2000 Isuzu Trooper Rodeo Amigo Lhd Workshop Service Repair Manual
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2000 Isuzu Trooper Rodeo Amigo Lhd Workshop Service Repair Manual
General Repair Instruction
1. If a floor jack is used, the following precautions are 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 Bag.
- This system is not to be serviced without consulting the appropriate service information.
- Consult Sections 9J1 and 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.
TABLE OF CONTENTS:
2000 Isuzu Trooper Rodeo Amigo Lhd Workshop Service Repair Manual
2000 WORKSHOP MANUAL.................................................................................................................................... 1 TROOPER............................................................................................................................................. 2 Section.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.................................................................................................... 16 Abbreviations Charts.................................................................................................................... 17 Service Parts Identification Plate...................................................................................................... 18 0B MAINTENANCE AND LUBRICATION............................................................................................................. 19 Maintenance Schedule List............................................................................................................... 19 Explanation of Complete Vehicle Maintenance Schedule.................................................................................... 23 Recommended Fluids and Lubricants................................................................................................... 26 Lubricant Viscosity Chart............................................................................................................... 27 Recommended Liquid Gasket........................................................................................................... 29 Recommended Thread Locking Agents................................................................................................... 30 Maintenance Service Data................................................................................................................ 31 Section.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)................................................................................... 32 1A HVAC SYSTEMS............................................................................................................................ 32 Service Precaution...................................................................................................................... 34 Heating and Ventilation System.......................................................................................................... 34 General Description..................................................................................................................... 34 Wiring Diagram.......................................................................................................................... 39 Diagnosis............................................................................................................................... 40 Individual Inspection................................................................................................................... 43 Heater Unit............................................................................................................................. 45 Heater Unit and Associated Parts.................................................................................................... 45 Removal............................................................................................................................. 45 Installation........................................................................................................................ 46 Heater Core and / or Mode Door.......................................................................................................... 47 Disassembled View................................................................................................................... 47 Removal............................................................................................................................. 47 Inspection.......................................................................................................................... 48 Installation........................................................................................................................ 48 Heater Mode Control Link Unit........................................................................................................... 49 Disassembled View................................................................................................................... 49 Removal............................................................................................................................. 49 Installation........................................................................................................................ 50 Heater Temperature Control Link Unit.................................................................................................... 50 Disassembled View................................................................................................................... 50 Removal............................................................................................................................. 50 Installation........................................................................................................................ 50 Blower Assembly......................................................................................................................... 51 Blower Assembly and Associated Parts................................................................................................ 51 Removal............................................................................................................................. 51 Installation........................................................................................................................ 52 Blower Link Unit and / or Mode door..................................................................................................... 52 Disassembled View................................................................................................................... 52 Removal............................................................................................................................. 52 Installation........................................................................................................................ 53 Blower Motor............................................................................................................................ 54 Blower Motor and Associated Parts................................................................................................... 54 Removal............................................................................................................................. 54 Installation........................................................................................................................ 54 Rear Heater Duct, Defroster Nozzle and Ventilation Duct................................................................................. 55 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts........................................................... 55 Removal............................................................................................................................. 55 Installation........................................................................................................................ 56 Center and / or Drive Side Vent......................................................................................................... 56 Center Vent, Drive Side Vent and Associated Parts................................................................................... 56 Removal............................................................................................................................. 56 Installation........................................................................................................................ 56 Control Lever Assembly and / or Control Cable........................................................................................... 57 Control Lever Assembly, Control Cable and Associated Parts.......................................................................... 57 Removal............................................................................................................................. 57 Installation........................................................................................................................ 58 Control Panel Illumination Bulb......................................................................................................... 59 Control Panel Illumination Bulb and Associated Parts................................................................................ 59 Removal............................................................................................................................. 59 Installation........................................................................................................................ 59 Resistor................................................................................................................................ 60 Resistor and Associated Parts....................................................................................................... 60 Removal............................................................................................................................. 60 Installation........................................................................................................................ 60 Air Conditioning System................................................................................................................. 61 General Description..................................................................................................................... 61 Diagnosis............................................................................................................................... 70 Individual Inspection................................................................................................................... 78 General Repair Procedure............................................................................................................ 79 Compressor Assembly..................................................................................................................... 86 Compressor Assembly and Associated Parts............................................................................................ 86 Removal............................................................................................................................. 86 Installation........................................................................................................................ 87 Condenser Assembly...................................................................................................................... 88 Condenser Assembly and Associated Parts............................................................................................. 88 Removal............................................................................................................................. 88 Installation........................................................................................................................ 88 Receiver / Drier........................................................................................................................ 89 Receiver / Drier and Associated Parts............................................................................................... 89 Removal............................................................................................................................. 89 Installation........................................................................................................................ 89 Pressure Switch......................................................................................................................... 90 Pressure Switch and Associated Parts................................................................................................ 90 Removal............................................................................................................................. 90 Installation........................................................................................................................ 90 Evaporator Assembly..................................................................................................................... 91 Evaporator Assembly and Associated Parts............................................................................................ 91 Removal............................................................................................................................. 91 Installation........................................................................................................................ 92 Electronic Thermostat, Evaporator Core and/or Expansion Valve........................................................................... 92 Disassembled View................................................................................................................... 92 Removal............................................................................................................................. 92 Installation........................................................................................................................ 93 Air Conditioning Switch and Illumination Bulb........................................................................................... 94 Air Conditioning Switch, Illumination Bulb and Associated Parts..................................................................... 94 Removal............................................................................................................................. 94 Installation........................................................................................................................ 94 Refrigerant Line........................................................................................................................ 95 Refrigerant Line and Associated Parts............................................................................................... 95 Removal............................................................................................................................. 95 Installation........................................................................................................................ 96 Main Data And Specifications............................................................................................................ 97 Compressor.............................................................................................................................. 99 Service Precaution.................................................................................................................. 99 General Description..................................................................................................................... 99 Metric Thread Size Information...................................................................................................... 101 Compressor Clutch Plate and Hub Assembly................................................................................................ 101 Removal............................................................................................................................. 101 Installation........................................................................................................................ 101 Compressor Clutch Rotor and/or Bearing.................................................................................................. 102 Removal............................................................................................................................. 102 Installation........................................................................................................................ 102 Compressor Clutch Coil.................................................................................................................. 103 Removal............................................................................................................................. 103 Installation........................................................................................................................ 104 Compressor Shaft Seal................................................................................................................... 105 Service Precaution...................................................................................................................... 105 Seal Leak Detection................................................................................................................. 105 Removal............................................................................................................................. 105 Cleaning............................................................................................................................ 106 Installation........................................................................................................................ 106 Compressor Pressure Relief Valve........................................................................................................ 107 Removal............................................................................................................................. 107 Installation........................................................................................................................ 107 Compressor Oil.......................................................................................................................... 107 Compressor Oil Check................................................................................................................ 107 Checking and Adjusting Oil Quantity for Used Compressor............................................................................. 107 Checking and Adjusting for Compressor Replacement................................................................................... 107 Contamination of Compressor Oil..................................................................................................... 108 Oil Return Operation................................................................................................................ 108 Replacement of Component Parts...................................................................................................... 108 Compressor Leak Testing (External and Internal)..................................................................................... 108 Special Tools........................................................................................................................... 110 Automatic Air Conditioning System....................................................................................................... 112 General Description..................................................................................................................... 112 Full Automatic Air Conditioner Parts Configuration.................................................................................. 112 Refrigerant Line and Associated Parts............................................................................................... 113 Circuit Diagram......................................................................................................................... 114 Functions and Features.................................................................................................................. 119 Automatic Air Conditioner Block Diagram................................................................................................. 120 Control Panel Layout.................................................................................................................... 121 Air Control Functions................................................................................................................... 122 Operation and Functions of Control Panel Switches....................................................................................... 123 Overview of Construction, Movement and Control of Major Parts of Automatic Air Conditioner System....................................... 125 Overview of Automatic Control of Automatic Air Conditioner.............................................................................. 129 Troubleshooting......................................................................................................................... 133 Troubleshooting, Its Overview and Procedures........................................................................................ 133 Auto Air Conditioner Control Unit Power Supply Diagnosis............................................................................ 134 Performance and Movement checklist for Automatic Air Conditioner Related Parts...................................................... 136 Troubleshooting With Self-Diagnosis Function........................................................................................ 138 Inspection By Failed Location........................................................................................................... 142 Inspection of the Sensors........................................................................................................... 142 Inspection of the Intake Actuator System............................................................................................ 146 Inspection of the Mix Actuator System............................................................................................... 149 Inspection of the Mode Actuator System.............................................................................................. 152 Inspection of the Fan Motor System.................................................................................................. 155 Inspection of the Magnetic Clutch System............................................................................................ 160 Individual Inspection............................................................................................................... 163 On-Vehicle Service...................................................................................................................... 166 Power Transistor.................................................................................................................... 166 Removal......................................................................................................................... 166 Installation.................................................................................................................... 166 Automatic Heater/Air Conditioner Control Unit....................................................................................... 166 Removal......................................................................................................................... 166 Installation.................................................................................................................... 166 In Car Sensor....................................................................................................................... 167 Removal......................................................................................................................... 167 Installation.................................................................................................................... 167 Ambient Sensor...................................................................................................................... 167 Removal......................................................................................................................... 167 Installation.................................................................................................................... 167 Sun Sensor.......................................................................................................................... 168 Removal......................................................................................................................... 168 Installation.................................................................................................................... 168 Electronic Thermostat............................................................................................................... 168 Removal......................................................................................................................... 168 Installation.................................................................................................................... 168 Mode Actuator....................................................................................................................... 169 Removal......................................................................................................................... 169 Installation.................................................................................................................... 169 Mix Actuator........................................................................................................................ 169 Removal......................................................................................................................... 169 Installation.................................................................................................................... 169 Intake Actuator..................................................................................................................... 170 Removal......................................................................................................................... 170 Installation.................................................................................................................... 170 Section.2 STEERING........................................................................................................................... 171 2A POWER ASSISTED SYSTEM................................................................................................................... 171 Service Precaution...................................................................................................................... 172 General Description..................................................................................................................... 172 Diagnosis............................................................................................................................... 175 Power Steering System Test.............................................................................................................. 181 Maintenance............................................................................................................................. 182 Fluid Level............................................................................................................................. 182 Bleeding The Power Steering System...................................................................................................... 182 Bleeding Procedure...................................................................................................................... 182 Flushing The Power Steering System...................................................................................................... 182 Steering Wheel Free Play Adjustment..................................................................................................... 183 Front End Alignment Inspection and Adjustment........................................................................................... 183 Main Data and Specifications............................................................................................................ 188 Special Tools........................................................................................................................... 189 Power Steering Gear..................................................................................................................... 190 Power Steering Gear and Associated Parts............................................................................................ 190 Removal............................................................................................................................. 190 Installation........................................................................................................................ 191 Steering Gear Disassembled View..................................................................................................... 192 Disassembly......................................................................................................................... 193 Inspection and Repair............................................................................................................... 194 Reassembly.......................................................................................................................... 195 Main Data and Specifications........................................................................................................ 197 Power Steering Pump..................................................................................................................... 198 Power Steering Pump and Associated Parts............................................................................................ 198 Removal............................................................................................................................. 198 Installation........................................................................................................................ 199 Power Steering Pump Disassembled View............................................................................................... 200 Disassembly......................................................................................................................... 200 Inspection and Repair............................................................................................................... 201 Reassembly.......................................................................................................................... 202 Main Data and Specifications........................................................................................................ 203 Center Track Rod Assembly............................................................................................................... 204 Center Track Rod Assembly and Associated Parts...................................................................................... 204 Removal............................................................................................................................. 205 Inspection and Repair............................................................................................................... 205 Installation........................................................................................................................ 205 Outer Track Rod Assembly................................................................................................................ 206 Outer Track Rod Assembly and Associated Parts....................................................................................... 206 Removal............................................................................................................................. 207 Inspection and Repair............................................................................................................... 207 Installation........................................................................................................................ 208 Relay Lever............................................................................................................................. 209 Relay Lever and Associated Parts.................................................................................................... 209 Removal............................................................................................................................. 209 Installation........................................................................................................................ 210 Steering Linkage and Associated Parts................................................................................................... 211 Main Data and Specifications........................................................................................................ 211 Special Tools....................................................................................................................... 212 Supplemental Restraint System Steering Wheel & Column................................................................................... 213 Service Precaution.................................................................................................................. 213 SRS Connectors...................................................................................................................... 213 Inflator Module......................................................................................................................... 215 Inflator Module and Associated Parts................................................................................................ 215 Removal............................................................................................................................. 215 Inspection and Repair............................................................................................................... 216 Installation........................................................................................................................ 216 Steering Wheel.......................................................................................................................... 217 Steering Wheel and Associated Parts................................................................................................. 217 Removal............................................................................................................................. 217 Installation........................................................................................................................ 219 Combination Switch...................................................................................................................... 220 Combination Switch and Associated Parts............................................................................................. 220 Removal............................................................................................................................. 220 Installation........................................................................................................................ 222 Lock Cylinder........................................................................................................................... 224 Lock Cylinder and Associated Parts.................................................................................................. 224 Removal............................................................................................................................. 224 Installation........................................................................................................................ 226 System Inspection................................................................................................................... 227 Steering Column......................................................................................................................... 228 Steering Column and Associated Parts................................................................................................ 228 Removal............................................................................................................................. 228 Inspection.......................................................................................................................... 230 Installation........................................................................................................................ 232 System Inspection................................................................................................................... 233 Supplemental Restraint System Steering Wheel & Column and Associated Parts.............................................................. 234 Main Data and Specifications........................................................................................................ 234 Special Tools....................................................................................................................... 235 Section.3 SUSPENSION......................................................................................................................... 236 3C FRONT SUSPENSION....................................................................................................................... 236 Service Precaution...................................................................................................................... 236 General Description..................................................................................................................... 237 General Diagnosis....................................................................................................................... 238 Shock Absorber.......................................................................................................................... 241 Shock Absorber and Associated Parts................................................................................................. 241 Removal............................................................................................................................. 241 Inspection and Repair............................................................................................................... 241 Installation........................................................................................................................ 241 Stabilizer Bar.......................................................................................................................... 242 Stabilizer Bar and Associated Parts................................................................................................. 242 Removal............................................................................................................................. 242 Inspection and Repair............................................................................................................... 242 Installation........................................................................................................................ 242 Torsion Bar............................................................................................................................. 243 Torsion Bar and Associated Parts.................................................................................................... 243 Removal............................................................................................................................. 243 Inspection and Repair............................................................................................................... 244 Installation........................................................................................................................ 244 Knuckle................................................................................................................................. 246 Knuckle and Associated Parts........................................................................................................ 246 Removal............................................................................................................................. 246 Inspection and Repair............................................................................................................... 247 Installation........................................................................................................................ 247 Upper Control Arm....................................................................................................................... 249 Upper Control Arm and Associated Parts.............................................................................................. 249 Removal............................................................................................................................. 249 Inspection and Repair............................................................................................................... 250 Installation........................................................................................................................ 251 Lower Control Arm....................................................................................................................... 253 Lower Control Arm and Associated Parts.............................................................................................. 253 Removal............................................................................................................................. 253 Inspection and Repair............................................................................................................... 255 Installation........................................................................................................................ 255 Upper Ball Joint........................................................................................................................ 257 Upper Ball Joint and Associated Parts............................................................................................... 257 Removal............................................................................................................................. 257 Inspection and Repair............................................................................................................... 258 Installation........................................................................................................................ 258 Lower Ball Joint........................................................................................................................ 259 Lower Ball Joint and Associated Parts............................................................................................... 259 Removal............................................................................................................................. 259 Inspection and Repair............................................................................................................... 260 Installation........................................................................................................................ 260 Main Data and Specifications............................................................................................................ 261 Special Tools........................................................................................................................... 262 3D REAR SUSPENSION........................................................................................................................ 263 Service Precaution...................................................................................................................... 263 General Description..................................................................................................................... 264 Coil Spring............................................................................................................................. 265 Coil Spring and Associated Parts.................................................................................................... 265 Removal............................................................................................................................. 265 Inspection and Repair............................................................................................................... 266 Installation........................................................................................................................ 266 Shock Absorber.......................................................................................................................... 267 Shock Absorber and Associated Parts................................................................................................. 267 Removal............................................................................................................................. 267 Inspection and Repair............................................................................................................... 267 Installation........................................................................................................................ 267 Trailing Link........................................................................................................................... 268 Trailing Link and Associated Parts.................................................................................................. 268 Removal............................................................................................................................. 268 Inspection and Repair............................................................................................................... 268 Installation........................................................................................................................ 269 Center Link............................................................................................................................. 270 Center Link and Associated Parts.................................................................................................... 270 Removal............................................................................................................................. 270 Inspection and Repair............................................................................................................... 270 Installation........................................................................................................................ 271 Lateral Rod............................................................................................................................. 272 Lateral Rod and Associated Parts.................................................................................................... 272 Removal............................................................................................................................. 272 Inspection and Repair............................................................................................................... 272 Installation........................................................................................................................ 273 Stabilizer Bar.......................................................................................................................... 274 Stabilizer Bar and Associated Parts................................................................................................. 274 Removal............................................................................................................................. 274 Inspection and Repair............................................................................................................... 274 Installation........................................................................................................................ 275 Main Data and Specifications............................................................................................................ 276 Special Tools........................................................................................................................... 278 3E WHEEL AND TIRE SYSTEM.................................................................................................................. 279 Service Precaution...................................................................................................................... 279 General Description..................................................................................................................... 280 Diagnosis............................................................................................................................... 281 Wheel................................................................................................................................... 287 Wheel and Associated Parts.......................................................................................................... 287 Removal............................................................................................................................. 287 Installation........................................................................................................................ 287 Tire.................................................................................................................................... 288 Tire Replacement.................................................................................................................... 288 General Balance Procedure............................................................................................................... 288 Balancing Wheel and Tire................................................................................................................ 289 Main Data and Specifications............................................................................................................ 290 Section.4 DRIVELINE/AXLE..................................................................................................................... 291 4A1 DIFFERENTIAL (FRONT).................................................................................................................. 291 Service Precaution...................................................................................................................... 291 Front Drive Axle........................................................................................................................ 292 Diagnosis............................................................................................................................... 292 Pinion Shaft Oil Seal................................................................................................................... 293 Pinion Shaft Oil Seal and Associated Parts.......................................................................................... 293 Removal............................................................................................................................. 293 Inspection and Repair............................................................................................................... 294 Installation........................................................................................................................ 294 Front Drive Axle Assembly............................................................................................................... 295 Front Drive Axle Assembly and Associated Parts...................................................................................... 295 Removal............................................................................................................................. 295 Installation........................................................................................................................ 297 Differential Assembly................................................................................................................... 299 Disassembled View................................................................................................................... 299 Disassembly......................................................................................................................... 299 Reassembly.......................................................................................................................... 302 Differential Cage Assembly.............................................................................................................. 311 Disassembled View................................................................................................................... 311 Disassembly......................................................................................................................... 311 Inspection and Repair............................................................................................................... 312 Reassembly.......................................................................................................................... 313 Main Data and Specifications............................................................................................................ 315 Special Tools........................................................................................................................... 317 4A2 DIFFERENTIAL (REAR)................................................................................................................... 319 Service Precaution...................................................................................................................... 319 General Description..................................................................................................................... 321 Diagnosis............................................................................................................................... 322 Axle Housing............................................................................................................................ 323 Axle Housing and Associated Parts................................................................................................... 323 Removal............................................................................................................................. 323 Oil Seal Replacement................................................................................................................ 324 Installation........................................................................................................................ 324 Axle Shaft.............................................................................................................................. 325 Axle Shaft and Associated Parts..................................................................................................... 325 Removal............................................................................................................................. 325 Inspection and Repair............................................................................................................... 326 Oil Seal Replacement................................................................................................................ 327 Installation........................................................................................................................ 327 Pinion Oil Seal......................................................................................................................... 328 Pinion Oil Seal and Associated Parts................................................................................................ 328 Removal............................................................................................................................. 328 Inspection and Repair............................................................................................................... 329 Installation........................................................................................................................ 329 Differential Assembly................................................................................................................... 330 Differential Assembly and Associated Parts.......................................................................................... 330 Removal............................................................................................................................. 330 Installation........................................................................................................................ 331 Disassembled View................................................................................................................... 332 Disassembly......................................................................................................................... 333 Reassembly.......................................................................................................................... 335 Differential Cage Assembly.............................................................................................................. 342 Disassembled View................................................................................................................... 342 Disassembly......................................................................................................................... 343 Inspection and Repair............................................................................................................... 343 Reassembly.......................................................................................................................... 344 Limited Slip Differential............................................................................................................... 346 Disassembled View................................................................................................................... 346 Disassembly......................................................................................................................... 347 Inspection and Repair............................................................................................................... 347 Reassembly.......................................................................................................................... 349 Main Data and Specifications............................................................................................................ 353 Special Tools........................................................................................................................... 354 4B1 DRIVELINE CONTROL SYSTEM (SHIFT ON THE FLY)........................................................................................... 357 Service Precaution...................................................................................................................... 357 Shift On The Fly System................................................................................................................. 358 Outline of Shift on The Fly System...................................................................................................... 358 Functions of Indicator Lamp............................................................................................................. 362 Diagnosis............................................................................................................................... 363 Front Axle Diagnosis.................................................................................................................... 373 Shift On The Fly Vacuum Piping And Electric Equipment................................................................................... 375 Vacuum piping diagram................................................................................................................... 375 Inspection And Repair................................................................................................................... 376 4WD Control Unit........................................................................................................................ 379 4WD Control Unit Associated Parts................................................................................................... 379 Removal............................................................................................................................. 380 Installation........................................................................................................................ 380 4B2 DRIVELINE CONTROL SYSTEM (TOD)........................................................................................................ 381 Service Precaution...................................................................................................................... 381 General Description..................................................................................................................... 382 System Components....................................................................................................................... 384 Parts Location...................................................................................................................... 384 Functions of Indicator Lamp............................................................................................................. 388 Diagnosis............................................................................................................................... 391 Basic Diagnostic Flow Chart............................................................................................................. 395 Parts Location.......................................................................................................................... 396 Circuit Diagram......................................................................................................................... 397 Connector List.......................................................................................................................... 400 Checking Failed Pin..................................................................................................................... 402 Checking Failed TOD Control Unit Pin.................................................................................................... 405 Tech 2 Scan Tool.................................................................................................................... 406 Diagnostic Trouble Codes................................................................................................................ 409 Diagnosis from Trouble Codes............................................................................................................ 410 Trouble Diagnosis Depending on The Status of TOD Indicator.............................................................................. 434 Diagnosis from Symptom.................................................................................................................. 463 4C DRIVE SHAFT SYSTEM .................................................................................................................. 473 Service Precaution...................................................................................................................... 474 General Description..................................................................................................................... 474 Diagnosis............................................................................................................................... 475 Front Hub and Disc (2WD Model).......................................................................................................... 476 Disassembled View................................................................................................................... 476 Disassembly......................................................................................................................... 476 Inspection and Repair............................................................................................................... 478 Reassembly.......................................................................................................................... 478 Main Data and Specifications........................................................................................................ 481 Special Tools....................................................................................................................... 482 Front Hub and Disc (4WD Model).......................................................................................................... 483 Disassembled View................................................................................................................... 483 Disassembly......................................................................................................................... 483 Inspection and Repair............................................................................................................... 484 Reassembly.......................................................................................................................... 484 Main Data and Specifications........................................................................................................ 488 Special Tools....................................................................................................................... 489 Front Drive Shaft Joint................................................................................................................. 490 Front Drive Shaft Joints Replace-ment............................................................................................... 490 Front Axle Drive Shaft.................................................................................................................. 491 Front Axle Drive Shaft and Associated Parts......................................................................................... 491 Disassembly......................................................................................................................... 492 Inspection and Repair............................................................................................................... 493 Bushing Replacement................................................................................................................. 493 Reassembly.......................................................................................................................... 494 Shift On The Fly System................................................................................................................. 496 Shift On The Fly System and Associated Parts........................................................................................ 496 Disassembly......................................................................................................................... 496 Inspection and Repair............................................................................................................... 498 Main Data and Specifications........................................................................................................ 503 Special Tools....................................................................................................................... 504 Front Propeller Shaft................................................................................................................... 505 General Description................................................................................................................. 505 Front Propeller Shaft and Associated Parts.......................................................................................... 506 Removal............................................................................................................................. 506 Installation........................................................................................................................ 507 Disassembly (Except TOD 4×4)........................................................................................................ 508 Universal Joint Disassembly......................................................................................................... 509 Inspection and Repair............................................................................................................... 510 Universal Joint Reassembly.......................................................................................................... 513 Reassembly (Except TOD 4ラ4)......................................................................................................... 514 Main Data and Specifications........................................................................................................ 515 Rear Propeller Shaft.................................................................................................................... 516 General Description................................................................................................................. 516 Rear Propeller Shaft and Associated Parts........................................................................................... 516 Removal............................................................................................................................. 516 Installation........................................................................................................................ 517 Disassembly......................................................................................................................... 518 Universal Joint Disassembly......................................................................................................... 519 Inspection and Repair............................................................................................................... 520 Universal Joint Reassembly.......................................................................................................... 521 Reassembly.......................................................................................................................... 522 Main Data and Specifications........................................................................................................ 523 4D1 TRANSFER CASE (STANDARD TYPE)......................................................................................................... 524 Service Precaution...................................................................................................................... 524 General Description..................................................................................................................... 