absorber..........................................................................................................................23336 Shock Absorber and Associated Parts.................................................................................................23336 Removal.............................................................................................................................23336 Inspection and Repair...............................................................................................................23336 Installation........................................................................................................................23336 Trailing Link...........................................................................................................................23337 Trailing Link and Associated Parts..................................................................................................23337 Removal.............................................................................................................................23337 Inspection and Repair...............................................................................................................23337 Installation........................................................................................................................23338 Upper Link..............................................................................................................................23339 Upper Link and Associated Parts.....................................................................................................23339 Removal.............................................................................................................................23339 Inspection and Repair...............................................................................................................23339 Installation........................................................................................................................23340 Lateral Rod.............................................................................................................................23341 Lateral Rod and Associated Parts....................................................................................................23341 Removal.............................................................................................................................23341 Inspection and Repair...............................................................................................................23341 Installation........................................................................................................................23342 Stabilizer Bar..........................................................................................................................23343 Stabilizer Bar and Associated Parts.................................................................................................23343 Removal.............................................................................................................................23343 Inspection and Repair...............................................................................................................23343 Installation........................................................................................................................23344 Main Data and Specifications............................................................................................................23344 Special Tools.......................................................................................................................23346 3E Wheel and Tire System....................................................................................................................23347 3F Intelligent Suspension Control...........................................................................................................23347 Sec.4 DRIVELINE/AXLE............................................................................................................................23349 4A1 Differential (Front)....................................................................................................................23348 4A2 Differential (Rear).....................................................................................................................23348 4B Driveline Control System.................................................................................................................23348 4C DRIVE SHAFT SYSTEM.......................................................................................................................23349 Service Precaution......................................................................................................................23350 Front Propeller Shaft...................................................................................................................23351 General Description.................................................................................................................23351 Diagnosis of Propeller Shaft and Universal Joint....................................................................................23353 Front Propeller Shaft and Associated Parts..........................................................................................23354 Removal.............................................................................................................................23354 Installation........................................................................................................................23354 Slip Joint Disassembly..............................................................................................................23355 Universal Joint Disassembly (Single Cardan Type)....................................................................................23356 Universal Joint Reassembly (Single Cardan Type).....................................................................................23358 Slip Joint Reassembly...............................................................................................................23360 Main Data And Specifications........................................................................................................23361 Rear Propeller Shaft....................................................................................................................23362 General Description.................................................................................................................23362 Diagnosis of Propeller Shaft and Universal Joint....................................................................................23364 Rear Propeller Shaft and Associated Parts...........................................................................................23365 Removal.............................................................................................................................23365 Installation........................................................................................................................23365 Slip Joint Disassembly (6VD1 Model Only)............................................................................................23366 Universal Joint Disassembly.........................................................................................................23367 Inspection..........................................................................................................................23369 Universal Joint Reassembly..........................................................................................................23370 Slip Joint Reassembly (6VD1 Model Only).............................................................................................23371 Main Data and Specifications........................................................................................................23372 4D Transfer Case............................................................................................................................23348 Sec.5 BRAKE CONTROL SYSTEM......................................................................................................................23373 5A Brake Control System.....................................................................................................................23373 5B Anti‐lock Brake System...................................................................................................................23373 5C Power‐assisted Brake System..............................................................................................................23373 5D1 Parking Brakes (4x4 Model)..............................................................................................................23373 5D2 Parking Brakes (4x2 Model)..............................................................................................................23373 Sec.6 ENGINE....................................................................................................................................23375 Y22SE 2.2L ENGINE...........................................................................................................................23375 6A Engine Mechanical....................................................................................................................23374 6B Engine Cooling.......................................................................................................................23374 6C ENGINE FUEL (Y22SE 2.2L) For Short Wheel Base........................................................................................23375 Service Precaution.................................................................................................................. 0 General Description............................................................................................................. 0 Fuel Metering................................................................................................................... 0 Fuel Filter......................................................................................................................... 0 Fuel Filter and Associated Parts................................................................................................ 0 Removal......................................................................................................................... 0 Inspection...................................................................................................................... 0 Installation.................................................................................................................... 0 Inspection...................................................................................................................... 0 In–Tank Fuel Filter............................................................................................................. 0 Fuel Pump Flow Test............................................................................................................. 0 Fuel Pump Relay..................................................................................................................... 0 General Description............................................................................................................. 0 Fuel Tank........................................................................................................................... 0 Fuel Tank and Associated Parts.................................................................................................. 0 Removal......................................................................................................................... 0 Installation.................................................................................................................... 0 Fuel Gauge Unit..................................................................................................................... 0 Removal and Installation........................................................................................................ 