525 Transfer Rear Oil Seal.................................................................................................................. 527 Removal............................................................................................................................. 527 Installation........................................................................................................................ 527 Transfer Case Assembly.................................................................................................................. 528 Removal............................................................................................................................. 528 Installation........................................................................................................................ 528 Transfer Rear Case Assembly............................................................................................................. 530 Removal............................................................................................................................. 530 Installation........................................................................................................................ 531 Disassembly......................................................................................................................... 534 Inspection and Repair............................................................................................................... 535 Reassembly.......................................................................................................................... 535 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)........................................................................... 537 Disassembled View................................................................................................................... 537 Disassembly......................................................................................................................... 537 Inspection and Repair............................................................................................................... 539 Reassembly.......................................................................................................................... 539 Transfer Case Assembly.................................................................................................................. 541 Disassembled View................................................................................................................... 541 Disassembly......................................................................................................................... 542 Inspection and Repair............................................................................................................... 544 Reassembly.......................................................................................................................... 548 Main Data and Specifications............................................................................................................ 554 Special Tools........................................................................................................................... 557 4D2 TRANSFER CASE (TOD)................................................................................................................... 559 Service Precaution...................................................................................................................... 559 Transfer Case Assembly.................................................................................................................. 560 Removal............................................................................................................................. 560 Installation........................................................................................................................ 561 Transfer Rear Oil Seal.................................................................................................................. 563 Transfer Rear Oil Seal and Associated Parts......................................................................................... 563 Removal............................................................................................................................. 563 Installation........................................................................................................................ 563 TOD ECU................................................................................................................................. 565 Removal............................................................................................................................. 565 Installation........................................................................................................................ 565 Unit Repair............................................................................................................................. 566 Inspection.......................................................................................................................... 566 Transfer Case........................................................................................................................... 567 Disassembled View................................................................................................................... 567 Disassembly......................................................................................................................... 567 Reassembly.......................................................................................................................... 568 Transfer Cover Assembly................................................................................................................. 570 Disassembled View................................................................................................................... 570 Disassembly......................................................................................................................... 570 Reassembly.......................................................................................................................... 572 Transfer Case Assembly Clutch Pack and Clutch Cam....................................................................................... 574 Disassembled View................................................................................................................... 574 Disassembly......................................................................................................................... 574 Sprocket and Mechanical Lock............................................................................................................ 576 Disassembled View................................................................................................................... 576 Disassembly......................................................................................................................... 576 Output Shafts and Shift Control Shaft................................................................................................... 578 Disassembled View................................................................................................................... 578 Disassembly......................................................................................................................... 579 Transfer Case........................................................................................................................... 581 Disassembled View................................................................................................................... 581 Disassembly......................................................................................................................... 582 Inspection and Repair............................................................................................................... 584 Transfer Case........................................................................................................................... 588 Disassembled View................................................................................................................... 588 Reassembly.......................................................................................................................... 588 Output Shafts and Shift Control Shaft................................................................................................... 591 Disassembled View................................................................................................................... 591 Reassembly.......................................................................................................................... 591 Sprocket and Mechanical Lock............................................................................................................ 594 Disassembled View................................................................................................................... 594 Reassembly.......................................................................................................................... 594 Clutch Pack and Clutch Cam.............................................................................................................. 596 Disassembled View................................................................................................................... 596 Reassembly.......................................................................................................................... 596 Main Data and Specifications............................................................................................................ 598 Special Tools........................................................................................................................... 600 Section.5 BRAKES............................................................................................................................. 601 5A BRAKE CONTROL SYSTEM................................................................................................................... 601 Service Precaution...................................................................................................................... 602 General Description..................................................................................................................... 603 System Components................................................................................................................... 603 Electronic Hydraulic Control Unit (EHCU)............................................................................................ 603 ABS Warning Light................................................................................................................... 604 Wheel Speed Sensor.................................................................................................................. 604 G-Sensor............................................................................................................................ 604 Normal and Anti-lock Braking........................................................................................................ 604 Brake Pedal Travel.................................................................................................................. 604 Acronyms and Abbreviations.......................................................................................................... 604 General Diagnosis....................................................................................................................... 605 General Information................................................................................................................. 605 ABS Service Precautions............................................................................................................. 605 Computer System Service Precautions................................................................................................. 605 General Service Precautions......................................................................................................... 605 Note on Intermittents............................................................................................................... 605 Test Driving ABS Complaint Vehicles................................................................................................. 605 "ABS" Warning Light................................................................................................................. 606 Normal Operation.................................................................................................................... 606 Basic Diagnostic Flow Chart......................................................................................................... 606 Basic Inspection Procedure.......................................................................................................... 607 Tech 2 Scan Tool.................................................................................................................... 608 Getting Started..................................................................................................................... 609 Operating Procedure................................................................................................................. 609 Data List............................................................................................................................... 611 EHCU Connector Pin-out Checks........................................................................................................... 612 Circuit Diagram..................................................................................................................... 613 Connector List...................................................................................................................... 616 Part Location....................................................................................................................... 618 Symptom Diagnosis....................................................................................................................... 619 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate...................................................................... 619 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................ 620 Chart A-2 Uneven Braking Occurs While ABS Works..................................................................................... 620 Chart A-3, TA-3 The Wheels Are Locked............................................................................................... 621 Chart A-4 Brake Pedal Feed Is Abnormal.............................................................................................. 621 Chart A-5,TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................. 622 Diagnostic Trouble Codes................................................................................................................ 623 Diagnosis By "ABS" Warning Light Illumination Pattern............................................................................... 624 Diagnostic Trouble Codes (DTCs)..................................................................................................... 624 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................ 627 Chart B-2 EHCU Abnormality (DTC 14)................................................................................................. 627 Chart B-3 Power Voltage Drop (DTC 15)............................................................................................... 628 Chart B-4 CLASS-2 Communication Line Abnormality (DTC 16)........................................................................... 628 Chart B-5 G-Sensor Circuit (DTC 21)................................................................................................. 628 Chart B-6 Abnormal Transmission Input (DTC 23)...................................................................................... 629 Chart B-7 Transfer Monitor (DTC 24)................................................................................................. 630 Chart B-8 EHCU Pump Motor And Motor Relay Circuit (DTC 32).......................................................................... 630 Chart B-9 EHCU Pump Valve And Valve Relay Circuit (DTC 35).......................................................................... 631 Chart B-10 FL Isolation Solenoid Valve Abnormality (DTC 41)......................................................................... 631 Chart B-11 FL Dump Solenoid Valve Abnormality (DTC 42).............................................................................. 631 Chart B-12 FR Isolation Solenoid Valve Abnormality (DTC 43)......................................................................... 632 Chart B-13 FR Dump Solenoid Valve Abnormality (DTC 44).............................................................................. 632 Chart B-14 Rear Isolation Solenoid Valve Abnormality (DTC 45)....................................................................... 632 Chart B-15 Rear Dump Solenoid Valve Abnormality (DTC 46)............................................................................ 633 Chart B-16 FL Speed Sensor Disconnection (DTC 51)................................................................................... 633 Chart B-17 FR Speed Sensor Disconnection (DTC 52)................................................................................... 634 Chart B-18 RL Speed Sensor Disconnection (DTC 53)................................................................................... 634 Chart B-19 RR Speed Sensor Disconnection (DTC 54)................................................................................... 635 Chart B-20 FL Speed Sensor Short Circuit (DTC 61)................................................................................... 636 Chart B-21 FR Speed Sensor Short Circuit (DTC 62)................................................................................... 637 Chart B-22 RL Speed Sensor Short Circuit (DTC 63)................................................................................... 638 Chart B-23 RR Speed Sensor Short Circuit (DTC 64)................................................................................... 639 Chart B-24 Sensor Signal Input Abnormality (DTC 65)................................................................................. 640 Sensor Signal Abnormality Criteria using TECH 2..................................................................................... 640 Unit Inspection Procedure............................................................................................................... 641 Chart C-1-1 FL Sensor Output Inspection Procedure................................................................................... 641 Chart C-1-2 FR Sensor Output Inspection Procedure................................................................................... 642 Chart C-1-3 RL Sensor Output Inspection Procedure................................................................................... 642 Chart C-1-4 RR Sensor Output Inspection Procedure................................................................................... 643 Chart TC-1 Sensor Output Inspection Procedure (Use TECH 2).......................................................................... 643 Chart C-2 Transmission Input Inspection Procedure................................................................................... 644 Chart TC-2 Transmission Input Inspection Procedure (Use TECH 2)..................................................................... 645 Special Tools........................................................................................................................... 646 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................. 647 Service Precaution...................................................................................................................... 647 Electronic Hydraulic Control Unit....................................................................................................... 648 Electronic Hydraulic Control Unit and Associated Parts.............................................................................. 648 Removal............................................................................................................................. 648 Installation........................................................................................................................ 648 G-Sensor................................................................................................................................ 649 Removal............................................................................................................................. 649 Inspection and Repair............................................................................................................... 649 Installation........................................................................................................................ 649 Front Wheel Speed Sensor................................................................................................................ 650 Front Wheel Speed Sensor and Associated Parts....................................................................................... 650 Removal............................................................................................................................. 650 Inspection and Repair............................................................................................................... 651 Installation........................................................................................................................ 651 Rear Wheel Speed Sensor................................................................................................................. 652 Rear Wheel Speed Sensor and Associated Parts........................................................................................ 652 Removal............................................................................................................................. 652 Inspection and Repair............................................................................................................... 652 Installation........................................................................................................................ 652 5C POWER-ASSISTED BRAKE SYSTEM............................................................................................................ 653 Service Precaution...................................................................................................................... 654 General Description..................................................................................................................... 654 Diagnosis............................................................................................................................... 657 General Diagnosis....................................................................................................................... 658 Hydraulic Brakes........................................................................................................................ 661 Filling Master Cylinder Reservoir................................................................................................... 661 Deterioration of Brake Fluid........................................................................................................ 661 Leakage of Brake Fluid.............................................................................................................. 661 Bleeding Brake Hydraulic System..................................................................................................... 661 Flushing Brake Hydraulic System..................................................................................................... 662 Brake Pipes and Hoses............................................................................................................... 662 Brake Hose Inspection............................................................................................................... 662 Front / Rear Caliper Brake Hose......................................................................................................... 663 Front / Rear Caliper Brake Hose and Associated Parts................................................................................ 663 Removal............................................................................................................................. 663 Installation........................................................................................................................ 663 Rear Axle Brake Hose.................................................................................................................... 664 Rear Axle Brake Hose and Associated Parts........................................................................................... 664 Removal............................................................................................................................. 664 Installation........................................................................................................................ 664 Brake Pipe.............................................................................................................................. 665 Removal............................................................................................................................. 665 Installation........................................................................................................................ 665 P & B (Proportioning and Bypass) Valve.................................................................................................. 666 P & B (Proportioning and Bypass) Valve Sectional View............................................................................... 666 Removal............................................................................................................................. 666 Installation........................................................................................................................ 666 Main Data and Specifications........................................................................................................ 667 Brake Pedal............................................................................................................................. 668 Checking Pedal Height............................................................................................................... 668 Checking Pedal Travel............................................................................................................... 668 Brake Pedal and Associated Parts.................................................................................................... 669 Removal............................................................................................................................. 669 Installation........................................................................................................................ 669 Stoplight Switch........................................................................................................................ 670 Removal............................................................................................................................. 670 Installation........................................................................................................................ 670 Main Data and Specifications........................................................................................................ 671 Fluid Reservoir Tank.................................................................................................................... 672 Fluid Reservoir Tank and Associated Parts........................................................................................... 672 Removal............................................................................................................................. 672 Installation........................................................................................................................ 672 Master Cylinder Assembly................................................................................................................ 673 Master Cylinder Assembly and Associated Parts....................................................................................... 673 Removal............................................................................................................................. 673 Inspection and Repair............................................................................................................... 673 Installation........................................................................................................................ 674 Main Data and Specifications........................................................................................................ 675 Special Tools....................................................................................................................... 676 Vacuum Booster Assembly................................................................................................................. 677 Vacuum Booster Assembly and Associated Parts........................................................................................ 677 Removal............................................................................................................................. 677 Inspection and Repair............................................................................................................... 677 Installation........................................................................................................................ 678 Exterior Components..................................................................................................................... 680 Exterior Components and Associated Parts............................................................................................ 680 Removal............................................................................................................................. 680 Inspection and Repair............................................................................................................... 681 Installation........................................................................................................................ 681 Vacuum Booster Overhaul................................................................................................................. 681 Vacuum Booster...................................................................................................................... 681 Main Data and Specifications........................................................................................................ 682 Special Tools....................................................................................................................... 683 Front Disc Brake Pads................................................................................................................... 684 Front Disc Brake Pads Inspection.................................................................................................... 684 Front Disc Brake Pads and Associated Parts.......................................................................................... 684 Removal............................................................................................................................. 685 Installation........................................................................................................................ 685 Front Disc Brake Rotor.................................................................................................................. 687 Inspection.......................................................................................................................... 687 Replacing Brake Rotors.............................................................................................................. 687 Refinishing Brake Rotors............................................................................................................ 687 Front Disc Brake Caliper Assembly....................................................................................................... 689 Front Disc Brake Caliper Assembly and Associated Parts.............................................................................. 689 Removal............................................................................................................................. 689 Installation........................................................................................................................ 690 Front Disc Brake Caliper................................................................................................................ 692 Front Disc Brake Caliper Disassembled View.......................................................................................... 692 Disassembly......................................................................................................................... 692 Inspection and Repair............................................................................................................... 693 Reassembly.......................................................................................................................... 693 Main Data and Specifications........................................................................................................ 695 Rear Disc Brake Pads.................................................................................................................... 696 Brake Pads Inspection............................................................................................................... 696 Brake Pads and Associated Parts..................................................................................................... 696 Removal............................................................................................................................. 697 Installation........................................................................................................................ 697 Rear Disc Brake Rotor................................................................................................................... 699 Inspection.......................................................................................................................... 699 Replacing Brake Rotors.............................................................................................................. 699 Refinishing Brake Rotors............................................................................................................ 699 Rear Drum (In Disc) Inside Diameter Check........................................................................................... 700 Rear Disc Brake Caliper Assembly........................................................................................................ 701 Rear Disc Brake Caliper Assembly and Associated Parts............................................................................... 701 Removal............................................................................................................................. 701 Installation........................................................................................................................ 702 Rear Disc Brake Caliper................................................................................................................. 704 Rear Disc Brake Caliper Disassembled View........................................................................................... 704 Disassembly......................................................................................................................... 704 Inspection and Repair............................................................................................................... 705 Reassembly.......................................................................................................................... 705 Main Data and Specifications........................................................................................................ 707 5D PARKING BRAKE SYSTEM................................................................................................................... 708 Service Precaution...................................................................................................................... 708 General Description..................................................................................................................... 708 Operation............................................................................................................................... 709 Parking Brake Lever and Front Cable..................................................................................................... 710 Parking Brake Lever, Front Cable and Associated Parts............................................................................... 710 Removal............................................................................................................................. 710 Installation........................................................................................................................ 711 Parking Brake Rear Cable................................................................................................................ 712 Parking Brake Rear Cable and Associated Parts....................................................................................... 712 Removal............................................................................................................................. 712 Installation........................................................................................................................ 713 Inspection and Repair............................................................................................................... 714 Parking Brake Adjustment................................................................................................................ 714 Main Data and Specifications............................................................................................................ 715 Section.6 ENGINE............................................................................................................................. 716 6A ENGINE MECHANICAL..................................................................................................................... 716 Service Precaution...................................................................................................................... 717 General Description..................................................................................................................... 718 Engine Diagnosis........................................................................................................................ 719 Cylinder Head Cover LH.................................................................................................................. 734 Removal............................................................................................................................. 734 Installation........................................................................................................................ 735 Cylinder Head Cover RH.................................................................................................................. 736 Removal............................................................................................................................. 736 Installation........................................................................................................................ 736 Common Chamber.......................................................................................................................... 737 Removal............................................................................................................................. 737 Installation........................................................................................................................ 737 Exhaust Manifold LH..................................................................................................................... 739 Removal............................................................................................................................. 739 Installation........................................................................................................................ 739 Exhaust Manifold RH..................................................................................................................... 740 Removal............................................................................................................................. 740 Installation........................................................................................................................ 740 Crankshaft Pulley....................................................................................................................... 741 Removal............................................................................................................................. 741 Installation........................................................................................................................ 741 Timing Belt............................................................................................................................. 742 Removal............................................................................................................................. 742 Installation........................................................................................................................ 743 Camshaft................................................................................................................................ 747 Removal............................................................................................................................. 747 Installation........................................................................................................................ 747 Cylinder Head........................................................................................................................... 750 Removal............................................................................................................................. 750 Installation........................................................................................................................ 750 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................ 752 Removal............................................................................................................................. 752 Installation........................................................................................................................ 752 Piston, Piston Ring and Connecting Rod.................................................................................................. 753 Removal............................................................................................................................. 753 Installation........................................................................................................................ 754 Crankshaft and Main Bearings............................................................................................................ 755 Removal............................................................................................................................. 755 Installation........................................................................................................................ 756 Rear Oil Seal........................................................................................................................... 760 Removal............................................................................................................................. 760 Installation........................................................................................................................ 760 Engine Assembly......................................................................................................................... 761 Removal............................................................................................................................. 761 Installation........................................................................................................................ 762 Cylinder Head........................................................................................................................... 764 Cylinder Head and Associated Parts.................................................................................................. 764 Disassembly......................................................................................................................... 765 Clean............................................................................................................................... 765 Inspection and Repair............................................................................................................... 765 Reassembly.......................................................................................................................... 766 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................ 768 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts............................................................... 768 Disassembly......................................................................................................................... 768 Inspection and Repair............................................................................................................... 769 Reassembly.......................................................................................................................... 772 Valve Clearance Adjustments......................................................................................................... 773 Camshaft................................................................................................................................ 775 Camshaft and Associated Parts....................................................................................................... 775 Disassembly......................................................................................................................... 775 Inspection and Repair............................................................................................................... 776 Reassembly.......................................................................................................................... 778 Crankshaft.............................................................................................................................. 781 Crankshaft and Associated Parts..................................................................................................... 781 Disassembly......................................................................................................................... 782 Inspection and Repair............................................................................................................... 782 Inspection and Repair............................................................................................................... 783 Reassembly.......................................................................................................................... 785 Piston and Connecting Rod............................................................................................................... 789 Piston, Connecting Rod and Associate Parts.......................................................................................... 789 Disassembly......................................................................................................................... 789 Inspection and Repair............................................................................................................... 790 Reassembly.......................................................................................................................... 794 Cylinder Block.......................................................................................................................... 796 Cylinder Block and Associated Parts................................................................................................. 796 Disassembly......................................................................................................................... 796 Inspection and Repair............................................................................................................... 797 Reassembly.......................................................................................................................... 798 Main Data and Specification............................................................................................................. 801 Special Tool............................................................................................................................ 807 6B ENGINE COOLING........................................................................................................................ 809 Service Precaution...................................................................................................................... 809 General Description..................................................................................................................... 810 Diagnosis............................................................................................................................... 813 Draining and Refilling Cooling System................................................................................................... 814 Water Pump.............................................................................................................................. 815 Water Pump and Associated Parts..................................................................................................... 815 Removal............................................................................................................................. 815 Inspection.......................................................................................................................... 815 Thermostat.............................................................................................................................. 816 Thermostat and Associated Parts..................................................................................................... 816 Removal............................................................................................................................. 816 Inspection.......................................................................................................................... 816 Installation........................................................................................................................ 816 Radiator................................................................................................................................ 817 Radiator and Associated Parts....................................................................................................... 817 Removal............................................................................................................................. 817 Inspection.......................................................................................................................... 818 Installation........................................................................................................................ 819 Drive Belt and Cooling Fan.............................................................................................................. 820 Drive Belt and Associated Parts..................................................................................................... 820 Inspection.......................................................................................................................... 820 Installation........................................................................................................................ 820 Main Data and Specifications............................................................................................................ 821 Special Tool............................................................................................................................ 822 6C ENGINE FUEL........................................................................................................................... 823 Service Precaution...................................................................................................................... 823 General Description..................................................................................................................... 824 Fuel Metering........................................................................................................................... 825 Fuel Filter............................................................................................................................. 826 Fuel Filter and Associated Parts.................................................................................................... 826 Removal............................................................................................................................. 826 Inspection.......................................................................................................................... 826 Installation........................................................................................................................ 826 Inspection.......................................................................................................................... 827 In-Tank Fuel Filter................................................................................................................. 827 Fuel Pump Flow Test................................................................................................................. 827 Fuel Pump............................................................................................................................... 828 Fuel Pump and Associated Parts...................................................................................................... 828 Removal............................................................................................................................. 828 Installation........................................................................................................................ 828 Fuel Pump Relay......................................................................................................................... 829 General Description................................................................................................................. 829 Fuel Tank............................................................................................................................... 829 Fuel Tank and Associated Parts...................................................................................................... 829 Removal............................................................................................................................. 829 Installation........................................................................................................................ 830 Fuel Tube / Quick-Connect Fittings...................................................................................................... 830 Precautions......................................................................................................................... 830 Cautions During Work................................................................................................................ 830 Removal............................................................................................................................. 830 Reuse of Quick Connector................................................................................................................ 832 Assembling Advice....................................................................................................................... 832 Fuel Gauge Unit......................................................................................................................... 833 Fuel Gauge Unit and Associated Parts................................................................................................ 833 Removal............................................................................................................................. 833 Installation........................................................................................................................ 833 Fuel Filler Cap......................................................................................................................... 834 General Description................................................................................................................. 834 Inspection.......................................................................................................................... 834 Main Data and Specifications............................................................................................................ 834 6D1 ENGINE ELECTRICAL..................................................................................................................... 835 Battery................................................................................................................................. 835 General Description................................................................................................................. 835 Diagnosis........................................................................................................................... 835 Battery Charging.................................................................................................................... 836 Jump Starting....................................................................................................................... 836 Battery Removal..................................................................................................................... 837 Battery Installation................................................................................................................ 837 Main Data and Specifications........................................................................................................ 838 6D2 IGNITION SYSTEM....................................................................................................................... 839 Service Precaution...................................................................................................................... 839 General Description..................................................................................................................... 840 Diagnosis............................................................................................................................... 840 Ignition Coil........................................................................................................................... 841 Removal............................................................................................................................. 841 Inspection and Repair............................................................................................................... 841 Installation........................................................................................................................ 841 Spark Plug.............................................................................................................................. 843 Removal............................................................................................................................. 843 Inspection and Repair............................................................................................................... 843 Installation........................................................................................................................ 843 Crankshaft Position Sensor.............................................................................................................. 844 Removal............................................................................................................................. 844 Installation........................................................................................................................ 844 Main Data and Specifications............................................................................................................ 845 6D3 STARTING AND CHARGING SYSTEM.......................................................................................................... 846 Service Precaution...................................................................................................................... 846 Starting System......................................................................................................................... 847 General Description..................................................................................................................... 847 Diagnosis............................................................................................................................... 849 Starter................................................................................................................................. 850 Removal............................................................................................................................. 850 Installation........................................................................................................................ 850 Disassembled View................................................................................................................... 851 Disassembly......................................................................................................................... 852 Inspection and Repair............................................................................................................... 854 Reassembly.......................................................................................................................... 858 Main Data and Specifications........................................................................................................ 860 Charging System......................................................................................................................... 863 General Description..................................................................................................................... 863 General On-Vehicle Inspection........................................................................................................... 863 Generator............................................................................................................................... 864 Removal............................................................................................................................. 864 Inspection.......................................................................................................................... 864 Installation........................................................................................................................ 864 Disassembled View................................................................................................................... 865 Disassembly......................................................................................................................... 866 Inspection and Repair............................................................................................................... 868 Reassembly.......................................................................................................................... 870 Bench Test.......................................................................................................................... 870 Main Data and Specifications........................................................................................................ 871 6E TROOPER 3.5L ENGINE DRIVEABILITY AND EMISSIONS....................................................................................... 872 Specifications.......................................................................................................................... 877 Tightening Specifications........................................................................................................... 877 Diagrams and Schematics................................................................................................................. 878 PCM Wiring Diagram (1 of 7)......................................................................................................... 878 PCM Wiring Diagram (2 of 7)......................................................................................................... 879 PCM Wiring Diagram (3 of 7)......................................................................................................... 880 PCM Wiring Diagram (4 of 7)......................................................................................................... 881 PCM Wiring Diagram (5 of 7)......................................................................................................... 882 PCM Wiring Diagram (6 of 7)......................................................................................................... 883 PCM Wiring Diagram (7 of 7)......................................................................................................... 884 PCM Pinouts............................................................................................................................. 885 PCM Pinout Table, 80-Way Blue Connector -Row "F1 ~ 20".............................................................................. 885 PCM Pinout Table, 80-Way Blue Connector -Row "F20 ~ 40"............................................................................. 887 PCM Pinout Table, 80-Way Blue Connector -Row "F41 ~ 60"............................................................................. 889 PCM Pinout Table, 80-Way Blue Connector -Row "F61 ~ 80"............................................................................. 891 PCM Pinout Table, 80-Way Red Connector -Row "S1 ~ 20"............................................................................... 893 PCM Pinout Table, 80-Way Red Connector -Row "S21 ~ 40".............................................................................. 895 PCM Pinout Table, 80-Way Red Connector -Row "S41 ~ 60".............................................................................. 897 PCM Pinout Table, 80-Way Red Connector -Row "S61 ~ 80............................................................................... 899 Component Locators.................................................................................................................. 901 Engine Component Locator Table...................................................................................................... 902 Undercarriage Component Locator..................................................................................................... 903 Undercarriage Component Locator Table............................................................................................... 903 Fuse and Relay Panel (Underhood Electrical Center).................................................................................. 904 Sensors and Miscellaneous Component Locators........................................................................................ 905 Diagnosis............................................................................................................................... 908 Strategy-Based Diagnostics.......................................................................................................... 908 DTC Stored.......................................................................................................................... 908 No DTC.............................................................................................................................. 908 No Matching Symptom................................................................................................................. 908 Intermittents....................................................................................................................... 908 No Trouble Found.................................................................................................................... 908 Verifying Vehicle Repair............................................................................................................ 908 General Service Information............................................................................................................. 909 OBD II Serviceablity Issues......................................................................................................... 909 Emissions Control Information Label................................................................................................. 909 Visual / Physical Engine Compartment Inspection..................................................................................... 909 Basic Knowledge of Tools Required................................................................................................... 910 Serial Data Communications.............................................................................................................. 910 Class II Serial Data Communications................................................................................................. 910 On-Board Diagnostic (OBD II)............................................................................................................ 910 On-Board Diagnostic Tests........................................................................................................... 910 Comprehensive Component Monitor Diagnostic Operation................................................................................ 910 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations................................... 911 Common OBD II Terms................................................................................................................. 911 The Diagnostic Executive............................................................................................................ 911 DTC Types........................................................................................................................... 912 Decimal/Binary/Hexadecimal Conversions.............................................................................................. 914 Verifying Vehicle Repair............................................................................................................ 914 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool......................................................................... 914 Tech 2.............................................................................................................................. 915 Tech 2 Features..................................................................................................................... 916 Getting Started..................................................................................................................... 916 Operating Procedure (For Example)................................................................................................... 917 DTC Modes........................................................................................................................... 918 DTC Information Mode................................................................................................................ 918 Miscellaneous Test.................................................................................................................. 919 Lamps Test.......................................................................................................................... 919 Relays Test......................................................................................................................... 921 EVAP Test........................................................................................................................... 922 Fuel System Test.................................................................................................................... 923 Instruments Test.................................................................................................................... 925 EGR Control Test.................................................................................................................... 927 Variable Intake Manifold Solenoid Test.............................................................................................. 927 Injector Balance Test............................................................................................................... 0 Plottong Snapshot Graph................................................................................................................. 929 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)...................................................... 930 Flow Chart for Snapshot Replay (Plotting Graph)..................................................................................... 931 Primary System-Based Diagnostic......................................................................................................... 932 Primary System-Based Diagnostic..................................................................................................... 932 Fuel Control Heated Oxygen Sensor................................................................................................... 932 HO2S Heater......................................................................................................................... 932 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation..................................................................... 932 Evaporative Emission (EVAP) Purge System Vacuum Switch.............................................................................. 933 Misfire Monitor Diagnostic Operation.................................................................................................... 933 Misfire Monitor Diagnostic Operation................................................................................................ 933 Misfire Counters.................................................................................................................... 933 Fuel Trim System Monitor Diagnostic Operation........................................................................................... 934 Fuel Trim Cell Diagnostic Weights................................................................................................... 934 On-Board Diagnostic (OBD II) System Check............................................................................................... 935 Circuit Description................................................................................................................. 935 Diagnostic Aids..................................................................................................................... 935 Test Description.................................................................................................................... 935 A/C Clutch Control Circuit Diagnosis.................................................................................................... 938 Circuit Description................................................................................................................. 938 Diagnostic Aids..................................................................................................................... 938 A/C Clutch Diagnosis................................................................................................................ 939 Test Description.................................................................................................................... 939 Electronic Ignition System Diagnosis.................................................................................................... 943 EVAP Canister Purge Solenoid and EVAP Vacuum Switch..................................................................................... 943 Visual Check of The Evaporative Emission Canister....................................................................................... 943 Fuel Metering System Check.............................................................................................................. 943 Fuel System Pressure Test............................................................................................................... 943 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure.............................................................. 943 Test Description.................................................................................................................... 943 Injector Coil Test Procedure (Steps 1-6) and Injector Balance Test Procedure (Steps 7-11)........................................... 944 Powertrain Control Module (PCM) Diagnosis............................................................................................... 948 Multiple PCM Information Sensor DTCs Set................................................................................................ 948 Circuit Description................................................................................................................. 948 Diagnostic Aids..................................................................................................................... 948 Exhaust Gas Recirculation (EGR) Diagnosis............................................................................................... 952 Engine Tech 2 Data Definitions and Ranges............................................................................................... 952 Typical Scan Data Values................................................................................................................ 954 Test Conditions..................................................................................................................... 954 3.5L V-6 Engine (Automatic and Manual Transmission)................................................................................. 955 No Malfunction Indicator Lamp (MIL)..................................................................................................... 960 Circuit Description................................................................................................................. 960 Diagnostic Aids..................................................................................................................... 960 Test Description.................................................................................................................... 960 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................ 963 Circuit description................................................................................................................. 963 Diagnostic Aids..................................................................................................................... 963 Test Description.................................................................................................................... 963 No Reduced Power Lamp (RPL)............................................................................................................. 965 Circuit Description................................................................................................................. 965 Diagnostic Aids..................................................................................................................... 965 Test Description.................................................................................................................... 965 Reduced Power Lamp (RPL) "ON" Steady.................................................................................................... 968 Circuit Description................................................................................................................. 968 Diagnostic Aids..................................................................................................................... 968 Test Description.................................................................................................................... 968 Engine Cranks But Will Not Run.......................................................................................................... 970 Circuit Description................................................................................................................. 972 Diagnostic Aids..................................................................................................................... 972 Test Description.................................................................................................................... 972 Fuel System Electrical Test............................................................................................................. 977 Circuit Description................................................................................................................. 978 Diagnostic Aids..................................................................................................................... 978 Test Description.................................................................................................................... 978 Fuel Pressure Relief Procedure...................................................................................................... 978 Fuel Gauge Installation............................................................................................................. 978 Electric Throttle Control (ETC) System Check............................................................................................ 981 Circuit Description................................................................................................................. 982 Diagnostic Aids..................................................................................................................... 982 Test Description.................................................................................................................... 982 Fuel System Diagnosis................................................................................................................... 985 Circuit Description................................................................................................................. 985 Test Description.................................................................................................................... 985 Fuel Pressure Relief Procedure...................................................................................................... 986 Fuel Gauge Installation............................................................................................................. 986 Exhaust Gas Recirculation (EGR) System Check............................................................................................ 990 Circuit Description................................................................................................................. 990 Diagnostic Aids..................................................................................................................... 990 Manifold Absolute Pressure (MAP) Output Check........................................................................................... 992 Circuit Description................................................................................................................. 992 Test Description.................................................................................................................... 992 Evaporative (EVAP) Emissions Canister Purge Valve Check................................................................................. 994 Circuit Description................................................................................................................. 994 Diagnostic Aids..................................................................................................................... 994 Test Description.................................................................................................................... 994 Upshift Lamp System Check (Manual Transmission Only).................................................................................... 997 Circuit Description................................................................................................................. 998 Diagnostic Aids..................................................................................................................... 998 Test Description.................................................................................................................... 998 PCM Diagnostic Trouble Codes............................................................................................................1000 DTC P0101 MAF System Performance........................................................................................................1004 DTC P0102 MAF Sensor Circuit Low Frequency..............................................................................................1007 DTC P0103 MAF Sensor Circuit High Frequency.............................................................................................1010 DTC P0106 MAP System Performance........................................................................................................1013 DTC P0107 MAP Sensor Circuit Low Voltage................................................................................................1016 DTC P0108 MAP Sensor Circuit High Voltage...............................................................................................1019 DTC P0112 IAT Sensor Circuit Low Voltage................................................................................................1022 DTC P0113 IAT Sensor Circuit High Voltage...............................................................................................1025 DTC P0117 ECT Sensor Circuit Low Voltage................................................................................................1028 DTC P0118 ECT Sensor Circuit High Voltage...............................................................................................1031 DTC P0125 ECT Excessive Time to Closed Loop Fuel Control................................................................................1034 DTC P0128 Thermostat Insufficient temperrature for Stable Opreation.....................................................................1037 DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1......................................................................................1040 DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.....................................................................................1043 DTC P0133 HO2S Slow Response Bank 1 Sensor 1............................................................................................1046 DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1............................................................................1050 DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1...........................................................................................1053 DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2......................................................................................1056 DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.....................................................................................1059 DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................................................1062 DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2...........................................................................................1065 DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1......................................................................................1068 DTC P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.....................................................................................1071 DTC P0153 HO2S Slow Response Bank 2 Sensor 1............................................................................................1074 DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1............................................................................1078 DTC P0155 HO2S Heater Circuit Bank 2 Sensor 1...........................................................................................1081 DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2......................................................................................1084 DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.....................................................................................1087 DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2............................................................................1090 DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2...........................................................................................1093 DTC P0171 Fuel Trim System Lean Bank 1..................................................................................................1096 DTC P0172 Fuel Trim System Rich Bank 1..................................................................................................1100 DTC P0174 Fuel Trim System Lean Bank 2..................................................................................................1104 DTC P0175 Fuel Trim System Rich Bank 2..................................................................................................1108 DTC P0201 Injector 1 Control Circuit....................................................................................................1112 DTC P0202 Injector 2 Control Circuit....................................................................................................1115 DTC P0203 Injector 3 Control Circuit....................................................................................................1118 DTC P0204 Injector 4 Control Circuit....................................................................................................1121 DTC P0205 Injector 5 Control Circuit....................................................................................................1124 DTC P0206 Injector 6 Control Circuit....................................................................................................1127 DTC P0300 Engine Misfire Detected.......................................................................................................1130 DTC P0301 Cylinder Misfire Detected.....................................................................................................1134 DTC P0302 Cylinder Misfire Detected.....................................................................................................1136 DTC P0303 Cylinder Misfire Detected.....................................................................................................1138 DTC P0304 Cylinder Misfire Detected.....................................................................................................1140 DTC P0305 Cylinder Misfire Detected.....................................................................................................1142 DTC P0306 Cylinder Misfire Detected.....................................................................................................1144 DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault..................................................................1146 DTC P0336 58X Reference Signal Circuit..................................................................................................1149 DTC P0337 CKP Sensor Circuit Low Frequency..............................................................................................1152 DTC P0341 CMP Sensor Circuit Performance................................................................................................1155 DTC P0342 CMP Sensor Circuit Low........................................................................................................1159 DTC P0351 Ignition 1 Control Circuit....................................................................................................1163 DTC P0352 Ignition 2 Control Circuit....................................................................................................1166 DTC P0353 Ignition 3 Control Circuit....................................................................................................1169 DTC P0354 Ignition 4 Control Circuit....................................................................................................1172 DTC P0355 Ignition 5 Control Circuit....................................................................................................1175 DTC P0356 Ignition 6 Control Circuit....................................................................................................1178 DTC P0401 EGR Flow Insufficient.........................................................................................................1181 DTC P0402 EGR Pintle Crank Error........................................................................................................1184 DTC P0404 EGR Open Stuck................................................................................................................1186 DTC P0405 EGR Low Voltage...............................................................................................................1188 DTC P0406 EGR High Voltage..............................................................................................................1191 DTC P0420 TWC System Low Efficiency Bank 1..............................................................................................1194 DTC P0430 TWC System Low Efficiency Bank 2..............................................................................................1197 DTC P0440 EVAP System...................................................................................................................1200 DTC P0442 EVAP System Small Leak Detected...............................................................................................1203 DTC P0446 EVAP Canister Vent Blocked....................................................................................................1206 DTC P0452 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) Low Voltage.................................................................1209 DTC P0453 Fuel Tank Pressure Sensor (Vapor Pressure Sensor) High Voltage................................................................1212 DTC P0456 EVAP Very Small Leak..........................................................................................................1215 DTC P0462 Fuel Level Sensor Circuit豊ow Voltage..........................................................................................1218 DTC P0463 Fuel Level Sensor Circuit-High Voktage........................................................................................1221 DTC P0502 VSS Circuit Low Input.........................................................................................................1223 DTC P0506 Idle Air Control System Low RPM...............................................................................................1226 DTC P0507 Idle Air Control System High RPM..............................................................................................1229 DTC P0562 System Voltage Low............................................................................................................1232 DTC P0563 System Voltage High...........................................................................................................1234 DTC P0601 PCM Memory....................................................................................................................1236 DTC P0602 PCM Programming Error.........................................................................................................1238 DTC P0604 PCM RAM Error.................................................................................................................1240 DTC P0606 PCM Internal Performance......................................................................................................1242 DTC P1106 MAP Sensor Circuit Intermittent High Voltage..................................................................................1244 DTC P1107 MAP Circuit Intermittent Low Voltage..........................................................................................1246 DTC P1111 IAT Sensor Circuit Intermittent High Voltage..................................................................................1248 DTC P1112 IAT Sensor Circuit Intermittent Low Voltage...................................................................................1251 DTC P1114 ECT Sensor Circuit Intermittent Low Voltage...................................................................................1253 DTC P1115 ECT Sensor Circuit Intermittent High Voltage..................................................................................1255 DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault...........................................................................1258 DTC P1125 ETC (Electric Throttle Control) Limit Performance Mode........................................................................1261 DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1...................................................................................1264 DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1....................................................................................1268 DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1...................................................................................1272 DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1............................................................................1276 DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)...........................................................................1280 DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)...........................................................................1282 DTC P1171 Fuel System Lean During Acceleration..........................................................................................1284 DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault................................................................................1287 DTC P1221 TPS1 ・TPS2 correlation(Circuit Performance)...................................................................................1290 DTC P1271 APS 1・2 Correlation Error.....................................................................................................1293 DTC P1272 APS 2-3 Correlation Error.....................................................................................................1296 DTC P1273 APS 1 ・3 Correlation Error....................................................................................................1299 DTC P1275 APS 1 Circuit Fault...........................................................................................................1302 DTC P1280 APS 2 Circuit Fault...........................................................................................................1304 DTC P1285 APS 3 Circuit Fault...........................................................................................................1306 DTC P1290 ETC Forced Idle Mode..........................................................................................................1308 DTC P1295 Power Management Mode.........................................................................................................1311 DTC P1299 ETC Forced Engine Shutdown Mode...............................................................................................1315 DTC P1310 ION Sensing Module Diagnosis..................................................................................................1319 DTC P1311 ION Sensing Module SEC line 1 Circuit Fault...................................................................................1323 DTC P1312 ION Sensing Module SEC line 2 Circuit Fault...................................................................................1326 DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault.....................................................................1329 DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)..........................................................1332 DTC P1404 EGR Stuck Closed..............................................................................................................1335 DTC P1441 EVAP System Flow During Non-Purge.............................................................................................1338 DTC P1514 TPS - MAF Correlation Error...................................................................................................1341 DTC P1515 Command - Actual TPS Correlation Error........................................................................................1345 DTC P1516 Command - Actual TPS Correlation Error........................................................................................1348 DTC P1523 Actuator Control Return Performance...........................................................................................1351 DTC P1625 PCM Unexpected Reset..........................................................................................................1354 DTC P1635 Reference Voltage # 1 Circuit Fault...........................................................................................1355 DTC P1639 Reference Voltage # 2 Circuit Fault...........................................................................................1357 DTC P1640 Driver-1-Output Circuit Fault (ODM)...........................................................................................1359 DTC P1650 Quad Driver Module "A" Fault..................................................................................................1362 Symptom Diagnosis.......................................................................................................................1365 Default Matrix Table....................................................................................................................1394 On-Vehicle ServiceCamshaft Position (CMP) Sensor........................................................................................1397 Crankshaft Position (CKP) Sensor........................................................................................................1398 Engine Coolant Temperature (ECT) Sensor.................................................................................................1398 Heated Oxygen Sensor (HO2S).............................................................................................................1399 Intake Air Temperature (IAT) Sensor.....................................................................................................1402 ION Sensing Module......................................................................................................................1402 Mass Air Flow (MAF) Sensor..............................................................................................................1403 Manifold Absolute Pressure (MAP) Sensor.................................................................................................1404 Malfunction Indicator Lamp (MIL)........................................................................................................1405 Reduced Power Lamp......................................................................................................................1405 Powertrain Control Module (PCM).........................................................................................................1405 Service Precaution..................................................................................................................1405 Removal Procedure...................................................................................................................1405 Installation Procedure..............................................................................................................1406 EEPROM..................................................................................................................................1406 Throttle Position (TP) Sensor...........................................................................................................1407 Vehicle Speed Sensor (VSS)..............................................................................................................1407 Air Cleaner/Air Filter..................................................................................................................1409 Common Chamber..........................................................................................................................1409 Accelerator Pedal Replacement...........................................................................................................1410 Fuel Filler Cap.........................................................................................................................1411 Fuel Filter.............................................................................................................................1411 Fuel Gauge Unit.........................................................................................................................1413 Fuel Injectors..........................................................................................................................1414 Fuel Metering System....................................................................................................................1415 Fuel Pump Assembly......................................................................................................................1416 Fuel Pump Relay.........................................................................................................................1416 Fuel Rail Assembly......................................................................................................................1417 Fuel Tank...............................................................................................................................1418 Throttle Body (TB)......................................................................................................................1420 Electronic Ignition System..............................................................................................................1422 Catalytic Converter.....................................................................................................................1423 Air Conditioning Thermo Relay...........................................................................................................1423 EVAP Canister Hoses.....................................................................................................................1423 EVAP Canister...........................................................................................................................1424 EVAP Canister Vent Solenoid.............................................................................................................1425 Fuel Tank Pressure Sensor...............................................................................................................1426 EVAP Canister Purge Solenoid............................................................................................................1426 Fuel Tank Vent Valve....................................................................................................................1427 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................1427 Positive Crankcase Ventilation (PCV) Valve..............................................................................................1428 Wiring and Connectors...................................................................................................................1429 PCM Connectors and Terminals............................................................................................................1429 Wire Harness Repair: Twisted Shielded Cable.............................................................................................1429 Twisted Leads...........................................................................................................................1430 Weather-Pack Connector..................................................................................................................1432 Com-Pack III............................................................................................................................1433 Metri-Pack..............................................................................................................................1433 General Description (PCM and Sensors)...................................................................................................1434 58X Reference PCM Input.............................................................................................................1434 A/C Request Signal..................................................................................................................1434 Crankshaft Position (CKP) Sensor....................................................................................................1434 Camshaft Position (CMP) Sensor and Signal...........................................................................................1434 Engine Coolant Temperature (ECT) Sensor.............................................................................................1434 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................1435 Fuel Control Heated Oxygen Sensors..................................................................................................1435 Catalyst Monitor Heated Oxygen Sensors..............................................................................................1435 Intake Air Temperature (IAT) Sensor.................................................................................................1436 Linear Exhaust Gas Recirculation (EGR) Control......................................................................................1436 Mass Air Flow (MAF) Sensor..........................................................................................................1436 Manifold Absolute Pressure (MAP) Sensor.............................................................................................1436 Powertrain Control Module (PCM).....................................................................................................1437 PCM Function........................................................................................................................1437 PCM Components......................................................................................................................1437 PCM Voltage Description.............................................................................................................1437 PCM Input/Outputs...................................................................................................................1438 PCM Service Precautions.............................................................................................................1438 Reprogramming The PCM...............................................................................................................1438 Throttle Position (TP) Sensor.......................................................................................................1438 Transmission Fluid Temperature (TFT) Sensor.........................................................................................1438 Transmission Range Switch...........................................................................................................1438 Vehicle Speed Sensor (VSS)..........................................................................................................1439 Use of Circuit Testing Tools........................................................................................................1439 Aftermarket Electrical and Vacuum Equipment.........................................................................................1439 Electrostatic Discharge Damage......................................................................................................1439 Upshift Lamp........................................................................................................................1439 General Description (Air Induction).....................................................................................................1439 Air Induction System................................................................................................................1439 General Description (Fuel Metering).....................................................................................................1440 Acceleration Mode...................................................................................................................1440 Battery Voltage Correction Mode.....................................................................................................1440 CMP Signal..........................................................................................................................1440 Clear Flood Mode....................................................................................................................1440 Deceleration Mode...................................................................................................................1440 Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................1440 Fuel Cutoff Mode....................................................................................................................1440 Fuel Injector.......................................................................................................................1440 Fuel Metering System Components.....................................................................................................1440 Fuel Metering System Purpose........................................................................................................1441 Fuel Pressure Regulator.............................................................................................................1441 Fuel Pump Electrical Circuit........................................................................................................1441 Fuel Rail...........................................................................................................................1441 Run Mode............................................................................................................................1442 Starting Mode.......................................................................................................................1442 Throttle Body Unit..................................................................................................................1442 General Description (Electronic Ignition System)........................................................................................1442 Camshaft Position (CMP) Sensor......................................................................................................1442 Crankshaft Position (CKP) Sensor....................................................................................................1442 Electronic Ignition.................................................................................................................1443 Ignition Coils......................................................................................................................1443 Ignition Control....................................................................................................................1443 Ignition Control PCM Output.........................................................................................................1444 Powertrain Control Module (PCM).....................................................................................................1444 Spark Plug..........................................................................................................................1445 A/C Clutch Diagnosis....................................................................................................................1446 A/C Clutch Circuit Operation........................................................................................................1446 A/C Clutch Circuit Purpose..........................................................................................................1446 A/C Request Signal..................................................................................................................1446 General Description (Evaporative (EVAP) Emission System)................................................................................1447 EVAP Emission Control System Purpose................................................................................................1447 EVAP Emission Control System Operation..............................................................................................1447 Enhanced Evaporative Emission Control System........................................................................................1447 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................1450 EGR Purpose.........................................................................................................................1450 Linear EGR Valve....................................................................................................................1451 Linear EGR Control..................................................................................................................1451 Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................1451 EGR Pintle Position Sensor..........................................................................................................1451 General Description (Positive Crankcase Ventilation (PCV) System).......................................................................1451 Crankcase Ventilation System Purpose................................................................................................1451 Crankcase Ventilation System Operation..............................................................................................1451 Special Tools...........................................................................................................................1453 6F ENGINE EXHAUST.......................................................................................................................1455 General Description.....................................................................................................................1456 Front Exhaust Pipe......................................................................................................................1457 Front Exhaust Pipe and Associated Parts.............................................................................................1457 Removal.............................................................................................................................1457 Installation........................................................................................................................1457 Three Way Catalytic Converter LH........................................................................................................1458 Removal.............................................................................................................................1458 Installation........................................................................................................................1458 Three Way Catalytic Converter RH........................................................................................................1459 Removal.............................................................................................................................1459 Installation........................................................................................................................1459 Exhaust Silencer........................................................................................................................1460 Exhaust Silencer and Associated Parts...............................................................................................1460 Removal.............................................................................................................................1460 Installation........................................................................................................................1460 Rear Exhaust pipe.......................................................................................................................1461 Rear Exhaust pipe and Associated Parts..............................................................................................1461 Removal.............................................................................................................................1461 Installation........................................................................................................................1461 Main Data and Specifications............................................................................................................1462 6G ENGINE LUBRICATION...................................................................................................................1463 Service Precaution......................................................................................................................1463 General Description.....................................................................................................................1464 Oil Pump................................................................................................................................1465 Oil Pump and Associated Parts.......................................................................................................1465 Disassembly.........................................................................................................................1465 Inspection and Repair...............................................................................................................1466 Reassembly..........................................................................................................................1467 Oil Pan and Crankcase...................................................................................................................1469 Removal.............................................................................................................................1469 Installation........................................................................................................................1469 Oil Pump................................................................................................................................1472 Removal.............................................................................................................................1472 Installation........................................................................................................................1472 Oil Pump Oil Seal.......................................................................................................................1474 Removal.............................................................................................................................1474 Installation........................................................................................................................1474 Oil Filter..............................................................................................................................1475 Removal.............................................................................................................................1475 Installation........................................................................................................................1475 Main Data and Specification.............................................................................................................1476 6H ENGINE SPEED CONTROL SYSTEM..........................................................................................................1477 Service Precaution......................................................................................................................1477 Accelerator Pedal.......................................................................................................................1478 Accelerator Pedal and Associated Parts..............................................................................................1478 Removal.............................................................................................................................1478 Installation........................................................................................................................1478 6J INDUCTION............................................................................................................................1479 Service Precaution......................................................................................................................1479 Air Cleaner Element.....................................................................................................................1480 Removal.............................................................................................................................1480 Inspection..........................................................................................................................1480 Installation........................................................................................................................1480 Section.7 TRANSMISSION.......................................................................................................................1481 7A AUTOMATIC TRANSMISSION (4L30-E).......................................................................................................1481 Service Precaution......................................................................................................................1483 Construction............................................................................................................................1483 Range Reference Chart...................................................................................................................1484 Normal Operation Of 2000 4L30-E Transmission ...........................................................................................1485 Diagnosis...............................................................................................................................1485 Driver Information......................................................................................................................1485 General Diagnosis Procedure.............................................................................................................1488 Preliminary Inspection Chart............................................................................................................1489 Checking Transmission Fluid Level and Condition.........................................................................................1490 Test Driving............................................................................................................................1491 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................1492 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................1493 Stall Test..............................................................................................................................1503 Line Pressure Test......................................................................................................................1503 Shift Speed Chart.......................................................................................................................1504 Lockup Speed Chart......................................................................................................................1506 Changing Transmission Fluid.............................................................................................................1507 Selector Lever..........................................................................................................................1507 Inspection..........................................................................................................................1507 Removal.............................................................................................................................1507 Installation........................................................................................................................1508 Mode Switch.............................................................................................................................1509 Removal.............................................................................................................................1509 Installation........................................................................................................................1509 Transmission (With Transfer Case / Extension Assembly)..................................................................................1511 Transmission And Associated Parts...................................................................................................1511 Removal.............................................................................................................................1512 Installation........................................................................................................................1513 Solenoid (Main Case Valve Body).........................................................................................................1518 Removal.............................................................................................................................1518 Installation........................................................................................................................1518 Solenoid (Adapter Case Valve Body)......................................................................................................1519 Removal.............................................................................................................................1519 Installation........................................................................................................................1519 Valve Body Assembly (Main Case).........................................................................................................1520 Removal.............................................................................................................................1520 Installation........................................................................................................................1520 Valve Body Assembly (Adapter Case)......................................................................................................1521 Removal.............................................................................................................................1521 Installation........................................................................................................................1521 Powertrain Control Module (PCM).........................................................................................................1521 Removal.............................................................................................................................1521 Installation........................................................................................................................1521 Speed Sensor (Extension Housing)........................................................................................................1522 Removal.............................................................................................................................1522 Installation........................................................................................................................1522 Transmission Oil Temperature Sensor (Main Case).........................................................................................1522 Removal.............................................................................................................................1522 Installation........................................................................................................................1522 Front Oil Seal (Converter Housing)......................................................................................................1523 Removal.............................................................................................................................1523 Installation........................................................................................................................1523 Rear Oil Seal (Extension Housing).......................................................................................................1523 Removal.............................................................................................................................1523 Installation........................................................................................................................1524 Transmission (4L30-E)...................................................................................................................1524 Disassembly.........................................................................................................................1524 Reassembly..........................................................................................................................1528 Converter Housing And Oil Pump Assembly.................................................................................................1538 Disassembled View...................................................................................................................1538 Disassembly.........................................................................................................................1538 Inspection And Repair...............................................................................................................1538 Reassembly..........................................................................................................................1538 Oil Pump................................................................................................................................1539 Disassembled View...................................................................................................................1539 Disassembly.........................................................................................................................1539 Inspection And Repair...............................................................................................................1540 Reassembly..........................................................................................................................1540 Main Case Valve Body....................................................................................................................1541 Disassembled View...................................................................................................................1541 Disassembly.........................................................................................................................1541 Inspection And Repair...............................................................................................................1542 Reassembly..........................................................................................................................1542 Adapter Case Valve Body.................................................................................................................1543 Disassembled View...................................................................................................................1543 Disassembly.........................................................................................................................1543 Inspection And Repair...............................................................................................................1543 Reassembly..........................................................................................................................1543 Third Clutch And Sprag Unit.............................................................................................................1545 Disassembled View...................................................................................................................1545 Disassembly.........................................................................................................................1545 Inspection And Repair...............................................................................................................1545 Reassembly..........................................................................................................................1546 Third Clutch............................................................................................................................1547 Disassembled View...................................................................................................................1547 Disassemble.........................................................................................................................1547 Inspection And Repair...............................................................................................................1547 Reassembly..........................................................................................................................1547 Sprag Unit..............................................................................................................................1549 Disassembled View...................................................................................................................1549 Disassembly.........................................................................................................................1549 Inspection And Repair...............................................................................................................1549 Reassembly..........................................................................................................................1549 Second Clutch...........................................................................................................................1550 Disassembled View...................................................................................................................1550 Disassembly.........................................................................................................................1550 Inspection And Repair...............................................................................................................1551 Reassembly..........................................................................................................................1551 3-4 Accumulator Piston..................................................................................................................1552 Disassembled View...................................................................................................................1552 Disassembly.........................................................................................................................1552 Inspection And Repair...............................................................................................................1553 Reassembly..........................................................................................................................1553 Reverse Clutch Piston And Center Support................................................................................................1554 Disassembled View...................................................................................................................1554 Disassembly.........................................................................................................................1554 Inspection And Repair...............................................................................................................1555 Reassembly..........................................................................................................................1555 Overrun Clutch And Turbine Shaft........................................................................................................1556 Disassembled View...................................................................................................................1556 Disassembly.........................................................................................................................1557 Inspection And Repair...............................................................................................................1557 Reassembly..........................................................................................................................1557 Main Data And Specification.............................................................................................................1559 