0 Fuel Tube / Quick – Connector Fittings.............................................................................................. 0 Precautions..................................................................................................................... 0 Cautions During Work............................................................................................................ 0 Removal......................................................................................................................... 0 Reuse of Quick–Connector........................................................................................................ 0 Assembling Advice............................................................................................................... 0 Fuel Filler Cap..................................................................................................................... 0 General Description............................................................................................................. 0 Inspection...................................................................................................................... 0 Fuel Pump........................................................................................................................... 0 Fuel Pump and Associated Parts.................................................................................................. 0 Removal......................................................................................................................... 0 Installation.................................................................................................................... 0 Main Data and Specifications........................................................................................................ 0 Special Tool.................................................................................................................... 0 6D1 Engine Electrical...................................................................................................................23374 6D2 Ignition System.....................................................................................................................23374 6D3 Starting and Charging System........................................................................................................23374 6E1 Driveability and Emissions..........................................................................................................23374 6F Engine Exhaust.......................................................................................................................23374 6G Engine Lubrication...................................................................................................................23374 6H Engine Speed Control System..........................................................................................................23374 6J Induction............................................................................................................................23374 6VD1 3.2L ENGINE...........................................................................................................................23388 6A Engine Mechanical....................................................................................................................23387 6B Engine Cooling.......................................................................................................................23387 6C ENGINE FUEL For Short Wheel Base.....................................................................................................23388 Service Precaution.................................................................................................................. 0 General Description............................................................................................................. 0 Fuel Metering................................................................................................................... 0 Fuel Filter......................................................................................................................... 0 Removal......................................................................................................................... 0 Inspection...................................................................................................................... 0 Installation.................................................................................................................... 0 Inspection...................................................................................................................... 0 In–Tank Fuel Filter............................................................................................................. 0 Fuel Pump Flow Test............................................................................................................. 0 Fuel Pump........................................................................................................................... 0 Fuel Pump and Associated Parts.................................................................................................. 0 Removal......................................................................................................................... 0 Installation.................................................................................................................... 0 Fuel Tube / Quick – Connector Fittings.............................................................................................. 0 Precautions..................................................................................................................... 0 Cautions During Work............................................................................................................ 0 Removal......................................................................................................................... 0 Reuse of Quick–Connector........................................................................................................ 0 Assembling Advice............................................................................................................... 0 Fuel Pump Relay..................................................................................................................... 0 General Description............................................................................................................. 0 Fuel Tank........................................................................................................................... 0 Fuel Tank and Associated Parts.................................................................................................. 0 Removal......................................................................................................................... 0 Installation.................................................................................................................... 0 Fuel Gauge Unit..................................................................................................................... 0 Removal and Installation........................................................................................................ 0 Fuel Filler Cap..................................................................................................................... 0 General Description............................................................................................................. 0 Inspection...................................................................................................................... 0 Main Data and Specifications........................................................................................................ 0 Special Tool.................................................................................................................... 0 6D1 Engine Electrical...................................................................................................................23387 6D2 Ignition System.....................................................................................................................23387 6D3 Starting and Charging System........................................................................................................23387 6E2 Driveability and Emissions..........................................................................................................23387 6F Engine Exhaust.......................................................................................................................23387 6G Engine Lubrication...................................................................................................................23387 6H Engine Speed Control System..........................................................................................................23387 6J Induction............................................................................................................................23387 Sec.7 AUTOMATIC TRANSMISSION....................................................................................................................23400 7B Manual Transmission......................................................................................................................23400 7C Clutch...................................................................................................................................23400 Sec.8 LIGHTING SYSTME...........................................................................................................................23401 8A Lighting System..........................................................................................................................23401 8B Wiper / Washer System....................................................................................................................23401 8C Entertainment............................................................................................................................23401 8D Wiring System............................................................................................................................23401 8E Meter and Gauge..........................................................................................................................23401 8F Body Structure...........................................................................................................................23401 8G Seats....................................................................................................................................23401 8H Security and Locks.......................................................................................................................23401 8I Sunroof / Convertible Top...............................................................................................................23401 8J Exterior / Interior Trim.................................................................................................................23401 Sec.9 SEAT BELT SYSTEM..........................................................................................................................23402 9A Seat Belt System.........................................................................................................................23402 9J Supplemental Restraint System (RSR)......................................................................................................23402 9J1 Restraint Control System................................................................................................................23402 Sec.10 CRUISE CONTROL SYSTEM....................................................................................................................23403 10A Cruise Control System...................................................................................................................23403
PLEASE NOTE:.
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