Special Tools...........................................................................................................................1563 4L30-L Parts List.......................................................................................................................1566 Extension Housing Assembly Oil Seal.....................................................................................................1574 Extension Housing Assembly Rear Oil Seal and Associated Parts.......................................................................1574 Removal.............................................................................................................................1574 Installation........................................................................................................................1574 Extension Housing Assembly..............................................................................................................1576 Extension Housing Assembly and Associated Parts.....................................................................................1576 Removal.............................................................................................................................1577 Installation........................................................................................................................1577 Extension Housing Assembly..............................................................................................................1579 Extension Housing Assembly and Associated Parts.....................................................................................1579 Removal.............................................................................................................................1580 Installation........................................................................................................................1580 Extension Housing Assembly..........................................................................................................1582 Disassembly.........................................................................................................................1583 Reassembly..........................................................................................................................1583 Inspection and Repair...............................................................................................................1584 Main Data and Specifications............................................................................................................1585 Special Tools...........................................................................................................................1586 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................1587 Service Precaution......................................................................................................................1588 General Description.....................................................................................................................1588 Electronic Control Diagram..........................................................................................................1589 Powertrain Control Module (PCM).....................................................................................................1590 Control System Diagram..............................................................................................................1591 Shift Control.......................................................................................................................1592 Band Apply Control..................................................................................................................1592 Torque Converter Clutch Control (Electronically Controlled Capacity Clutch = ECCC)..................................................1592 Line Pressure Control...............................................................................................................1592 On-Board Diagnostic System..........................................................................................................1592 Fail Safe Mechanism.................................................................................................................1592 Torque Management Control...........................................................................................................1592 ATF Warning Control.................................................................................................................1592 ABS Control.........................................................................................................................1592 Reverse Lock Out Control............................................................................................................1592 Downhill Control....................................................................................................................1592 Uphill Control......................................................................................................................1592 Shift Mode Control..................................................................................................................1593 Gear Shift Control..................................................................................................................1594 Winter Drive Mode...................................................................................................................1595 Backup Mode.........................................................................................................................1595 Functions of Input / Output Components..............................................................................................1596 Diagnosis...............................................................................................................................1597 Electronic Diagnosis................................................................................................................1597 Check Trans Indicator...............................................................................................................1597 Diagnostic Check....................................................................................................................1597 "Check Trans" Check.................................................................................................................1598 Tech 2 OBD II Connection............................................................................................................1599 Transmission Data...................................................................................................................1604 OBD II Diagnostic Management System.................................................................................................1605 16 - Terminal Data Link Connector (DLC).............................................................................................1606 Malfunction Indicator Lamp (MIL)....................................................................................................1607 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................1607 Clear DTC...........................................................................................................................1607 DTC Check...........................................................................................................................1608 PCM Precaution......................................................................................................................1608 Information On PCM..................................................................................................................1608 Intermittent Conditions.............................................................................................................1608 Transmission And PCM Identification.................................................................................................1609 Isuzu Trooper.......................................................................................................................1609 Diagnostic Trouble Code (DTC) Identification........................................................................................1610 DTC P0218 Transmission Fluid Over Temperature...........................................................................................1611 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................1613 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................1616 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................1619 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................1622 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................1625 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................1628 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................1631 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................1634 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................1637 DTC P0730 Gear Error Without Input Speed................................................................................................1639 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................1642 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................1644 DTC P0751 Shift Solenoid A Performance (Stuck OFF)......................................................................................1646 DTC P0752 Shift Solenoid A Performance (Stuck ON).......................................................................................1648 DTC P0753 Shift Solenoid A Electrical...................................................................................................1650 DTC P0756 Shift Solenoid B Performance (Stuck OFF)......................................................................................1653 DTC P0757 Shift Solenoid B Performance (Stuck ON).......................................................................................1655 DTC P0758 Shift Solenoid B Electrical...................................................................................................1657 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................1661 DTC P1860 TCC PWM Solenoid Electrical...................................................................................................1665 DTC P1870 Transmission Component Slipping (TCC Stuck OFF)...............................................................................1668 Connector List..........................................................................................................................1670 7B MANUAL TRANSMISSION...................................................................................................................1672 Service Precaution......................................................................................................................1672 General Description.....................................................................................................................1673 Diagnosis...............................................................................................................................1674 Manual Transmission Assembly............................................................................................................1675 Removal.............................................................................................................................1675 Installation........................................................................................................................1679 Disassembled View...................................................................................................................1684 Disassembly.........................................................................................................................1687 Inspection..........................................................................................................................1705 Reassembly..........................................................................................................................1707 Main Data and Specifications............................................................................................................1733 Special Tools...........................................................................................................................1735 7C CLUTCH................................................................................................................................1737 Service Precaution......................................................................................................................1737 General Description.....................................................................................................................1738 Diagnosis...............................................................................................................................1742 Clutch Assembly.........................................................................................................................1743 Clutch Assembly and Associated Parts................................................................................................1743 Removal.............................................................................................................................1743 Inspection and Repair...............................................................................................................1744 Installation........................................................................................................................1748 Clutch Control..........................................................................................................................1751 Clutch Control Parts................................................................................................................1751 Removal.............................................................................................................................1751 Inspection and Repair...............................................................................................................1751 Installation........................................................................................................................1752 Adjustment..........................................................................................................................1752 Master Cylinder.........................................................................................................................1755 Inspection and Repair...............................................................................................................1755 Slave Cylinder..........................................................................................................................1756 Disassembled View...................................................................................................................1756 Disassembly.........................................................................................................................1756 Inspection and Repair...............................................................................................................1756 Reassembly..........................................................................................................................1757 Main Data and Specifications............................................................................................................1758 Special Tools...........................................................................................................................1760 Section.8 BODY AND ACCESSORIES...............................................................................................................1761 8A LIGHTING SYSTEM........................................................................................................................1761 Service Precaution......................................................................................................................1762 Headlight Bulb..........................................................................................................................1762 Removal.............................................................................................................................1762 Installation........................................................................................................................1762 Headlight...............................................................................................................................1763 Headlight and Associated Parts......................................................................................................1763 Removal.............................................................................................................................1763 Installation........................................................................................................................1763 Headlight Adjustment................................................................................................................1763 Fog Light Bulb..........................................................................................................................1764 Removal.............................................................................................................................1764 Installation........................................................................................................................1764 Fog Light Assembly......................................................................................................................1765 Removal.............................................................................................................................1765 Installation........................................................................................................................1765 Fog Light Adjustment................................................................................................................1765 Front Side Marker Light Bulb............................................................................................................1765 Removal.............................................................................................................................1765 Installation........................................................................................................................1765 Parking Light Bulb......................................................................................................................1766 Removal and Installation............................................................................................................1766 Taillight Bulb..........................................................................................................................1766 Removal.............................................................................................................................1766 Installation........................................................................................................................1766 License Plate Light Bulb................................................................................................................1767 Removal.............................................................................................................................1767 Installation........................................................................................................................1767 Stoplight Bulb..........................................................................................................................1767 Removal and Installation............................................................................................................1767 High Mount Stoplight....................................................................................................................1767 Removal.............................................................................................................................1767 Installation........................................................................................................................1768 Front Turn Signal Light Bulb............................................................................................................1768 Removal.............................................................................................................................1768 Installation........................................................................................................................1768 Rear Turn Signal Light Bulb.............................................................................................................1769 Removal.............................................................................................................................1769 Installation........................................................................................................................1769 Cornering Light Bulb....................................................................................................................1769 Removal.............................................................................................................................1769 Installation........................................................................................................................1769 Backup Light Bulb.......................................................................................................................1770 Removal.............................................................................................................................1770 Installation........................................................................................................................1770 Dome Light Bulb.........................................................................................................................1770 Removal.............................................................................................................................1770 Installation........................................................................................................................1770 Luggage Room Light Bulb.................................................................................................................1771 Removal.............................................................................................................................1771 Installation........................................................................................................................1771 Courtesy Light Bulb.....................................................................................................................1771 Removal.............................................................................................................................1771 Installation........................................................................................................................1771 Map Light Switch/Bulb...................................................................................................................1772 Removal.............................................................................................................................1772 Installation........................................................................................................................1772 Cigarette Lighter Illumination Bulb.....................................................................................................1772 Removal.............................................................................................................................1772 Installation........................................................................................................................1772 Ashtray Illumination Bulb...............................................................................................................1773 Removal.............................................................................................................................1773 Installation........................................................................................................................1773 Glove Box Illumination Bulb.............................................................................................................1773 Removal.............................................................................................................................1773 Installation........................................................................................................................1773 Vanity Mirror Illumination Bulb.........................................................................................................1774 Removal.............................................................................................................................1774 Installation........................................................................................................................1774 Starter Switch..........................................................................................................................1774 Removal.............................................................................................................................1774 Installation........................................................................................................................1775 Lighting Switch (Combination Switch)....................................................................................................1775 Removal.............................................................................................................................1775 Installation........................................................................................................................1776 Fog Light Switch........................................................................................................................1776 Removal.............................................................................................................................1776 Installation........................................................................................................................1777 Stoplight Switch (W/O Cruise Control)...................................................................................................1777 Removal.............................................................................................................................1777 Installation........................................................................................................................1777 Brake Switch (W/Cruise Control).........................................................................................................1778 Removal.............................................................................................................................1778 Installation........................................................................................................................1778 Turn Signal Switch/Cornering Light Switch (Combination Switch)..........................................................................1778 Removal and Installation............................................................................................................1778 Hazard Warning Switch...................................................................................................................1778 Removal.............................................................................................................................1778 Installation........................................................................................................................1779 Tailgate Switch.........................................................................................................................1779 Removal.............................................................................................................................1779 Installation........................................................................................................................1779 Door Switch.............................................................................................................................1780 Removal.............................................................................................................................1780 Installation........................................................................................................................1780 Rear Defogger Switch....................................................................................................................1780 Removal.............................................................................................................................1780 Installation........................................................................................................................1781 Seat Heater Switch......................................................................................................................1781 Removal.............................................................................................................................1781 Installation........................................................................................................................1781 Key Remind Switch (Starter Switch)......................................................................................................1781 Removal and Installation............................................................................................................1781 Illumination Controller.................................................................................................................1782 Removal.............................................................................................................................1782 Installation........................................................................................................................1782 Main Data and Specifications............................................................................................................1783 8B WIPER / WASHER SYSTEM..................................................................................................................1785 Service Precaution......................................................................................................................1785 Windshield Wiper/Washer System..........................................................................................................1786 General Description.................................................................................................................1786 Windshield Wiper And Washer Switch......................................................................................................1786 Removal and Installation............................................................................................................1786 Windshield Wiper Motor..................................................................................................................1786 Removal.............................................................................................................................1786 Installation........................................................................................................................1786 Windshield Washer Motor.................................................................................................................1787 Removal.............................................................................................................................1787 Installation........................................................................................................................1787 Windshield Wiper Linkage................................................................................................................1788 Windshield Wiper Linkage and Associated Parts.......................................................................................1788 Removal.............................................................................................................................1788 Installation........................................................................................................................1788 Windshield Wiper Arm/Blade..............................................................................................................1789 Removal.............................................................................................................................1789 Installation........................................................................................................................1789 Windshield Wiper Blade Rubber...........................................................................................................1790 Removal.............................................................................................................................1790 Installation........................................................................................................................1790 Rear Wiper/Washer System................................................................................................................1791 General Description.................................................................................................................1791 Rear Wiper and Washer Switch............................................................................................................1791 Removal.............................................................................................................................1791 Installation........................................................................................................................1791 Rear Wiper Motor........................................................................................................................1792 Removal.............................................................................................................................1792 Installation........................................................................................................................1792 Alarm & Relay Control Unit..............................................................................................................1793 Removal.............................................................................................................................1793 Installation........................................................................................................................1793 Rear Washer Motor.......................................................................................................................1793 Removal.............................................................................................................................1793 Installation........................................................................................................................1793 Rear Wiper Arm/Blade....................................................................................................................1794 Removal.............................................................................................................................1794 Installation........................................................................................................................1794 Rear Washer Nozzle......................................................................................................................1794 Removal.............................................................................................................................1794 Installation........................................................................................................................1794 Rear Washer Nozzle Angle Adjustment.................................................................................................1794 Rear Wiper Blade Rubber.................................................................................................................1795 Removal and Installation............................................................................................................1795 Main Data and Specifications............................................................................................................1795 8C ENTERTAINMENT..........................................................................................................................1796 Service Precaution......................................................................................................................1796 Cigarette Lighter.......................................................................................................................1797 General Description.................................................................................................................1797 Removal.............................................................................................................................1797 Installation........................................................................................................................1797 Digital Clock...........................................................................................................................1797 Removal.............................................................................................................................1797 Installation........................................................................................................................1798 Rod Type Antenna........................................................................................................................1798 Removal.............................................................................................................................1798 Installation........................................................................................................................1798 Diversity Glass Antenna.................................................................................................................1799 Glass Antenna System Parts Location.................................................................................................1799 Glass Antenna Pattern...............................................................................................................1800 Glass Antenna Amplifier Removal.....................................................................................................1800 Glass Antenna Amplifier Installation................................................................................................1800 Radio...................................................................................................................................1801 Removal.............................................................................................................................1801 Installation........................................................................................................................1801 Front Speaker...........................................................................................................................1802 Removal.............................................................................................................................1802 Installation........................................................................................................................1802 Tweeter Assembly........................................................................................................................1802 Removal.............................................................................................................................1802 Installation........................................................................................................................1802 Rear Speaker............................................................................................................................1803 Removal.............................................................................................................................1803 Installation........................................................................................................................1803 8D WIRING SYSTEM..........................................................................................................................1804 Fuse, Relay and Diode...................................................................................................................1805 Relay and Fuse Box / Fuse Box Location..............................................................................................1805 Relay & Fuse Box....................................................................................................................1806 Fuse Box............................................................................................................................1807 Circuit Diagram.........................................................................................................................1808 8E METER AND GAUGE........................................................................................................................1841 Service Precaution......................................................................................................................1841 General Description.....................................................................................................................1841 Meter Assembly..........................................................................................................................1842 General Description.................................................................................................................1842 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................1842 Table for Meter/Gauge Connector Terminal Connections................................................................................1846 Removal.............................................................................................................................1850 Installation........................................................................................................................1850 Warning Light Bulb, Indicator Light Bulb, Illumination Light Bulb, A/T Indicator Light Bulb.............................................1850 Removal.............................................................................................................................1850 Installation........................................................................................................................1850 Vehicle Speed Sensor....................................................................................................................1851 Removal.............................................................................................................................1851 Installation........................................................................................................................1851 Fuel Tank Unit..........................................................................................................................1851 Removal.............................................................................................................................1851 Installation........................................................................................................................1851 Multi Meter.............................................................................................................................1852 Removal.............................................................................................................................1852 Installation........................................................................................................................1852 Ambient Sensor..........................................................................................................................1852 Removal.............................................................................................................................1852 Installation........................................................................................................................1852 Main Data and Specifications............................................................................................................1853 8F BODY STRUCTURE.........................................................................................................................1854 Service Precaution......................................................................................................................1856 Frame...................................................................................................................................1856 General Description.................................................................................................................1856 Frame Dimensions....................................................................................................................1857 General Description.....................................................................................................................1858 Front Bumper............................................................................................................................1858 Parts Location......................................................................................................................1858 Removal.............................................................................................................................1859 Installation........................................................................................................................1859 Front Bumper Slider Bracket.............................................................................................................1859 Removal.............................................................................................................................1859 Installation........................................................................................................................1859 Rear Bumper.............................................................................................................................1860 Parts Location......................................................................................................................1860 Removal.............................................................................................................................1860 Installation........................................................................................................................1861 Rear Bumper Slider......................................................................................................................1862 Removal.............................................................................................................................1862 Installation........................................................................................................................1862 General Description.....................................................................................................................1863 Cowl Cover..............................................................................................................................1863 Parts Location......................................................................................................................1863 Removal.............................................................................................................................1863 Installation........................................................................................................................1864 Engine Hood.............................................................................................................................1864 Removal.............................................................................................................................1864 Installation........................................................................................................................1864 Engine Hood Hinge.......................................................................................................................1865 Parts Location......................................................................................................................1865 Removal.............................................................................................................................1865 Installation........................................................................................................................1865 Engine Hood Lock........................................................................................................................1866 Parts Location......................................................................................................................1866 Removal.............................................................................................................................1866 Installation........................................................................................................................1867 Radiator Grille And Front End Lower Panel...............................................................................................1867 Parts Location......................................................................................................................1867 Removal.............................................................................................................................1867 Installation........................................................................................................................1868 Front Fender Panel......................................................................................................................1869 Parts Location......................................................................................................................1869 Removal.............................................................................................................................1869 Installation........................................................................................................................1870 Body Mounting...........................................................................................................................1871 Parts Location......................................................................................................................1871 Removal (No.1 - No. 2)..............................................................................................................1871 Removal (No. 3 - No. 6).............................................................................................................1872 Installation........................................................................................................................1873 General Description.....................................................................................................................1874 Body Dimension..........................................................................................................................1875 Instrument Panel Assembly...............................................................................................................1893 Parts Location......................................................................................................................1893 Removal.............................................................................................................................1893 Installation........................................................................................................................1898 Cross Beam Assembly.....................................................................................................................1899 Parts Location......................................................................................................................1899 Removal.............................................................................................................................1899 Installation........................................................................................................................1900 Front Door Assembly.....................................................................................................................1901 Parts Location......................................................................................................................1901 Removal.............................................................................................................................1901 Installation........................................................................................................................1901 Rear Door Assembly......................................................................................................................1902 Parts Location......................................................................................................................1902 Removal.............................................................................................................................1902 Installation........................................................................................................................1903 Door Strikers...........................................................................................................................1903 Adjustment..........................................................................................................................1903 Door Check Arm Assembly (Front & Rear)..................................................................................................1904 Parts Location......................................................................................................................1904 Removal.............................................................................................................................1904 Installation........................................................................................................................1905 Front Window Regulator, Glass And Glass Run.............................................................................................1905 Parts Location......................................................................................................................1905 Removal.............................................................................................................................1905 Installation........................................................................................................................1907 Rear Window Regulator And Glass.........................................................................................................1908 Parts Location......................................................................................................................1908 Removal.............................................................................................................................1908 Installation........................................................................................................................1909 Rear Door Fixed Glass And Glass Run.....................................................................................................1910 Parts Location......................................................................................................................1910 Removal.............................................................................................................................1910 Installation........................................................................................................................1911 Front Door Sash Moulding................................................................................................................1912 Parts Location......................................................................................................................1912 Removal.............................................................................................................................1912 Installation........................................................................................................................1912 Rear Door Moulding......................................................................................................................1913 Parts Location......................................................................................................................1913 Removal.............................................................................................................................1913 Installation........................................................................................................................1913 Front Door Waist Seal...................................................................................................................1914 Parts Location......................................................................................................................1914 Removal.............................................................................................................................1914 Installation........................................................................................................................1914 Rear Door Waist Seal....................................................................................................................1915 Parts Location......................................................................................................................1915 Removal and Installation............................................................................................................1915 Front Door Weatherstrip.................................................................................................................1916 Parts Location......................................................................................................................1916 Removal.............................................................................................................................1916 Installation........................................................................................................................1917 Rear Door Weatherstrip..................................................................................................................1918 Parts Location......................................................................................................................1918 Removal and Installation............................................................................................................1918 Front Door Seal Finisher................................................................................................................1919 Parts Location......................................................................................................................1919 Removal.............................................................................................................................1919 Installation........................................................................................................................1919 Rear Door Seal Finisher.................................................................................................................1920 Parts Location......................................................................................................................1920 Removal.............................................................................................................................1920 Installation........................................................................................................................1920 Tailgate Assembly (LH)..................................................................................................................1921 Parts Location......................................................................................................................1921 Removal.............................................................................................................................1921 Installation........................................................................................................................1922 Tailgate Assembly (RH)..................................................................................................................1923 Parts Location......................................................................................................................1923 Removal.............................................................................................................................1923 Installation........................................................................................................................1924 Tailgate Strikers.......................................................................................................................1925 Adjustment..........................................................................................................................1925 Tailgate Stopper Assembly...............................................................................................................1925 Parts Location......................................................................................................................1925 Removal.............................................................................................................................1925 Installation........................................................................................................................1925 Tailgate Dove-Tail......................................................................................................................1926 Parts Location......................................................................................................................1926 Removal.............................................................................................................................1926 Installation........................................................................................................................1926 Tailgate Dove-Tail Striker..............................................................................................................1927 Adjustment..........................................................................................................................1927 Tailgate Frame Cover (LH)...............................................................................................................1928 Parts Location......................................................................................................................1928 Removal.............................................................................................................................1928 Installation........................................................................................................................1928 Tailgate Frame Cover (RH)...............................................................................................................1929 Removal.............................................................................................................................1929 Installation........................................................................................................................1929 Tailgate Sash Trim Cover................................................................................................................1930 Parts Location......................................................................................................................1930 Removal.............................................................................................................................1930 Installation........................................................................................................................1930 Tailgate Outer Weatherstrip.............................................................................................................1931 Parts Location......................................................................................................................1931 Removal.............................................................................................................................1931 Installation........................................................................................................................1931 Tailgate Center Weatherstrip............................................................................................................1932 Parts Location......................................................................................................................1932 Removal.............................................................................................................................1932 Installation........................................................................................................................1932 Tailgate Main Weatherstrip..............................................................................................................1933 Parts Location......................................................................................................................1933 Removal.............................................................................................................................1933 Installation........................................................................................................................1933 Spare Tire Carrier......................................................................................................................1934 Parts Location......................................................................................................................1934 Removal.............................................................................................................................1934 Installation........................................................................................................................1934 Headlining..............................................................................................................................1935 Parts Location......................................................................................................................1935 Removal.............................................................................................................................1935 Installation........................................................................................................................1936 Rear Air Deflector......................................................................................................................1937 Parts Location......................................................................................................................1937 Removal.............................................................................................................................1937 Installation........................................................................................................................1937 Roof Moulding...........................................................................................................................1939 Parts Location......................................................................................................................1939 Removal.............................................................................................................................1939 Installation........................................................................................................................1939 Windshield..............................................................................................................................1941 Parts Location......................................................................................................................1941 Removal.............................................................................................................................1941 Installation........................................................................................................................1942 Rear Quarter Side Glass.................................................................................................................1946 Parts Location......................................................................................................................1946 Removal.............................................................................................................................1946 Installation........................................................................................................................1946 Tailgate Glass..........................................................................................................................1948 Parts Location......................................................................................................................1948 Removal.............................................................................................................................1948 Installation........................................................................................................................1949 Main Data and Specifications............................................................................................................1950 Special Tools...........................................................................................................................1960 8G SEATS..................................................................................................................................1961 Service Precaution......................................................................................................................1961 Front Seat Assembly.....................................................................................................................1962 Front Seat Assembly and Associated Parts............................................................................................1962 Removal.............................................................................................................................1962 Installation........................................................................................................................1962 Disassembled View...................................................................................................................1963 Disassembly.........................................................................................................................1964 Reassembly..........................................................................................................................1965 Power Seat Assembly.....................................................................................................................1966 General Description.................................................................................................................1966 Disassembled View...................................................................................................................1966 Disassembly.........................................................................................................................1967 Reassembly..........................................................................................................................1969 Power Seat Switch.......................................................................................................................1969 Removal.............................................................................................................................1969 Installation........................................................................................................................1969 Front Tilt Motor / Rear Tilt Motor / Slide Motor / Recliner Motor.......................................................................1970 Parts Location......................................................................................................................1970 Removal and Installation............................................................................................................1970 Seat Heater System......................................................................................................................1971 General Description.................................................................................................................1971 Seat Heater Switch Removal and Installation.........................................................................................1971 Heat Unit Parts Location............................................................................................................1971 Heat Unit Removal and Installation..................................................................................................1971 Rear Seat Assembly......................................................................................................................1972 Rear Seat Assembly and Associated Parts.............................................................................................1972 Removal.............................................................................................................................1972 Installation........................................................................................................................1972 Disassembled View (Split Type)......................................................................................................1973 Disassembly (Split Type)............................................................................................................1974 Reassembly (Split Type).............................................................................................................1975 Disassembled View (Bench Type)......................................................................................................1976 Disassembly (Bench Type)............................................................................................................1977 Reassembly (Bench Type).............................................................................................................1978 Rear Seat Foot Rest.....................................................................................................................1978 Rear Seat Foot Rest and Associated Parts............................................................................................1978 Removal.............................................................................................................................1979 Installation........................................................................................................................1979 Main Data and Specifications............................................................................................................1979 8H SECURITY AND LOCKS.....................................................................................................................1981 Service Precaution......................................................................................................................1982 Front Door Lock Assembly................................................................................................................1982 Front Door Lock Assembly and Associated Parts.......................................................................................1982 Removal.............................................................................................................................1982 Installation........................................................................................................................1983 Front Outside Handle and Door Lock Cylinder.............................................................................................1984 Front Outside Handle, Door Lock Cylinder and Associated Parts.......................................................................1984 Removal.............................................................................................................................1984 Installation........................................................................................................................1986 Rear Door Lock Assembly.................................................................................................................1987 Rear Door Lock Assembly and Associated Parts........................................................................................1987 Removal.............................................................................................................................1987 Installation........................................................................................................................1988 Rear Outside Handle.....................................................................................................................1989 Rear Outside Handle and Associated Parts............................................................................................1989 Removal.............................................................................................................................1989 Installation........................................................................................................................1990 Rear Door Inside Lock Knob Link.........................................................................................................1990 Removal.............................................................................................................................1990 Installation........................................................................................................................1990 Door Inside Lock Knob...................................................................................................................1991 Removal.............................................................................................................................1991 Installation........................................................................................................................1991 Door Inside Handle......................................................................................................................1991 Removal and Installation............................................................................................................1991 Tailgate Lock Assembly (LH).............................................................................................................1992 Tailgate Lock Assembly (LH) and Associated Parts....................................................................................1992 Removal.............................................................................................................................1992 Installation........................................................................................................................1993 Tailgate Lock Assembly (RH).............................................................................................................1994 Tailgate Lock Assembly (RH) and Associated Parts....................................................................................1994 Removal.............................................................................................................................1994 Installation........................................................................................................................1995 Tailgate Inside Lock Knob...............................................................................................................1996 Removal.............................................................................................................................1996 Installation........................................................................................................................1996 Tailgate Outside Handle and/or Tailgate Lock Cylinder...................................................................................1997 Tailgate Outside Handle and/or Tailgate Lock Cylinder and Associated Parts..........................................................1997 Removal.............................................................................................................................1997 Installation........................................................................................................................1998 Key.....................................................................................................................................1999 Key Coding..........................................................................................................................1999 Key Styles..........................................................................................................................1999 Power Door Lock System..................................................................................................................2000 General Description.................................................................................................................2000 Front Door Lock Actuator Removal....................................................................................................2000 Front Door Lock Actuator Installation...............................................................................................2000 Rear Door Lock Actuator Removal.....................................................................................................2000 Rear Door Lock Actuator Installation................................................................................................2001 Tailgate Lock Actuator Removal......................................................................................................2001 Tailgate Lock Actuator Installation.................................................................................................2001 Anti-theft System.......................................................................................................................2002 General Description.................................................................................................................2002 Anti-theft & Keyless Entry Control Unit Removal.....................................................................................2002 Anti-theft & Keyless Entry Control Unit Installation................................................................................2002 Anti-theft Indicator Removal........................................................................................................2002 Anti-theft Indicator Installation...................................................................................................2003 Anti-theft Horn Removal.............................................................................................................2003 Anti-Theft Horn Installation........................................................................................................2003 Engine Hood Switch Removal..........................................................................................................2003 Engine Hood Switch Installation.....................................................................................................2003 Keyless Entry System....................................................................................................................2004 ID Code Registration................................................................................................................2004 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................2006 Main Data and Specifications............................................................................................................2007 8I SUN ROOF/CONVERTIBLE TOP..............................................................................................................2008 Service Precaution......................................................................................................................2008 Sun Roof Glass..........................................................................................................................2009 Sun Roof Glass and Associated Parts.................................................................................................2009 Removal.............................................................................................................................2009 Installation........................................................................................................................2010 Sun Roof Deflector......................................................................................................................2011 Removal.............................................................................................................................2011 Installation........................................................................................................................2011 Sunshade................................................................................................................................2011 Disassembled View...................................................................................................................2011 Removal.............................................................................................................................2012 Installation........................................................................................................................2012 Sun Roof Frame Complete Assembly........................................................................................................2013 Sun Roof Frame Complete Assembly and Associated Parts...............................................................................2013 Removal.............................................................................................................................2013 Installation........................................................................................................................2014 Disassembled View...................................................................................................................2014 Disassembly.........................................................................................................................2014 Reassembly..........................................................................................................................2015 Sun Roof Drain Hose (Front Side)........................................................................................................2016 Sun Roof Drain Hose (Front Side) and Associated Parts...............................................................................2016 Removal.............................................................................................................................2016 Installation........................................................................................................................2016 Sun Roof Drain Hose (Rear Side).........................................................................................................2017 Sun Roof Drain Hose (Rear Side) and Associated Parts................................................................................2017 Removal.............................................................................................................................2017 Installation........................................................................................................................2017 Sun Roof Switch.........................................................................................................................2018 General Description.................................................................................................................2018 Removal.............................................................................................................................2018 Installation........................................................................................................................2018 Sun Roof Motor..........................................................................................................................2019 Removal.............................................................................................................................2019 Installation........................................................................................................................2019 Main Data and Specifications............................................................................................................2020 8J EXTERIOR / INTERIOR TRIM...............................................................................................................2021 Service Precaution......................................................................................................................2022 Dash Side Trim Panel....................................................................................................................2023 Removal.............................................................................................................................2023 Installation........................................................................................................................2023 Assist Grip.............................................................................................................................2023 Parts Location......................................................................................................................2023 Removal and Installation............................................................................................................2023 Consoles................................................................................................................................2024 Consoles and Associated Parts.......................................................................................................2024 Removal.............................................................................................................................2024 Installation........................................................................................................................2025 Front Door Trim Panel...................................................................................................................2026 Front Door Trim Panel and Associated Parts..........................................................................................2026 Removal.............................................................................................................................2026 Installation........................................................................................................................2029 Rear Door Trim Panel....................................................................................................................2030 Rear Door Trim Panel and Associated Parts...........................................................................................2030 Removal.............................................................................................................................2030 Installation........................................................................................................................2031 Door Wood Panel Assembly................................................................................................................2033 Door Wood Panel Assembly and Associated Parts.......................................................................................2033 Removal.............................................................................................................................2033 Installation........................................................................................................................2033 Door Mirror.............................................................................................................................2034 Door Mirror and Associated Parts....................................................................................................2034 Removal.............................................................................................................................2034 Installation........................................................................................................................2034 Luggage Side and Quarter Upper Trim Cover...............................................................................................2035 Luggage Side, Quarter Upper Trim Cover and Associated Parts.........................................................................2035 Removal.............................................................................................................................2035 Installation........................................................................................................................2037 Center Pillar and Roof Side Trim Cover..................................................................................................2037 Center Pillar, Roof Side Trim Cover and Associated Parts............................................................................2037 Removal.............................................................................................................................2038 Installation........................................................................................................................2039 Front Pillar Trim Cover.................................................................................................................2039 Front Pillar Trim Cover and Associated Parts........................................................................................2039 Removal.............................................................................................................................2039 Installation........................................................................................................................2040 Center Pillar Assist Grip...............................................................................................................2040 Parts Location......................................................................................................................2040 Removal and Installation............................................................................................................2040 Assist Grip.............................................................................................................................2041 Parts Location......................................................................................................................2041 Removal and Installation............................................................................................................2041 Fuel Filler Lid Opener Cable............................................................................................................2042 Fuel Filler Lid Opener Cable and Associated Parts...................................................................................2042 Removal.............................................................................................................................2042 Installation........................................................................................................................2043 Fuel Filler Door........................................................................................................................2043 Parts Location......................................................................................................................2043 Removal.............................................................................................................................2043 Installation........................................................................................................................2043 Rocker Protector (Without Wheel Opening Extension)......................................................................................2044 Rocker Protector (Without Wheel Opening Extension) and Associated Parts.............................................................2044 Removal.............................................................................................................................2044 Installation........................................................................................................................2044 Wheel Opening Extension and Rocker Protector Assembly...................................................................................2045 Wheel Opening Extension, Rocker Protector Assembly and Associated Parts.............................................................2045 Removal.............................................................................................................................2045 Installation........................................................................................................................2046 Mud Flaps (With Wheel Opening Extension)................................................................................................2047 Mud Flaps (With Wheel Opening Extension) and Associated Parts.......................................................................2047 Removal.............................................................................................................................2047 Installation........................................................................................................................2047 Ventilation Assembly....................................................................................................................2048 Ventilation Assembly and Associated Parts...........................................................................................2048 Removal.............................................................................................................................2048 Installation........................................................................................................................2048 Tailgate Trim Panel (LH)................................................................................................................2049 Tailgate Trim Panel (LH) and Associated Parts.......................................................................................2049 Removal.............................................................................................................................2049 Installation........................................................................................................................2049 Tailgate Trim Panel (RH)................................................................................................................2050 Parts Location......................................................................................................................2050 Removal.............................................................................................................................2050 Installation........................................................................................................................2050 Luggage Floor Box.......................................................................................................................2051 Luggage Floor Box and Associated Parts..............................................................................................2051 Remove..............................................................................................................................2051 Installation........................................................................................................................2051 Rope Hook Set...........................................................................................................................2051 Rope Hook Set and Associated Parts..................................................................................................2051 Removal.............................................................................................................................2051 Installation........................................................................................................................2051 Power Door Mirror System................................................................................................................2052 General Description.................................................................................................................2052 Door Mirror Switch Assembly (Control Switch, Folding Switch and Defogger Switch) Removal............................................2052 Installation........................................................................................................................2052 Power Door Mirror.......................................................................................................................2052 General Description.................................................................................................................2052 Removal and Installation............................................................................................................2052 Power Window System.....................................................................................................................2053 General Description.................................................................................................................2053 Power Window Switch Removal and Installation........................................................................................2053 Power Window Motor Removal and Installation.........................................................................................2054 Main Data and Specifications............................................................................................................2055 Section.9 RESTRAINTS.........................................................................................................................2056 9A SEAT BELT SYSTEM......................................................................................................................2056 Service Precaution......................................................................................................................2056 Seat Belt...............................................................................................................................2057 Front Seat Belt and Associated Parts................................................................................................2057 Removal.............................................................................................................................2057 Inspection..........................................................................................................................2057 Installation........................................................................................................................2058 Rear Seat Belt and Associated Parts.................................................................................................2058 Removal.............................................................................................................................2059 Inspection..........................................................................................................................2059 Installation........................................................................................................................2059 Front Seat Buckle Assembly..............................................................................................................2059 Removal.............................................................................................................................2059 Installation........................................................................................................................2059 Rear Center Seat Belt / Buckle Assembly.................................................................................................2060 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................2060 Removal.............................................................................................................................2060 Installation........................................................................................................................2060 Rear Seat Lock Assembly.................................................................................................................2061 Removal.............................................................................................................................2061 Installation........................................................................................................................2061 Rear Seat Lock Assembly (Bench Type)....................................................................................................2061 Removal.............................................................................................................................2061 Installation........................................................................................................................2061 Rear Seat Strikers......................................................................................................................2062 Removal.............................................................................................................................2062 Installation........................................................................................................................2062 Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................2062 General Description.................................................................................................................2062 Child Seat Tether Anchor Bracket and Associated Parts...............................................................................2062 Installation........................................................................................................................2062 Main Data and Specifications............................................................................................................2063 9J SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................2064 Service Precaution......................................................................................................................2064 General Description.....................................................................................................................2065 SRS Component And Wiring Location View..................................................................................................2067 Component Description...................................................................................................................2067 Definitions.............................................................................................................................2070 Diagnosis...............................................................................................................................2071 SRS Connector Body Face Views...........................................................................................................2072 Repairs And Inspections Required After An Accident......................................................................................2072 On-Vehicle Service......................................................................................................................2073 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................2074 Special Tools...........................................................................................................................2083 Service Precautions for SRS Component Service...........................................................................................2087 SRS Connectors..........................................................................................................................2088 Sensing And Diagnostic Module (SDM).....................................................................................................2090 Service Precautions.................................................................................................................2090 Removal.............................................................................................................................2090 Installation........................................................................................................................2090 Driver Air Bag Assembly.................................................................................................................2092 Service Precautions.................................................................................................................2092 Removal.............................................................................................................................2092 Installation........................................................................................................................2093 Steering Wheel..........................................................................................................................2094 Service Precautions.................................................................................................................2094 Removal.............................................................................................................................2094 Installation........................................................................................................................2095 SRS Coil Assembly.......................................................................................................................2097 Service Precautions.................................................................................................................2097 Removal.............................................................................................................................2097 Installation........................................................................................................................2098 Steering Column.........................................................................................................................2100 Service Precautions.................................................................................................................2100 Removal.............................................................................................................................2100 Installation........................................................................................................................2102 Passenger Air Bag Assembly..............................................................................................................2104 Service Precautions.................................................................................................................2104 Removal.............................................................................................................................2104 Installation........................................................................................................................2105 Main Data and Specifications............................................................................................................2105 9J1 RESTRAINT CONTROL SYSTEM...............................................................................................................2106 Service Precaution......................................................................................................................2106 Diagnostic Information..................................................................................................................2107 System Schematic........................................................................................................................2109 SRS Diagnostic System Check.............................................................................................................2109 Chart A SDM Integrity Check.............................................................................................................2111 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................2113 Chart C "AIR BAG" Warning Lamp Does Not Come "ON" Steady (1/2)..........................................................................2115 DTC 15 Passenger Deployment Loop Resistance High........................................................................................2118 DTC 16 Passenger Deployment loop Resistance Low.........................................................................................2120 DTC 17 Passenger Deployment Loop Open...................................................................................................2122 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................2124 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................2126 DTC 21 Driver Deployment Loop Resistance High...........................................................................................2128 DTC 22 Driver Deployment Loop Resistance Low............................................................................................2131 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................2133 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................2135 DTC 26 Driver Deployment Loop Open......................................................................................................2137 DTC 51 Deployment Event Commanded.......................................................................................................2139 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................2141 DTC 61 Warning Lamp Circuit Failure.....................................................................................................2143 DTC 71 Internal SDM Fault...............................................................................................................2145 Section.10 CONTROL SYSTEM.....................................................................................................................2147 10A CRUISE CONTROL SYSTEM.................................................................................................................2147 Service Precaution......................................................................................................................2147 General Description.....................................................................................................................2147 Brake Switch............................................................................................................................2148 Removal.............................................................................................................................2148 Installation........................................................................................................................2148 Adjustment..........................................................................................................................2149 Clutch Switch...........................................................................................................................2149 Removal and Installation............................................................................................................2149 Adjustment..........................................................................................................................2149 Starter Switch..........................................................................................................................2150 Removal.............................................................................................................................2150 Installation........................................................................................................................2150 Cruise Control Main Switch..............................................................................................................2151 Removal.............................................................................................................................2151 Installation........................................................................................................................2151 Cruise Control Switch (Combination Switch)..............................................................................................2151 Removal and Installation............................................................................................................2151 Powertrain Control Module (PCM).........................................................................................................2151 Removal and Installation............................................................................................................2151 Mode Switch.............................................................................................................................2151 Removal and Installation............................................................................................................2151 Diagnosis...............................................................................................................................2152 RODEO...............................................................................................................................................2153 Section.0 GENERAL INFORMATION................................................................................................................2155 0A General Information....................................................................................................................2155 General Repair Instruction..............................................................................................................2155 Illustration Arrows.....................................................................................................................2156 Identification..........................................................................................................................2157 Theft Prevention Standard...............................................................................................................2160 Lifting Instructions....................................................................................................................2165 Standard Bolts Torque Specifications....................................................................................................2167 Abbreviations Charts....................................................................................................................2168 Service Parts Identification Plate......................................................................................................2169 0B Maintenance and Lubrication............................................................................................................2170 Maintenance Schedule List...............................................................................................................2170 Explanation of Complete Vehicle Maintenance Schedule....................................................................................2174 Recommended Fluids and Lubricants...................................................................................................2177 Lubricant Viscosity Chart...............................................................................................................2178 Recommended Liquid Gasket...........................................................................................................2180 Recommended Thread Locking Agents...................................................................................................2180 Maintenance Service Data................................................................................................................2181 Section.1 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)...................................................................................2182 1A HVAC SYSTEMS...........................................................................................................................2182 Service Precaution......................................................................................................................2183 Heating and Ventilation System..........................................................................................................2183 General Description.................................................................................................................2183 Wiring Diagram......................................................................................................................2187 Diagnosis...........................................................................................................................2188 Individual Inspection...............................................................................................................2192 Heater Unit.............................................................................................................................2194 Heater Unit and Associated Parts....................................................................................................2194 Removal.............................................................................................................................2194 Installation........................................................................................................................2195 Heater Core and / or Mode Door..........................................................................................................2195 Disassembled View...................................................................................................................2195 Removal.............................................................................................................................2195 Inspection..........................................................................................................................2196 Installation........................................................................................................................2196 Heater Mode Control Link Unit...........................................................................................................2197 Disassembled View...................................................................................................................2197 Removal.............................................................................................................................2197 Installation........................................................................................................................2198 Heater Temperature Control Link Unit....................................................................................................2198 Disassembled View...................................................................................................................2198 Removal.............................................................................................................................2198 Installation........................................................................................................................2199 Blower Assembly.........................................................................................................................2199 Blower Assembly and Associated Parts................................................................................................2199 Removal.............................................................................................................................2199 Installation........................................................................................................................2200 Blower Link Unit and / or Mode door.....................................................................................................2200 Disassembled View...................................................................................................................2200 Removal.............................................................................................................................2200 Installation........................................................................................................................2201 Blower Motor............................................................................................................................2202 Blower Motor and Associated Parts...................................................................................................2202 Removal.............................................................................................................................2202 Installation........................................................................................................................2202 Rear Heater Duct, Defroster Nozzle and Ventilation Duct.................................................................................2203 Rear Heater Duct, Defroster Nozzle, Ventilation Duct and Associated Parts...........................................................2203 Removal.............................................................................................................................2203 Installation........................................................................................................................2204 Control Lever Assembly and / or Control Cable...........................................................................................2204 Control Lever Assembly, Control Cable and Associated Parts..........................................................................2204 Removal.............................................................................................................................2205 Installation........................................................................................................................2206 Control Panel Illumination Bulb.........................................................................................................2207 Control Panel Illumination Bulb and Associated Parts................................................................................2207 Removal.............................................................................................................................2207 Installation........................................................................................................................2207 Resistor................................................................................................................................2207 Resistor and Associated Parts.......................................................................................................2207 Removal.............................................................................................................................2207 Installation........................................................................................................................2207 Air Conditioning System.................................................................................................................2208 General Description.................................................................................................................2208 Wiring Diagram......................................................................................................................2215 Diagnosis...........................................................................................................................2218 Air Source Select Lever Diagnosis...................................................................................................2228 Individual Inspection...............................................................................................................2231 General Repair Procedure............................................................................................................2232 Leak Check..........................................................................................................................2234 Compressor Assembly.....................................................................................................................2239 Compressor Assembly and Associated Parts............................................................................................2239 Removal.............................................................................................................................2239 Installation........................................................................................................................2240 New Compressor Installation.........................................................................................................2240 Condenser Assembly......................................................................................................................2241 Condenser Assembly and Associated Parts.............................................................................................2241 Removal.............................................................................................................................2241 Installation........................................................................................................................2241 Condenser Fan Motor.....................................................................................................................2242 Condenser Fan Motor and Associated Parts............................................................................................2242 Removal.............................................................................................................................2242 Installation........................................................................................................................2242 Receiver / Drier........................................................................................................................2243 Receiver / Drier and Associated Parts...............................................................................................2243 Removal.............................................................................................................................2243 Installation........................................................................................................................2243 Pressure Switch.........................................................................................................................2244 Pressure Switch and Associated Parts................................................................................................2244 Removal.............................................................................................................................2244 Installation........................................................................................................................2244 Evaporator Assembly.....................................................................................................................2245 Evaporator Assembly and Associated Parts............................................................................................2245 Removal.............................................................................................................................2245 Installation........................................................................................................................2246 Electronic Thermostat, Evaporator Core and/or Expansion Valve...........................................................................2246 Disassembled View...................................................................................................................2246 Removal.............................................................................................................................2247 Installation........................................................................................................................2247 Refrigerant Line........................................................................................................................2248 Refrigerant Line and Associated Parts...............................................................................................2248 Removal.............................................................................................................................2249 Installation........................................................................................................................2249 Main Data And Specifications............................................................................................................2249 Compressor..............................................................................................................................2252 Service Precaution..................................................................................................................2252 General Description.................................................................................................................2252 Diagnosis...........................................................................................................................2253 Magnetic Clutch Assembly (DKV-14G Type).................................................................................................2254 Parts Location View.................................................................................................................2254 Removal.............................................................................................................................2254 Inspection and Repair...............................................................................................................2256 Installation........................................................................................................................2256 Compressor Oil..........................................................................................................................2258 Oil Specification...................................................................................................................2258 Handling of Oil.....................................................................................................................2258 Compressor Oil Check................................................................................................................2258 Checking and Adjusting Oil Quantity for Used Compressor.............................................................................2258 Checking and Adjusting for Compressor Replacement...................................................................................2259 Contamination of Compressor Oil.....................................................................................................2259 Oil Return Operation................................................................................................................2259 Replacement of Component Parts......................................................................................................2259 Main Data and Specifications............................................................................................................2260 Special Tools...........................................................................................................................2262 Section.2 STEERING...........................................................................................................................2263 2A POWER-ASSISTED STEERING SYSTEM.........................................................................................................2263 Service Precaution......................................................................................................................2264 Diagnosis...............................................................................................................................2264 General Description.....................................................................................................................2270 Power Steering System Test..............................................................................................................2272 Maintenance.............................................................................................................................2273 Fluid Level.............................................................................................................................2273 Bleeding The Power Steering System......................................................................................................2273 Bleeding Procedure......................................................................................................................2273 Flushing The Power Steering System......................................................................................................2273 Steering Wheel Free Play Inspection.....................................................................................................2274 Front End Alignment Inspection and Adjustment...........................................................................................2274 Main Data and Specifications............................................................................................................2278 Special Tools...........................................................................................................................2279 Power Steering Unit.....................................................................................................................2280 Power Steering Unit and Associated Parts............................................................................................2280 Removal.............................................................................................................................2280 Installation (4 × 2 Model)..........................................................................................................2281 Installation (4 × 4 Model)..........................................................................................................2281 Power Steering Unit Disassembled View...............................................................................................2282 Disassembly.........................................................................................................................2282 Inspection and Repair...............................................................................................................2282 Reassembly..........................................................................................................................2282 Main Data and Specifications........................................................................................................2283 Special Tools.......................................................................................................................2283 Power Steering Pump.....................................................................................................................2284 Power Steering Pump and Associated Parts............................................................................................2284 Removal.............................................................................................................................2284 Installation........................................................................................................................2284 Power Steering Pump Disassembled View...............................................................................................2285 Disassembly.........................................................................................................................2285 Inspection and Repair...............................................................................................................2286 Reassembly..........................................................................................................................2286 Main Data and Specifications........................................................................................................2288 Transfer Gear Assembly..................................................................................................................2289 Transfer Gear Assembly and Associated Parts.........................................................................................2289 Removal.............................................................................................................................2289 Inspection and Repair...............................................................................................................2289 Installation........................................................................................................................2289 Supplemental Restraint System Steering Wheel & Column...................................................................................2290 Service Precaution..................................................................................................................2290 SRS Connectors......................................................................................................................2290 Inflator Module.........................................................................................................................2292 Inflator Module and Associated Parts................................................................................................2292 Removal.............................................................................................................................2292 Inspection and Repair...............................................................................................................2293 Installation........................................................................................................................2293 Steering Wheel..........................................................................................................................2294 Steering Wheel and Associated Parts.................................................................................................2294 Removal.............................................................................................................................2294 Installation........................................................................................................................2296 Combination Switch......................................................................................................................2297 Combination Switch and Associated Parts.............................................................................................2297 Removal.............................................................................................................................2297 Installation........................................................................................................................2299 Lock Cylinder...........................................................................................................................2301 Lock Cylinder and Associated Parts..................................................................................................2301 Removal.............................................................................................................................2301 System Inspection...................................................................................................................2304 Steering Column.........................................................................................................................2305 Steering Column and Associated Parts................................................................................................2305 Removal.............................................................................................................................2305 Insepction..........................................................................................................................2307 Installation........................................................................................................................2309 System Inspection...................................................................................................................2310 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................2311 Main Data and Specifications........................................................................................................2311 Special Tools.......................................................................................................................2311 Section.3 SUSPENSION.........................................................................................................................2312 3C FRONT SUSPENSION.......................................................................................................................2312 Service Precaution......................................................................................................................2312 General Description.....................................................................................................................2313 Diagnosis...............................................................................................................................2313 Shock Absorber..........................................................................................................................2316 Shock Absorber and Associated Parts.................................................................................................2316 Removal.............................................................................................................................2316 Inspection and Repair...............................................................................................................2316 Installation........................................................................................................................2316 Stabilizer Bar..........................................................................................................................2317 Stabilizer Bar and Associated Parts.................................................................................................2317 Removal.............................................................................................................................2317 Inspection and Repair...............................................................................................................2317 Installation........................................................................................................................2317 Torsion Bar.............................................................................................................................2318 Torsion Bar and Associated Parts....................................................................................................2318 Removal.............................................................................................................................2318 Inspection and Repair...............................................................................................................2319 Installation........................................................................................................................2319 Knuckle.................................................................................................................................2321 Knuckle and Associated Parts........................................................................................................2321 Removal.............................................................................................................................2321 Inspection and Repair...............................................................................................................2322 Installation........................................................................................................................2322 Upper Control Arm.......................................................................................................................2324 Upper Control Arm and Associated Parts..............................................................................................2324 Removal.............................................................................................................................2324 Inspection and Repair...............................................................................................................2325 Installation........................................................................................................................2325 Lower Control Arm.......................................................................................................................2327 Lower Control Arm and Associated Parts..............................................................................................2327 Removal.............................................................................................................................2327 Inspection and Repair...............................................................................................................2328 Installation........................................................................................................................2329 Upper Ball Joint........................................................................................................................2330 Upper Ball Joint and Associated Parts...............................................................................................2330 Removal.............................................................................................................................2330 Inspection and Repair...............................................................................................................2331 Installation........................................................................................................................2331 Lower Ball Joint........................................................................................................................2332 Lower Ball Joint and Associated Parts...............................................................................................2332 Removal.............................................................................................................................2332 Inspection and Repair...............................................................................................................2333 Installation........................................................................................................................2333 Main Data and Specifications............................................................................................................2334 Special Tools...........................................................................................................................2335 3D REAR SUSPENSION........................................................................................................................2336 Service Precaution......................................................................................................................2336 General Description.....................................................................................................................2336 Diagnosis...............................................................................................................................2337 Coil Spring.............................................................................................................................2340 Coil Spring and Associated Parts....................................................................................................2340 Removal.............................................................................................................................2340 Inspection and Repair...............................................................................................................2341 Installation........................................................................................................................2341 Shock Absorber..........................................................................................................................2342 Shock Absorber and Associated Parts.................................................................................................2342 Removal.............................................................................................................................2342 Inspection and Repair...............................................................................................................2342 Installation........................................................................................................................2342 Trailing Link...........................................................................................................................2343 Trailing Link and Associated Parts..................................................................................................2343 Removal.............................................................................................................................2343 Inspection and Repair...............................................................................................................2343 Installation........................................................................................................................2344 Upper Link..............................................................................................................................2345 Upper Link and Associated Parts.....................................................................................................2345 Removal.............................................................................................................................2345 Inspection and Repair...............................................................................................................2345 Installation........................................................................................................................2346 Lateral Rod.............................................................................................................................2347 Lateral Rod and Associated Parts....................................................................................................2347 Removal.............................................................................................................................2347 Inspection and Repair...............................................................................................................2347 Installation........................................................................................................................2348 Stabilizer Bar..........................................................................................................................2349 Stabilizer Bar and Associated Parts.................................................................................................2349 Removal.............................................................................................................................2349 Inspection and Repair...............................................................................................................2349 Installation........................................................................................................................2350 Main Data and Specifications............................................................................................................2351 Special Tools...........................................................................................................................2353 3E WHEEL AND TIRE SYSTEM..................................................................................................................2354 Service Precaution......................................................................................................................2354 General Description.....................................................................................................................2355 Diagnosis...............................................................................................................................2356 Wheel...................................................................................................................................2364 Wheel and Associated Parts..........................................................................................................2364 Removal.............................................................................................................................2364 Installation........................................................................................................................2364 Tire....................................................................................................................................2365 Tire Replacement....................................................................................................................2365 General Balance Procedure...............................................................................................................2365 Balancing Wheel and Tire................................................................................................................2366 Main Data and Specifications............................................................................................................2367 3F INTELLIGENT SUSPENSION SYSTEM..........................................................................................................2368 Service Precaution......................................................................................................................2369 General Description.....................................................................................................................2369 PIN ASSIGNMENT TABLE................................................................................................................2371 System Components...................................................................................................................2371 Control Unit........................................................................................................................2371 Actuator............................................................................................................................2371 Adjustable Damping Force Shock Absorber.............................................................................................2371 Warning Lamp........................................................................................................................2371 Vertical G-Sensor...................................................................................................................2372 Horizontal G-Sensor.................................................................................................................2372 Acronyms and Abbreviations..........................................................................................................2372 General Diagnosis.......................................................................................................................2372 General Information.................................................................................................................2372 Service Precautions.................................................................................................................2372 Computer System Service Precautions.................................................................................................2372 General Service Precautions.........................................................................................................2372 Parts Handling......................................................................................................................2372 FLASHING CODES......................................................................................................................2373 CLEAR DTC...........................................................................................................................2374 INTERMITTENT CONDITIONS.............................................................................................................2375 BULB CHECK..........................................................................................................................2375 DTC CHECK...........................................................................................................................2375 Basic Diagnosis Flow................................................................................................................2376 Circuit Diagram.....................................................................................................................2377 Parts Location......................................................................................................................2380 Connector List......................................................................................................................2381 Diagnostic Trouble Code (DTC) Identification........................................................................................2383 DTC2 Actuator Coil Over Current.........................................................................................................2384 Circuit Description.................................................................................................................2384 Diagnostic Aids.....................................................................................................................2384 DTC2 Actuator Coil Over Current.....................................................................................................2384 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................2386 Circuit Description.................................................................................................................2386 Diagnostic Aids.....................................................................................................................2386 DTC3 Actuator Coil/Position Sensor Open Circuit or Short............................................................................2386 DTC4 G-Sensor Open Circuit or Short.....................................................................................................2389 Circuit Description.................................................................................................................2389 Diagnostic Aids.....................................................................................................................2389 DTC4 G-Sensor Open Circuit or Short.................................................................................................2389 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................2390 Circuit Description.................................................................................................................2390 Diagnostic Aids.....................................................................................................................2390 DTC5 Vehicle Speed Sensor Open Circuit or Short.....................................................................................2391 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................2392 Circuit Description.................................................................................................................2392 Diagnostic Aids.....................................................................................................................2392 DTC6 Stop Lamp Switch Open Circuit or Short.........................................................................................2392 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................2394 Circuit Description.................................................................................................................2394 Diagnostic Aids.....................................................................................................................2394 DTC7 Engine Speed Signal Open Circuit or Short......................................................................................2394 DTC9 Control Unit Abnormality.......................................................................................................2395 DTC9-1 Control Unit Blown Fuse for FR Actuator......................................................................................2395 DTC9-2 Control Unit Blown Fuse for FL Actuator......................................................................................2396 DTC9-3 Control Unit Blown Fuse for RR Shock Absorber................................................................................2397 DTC9-4 Control Unit Blown Fuse for RL Shock Absorber................................................................................2398 Control Unit........................................................................................................................2399 Control Unit and Associated Parts...................................................................................................2399 Removal.............................................................................................................................2399 Installation........................................................................................................................2400 Front Actuator......................................................................................................................2401 Front Actuator and Associated Parts.................................................................................................2401 Removal.............................................................................................................................2402 View B..............................................................................................................................2402 Inspection and Repair...............................................................................................................2402 Installation........................................................................................................................2402 Rear Shock Absorber.................................................................................................................2403 Rear Shock Absorber and Associated Parts............................................................................................2403 Removal.............................................................................................................................2404 Inspection and Repair...............................................................................................................2404 Installation........................................................................................................................2404 Section.4 DRIVELINE/AXLE.....................................................................................................................2405 4A1 Differential (Front)..................................................................................................................2405 Service Precaution......................................................................................................................2405 Front Drive Axle........................................................................................................................2406 Diagnosis...............................................................................................................................2406 Pinion Shaft Oil Seal...................................................................................................................2407 Pinion Shaft Oil Seal and Associated Parts..........................................................................................2407 Removal.............................................................................................................................2407 Inspection and Repair...............................................................................................................2408 Installation........................................................................................................................2408 Front Drive Axle Assembly...............................................................................................................2409 Front Drive Axle Assembly and Associated Parts......................................................................................2409 Removal.............................................................................................................................2410 Installation........................................................................................................................2410 Differential Assembly...................................................................................................................2412 Disassembled View...................................................................................................................2412 Disassembly.........................................................................................................................2413 Reassembly..........................................................................................................................2415 Differential Cage Assembly..............................................................................................................2423 Disassembled View...................................................................................................................2423 Disassembly.........................................................................................................................2423 Inspection and Repair...............................................................................................................2424 Reassembly..........................................................................................................................2424 Main Data and Specifications............................................................................................................2426 Special Tools...........................................................................................................................2429 4A2 Differential (Rear)...................................................................................................................2431 Service Precaution......................................................................................................................2431 General Description.....................................................................................................................2432 Diagnosis...............................................................................................................................2433 Axle Housing............................................................................................................................2435 Axle Housing and Associated Parts...................................................................................................2435 Removal.............................................................................................................................2435 Installation........................................................................................................................2437 Axle Shaft, Oil Seal and Bearing........................................................................................................2437 Axle Shaft and Associated Parts.....................................................................................................2437 Removal.............................................................................................................................2438 Inspection..........................................................................................................................2438 Installation........................................................................................................................2438 Pinion Oil Seal.........................................................................................................................2440 Pinion Oil Seal and Associated Parts................................................................................................2440 Removal.............................................................................................................................2440 Inspection and Repair...............................................................................................................2441 Installation........................................................................................................................2441 Differential Assembly...................................................................................................................2443 Disassembled View...................................................................................................................2443 Inspecting the Axle Before Disassembly..............................................................................................2444 Disassembly.........................................................................................................................2444 Inspection and Repair...............................................................................................................2446 Reassembly..........................................................................................................................2446 Side Bearing Preload Adjustment.....................................................................................................2450 Pinion Installation.................................................................................................................2451 Determination of Backlash & Preload Shims...........................................................................................2452 Backlash Adjustment.................................................................................................................2453 Gear Tooth Pattern Check............................................................................................................2453 Adjustments Affecting Tooth Contact.................................................................................................2454 Differential Case Assembly..............................................................................................................2455 Disassembled View...................................................................................................................2455 Disassembly.........................................................................................................................2456 Inspection and Repair...............................................................................................................2456 Reassembly..........................................................................................................................2456 Limited Slip Differential Assembly......................................................................................................2457 Disassembled View...................................................................................................................2457 Disassembly.........................................................................................................................2457 Inspection and Repair...............................................................................................................2459 Reassembly..........................................................................................................................2459 Main Data And Specifications............................................................................................................2461 Special Tools...........................................................................................................................2463 4B DRIVELINE CONTROL SYSTEM..............................................................................................................2465 Service Precaution......................................................................................................................2465 Shift On The Fly System.................................................................................................................2466 Outline of Shift on The Fly System......................................................................................................2466 Functions of Indicator Lamp.............................................................................................................2470 Diagnosis...............................................................................................................................2471 Shift On The Fly Electrical Equipment...................................................................................................2481 Axle Shaft Connection and Disconnection.................................................................................................2481 4WD Control Unit........................................................................................................................2484 4WD Control Unit Associated Parts...................................................................................................2484 Removal.............................................................................................................................2484 Installation........................................................................................................................2485 Shift On The Fly Controller.............................................................................................................2486 Shift On The Fly Controller and Associated Parts....................................................................................2486 Removal.............................................................................................................................2486 Installation........................................................................................................................2486 4C DRIVE SHAFT SYSTEM....................................................................................................................2487 Service Precaution......................................................................................................................2487 General Description.....................................................................................................................2488 Diagnosis...............................................................................................................................2488 Front Hub and Disc (2WD Model)..........................................................................................................2489 Disassembled View...................................................................................................................2489 Disassembly.........................................................................................................................2489 Inspection and Repair...............................................................................................................2490 Reassembly..........................................................................................................................2491 Front Hub and Disc (4WD Model)..........................................................................................................2494 Disassembled View...................................................................................................................2494 Disassembly.........................................................................................................................2494 Inspection and Repair...............................................................................................................2495 Reassembly..........................................................................................................................2496 Front Drive Shaft Joint.................................................................................................................2499 Front Drive Shaft Joints Replacement................................................................................................2499 Front Axle Drive Shaft..................................................................................................................2500 Front Axle Drive Shaft and Associated Parts.........................................................................................2500 Disassembly.........................................................................................................................2501 Inspection And Repair...............................................................................................................2502 Bushing Replacement.................................................................................................................2502 Reassembly..........................................................................................................................2502 Shift On The Fly System.................................................................................................................2505 Shift On The Fly System and Associated Parts........................................................................................2505 Disassembly.........................................................................................................................2505 Inspection And Repair...............................................................................................................2507 Reassembly..........................................................................................................................2509 Main Data and Specifications........................................................................................................2512 Special Tools.......................................................................................................................2514 Propeller Shaft.........................................................................................................................2515 General Description.....................................................................................................................2515 Universal Joint.........................................................................................................................2516 Diagnosis of Propeller Shaft and Universal Joint........................................................................................2517 Front Propeller Shaft...................................................................................................................2518 Front Propeller Shaft and Associated Parts..........................................................................................2518 Removal.............................................................................................................................2518 Installation........................................................................................................................2518 Disassembly.........................................................................................................................2519 Universal Joint Disassembly.........................................................................................................2520 Inspection and Repair...............................................................................................................2521 Universal Joint Reassembly..........................................................................................................2522 Reassembly..........................................................................................................................2523 Main Data and Specifications........................................................................................................2524 Rear Propeller Shaft....................................................................................................................2525 Rear Propeller Shaft and Associated Parts...........................................................................................2525 Removal.............................................................................................................................2525 Installation........................................................................................................................2525 Slip Joint Disassembly..............................................................................................................2526 Universal Joint Disassembly.........................................................................................................2527 Inspection..........................................................................................................................2529 Universal Joint Reassembly..........................................................................................................2530 Slip Joint Reassembly...............................................................................................................2531 Main Data and Specifications........................................................................................................2532 4D TRANSFER CASE.........................................................................................................................2533 Service Precaution......................................................................................................................2533 General Description.....................................................................................................................2534 Transfer Rear Oil Seal..................................................................................................................2536 Transfer Rear Oil Seal and Associated Parts.........................................................................................2536 Removal.............................................................................................................................2536 Installation........................................................................................................................2536 Transfer Case Assembly (A/T)............................................................................................................2538 Transfer Case Assembly (A/T) and Associated Parts...................................................................................2538 Removal.............................................................................................................................2538 Installation........................................................................................................................2540 Transfer Rear Case Assembly (A/T).......................................................................................................2543 Transfer Rear Case Assembly (A/T) and Associated Parts..............................................................................2543 Removal.............................................................................................................................2543 Installation........................................................................................................................2545 Transfer Rear Cover Assembly........................................................................................................2548 Disassembly.........................................................................................................................2548 Inspection and Repair...............................................................................................................2549 Reassembly..........................................................................................................................2549 Detent, Shift Arm, and Interlock Pin (Transfer Case Assembly)...........................................................................2551 Disassembled View...................................................................................................................2551 Disassembly.........................................................................................................................2552 Inspection and Repair...............................................................................................................2553 Reassembly..........................................................................................................................2553 Transfer Case Assembly..................................................................................................................2555 Disassembled View...................................................................................................................2555 Disassembly.........................................................................................................................2556 Inspection and Repair...............................................................................................................2559 Reassembly..........................................................................................................................2562 Main Data and Specifications............................................................................................................2569 Special Tools...........................................................................................................................2572 Section.5 BRAKES.............................................................................................................................2573 5A Brake Control System..................................................................................................................2573 Service Precaution......................................................................................................................2574 General Description.....................................................................................................................2575 Functional Description..............................................................................................................2576 System Components...................................................................................................................2582 Electronic Hydraulic Control Unit (EHCU)............................................................................................2582 ABS Warning Light...................................................................................................................2582 Wheel Speed Sensor..................................................................................................................2582 G-Sensor............................................................................................................................2582 Normal and Anti-lock Braking........................................................................................................2582 Brake Pedal Travel..................................................................................................................2582 Acronyms and Abbreviations..........................................................................................................2582 General Diagnosis.......................................................................................................................2583 General Information.................................................................................................................2583 ABS Service Precautions.............................................................................................................2583 Computer System Service Precautions.................................................................................................2583 General Service Precautions.........................................................................................................2583 Note on Intermittents...............................................................................................................2583 Test Driving ABS Complaint Vehicles.................................................................................................2584 "ABS" Warning Light.................................................................................................................2584 Normal Operation....................................................................................................................2584 Tech 2 Scan Tool....................................................................................................................2585 DATA LIST...........................................................................................................................2588 ACTUATOR TEST.......................................................................................................................2589 Tech 2 Service Bleed................................................................................................................2593 Basic Diagnostic Flow Chart.........................................................................................................2594 Basic Inspection Procedure..........................................................................................................2595 EHCU Connector Pin-out Checks...........................................................................................................2596 Circuit Diagram.....................................................................................................................2597 Connector List......................................................................................................................2600 Part Location.......................................................................................................................2601 Symptom Diagnosis.......................................................................................................................2602 Chart A-1 ABS Works Frequently But Vehicle Does Not Decelerate......................................................................2602 Chart TA-1 ABS Works Frequently But Vehicle Does Not Decelerate (Use TECH 2)........................................................2603 Chart A-2 Uneven Braking Occurs While ABS Works.....................................................................................2603 Chart TA-2 Uneven Braking Occurs While ABS Works (Use TECH 2).......................................................................2603 Chart A-3, TA-3 The Wheels Are Locked...............................................................................................2604 Chart A-4 Brake Pedal Feed Is Abnormal..............................................................................................2605 Chart A-5, TA-5 Braking Sound (From EHCU) Is Heard While Not Braking................................................................2606 Diagnostic Trouble Codes................................................................................................................2607 Diagnosis By "ABS" Warning Light Illumination Pattern...................................................................................2609 Diagnostic Trouble Codes (DTCs).....................................................................................................2610 Chart B-1 With the key in the ON position (Before starting the engine). Warning light (W/L) is not activated........................2612 Chart B-2 CPU Error (DTC 14 (Flash out) / C0271, C0272, C0273, C0284 (Serial communications)).......................................2613 Chart B-3 Low or High Ignition Voltage (DTC 15 (Flash out) / C0277, 0278 (Serial communications))...................................2613 Chart B-4 Excessive Dump Time (DTC 17 (Flash out) / C0269 (Serial communications))..................................................2613 Chart B-5 Excessive Isolation Time (DTC 18 (Flash out) / C0274 (Serial communications)).............................................2614 Chart B-6 G-Sensor Output Failure (DTC 21 (Flash out) / C0276 (Serial communications))..............................................2614 Chart B-7 Brake Switch Failure (DTC 22 (Flash out) / C0281 (Serial communications)).................................................2614 Chart B-8 2WD Controller in 4WD Vehicle Controller (DTC 13 (Flash out) / C0285 (Serial communications)), 4WD State Input Signal ....2615 Chart B-9 Pump Motor Failure (DTC 32 (Flash out) / C0267, C0268 (Serial communications))............................................2615 Chart B-11 FL Isolation Solenoid Coil Failure (DTC 41 (Flash out) / C0245, C0247 (Serial communications))...........................2616 Chart B-12 FL Dump Solenoid Coil Failure (DTC 42 (Flash out) / C0246, C0248 (Serial communications))................................2616 Chart B-13 FR Isolation Solenoid Coil Failure (DTC 43 (Flash out) / C0241, C0243 (Serial communications))...........................2617 Chart B-14 FR Dump Solenoid Coil Failure (DTC 44(Flash out) / C0242, C0244 (Serial communications)).................................2617 Chart B-15 Rear Isolation Solenoid Coil Failure (DTC 45 (Flash out) / C0251, C0253 (Serial communications)).........................2617 Chart B-16 Rear Dump Solenoid Coil Failure (DTC 46 (Flash out) / C0252, C0254 (Serial communications))..............................2618 Chart B-17 FL Speed Sensor Open or Shorted (DTC 51 (Flash out) / C0225 (Serial communications)).....................................2618 Chart B-18 FR Speed Sensor Open or Shorted (DTC 52 (Flash out) / C0221 (Serial communications)).....................................2619 Chart B-19 Rear Speed Sensor Open or Shorted (DTC 53 (Flash out) / C0235 (Serial communications))...................................2620 Chart B-20 FL Speed Sensor Missing (DTC 61 (Flash out) / C0226, C0227 (Serial communications))......................................2621 Chart B-21 FR Speed Sensor Missing (DTC 62 (Flash out) / C0222, C0223 (Serial communications))......................................2622 Chart B-22 Rear Speed Sensor Missing (DTC 63 (Flash out) / C0236, C0237 (Serial communications))....................................2623 Chart B-23 Simultaneous Drop-out of Front Speed Sensor Signal (DTC 64 (Flash out) / C0229 (Serial communications))..................2624 Chart B-24 Wheel Speed Input Abnormality (DTC 65 (Flash out) / C0238 (Serial communications)).......................................2625 Unit Inspection Procedure...............................................................................................................2626 Chart C-1-1 FL Sensor Output Inspection Procedure...................................................................................2626 Chart C-1-2 FR Sensor Output Inspection Procedure...................................................................................2627 Chart C-1-3 Rear Sensor Output Inspection Procedure.................................................................................2627 Chart TC-1 Sensor Output Inspection Procedure.......................................................................................2628 Special Tools...........................................................................................................................2629 5B ANTI-LOCK BRAKE SYSTEM................................................................................................................2630 Service Precaution......................................................................................................................2630 Electronic Hydraulic Control Unit.......................................................................................................2631 Electronic Hydraulic Control Unit and Associated Parts..............................................................................2631 Removal.............................................................................................................................2631 Disassembled View...................................................................................................................2632 Disassembly.........................................................................................................................2632 Reassembly..........................................................................................................................2632 Installation........................................................................................................................2632 Front Wheel Speed Sensor................................................................................................................2633 Front Wheel Speed Sensor and Associated Parts.......................................................................................2633 Removal.............................................................................................................................2633 Inspection and Repair...............................................................................................................2633 Installation........................................................................................................................2633 Rear Wheel Speed Sensor.................................................................................................................2634 Removal.............................................................................................................................2634 Inspection and Repair...............................................................................................................2634 Installation........................................................................................................................2634 5C POWER-ASSISTED BRAKE SYSTEM...........................................................................................................2635 Service Precaution......................................................................................................................2636 General Description.....................................................................................................................2636 Diagnosis...............................................................................................................................2640 General Diagnosis.......................................................................................................................2641 Hydraulic Brakes........................................................................................................................2644 Filling Master Cylinder Reservoir...................................................................................................2644 Deterioration of Brake Fluid........................................................................................................2644 Leakage of Brake Fluid..............................................................................................................2644 Bleeding Brake Hydraulic System.....................................................................................................2644 Flushing Brake Hydraulic System.....................................................................................................2645 Brake Pipes and Hoses...............................................................................................................2645 Brake Hose Inspection...............................................................................................................2645 Front Caliper Brake Hose................................................................................................................2646 Front Caliper Brake Hose and Associated Parts.......................................................................................2646 Removal.............................................................................................................................2646 Installation........................................................................................................................2646 Rear Axle Brake Hose....................................................................................................................2647 Rear Axle Brake Hose and Associated Parts...........................................................................................2647 Removal.............................................................................................................................2647 Installation........................................................................................................................2647 Brake Pipe..............................................................................................................................2648 Removal.............................................................................................................................2648 Installation........................................................................................................................2648 P & B (Proportioning and Bypass) Valve..................................................................................................2649 P & B (Proportioning and Bypass) Valve Sectional View...............................................................................2649 Removal.............................................................................................................................2649 Installation........................................................................................................................2649 Main Data and Specifications............................................................................................................2650 Brake Pedal.............................................................................................................................2651 Checking Pedal Height...............................................................................................................2651 Checking Pedal Travel...............................................................................................................2651 Brake Pedal and Associated Parts....................................................................................................2652 Removal.............................................................................................................................2652 Installation........................................................................................................................2652 Stoplight Switch........................................................................................................................2653 Parts Location......................................................................................................................2653 Removal.............................................................................................................................2653 Installation........................................................................................................................2653 Main Data and Specifications............................................................................................................2654 Fluid Reservoir Tank....................................................................................................................2655 Fluid Reservoir Tank and Associated Parts...........................................................................................2655 Removal.............................................................................................................................2655 Installation........................................................................................................................2655 Master Cylinder Assembly................................................................................................................2656 Master Cylinder Assembly and Associated Parts.......................................................................................2656 Removal.............................................................................................................................2656 Inspection and Repair...............................................................................................................2656 Installation........................................................................................................................2657 Main Data and Specifications............................................................................................................2658 Special Tools...........................................................................................................................2658 Vacuum Booster Assembly.................................................................................................................2659 Vacuum Booster Assembly and Associated Parts........................................................................................2659 Removal.............................................................................................................................2659 Inspection and Repair...............................................................................................................2659 Installation........................................................................................................................2660 Exterior Components.....................................................................................................................2662 Exterior Components and Associated Parts............................................................................................2662 Removal.............................................................................................................................2662 Inspection and Repair...............................................................................................................2663 Installation........................................................................................................................2663 Vacuum Booster Overhaul.................................................................................................................2663 Vacuum Booster......................................................................................................................2663 Main Data and Specifications............................................................................................................2664 Special Tools...........................................................................................................................2665 Front Disc Brake Pads...................................................................................................................2666 Front Disc Brake Pads Inspection....................................................................................................2666 Front Disc Brake Pads and Associated Parts..........................................................................................2666 Removal.............................................................................................................................2667 Installation........................................................................................................................2667 Front Disc Brake Rotor..................................................................................................................2669 Inspection..........................................................................................................................2669 Replacing Brake Rotors..............................................................................................................2669 Refinishing Brake Rotors............................................................................................................2669 Front Disc Brake Caliper Assembly.......................................................................................................2670 Front Disc Brake Caliper Assembly and Associated Parts..............................................................................2670 Removal.............................................................................................................................2671 Installation........................................................................................................................2671 Front Disc Brake Caliper................................................................................................................2673 Front Disc Brake Caliper Disassembled View..........................................................................................2673 Disassembly.........................................................................................................................2673 Inspection and Repair...............................................................................................................2674 Reassembly..........................................................................................................................2674 Main Data and Specifications............................................................................................................2676 Rear Disc Brake Pads (4 × 4 Model)......................................................................................................2677 Brake Pads Inspection...............................................................................................................2677 Brake Pads and Associated Parts.....................................................................................................2677 Removal.............................................................................................................................2678 Installation........................................................................................................................2678 Rear Disc Brake Rotor (4 × 4 Model).....................................................................................................2680 Inspection..........................................................................................................................2680 Replacing Brake Rotors..............................................................................................................2680 Refinishing Brake Rotors............................................................................................................2680 Rear Drum (In Disc) Inside Diameter Check...........................................................................................2681 Rear Disc Brake Caliper Assembly (4 × 4 Model)..........................................................................................2682 Rear Disc Brake Caliper Assembly and Associated Parts...............................................................................2682 Removal.............................................................................................................................2682 Installation........................................................................................................................2683 Rear Disc Brake Caliper (4 × 4 Model)...................................................................................................2684 Rear Disc Brake Caliper Disassembled View...........................................................................................2684 Disassembly.........................................................................................................................2685 Inspection and Repair...............................................................................................................2685 Reassembly..........................................................................................................................2685 Main Data and Specifications (4 × 4 Model)..............................................................................................2687 Brake Lining............................................................................................................................2688 Brake Lining and Associated Parts...................................................................................................2688 Removal.............................................................................................................................2688 Brake Lining Inspection.............................................................................................................2689 Installation........................................................................................................................2689 Drum Brake Adjustment (4 × 2 Model).................................................................................................2690 Servicing The Brake Drum............................................................................................................2690 Wheel Cylinder Assembly (4 × 2 Model)...................................................................................................2691 Wheel Cylinder Assembly and Associated Parts........................................................................................2691 Removal.............................................................................................................................2691 Installation........................................................................................................................2691 Disassembled View...................................................................................................................2692 Disassembly.........................................................................................................................2692 Inspection and Repair...............................................................................................................2692 Reassembly..........................................................................................................................2692 Main Data and Specifications............................................................................................................2694 5D1 PARKING BRAKE SYSTEM (4ラ4 Model)......................................................................................................2695 Service Precaution......................................................................................................................2695 General Description.....................................................................................................................2695 Operation...............................................................................................................................2696 Parking Brake Lever and Front Cable.....................................................................................................2697 Parking Brake Lever Assembly and Associated Parts...................................................................................2697 Removal.............................................................................................................................2697 Installation........................................................................................................................2697 Parking Brake Rear Cable................................................................................................................2698 Parking Brake Rear Cable and Associated Parts.......................................................................................2698 Removal.............................................................................................................................2699 Installation........................................................................................................................2699 Inspection and Repair...............................................................................................................2700 Parking Brake Adjustment............................................................................................................2700 Main Data and Specifications............................................................................................................2701 5D2 PARKING BRAKE SYSTEM (4ラ2 Model)......................................................................................................2702 Service Precaution......................................................................................................................2702 General Description.....................................................................................................................2702 Parking Brake Lever.....................................................................................................................2703 Parking Brake Lever Assembly and Associated Parts...................................................................................2703 Removal.............................................................................................................................2703 Installation........................................................................................................................2703 Parking Brake Rear Cable................................................................................................................2704 Parking Brake Rear Cable and Associated Parts.......................................................................................2704 Removal.............................................................................................................................2705 Installation........................................................................................................................2705 Parking Brake Adjustment............................................................................................................2705 Main Data and Specifications............................................................................................................2706 Section.6 ENGINE.............................................................................................................................2707 6A ENGINE MECHANICAL (X22SE 2.2L).........................................................................................................2707 Service Precaution......................................................................................................................2708 General Description.....................................................................................................................2708 Engine Diagnosis........................................................................................................................2709 Cylinder Head Cover.....................................................................................................................2722 Removal.............................................................................................................................2722 Installation........................................................................................................................2723 Exhaust Manifold........................................................................................................................2724 Removal.............................................................................................................................2724 Installation........................................................................................................................2724 Crankshaft Pulley.......................................................................................................................2725 Removal.............................................................................................................................2725 Installation........................................................................................................................2725 Intake Manifold.........................................................................................................................2726 Removal.............................................................................................................................2726 Installation........................................................................................................................2727 Cylinder Head Assembly..................................................................................................................2728 Removal.............................................................................................................................2728 Installation........................................................................................................................2730 Timing Belt.............................................................................................................................2734 Removal.............................................................................................................................2734 Installation........................................................................................................................2735 Camshaft................................................................................................................................2738 Removal.............................................................................................................................2738 Installation........................................................................................................................2739 Engine Assembly.........................................................................................................................2741 Removal.............................................................................................................................2742 Installation........................................................................................................................2743 Cylinder Head...........................................................................................................................2745 Cylinder Head and Associated Parts..................................................................................................2745 Disassembly.........................................................................................................................2745 Inspection and Repair...............................................................................................................2746 Reassembly..........................................................................................................................2747 Valve Spring, Valve, Valve Guide........................................................................................................2748 Valve Spring, Valve, Valve Guide and Associated Parts...............................................................................2748 Disassembly.........................................................................................................................2748 Inspection and Repair...............................................................................................................2749 Reassembly..........................................................................................................................2750 Camshaft................................................................................................................................2751 Camshaft and Associated Parts.......................................................................................................2751 Disassembly.........................................................................................................................2751 Reassembly..........................................................................................................................2752 Crankshaft..............................................................................................................................2753 Crankshaft and Associated Parts.....................................................................................................2753 Disassembly.........................................................................................................................2753 Inspection and Repair...............................................................................................................2754 Inspection and Repair...............................................................................................................2755 Reassembly..........................................................................................................................2756 Piston and Connecting Rod...............................................................................................................2759 Piston, Connecting Rod and Associate Parts..........................................................................................2759 Disassembly.........................................................................................................................2759 Inspection and Repair...............................................................................................................2760 Reassembly..........................................................................................................................2762 Cylinder Block..........................................................................................................................2763 Cylinder Block and Associated Parts.................................................................................................2763 Disassembly.........................................................................................................................2764 Inspection and Repair...............................................................................................................2764 Reassembly..........................................................................................................................2765 Cylinder Head Cover.....................................................................................................................2766 Cylinder Head Cover and Associated parts............................................................................................2766 Removal.............................................................................................................................2767 Installation........................................................................................................................2767 Balance Unit Assembly...................................................................................................................2769 Balance Unit Assembly Associated Parts..............................................................................................2769 Disassembly.........................................................................................................................2770 Adjustment..........................................................................................................................2770 Reassembly..........................................................................................................................2772 Main Data and Specifications............................................................................................................2774 Special Tools...........................................................................................................................2779 6B ENGINE COOLING (X22SE 2.2L)............................................................................................................2780 Service Precaution......................................................................................................................2780 General Description.....................................................................................................................2781 Diagnosis...............................................................................................................................2783 Draining and Refilling Cooling System...................................................................................................2783 Water Pump..............................................................................................................................2784 Water Pump and Associated Parts.........................................................................................................2784 Removal.............................................................................................................................2784 Inspection..........................................................................................................................2784 Installation........................................................................................................................2784 Thermostat..............................................................................................................................2785 Removal.............................................................................................................................2785 Inspection..........................................................................................................................2785 Installation........................................................................................................................2785 Radiator................................................................................................................................2786 Radiator and Associated Parts.......................................................................................................2786 Removal.............................................................................................................................2786 Inspection..........................................................................................................................2787 Installation........................................................................................................................2787 Main Data and Specifications............................................................................................................2788 Special Tool............................................................................................................................2788 6C ENGINE FUEL (X22SE 2.2L)...............................................................................................................2789 Service Precaution......................................................................................................................2789 General Description.....................................................................................................................2790 Fuel Metering...........................................................................................................................2791 Fuel Filter.............................................................................................................................2792 Fuel Filter and Associated Parts....................................................................................................2792 Removal.............................................................................................................................2792 Inspection..........................................................................................................................2792 Installation........................................................................................................................2792 Inspection..........................................................................................................................2792 In-Tank Fuel Filter.................................................................................................................2792 Fuel Pump Flow Test.................................................................................................................2793 Fuel Pump...............................................................................................................................2794 Fuel Pump and Associated Parts......................................................................................................2794 Removal.............................................................................................................................2794 Installation........................................................................................................................2794 Fuel Tube / Quick-Connector Fittings....................................................................................................2795 Precautions.........................................................................................................................2795 Cautions During Work................................................................................................................2795 Removal.............................................................................................................................2795 Reuse of Quick-Connector............................................................................................................2797 Assembling Advice...................................................................................................................2797 Fuel Pump Relay.........................................................................................................................2798 General Description.................................................................................................................2798 Fuel Tank...............................................................................................................................2798 Fuel Tank and Associated Parts......................................................................................................2798 Removal.............................................................................................................................2799 Installation........................................................................................................................2799 Fuel Gage Unit..........................................................................................................................2799 Removal and Installation............................................................................................................2799 Fuel Filler Cap.........................................................................................................................2800 General Description.................................................................................................................2800 Inspection..........................................................................................................................2800 Main Data and Specifications............................................................................................................2801 Special Tool............................................................................................................................2801 6D1 ENGINE ELECTRICAL (X22SE 2.2L).........................................................................................................2802 Service Precaution......................................................................................................................2802 Battery.................................................................................................................................2803 General Description.................................................................................................................2803 Diagnosis...........................................................................................................................2803 Battery Charging....................................................................................................................2804 Jump Starting.......................................................................................................................2804 Battery Removal.....................................................................................................................2805 Battery Installation................................................................................................................2805 Main Data and Specifications............................................................................................................2806 6D2 IGNITION SYSTEM (X22SE 2.2L)...........................................................................................................2807 Service Precaution......................................................................................................................2807 General Description.....................................................................................................................2807 Diagnosis...............................................................................................................................2807 Ignition Module.........................................................................................................................2808 Removal.............................................................................................................................2808 Installation........................................................................................................................2808 Spark Plug..............................................................................................................................2808 Removal.............................................................................................................................2808 Inspection and Repair...............................................................................................................2808 Installation........................................................................................................................2809 Crankshaft Angle Sensor.................................................................................................................2809 Removal.............................................................................................................................2809 Installation........................................................................................................................2809 Main Data and Specifications............................................................................................................2810 6D3 STARTING AND CHARGING SYSTEM (X22SE 2.2L)..............................................................................................2811 Service Precaution......................................................................................................................2811 Starting System.........................................................................................................................2812 General Description.................................................................................................................2812 Diagnosis...........................................................................................................................2812 Starter.................................................................................................................................2813 Removal.............................................................................................................................2813 Installation........................................................................................................................2813 Disassembled View...................................................................................................................2814 Inspection and Repair...............................................................................................................2815 Characteristic Test.................................................................................................................2816 Charging System.........................................................................................................................2817 General Description.....................................................................................................................2817 General On-Vehicle Inspection...........................................................................................................2817 Generator...............................................................................................................................2818 Removal.............................................................................................................................2818 Inspection..........................................................................................................................2818 Installation........................................................................................................................2819 Disassembly.........................................................................................................................2819 Inspection and Repair...............................................................................................................2821 Reassembly..........................................................................................................................2823 Main Data and Specifications............................................................................................................2824 6E1 2.2L ENGINE DRIVEABILITY AND EMISSIONS.................................................................................................2825 SPECIFICATIONS..........................................................................................................................2830 TIGHTENING SPECIFICATIONS...........................................................................................................2830 DIAGRAMS AND SCHEMATICS.................................................................................................................2831 PCM WIRING DIAGRAM (1 of 10)........................................................................................................2831 PCM WIRING DIAGRAM (2 of 10)........................................................................................................2832 PCM WIRING DIAGRAM (3 of 10)........................................................................................................2833 PCM WIRING DIAGRAM (4 of 10)........................................................................................................2834 PCM WIRING DIAGRAM (5 of 10)........................................................................................................2835 PCM WIRING DIAGRAM (6 of 10)........................................................................................................2836 PCM WIRING DIAGRAM (7 of 10)........................................................................................................2837 PCM WIRING DIAGRAM (8 of 10)........................................................................................................2838 PCM WIRING DIAGRAM (9 of 10)........................................................................................................2839 PCM WIRING DIAGRAM (10 of 10).......................................................................................................2840 PCM PINOUTS.............................................................................................................................2841 PCM Pinout Table, 32-Pin Red Connector - Row "A"....................................................................................2841 PCM Pinout Table, 32-Pin Red Connector - Row "B"....................................................................................2842 PCM Pinout Table, 32-Pin White Connector - Row "C"..................................................................................2843 PCM Pinout Table, 32-Pin White Connector - Row "D"..................................................................................2844 PCM Pinout Table, 32-Pin White Connector - Row "E"..................................................................................2845 PCM Pinout Table, 32-Pin White Connector - Row "F"..................................................................................2846 COMPONENT LOCATOR.......................................................................................................................2847 Engine Component Locator Table......................................................................................................2849 Undercarriage Component Locator Table...............................................................................................2849 Fuse And Relay Panel (Underhood Electrical Center)..................................................................................2849 DIAGNOSIS Strategy-Based Diagnostics....................................................................................................2851 Strategy-Based Diagnostics..........................................................................................................2851 DTC Stored..........................................................................................................................2851 No DTC..............................................................................................................................2851 No Matching Symptom.................................................................................................................2851 Intermittents.......................................................................................................................2851 No Trouble Found....................................................................................................................2851 Verifying Vehicle Repair............................................................................................................2851 GENERAL SERVICE INFORMATION.............................................................................................................2852 OBD II Serviceability Issues........................................................................................................2852 Emissions Control Information Label.................................................................................................2852 Maintenance Schedule................................................................................................................2853 Visual/Physical Engine Compartment Inspection.......................................................................................2853 Basic Knowledge Of Tools Required...................................................................................................2853 SERIAL DATA COMMUNICATIONS..............................................................................................................2853 Class II Serial Data Communications.................................................................................................2853 ON-BOARD DIAGNOSTIC (OBD II)............................................................................................................2853 On-Board Diagnostic Tests...........................................................................................................2853 Comprehensive Component Monitor Diagnostic Operation................................................................................2853 System Status And Drive Cycle For Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................2854 Common OBD II Terms.................................................................................................................2854 The Diagnostic Executive............................................................................................................2855 DTC Types...........................................................................................................................2856 Decimal/Binary/Hexadecimal Conversions..............................................................................................2857 Verifying Vehicle Repair............................................................................................................2857 Reading Diagnostic Trouble Codes Using A Tech 2 Scan Tool...........................................................................2857 Tech 2 Features.....................................................................................................................2859 Getting Started.....................................................................................................................2859 Operating Procedure (Example).......................................................................................................2860 DTC Modes...........................................................................................................................2861 DTC Information Mode................................................................................................................2861 Miscellaneous Test..................................................................................................................2862 Lamps Test..........................................................................................................................2862 Relays Test.........................................................................................................................2863 EVAP Test...........................................................................................................................2865 Idle Air Control System Test........................................................................................................2866 Fuel System Test....................................................................................................................2868 EGR Control Test....................................................................................................................2869 Injector Balance Test...............................................................................................................2870 Plotting Snapshot Graph.................................................................................................................2871 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................2872 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................2873 PRIMARY SYSTEM-BASED DIAGNOSTICS........................................................................................................2874 Primary System-Based Diagnostics....................................................................................................2874 Fuel Control Heated Oxygen Sensors..................................................................................................2874 HO2S Heater.........................................................................................................................2874 Catalyst Monitor Heated Oxygen Sensors And Diagnostic Operation.....................................................................2874 MISFIRE MONITOR DIAGNOSTIC OPERATION....................................................................................................2875 Misfire Monitor Diagnostic Operation................................................................................................2875 Misfire Counters....................................................................................................................2875 FUEL TRIM SYSTEM MONITOR DIAGNOSTIC OPERATION...........................................................................................2876 Fuel Trim System Monitor Diagnostic Operation.......................................................................................2876 Fuel Trim Cell Diagnostic Weights...................................................................................................2876 ON-BOARD DIAGNOSTIC (OBD II) SYSTEM CHECK...............................................................................................2877 A/C CLUTCH CONTROL CIRCUIT DIAGNOSIS....................................................................................................2880 ELECTRONIC IGNITION SYSTEM DIAGNOSIS....................................................................................................2883 EVAP CANISTER PURGE SOLENOID............................................................................................................2883 VISUAL CHECK OF THE EVAPORATIVE EMISSION CANISTER.......................................................................................2883 IDLE AIR CONTROL (IAC) VALVE............................................................................................................2883 FUEL SYSTEM PRESSURE TEST...............................................................................................................2883 FUEL METERING SYSTEM CHECK..............................................................................................................2883 FUEL INJECTOR COIL TEST PROCEDURE AND FUEL INJECTOR BALANCE TEST PROCEDURE..............................................................2884 Test Description....................................................................................................................2884 Injector Coil Test Procedure (Steps 1-6) And Injector Balance Test Procedure (Steps 7-11)...........................................2885 POWERTRAIN CONTROL MODULE (PCM) DIAGNOSIS...............................................................................................2889 MULTIPLE PCM INFORMATION SENSOR DTCs SET................................................................................................2889 EXHAUST GAS RECIRCULATION (EGR) DIAGNOSIS...............................................................................................2893 ENGINE Tech 2 DATA DEFINITIONS AND RANGES...............................................................................................2893 TYPICAL SCAN DATA VALUES................................................................................................................2896 NO MALFUNCTION INDICATOR LAMP (MIL).....................................................................................................2900 MALFUNCTION INDICATOR LAMP (MIL) ON STEADY..............................................................................................2903 ENGINE CRANKS BUT WILL NOT RUN..........................................................................................................2905 FUEL SYSTEM ELECTRICAL TEST.............................................................................................................2911 FUEL SYSTEM DIAGNOSIS...................................................................................................................2914 IDLE AIR CONTROL (IAC) SYSTEM CHECK.....................................................................................................2919 EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK............................................................................................2922 MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK...........................................................................................2924 EVAPORATIVE (EVAP) EMISSIONS CANISTER PURGE VALVE SOLENOID CHECK........................................................................2926 Upshift Lamp System Check (Manual Transmission Only)....................................................................................2929 PCM DIAGNOSTIC TROUBLE CODES............................................................................................................2932 DTC P0106 MANIFOLD ABSOLUTE PRESSURE....................................................................................................2935 DTC P0107 MANIFOLD ABSOLUTE PRESSURE....................................................................................................2938 DTC P0108 MANIFOLD ABSOLUTE PRESSURE....................................................................................................2941 DTC P0112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT LOW INPUT.........................................................................2944 DTC P0113 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT HIGH INPUT........................................................................2947 DTC P0117 ENGINE COOLANT TEMPERATURE....................................................................................................2950 DTC P0118 ENGINE COOLANT TEMPERATURE....................................................................................................2953 DTC P0121 THROTTLE POSITION (TP) SENSOR.................................................................................................2956 DTC P0122 THROTTLE POSITION (TP) SENSOR CIRCUITLOW INPUT................................................................................2959 DTC P0123 THROTTLE POSITION (TP) SENSOR.................................................................................................2962 DTC P0125 INSUFFICIENT COOLANT TEMPERATURE..............................................................................................2965 DTC P0131 O2 SENSOR CIRCUIT LOW VOLTAGE.................................................................................................2968 DTC P0132 O2 SENSOR CIRCUIT HIGH VOLTAGE................................................................................................2971 DTC P0133 O2 SENSOR CIRCUIT SLOW RESPONSE...............................................................................................2974 DTC P0134 O2 SENSOR CIRCUIT NO ACTIVITY.................................................................................................2977 DTC P0135 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 1)........................................................................2980 DTC P0137 O2 SENSOR CIRCUIT LOW VOLTAGE (BANK 1 SENSOR 2)...............................................................................2983 DTC P0138 O2 SENSOR CIRCUIT HIGH VOLTAGE (BANK 1 SENSOR 2)..............................................................................2986 DTC P0140 O2 SENSOR CIRCUIT NO ACTIVITY DETECTED (BANK 1 SENSOR 2)......................................................................2989 DTC P0141 O2 SENSOR HEATER CIRCUIT MALFUNCTION (BANK 1 SENSOR 2)........................................................................2992 DTC P0171 SYSTEM TOO LEAN (BANK 1)......................................................................................................2995 DTC P0172 SYSTEM TOO RICH (BANK 1)......................................................................................................2999 DTC P0201 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 1.....................................................................................3003 DTC P0202 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 2.....................................................................................3006 DTC P0203 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 3.....................................................................................3009 DTC P0204 INJECTOR CIRCUIT MALFUNCTION - CYLINDER 4.....................................................................................3012 DTC P0300 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED.....................................................................................3015 DTC P0301 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED.....................................................................................3019 DTC P0302 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED.....................................................................................3023 DTC P0303 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED.....................................................................................3027 DTC P0304 RANDOM/MULTIPLE CYLINDER MISFIRE DETECTED.....................................................................................3031 DTC P0325 KNOCK SENSOR (KS) CIRCUIT MALFUNCTION.........................................................................................3035 DTC P0327 KNOCK SENSOR (KS) CIRCUIT LOW INPUT...........................................................................................3038 DTC P0336 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT RANGE/PERFORMANCE....................................................................3041 DTC P0337 CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT LOW INPUT............................................................................3043 DTC P0341 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT RANGE/PERFORMANCE......................................................................3046 DTC P0342 CAMSHAFT POSITION (CMP) SENSOR CIRCUIT LOW INPUT..............................................................................3049 DTC P0351 IGNITION COIL "A" PRIMARY/SECONDARY CIRCUIT MALFUNCTION.......................................................................3052 DTC P0352 IGNITION COIL "B" PRIMARY/SECONDARY CIRCUIT MALFUNCTION.......................................................................3054 DTC P0401 EXHAUST GAS RECIRCULATION (EGR) FLOW INSUFFICIENT DETECTED....................................................................3056 DTC P0402 EXHAUST GAS RECIRCULATION (EGR) EXCESSIVE FLOW DETECTED.......................................................................3059 DTC P0404 EXHAUST GAS RECIRCULATION (EGR) CIRCUIT RANGE/PERFORMANCE.....................................................................3061 DTC P0405 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT LOW............................................................................3065 DTC P0406 EXHAUST GAS RECIRCULATION (EGR) SENSOR CIRCUIT HIGH...........................................................................3068 DTC P0420 CATALYST SYSTEM EFFICIENCY BELOW THRESHOLD....................................................................................3072 DTC P0440 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM MALFUNCTION........................................................................3075 DTC P0442 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM SMALL LEAK DETECTED................................................................3080 DTC P0443 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM PURGE CONTROL VALVE CIRCUIT MALFUNCTION............................................3084 DTC P0446 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT CONTROL CIRCUIT MALFUNCTION...................................................3087 DTC P0449 EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM VENT VALVE/SOLENOID CIRCUIT MALFUNCTION............................................3091 DTC P0461 FUEL LEVEL SENSOR CIRCUIT RANGE/PERFORMANCE...................................................................................3094 DTC P0462 FUEL LEVEL SENSOR CIRCUIT LOW INPUT...........................................................................................3096 DTC P0463 FUEL LEVEL SENSOR CIRCUIT HIGH INPUT..........................................................................................3098 DTC P0480 COOLING FAN 1 CONTROL CIRCUIT MALFUNCTION.....................................................................................3100 DTC P0481 COOLING FAN 2 CONTROL CIRCUIT MALFUNCTION.....................................................................................3103 DTC P0502 VEHICLE SPEED SENSOR (VSS) CIRCUIT LOW INPUT..................................................................................3106 DTC P0506 IDLE CONTROL SYSTEM RPM LOWER THAN EXPECTED...................................................................................3108 DTC P0507 IDLE CONTROL SYSTEM RPM HIGHER THAN EXPECTED..................................................................................3111 DTC P0532 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT LOW INPUT.............................................................................3114 DTC P0533 A/C REFRIGERANT PRESSURE SENSOR CIRCUIT HIGH INPUT............................................................................3117 DTC P0562 SYSTEM VOLTAGE LOW............................................................................................................3120 DTC P0563 SYSTEM VOLTAGE HIGH...........................................................................................................3122 DTC P0601 INTERNAL CONTROL MODULE MEMORY CHECK SUM ERROR................................................................................3124 DTC P1106 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.....................................................3126 DTC P1107 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE......................................................3128 DTC P1111 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.........................................................3130 DTC P1112 INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE..........................................................3133 DTC P1114 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE......................................................3135 DTC P1115 ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE.....................................................3137 DTC P1121 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT HIGH VOLTAGE...............................................................3140 DTC P1122 THROTTLE POSITION (TP) SENSOR CIRCUIT INTERMITTENT LOW VOLTAGE................................................................3142 DTC P1133 O2 SENSOR INSUFFICIENT SWITCHING (BANK 1 SENSOR 1)............................................................................3144 DTC P1134 O2 SENSOR TRANSITION TIME RATIO (BANK 1 SENSOR 1).............................................................................3147 DTC P1171 FUEL SYSTEM LEAN DURING ACCELERATION..........................................................................................3150 DTC P1336 CRANKSHAFT POSITION SENSOR (CKP) SYSTEM VARIATION NOT LEARNED.................................................................3153 DTC P1380 ABS ROUGH ROAD SYSTEM FAULT...................................................................................................3156 DTC P1381 ABS ROUGH ROAD CLASS 2 SERIAL DATA FAULT......................................................................................3158 DTC 1404 EXHAUST GAS RECIRCULATION (EGR) CLOSED VALVE...................................................................................3161 DTC P1441 EVAPORATIVE EMISSION (EVAP) SYSTEM FLOW DURING NON-PURGE......................................................................3164 DTC P1546 A/C COMPRESSOR CLUTCH OUTPUT CIRCUIT MALFUNCTION .............................................................................3167 DTC P1625 PCM Unexpected Reset..........................................................................................................3170 DTC P1627 PCM A/D CONVERSION MALFUNCTION................................................................................................3172 DTC P1635 5 VOLT REFERENCE VOLTAGE CIRCUIT MALFUNCTION..................................................................................3174 DTC P1640 ODM OUTPUT CIRCUIT FAULT......................................................................................................3176 SYMPTOM DIAGNOSIS.......................................................................................................................3179 DEFAULT MATRIX TABLE....................................................................................................................3202 Camshaft Position (CMP) Sensor..........................................................................................................3205 Crankshaft Position (CKP) Sensor........................................................................................................3206 EEPROM..................................................................................................................................3208 Engine Coolant Temperature (ECT) Sensor.................................................................................................3208 Heated Oxygen Sensor (HO2S).............................................................................................................3209 Intake Air Temperature (IAT) Sensor.....................................................................................................3210 Manifold Absolute Pressure (MAP) Sensor.................................................................................................3211 Malfunction Indicator Lamp (MIL)........................................................................................................3212 Powertrain Control Module (PCM).........................................................................................................3212 Throttle Position (TP) Sensor...........................................................................................................3215 Vehicle Speed Sensor (VSS)..............................................................................................................3216 Air Filter..............................................................................................................................3217 Idle Air Control (IAC) Valve............................................................................................................3218 Intake Air Duct.........................................................................................................................3219 Knock Sensor............................................................................................................................3221 Oil Pressure Switch.....................................................................................................................3222 FUEL METERING SYSTEM Accelerator Cable Assembly.........................................................................................3222 Fuel Filler Cap.........................................................................................................................3225 Fuel Filter.............................................................................................................................3225 Fuel Injectors..........................................................................................................................3227 Fuel Pressure Regulator.................................................................................................................3228 Fuel Pump Assembly......................................................................................................................3230 Fuel Pump Relay.........................................................................................................................3232 Fuel Rail Assembly......................................................................................................................3232 Fuel Tank...............................................................................................................................3234 Throttle body (TB)......................................................................................................................3235 ELECTRONIC IGNITION SYSTEM Ignition Control Module (ICM)................................................................................3237 Ignition Coil...........................................................................................................................3237 Spark Plugs.............................................................................................................................3238 Spark Plug Cables.......................................................................................................................3239 EMISSIONS Catalytic Converter...........................................................................................................3240 Air Conditioning Relay..................................................................................................................3240 Ignition Timing Adjustment..............................................................................................................3240 EVAP Canister Hoses.....................................................................................................................3240 EVAP Canister...........................................................................................................................3240 EVAP Canister Vent Solenoid.............................................................................................................3241 EVAP Canister Purge Valve Solenoid......................................................................................................3241 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................3242 Wiring and Connectors...................................................................................................................3244 PCM Connectors And Terminals............................................................................................................3244 Connectors And Terminals................................................................................................................3244 Wire Harness Repair: Twisted Shielded Cable.............................................................................................3244 Twisted Leads...........................................................................................................................3245 Weather-Pack Connector..................................................................................................................3246 Com-Pack III............................................................................................................................3248 Metri-Pack..............................................................................................................................3248 GENERAL DESCRIPTION - PCM AND SENSORS...................................................................................................3249 58X Reference PCM Input.............................................................................................................3249 A/C Request Signal..................................................................................................................3249 Crankshaft Position (CKP) Sensor....................................................................................................3249 Camshaft Position (CMP) Sensor And Signal...........................................................................................3249 Engine Coolant Temperature (ECT) Sensor.............................................................................................3249 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................3250 Fuel Control Heated Oxygen Sensor (Pre Catalyst)....................................................................................3250 Catalyst Monitor Heated Oxygen Sensor (Post Catalyst)...............................................................................3250 Intake Air Temperature (IAT) Sensor.................................................................................................3251 Linear Exhaust Gas Recirculation (EGR) Control......................................................................................3251 Manifold Absolute Pressure (MAP) Sensor.............................................................................................3251 Powertrain Control Module (PCM).....................................................................................................3252 PCM Function........................................................................................................................3252 PCM Components......................................................................................................................3252 PCM Voltage Description.............................................................................................................3252 PCM Inputs/Outputs..................................................................................................................3252 PCM Service Precautions.............................................................................................................3253 Reprogramming the PCM...............................................................................................................3253 Tooth Error Correction (TEC) Service Bay Guidelines.................................................................................3253 Throttle Position (TP) Sensor.......................................................................................................3254 Transmission Range Switch...........................................................................................................3254 Vehicle Speed Sensor (VSS)..........................................................................................................3254 Use of Circuit Testing Tools........................................................................................................3255 Aftermarket Electrical And Vacuum Equipment.........................................................................................3255 Electrostatic Discharge Damage......................................................................................................3255 Upshift Lamp........................................................................................................................3255 GENERAL DESCRIPTION - AIR INDUCTION.....................................................................................................3255 Air Induction System................................................................................................................3255 GENERAL DESCRIPTION - FUEL METERING.....................................................................................................3256 Acceleration Mode...................................................................................................................3256 Accelerator Controls................................................................................................................3256 Battery Voltage Correction Mode.....................................................................................................3256 CMP Signal..........................................................................................................................3256 Clear Flood Mode....................................................................................................................3256 Deceleration Fuel Cutoff (DFCO) Mode................................................................................................3256 Engine Speed/Vehicle Speed/ Fuel Disable Mode.......................................................................................3256 Fuel Cutoff Mode....................................................................................................................3256 Fuel Injector.......................................................................................................................3256 Fuel Metering System Components.....................................................................................................3257 Fuel Metering System Purpose........................................................................................................3257 Fuel Pressure Regulator.............................................................................................................3257 Fuel Pump Electrical Circuit........................................................................................................3257 Fuel Rail...........................................................................................................................3257 Idle Air Control (IAC) Valve........................................................................................................3258 Run Mode............................................................................................................................3258 Starting Mode.......................................................................................................................3258 Throttle Body Unit..................................................................................................................3258 GENERAL DESCRIPTION - ELECTRONIC IGNITION SYSTEM.......................................................................................3259 Camshaft Position (CMP) Sensor......................................................................................................3259 Crankshaft Position (CKP) Sensor....................................................................................................3259 Electronic Ignition.................................................................................................................3259 Ignition Coils......................................................................................................................3259 Ignition Control....................................................................................................................3259 Ignition Control Module (ICM).......................................................................................................3260 Ignition Control PCM Output.........................................................................................................3260 Powertrain Control Module (PCM).....................................................................................................3260 Spark Plug..........................................................................................................................3261 A/C CLUTCH DIAGNOSIS....................................................................................................................3262 A/C Clutch Circuit Operation........................................................................................................3262 A/C Clutch Circuit Purpose..........................................................................................................3262 A/C Request Signal..................................................................................................................3262 GENERAL DESCRIPTION - EVAPORATIVE EMISSION (EVAP) SYSTEM................................................................................3263 EVAP Emission Control System Purpose................................................................................................3263 EVAP Emission Control System Operation..............................................................................................3263 Enhanced Evaporative Emission Control System........................................................................................3263 Enhanced Evaporative Emission Control System........................................................................................3263 System Fault Detection..............................................................................................................3264 GENERAL DESCRIPTION - EXHAUST GAS RECIRCULATION (EGR) SYSTEM............................................................................3264 EGR Purpose.........................................................................................................................3264 Linear EGR Valve....................................................................................................................3264 Linear EGR Control..................................................................................................................3264 Linear EGR Valve Operation And Results Of Incorrect Operation.......................................................................3265 EGR Pintle Position Sensor..........................................................................................................3265 GENERAL DESCRIPTION - POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM.......................................................................3265 Crankcase Ventilation System Purpose................................................................................................3265 SPECIAL TOOLS...........................................................................................................................3266 6F ENGINE EXHAUST (X22SE 2.2L)............................................................................................................3268 Service Precaution......................................................................................................................3268 General Description.....................................................................................................................3269 Front Exhaust Pipe......................................................................................................................3270 Front Exhaust Pipe and Associated Parts.............................................................................................3270 Removal.............................................................................................................................3270 Installation........................................................................................................................3270 Exhaust Silencer........................................................................................................................3271 Exhaust Silencer and Associated Parts...............................................................................................3271 Removal.............................................................................................................................3271 Installation........................................................................................................................3271 Rear Exhaust pipe.......................................................................................................................3272 Rear Exhaust pipe and Associated Parts..............................................................................................3272 Removal.............................................................................................................................3272 Installation........................................................................................................................3272 Main Data and Specifications............................................................................................................3273 6G ENGINE LUBRICATION (X22SE 2.2L)........................................................................................................3274 Service Precaution......................................................................................................................3274 General Description.....................................................................................................................3275 Oil Pump................................................................................................................................3276 Oil Pump and Associated Parts.......................................................................................................3276 Disassembly.........................................................................................................................3277 Inspection and Repair...............................................................................................................3277 Reassembly..........................................................................................................................3277 6H ENGINE SPEED CONTROL SYSTEM (X22SE 2.2L)...............................................................................................3278 Service Precaution......................................................................................................................3278 Accelerator Pedal Control Cable.........................................................................................................3279 Removal.............................................................................................................................3279 Inspection..........................................................................................................................3279 Installation........................................................................................................................3279 Accelerator Pedal.......................................................................................................................3280 Accelerator Pedal and Associated Parts..............................................................................................3280 Removal.............................................................................................................................3280 Installation........................................................................................................................3280 6J INDUCTION (X22SE 2.2L).................................................................................................................3281 Service Precaution......................................................................................................................3281 Air Cleaner Filter......................................................................................................................3282 Removal.............................................................................................................................3282 Inspection..........................................................................................................................3282 Installation........................................................................................................................3282 6A ENGINE MECHANICAL (6VD1 3.2L)..........................................................................................................3283 Service Precaution......................................................................................................................3284 General Description.....................................................................................................................3285 Engine Diagnosis........................................................................................................................3286 Cylinder Head Cover LH..................................................................................................................3301 Removal.............................................................................................................................3301 Installation........................................................................................................................3302 Cylinder Head Cover RH..................................................................................................................3303 Removal.............................................................................................................................3303 Installation........................................................................................................................3303 Common Chamber..........................................................................................................................3304 Removal.............................................................................................................................3304 Installation........................................................................................................................3304 Exhaust Manifold LH.....................................................................................................................3306 Removal.............................................................................................................................3306 Installation........................................................................................................................3306 Exhaust Manifold RH.....................................................................................................................3307 Removal.............................................................................................................................3307 Installation........................................................................................................................3307 Crankshaft Pulley.......................................................................................................................3308 Removal.............................................................................................................................3308 Installation........................................................................................................................3308 Timing Belt.............................................................................................................................3309 Removal.............................................................................................................................3309 Installation........................................................................................................................3310 Camshaft................................................................................................................................3314 Removal.............................................................................................................................3314 Installation........................................................................................................................3315 Cylinder Head...........................................................................................................................3317 Removal.............................................................................................................................3317 Installation........................................................................................................................3317 Valve Stem Oil Controller , Valve Spring and Valve Guide................................................................................3319 Removal.............................................................................................................................3319 Installation........................................................................................................................3319 Piston, Piston Ring and Connecting Rod..................................................................................................3320 Removal.............................................................................................................................3320 Installation........................................................................................................................3321 Crankshaft and Main Bearings............................................................................................................3322 Removal.............................................................................................................................3322 Installation........................................................................................................................3323 Rear Oil Seal...........................................................................................................................3327 Removal.............................................................................................................................3327 Installation........................................................................................................................3327 Engine Assembly.........................................................................................................................3328 Removal.............................................................................................................................3328 Installation........................................................................................................................3329 Cylinder Head...........................................................................................................................3331 Cylinder Head and Associated Parts..................................................................................................3331 Disassembly.........................................................................................................................3331 Clean...............................................................................................................................3332 Inspection and Repair...............................................................................................................3332 Reassembly..........................................................................................................................3333 Valve Spring, Oil Controller, Valve, Valve Guide........................................................................................3335 Valve Spring, Oil Controller, Valve, Valve Guide and Associated Parts...............................................................3335 Disassembly.........................................................................................................................3335 Inspection and Repair...............................................................................................................3336 Reassembly..........................................................................................................................3339 Camshaft................................................................................................................................3342 Camshaft and Associated Parts.......................................................................................................3342 Disassembly.........................................................................................................................3342 Inspection and Repair...............................................................................................................3343 Reassembly..........................................................................................................................3345 Crankshaft..............................................................................................................................3348 Crankshaft and Associated Parts.....................................................................................................3348 Disassembly.........................................................................................................................3348 Inspection and Repair...............................................................................................................3349 Inspection and Repair...............................................................................................................3351 Reassembly..........................................................................................................................3352 Piston and Connecting Rod...............................................................................................................3356 Piston, Connecting Rod and Associate Parts..........................................................................................3356 Disassembly.........................................................................................................................3356 Inspection and Repair...............................................................................................................3357 Reassembly..........................................................................................................................3361 Cylinder Block..........................................................................................................................3363 Cylinder Block and Associated Parts.................................................................................................3363 Disassembly.........................................................................................................................3363 Inspection and Repair...............................................................................................................3364 Reassembly..........................................................................................................................3365 Main Data and Specification.............................................................................................................3368 Special Tool............................................................................................................................3374 6B ENGINE COOLING (6VD1 3.2L).............................................................................................................3376 Service Precaution......................................................................................................................3376 General Description.....................................................................................................................3377 Diagnosis...............................................................................................................................3379 Draining and Refilling Cooling System...................................................................................................3380 Water Pump..............................................................................................................................3381 Water Pump and Associated Parts.....................................................................................................3381 Removal.............................................................................................................................3381 Inspection..........................................................................................................................3381 Installation........................................................................................................................3381 Thermostat..............................................................................................................................3382 Thermostat and Associated Parts.....................................................................................................3382 Removal.............................................................................................................................3382 Inspection..........................................................................................................................3382 Installation........................................................................................................................3382 Radiator................................................................................................................................3383 Radiator and Associated Parts.......................................................................................................3383 Removal.............................................................................................................................3383 Inspection..........................................................................................................................3384 Installation........................................................................................................................3385 Drive Belt and Cooling Fan..............................................................................................................3386 Drive Belt and Associated Parts.....................................................................................................3386 Inspection..........................................................................................................................3386 Installation........................................................................................................................3386 Main Data and Specifications............................................................................................................3387 Special Tool............................................................................................................................3388 6C ENGINE FUEL (6VD1 3.2L)................................................................................................................3389 Service Precaution......................................................................................................................3389 General Description.....................................................................................................................3390 Fuel Metering...........................................................................................................................3391 Fuel Filter.............................................................................................................................3392 Removal.................................................................................................................................3392 Inspection..............................................................................................................................3392 Installation............................................................................................................................3392 Inspection..............................................................................................................................3392 In-Tank Fuel Filter.....................................................................................................................3392 Fuel Pump Flow Test.....................................................................................................................3393 Fuel Pump...............................................................................................................................3394 Fuel Pump and Associated Parts......................................................................................................3394 Removal.............................................................................................................................3394 Installation........................................................................................................................3394 Fuel Tube / Quick - Connector Fittings..................................................................................................3395 Precautions.........................................................................................................................3395 Cautions During Work................................................................................................................3395 Removal.............................................................................................................................3395 Reuse of Quick-Connector............................................................................................................3396 Assembling Advice...................................................................................................................3397 Fuel Pump Relay.........................................................................................................................3397 General Description.................................................................................................................3397 Fuel Tank...............................................................................................................................3398 Fuel Tank and Associated Parts......................................................................................................3398 Removal.............................................................................................................................3398 Installation........................................................................................................................3399 Fuel Gauge Unit.........................................................................................................................3399 Removal and Installation............................................................................................................3399 Fuel Filler Cap.........................................................................................................................3399 General Description.................................................................................................................3399 Inspection..........................................................................................................................3399 Main Data and Specifications............................................................................................................3400 6D1 ENGINE ELECTRICAL (6VD1 3.2L)..........................................................................................................3401 Service Precaution......................................................................................................................3401 Battery.................................................................................................................................3402 General Description.................................................................................................................3402 Diagnosis...........................................................................................................................3402 Battery Charging....................................................................................................................3403 Jump Starting.......................................................................................................................3403 Battery Removal.....................................................................................................................3404 Battery Installation................................................................................................................3404 Main Data and Specifications............................................................................................................3405 6D2 IGNITION SYSTEM (6VD1 3.2L)............................................................................................................3406 Service Precaution......................................................................................................................3406 General Description.....................................................................................................................3407 Diagnosis...............................................................................................................................3407 Ignition Coil...........................................................................................................................3408 Removal.............................................................................................................................3408 Inspection and Repair...............................................................................................................3408 Installation........................................................................................................................3408 Spark Plug..............................................................................................................................3410 Removal.............................................................................................................................3410 Inspection and Repair...............................................................................................................3410 Installation........................................................................................................................3410 Crankshaft Position Sensor..............................................................................................................3411 Removal.............................................................................................................................3411 Installation........................................................................................................................3411 Main Data and Specifications............................................................................................................3412 6D3 STARTING AND CHARGING SYSTEM (6VD1 3.2L)...............................................................................................3413 Service Precaution......................................................................................................................3413 Starting System.........................................................................................................................3414 General Description.....................................................................................................................3414 Diagnosis...............................................................................................................................3416 Starter.................................................................................................................................3417 Removal.............................................................................................................................3417 Installation........................................................................................................................3417 Disassembled View...................................................................................................................3418 Disassembly.........................................................................................................................3419 Inspection and Repair...............................................................................................................3421 Reassembly..........................................................................................................................3425 Main Data and Specifications........................................................................................................3427 Charging System.........................................................................................................................3430 General Description.....................................................................................................................3430 General On-Vehicle Inspection...........................................................................................................3430 Generator...............................................................................................................................3431 Removal.............................................................................................................................3431 Inspection..........................................................................................................................3431 Installation........................................................................................................................3432 Disassembled View...................................................................................................................3432 Disassembly.........................................................................................................................3433 Inspection and Repair...............................................................................................................3434 Reassembly..........................................................................................................................3436 Bench Test..........................................................................................................................3437 Main Data and Specifications............................................................................................................3438 6E2 3.2L ENGINE DRIVEABILITY AND EMISSIONS.................................................................................................3439 Specifications..........................................................................................................................3444 Diagrams and Schematics.................................................................................................................3445 PCM Wiring Diagram (1 of 7).........................................................................................................3445 PCM Wiring Diagram (2 of 7).........................................................................................................3446 PCM Wiring Diagram (3 of 7).........................................................................................................3447 PCM Wiring Diagram (4 of 7).........................................................................................................3448 PCM Wiring Diagram (5 of 7).........................................................................................................3449 PCM Wiring Diagram (6 of 7).........................................................................................................3450 PCM Wiring Diagram (7 of 7).........................................................................................................3451 Tightening Specifications...........................................................................................................3444 PCM Pinouts.............................................................................................................................3452 PCM Pinout Table, 80-Way Blue Connector - Row "F1 ~ 20".............................................................................3452 PCM Pinout Table, 80-Way Blue Connector - Row "F20 ~ 40"............................................................................3454 PCM Pinout Table, 80-Way Blue Connector - Row "F41 ~ 60"............................................................................3455 PCM Pinout Table, 80-Way Blue Connector - Row "F61 ~ 80"............................................................................3456 PCM Pinout Table, 80-Way Red Connector - Row "S1 ~ 20"..............................................................................3458 PCM Pinout Table, 80-Way Red Connector - Row "S21 ~ 40".............................................................................3460 PCM Pinout Table, 80-Way Red Connector - Row "S41 ~ 60".............................................................................3462 PCM Pinout Table, 80-Way Red Connector - Row "S61 ~ 80".............................................................................3464 Component Locators......................................................................................................................3466 Engine Component Locator Table......................................................................................................3467 Undercarriage Component Locator.....................................................................................................3468 Undercarriage Component Locator Table...............................................................................................3468 Fuse and Relay Panel (Underhood Electrical Center)..................................................................................3469 Sensors and Miscellaneous Component Locators........................................................................................3470 Diagnosis Strategy-Based Diagnostics....................................................................................................3473 Strategy-Based Diagnostics..........................................................................................................3473 DTC Stored..........................................................................................................................3473 No DTC..............................................................................................................................3473 No Matching Symptom.................................................................................................................3473 Intermittents.......................................................................................................................3473 No Trouble Found....................................................................................................................3473 Verifying Vehicle Repair............................................................................................................3473 General Service Information.............................................................................................................3473 OBD II Serviceablity Issues.........................................................................................................3473 Emissions Control Information Label.................................................................................................3474 Visual / Physical Engine Compartment Inspection.....................................................................................3474 Basic Knowledge of Tools Required...................................................................................................3475 Serial Data Communications..............................................................................................................3475 Class II Serial Data Communications.................................................................................................3475 On-Board Diagnostic (OBD II)............................................................................................................3475 On-Board Diagnostic Tests...........................................................................................................3475 Comprehensive Component Monitor Diagnostic Operation................................................................................3475 System Status and Drive Cycle for Satisfying Federal Inspection/Maintenance (I/M 240) Regulations...................................3476 Common OBD II Terms.................................................................................................................3476 The Diagnostic Executive............................................................................................................3476 DTC Types...........................................................................................................................3477 Decimal/Binary/Hexadecimal Conversions..............................................................................................3479 Verifying Vehicle Repair............................................................................................................3479 Reading Diagnostic Trouble Codes Using The Tech 2 Scan Tool.........................................................................3479 Tech 2..............................................................................................................................3480 Tech 2 Features.....................................................................................................................3481 Getting Started.....................................................................................................................3481 Operating Procedure (For Example)...................................................................................................3482 DTC Modes...........................................................................................................................3483 DTC Information Mode................................................................................................................3483 Miscellaneous Test..................................................................................................................3484 Lamps Test..........................................................................................................................3484 Relays Test.........................................................................................................................3486 EVAP Test...........................................................................................................................3487 Fuel System Test....................................................................................................................3488 Instruments Test....................................................................................................................3490 EGR Control Test....................................................................................................................3492 Variable Intake Manifold Solenoid Test..............................................................................................3492 Injector Balance Test............................................................................................................... 0 Plotting Snapshot Graph.................................................................................................................3494 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................3495 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................3496 Primary System-Based Diagnostic.........................................................................................................3497 Primary System-Based Diagnostic.....................................................................................................3497 Fuel Control Heated Oxygen Sensor...................................................................................................3497 HO2S Heater.........................................................................................................................3497 Catalyst Monitor Heated Oxygen Sensors and Diagnostic Operation.....................................................................3497 Evaporative Emission (EVAP) Purge System Vacuum Switch..............................................................................3498 Misfire Monitor Diagnostic Operation....................................................................................................3498 Misfire Monitor Diagnostic Operation................................................................................................3498 Misfire Counters....................................................................................................................3499 Fuel Trim System Monitor Diagnostic Operation...........................................................................................3499 Fuel Trim System Monitor Diagnostic Operation.......................................................................................3499 Fuel Trim Cell Diagnostic Weights...................................................................................................3499 On-Board Diagnostic (OBD II) System Check...............................................................................................3500 A/C Clutch Control Circuit Diagnosis....................................................................................................3503 Electronic Ignition System Diagnosis....................................................................................................3508 EVAP Canister Purge Solenoid and EVAP Vacuum Switch.....................................................................................3508 Visual Check of The Evaporative Emission Canister.......................................................................................3508 Fuel Metering System Check..............................................................................................................3508 Fuel System Pressure Test...............................................................................................................3508 Fuel Injector Coil Test Procedure and Fuel Injector Balance Test Procedure..............................................................3508 Powertrain Control Module (PCM) Diagnosis...............................................................................................3513 Multiple PCM Information Sensor DTCs Set................................................................................................3513 Exhaust Gas Recirculation (EGR) Diagnosis...............................................................................................3517 Engine Tech 2 Data Definitions and Ranges...............................................................................................3517 Typical Scan Data Values................................................................................................................3519 3.5L V-6 Engine (Automatic and Manual Transmission).................................................................................3520 No Malfunction Indicator Lamp (MIL).....................................................................................................3525 Malfunction Indicator Lamp (MIL) "ON" Steady............................................................................................3528 No Reduced Power Lamp (RPL).............................................................................................................3530 Reduced Power Lamp (RPL) "ON" Steady....................................................................................................3534 Engine Cranks But Will Not Run..........................................................................................................3537 Fuel System Electrical Test.............................................................................................................3544 Electric Throttle Control (ETC) System Check............................................................................................3548 Fuel System Diagnosis...................................................................................................................3552 Exhaust Gas Recirculation (EGR) System Check............................................................................................3557 Manifold Absolute Pressure (MAP) Output Check...........................................................................................3559 Evaporative (EVAP) Emissions Canister Purge Valve Check.................................................................................3561 Upshift Lamp System Check (Manual Transmission Only)....................................................................................3564 PCM Diagnostic Trouble Codes............................................................................................................3568 DTC P0101 MAF System Performance........................................................................................................3572 DTC P0102 MAF Sensor Circuit Low Frequency..............................................................................................3575 DTC P0103 MAF Sensor Circuit High Frequency.............................................................................................3578 DTC P0106 MAP System Performance........................................................................................................3581 DTC P0107 MAP Sensor Circuit Low Voltage................................................................................................3584 DTC P0108 MAP Sensor Circuit High Voltage...............................................................................................3587 DTC P0112 IAT Sensor Circuit Low Voltage................................................................................................3590 DTC P0113 IAT Sensor Circuit High Voltage...............................................................................................3593 DTC P0117 ECT Sensor Circuit Low Voltage................................................................................................3596 DTC P0118 ECT Sensor Circuit High Voltage...............................................................................................3599 DTC P0125 ECT Excessive Time to Closed Loop Fuel Control................................................................................3602 DTC P0128 Thermostat Insufficient temperrature for Stable Opreation.....................................................................3605 DTC P0131 HO2S Circuit Low Voltage Bank 1 Sensor 1......................................................................................3608 DTC P0132 HO2S Circuit High Voltage Bank 1 Sensor 1.....................................................................................3611 DTC P0133 HO2S Slow Response Bank 1 Sensor 1............................................................................................3614 DTC P0134 HO2S Circuit Insufficient Activity Bank 1 Sensor 1............................................................................3618 DTC P0135 HO2S Heater Circuit Bank 1 Sensor 1...........................................................................................3621 DTC P0137 HO2S Circuit Low Voltage Bank 1 Sensor 2......................................................................................3624 DTC P0138 HO2S Circuit High Voltage Bank 1 Sensor 2.....................................................................................3627 DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2............................................................................3630 DTC P0141 HO2S Heater Circuit Bank 1 Sensor 2...........................................................................................3633 DTC P0151 HO2S Circuit Low Voltage Bank 2 Sensor 1......................................................................................3636 DTC P0152 HO2S Circuit HIGH Voltage Bank 2 Sensor 1.....................................................................................3639 DTC P0153 HO2S Slow Response Bank 2 Sensor 1............................................................................................3642 DTC P0154 HO2S Circuit Insufficient Activity Bank 2 Sensor 1............................................................................3646 DTC P0155 HO2S Heater Circuit Bank 2 Sensor 1...........................................................................................3649 DTC P0157 HO2S Circuit Low Voltage Bank 2 Sensor 2......................................................................................3652 DTC P0158 HO2S Circuit High Voltage Bank 2 Sensor 2.....................................................................................3655 DTC P0160 HO2S Circuit Insufficient Activity Bank 2 Sensor 2............................................................................3658 DTC P0161 HO2S Heater Circuit Bank 2 Sensor 2...........................................................................................3661 DTC P0171 Fuel Trim System Lean Bank 1..................................................................................................3664 DTC P0172 Fuel Trim System Rich Bank 1..................................................................................................3668 DTC P0174 Fuel Trim System Lean Bank 2..................................................................................................3672 DTC P0175 Fuel Trim System Rich Bank 2..................................................................................................3676 DTC P0201 Injector 1 Control Circuit....................................................................................................3680 DTC P0202 Injector 2 Control Circuit....................................................................................................3683 DTC P0203 Injector 3 Control Circuit....................................................................................................3686 DTC P0204 Injector 4 Control Circuit....................................................................................................3689 DTC P0205 Injector 5 Control Circuit....................................................................................................3692 DTC P0206 Injector 6 Control Circuit....................................................................................................3695 DTC P0300 Engine Misfire Detected.......................................................................................................3698 DTC P0301 Cylinder Misfire Detected.....................................................................................................3702 DTC P0302 Cylinder Misfire Detected.....................................................................................................3704 DTC P0303 Cylinder Misfire Detected.....................................................................................................3706 DTC P0304 Cylinder Misfire Detected.....................................................................................................3708 DTC P0305 Cylinder Misfire Detected.....................................................................................................3710 DTC P0306 Cylinder Misfire Detected.....................................................................................................3712 DTC P0325 ION Sensing Module/ION Sensing Knock Intensity Circuit Fault..................................................................3714 DTC P0336 58X Reference Signal Circuit..................................................................................................3717 DTC P0337 CKP Sensor Circuit Low Frequency..............................................................................................3720 DTC P0341 CMP Sensor Circuit Performance................................................................................................3723 DTC P0342 CMP Sensor Circuit Low........................................................................................................3727 DTC P0351 Ignition 1 Control Circuit....................................................................................................3731 DTC P0352 Ignition 2 Control Circuit....................................................................................................3734 DTC P0353 Ignition 3 Control Circuit....................................................................................................3737 DTC P0354 Ignition 4 Control Circuit....................................................................................................3740 DTC P0355 Ignition 5 Control Circuit....................................................................................................3743 DTC P0356 Ignition 6 Control Circuit....................................................................................................3746 DTC P0401 EGR Flow Insufficient.........................................................................................................3749 DTC P0402 EGR Pintle Crank Error........................................................................................................3752 DTC P0404 EGR Open Stuck................................................................................................................3754 DTC P0405 EGR Low Voltage...............................................................................................................3756 DTC P0406 EGR High Voltage..............................................................................................................3759 DTC P0420 TWC System Low Efficiency Bank 1..............................................................................................3762 DTC P0430 TWC System Low Efficiency Bank 2..............................................................................................3765 DTC P0440 EVAP System...................................................................................................................3768 DTC P0442 EVAP System Small Leak Detected...............................................................................................3771 DTC P0446 EVAP Canister Vent Blocked....................................................................................................3774 DTC P0452 Fuel Tank Pressure Sensor Low Voltage.........................................................................................3777 DTC P0453 Fuel Tank Pressure Sensor (Vapor pressure Sensor) High Voltage................................................................3780 DTC P0456 EVAP Very Small Leak..........................................................................................................3783 DTC P0462 Fuel Level Sensor Circuit-Row Voltage.........................................................................................3786 DTC P0463 Fuel Level Sensor Circuit-High Voltage........................................................................................3789 DTC P0502 VSS Circuit Low Input.........................................................................................................3791 DTC P0506 Idle Air Control System Low RPM...............................................................................................3794 DTC P0507 Idle Air Control System High RPM..............................................................................................3797 DTC P0562 System Voltage Low............................................................................................................3800 DTC P0563 System Voltage High...........................................................................................................3802 DTC P0601 PCM Memory....................................................................................................................3804 DTC P0602 PCM Programming Error.........................................................................................................3806 DTC P0604 PCM RAM Error.................................................................................................................3808 DTC P0606 PCM Internal Performance......................................................................................................3810 DTC P1106 MAP Sensor Circuit Intermittent High Voltage..................................................................................3812 DTC P1107 MAP Circuit Intermittent Low Voltage..........................................................................................3814 DTC P1111 IAT Sensor Circuit Intermittent High Voltage..................................................................................3816 DTC P1112 IAT Sensor Circuit Intermittent Low Voltage...................................................................................3819 DTC P1114 ECT Sensor Circuit Intermittent Low Voltage...................................................................................3821 DTC P1115 ECT Sensor Circuit Intermittent High Voltage..................................................................................3823 DTC P1120-TPS 1 Throttle Position Sensor (TPS1) Circuit Fault...........................................................................3826 DTC P1125 ETC (Electric throttle control) Limit Performance Mode........................................................................3829 DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1...................................................................................3832 DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1....................................................................................3836 DTC P1153 HO2S Insufficient Switching Bank 2 Sensor 1...................................................................................3840 DTC P1154 HO2S Circuit Transition Time Ratio Bank 2 Sensor 1............................................................................3844 DTC P1167 Fuel System Rich During Decel Fuel Cut Off (Bank 1)...........................................................................3848 DTC P1169 Fuel System Rich During Decel Fuel Cut Off (Bank 2)...........................................................................3850 DTC P1171 Fuel System Lean During Acceleration..........................................................................................3852 DTC P1220 Throttle Position Senser2 (TPS2) Circuit Fault................................................................................3855 DTC P1221 TPS1 - TPS2 correlation(Circuit Performance)..................................................................................3858 DTC P1271 APS 1 - 2 Correlation Error...................................................................................................3861 DTC P1272 APS 2 - 3 Correlation Error...................................................................................................3864 DTC P1273 APS 1 - 3 Correlation Error...................................................................................................3867 DTC P1275 APS 1 Circuit Fault...........................................................................................................3870 DTC P1280 APS 2 Circuit Fault...........................................................................................................3872 DTC P1285 APS 3 Circuit Fault...........................................................................................................3874 DTC P1290 ETC Forced Idle Mode..........................................................................................................3876 DTC P1295 Power Management Mode.........................................................................................................3879 DTC P1299 ETC Forced Engine Shutdown Mode...............................................................................................3883 DTC P1310 ION Sensing Module Diagnosis..................................................................................................3887 DTC P1311 ION Sensing Module SEC line 1 Circuit Fault...................................................................................3890 DTC P1312 ION Sensing Module SEC line 2 Circuit Fault...................................................................................3893 DTC P1326 ION Sensing Module Combustion Quality Input Circuit Fault.....................................................................3896 DTC P1340 ION Sensing Module Cylinder ID Fault (Cylinder Synchronization Fail)..........................................................3899 DTC P1404 EGR Stuck Closed..............................................................................................................3902 DTC P1441 EVAP System Flow During Non-Purge.............................................................................................3905 DTC P1514 TPS - MAF Correlation Error...................................................................................................3908 DTC P1515 Command - Actual TPS Correlation Error........................................................................................3912 DTC P1516 Command - Actual TPS Correlation Error........................................................................................3915 DTC P1523 Actuator Control Return Performance...........................................................................................3918 DTC P1625 PCM Unexpected Reset..........................................................................................................3921 DTC P1639 Reference Voltage # 2 Circuit Fault...........................................................................................3924 DTC P1640 Driver-1-Output Circuit Fault (ODM)...........................................................................................3926 DTC P1650 Quad Driver Module "A" Fault..................................................................................................3929 Symptom Diagnosis.......................................................................................................................3932 Default Matrix Table....................................................................................................................3961 On-Vehicle Service Camshaft Position (CMP) Sensor.......................................................................................3964 Crankshaft Position (CKP) Sensor........................................................................................................3965 Engine Coolant Temperature (ECT) Sensor.................................................................................................3965 Heated Oxygen Sensor (HO2S).............................................................................................................3966 Intake Air Temperature (IAT) Sensor.....................................................................................................3969 ION Sensing Module......................................................................................................................3969 Mass Air Flow (MAF) Sensor..............................................................................................................3970 Manifold Absolute Pressure (MAP) Sensor.................................................................................................3971 Malfunction Indicator Lamp (MIL)........................................................................................................3972 Reduced Power Lamp......................................................................................................................3972 Powertrain Control Module (PCM).........................................................................................................3972 EEPROM..................................................................................................................................3973 Throttle Position (TP) Sensor...........................................................................................................3974 Vehicle Speed Sensor (VSS)..............................................................................................................3974 Air Cleaner/Air Filter..................................................................................................................3976 Common Chamber..........................................................................................................................3976 Accelerator Pedal Replacement...........................................................................................................3977 Fuel Filler Cap.........................................................................................................................3978 Fuel Filter.............................................................................................................................3978 Fuel Gauge Unit.........................................................................................................................3979 Fuel Injectors..........................................................................................................................3980 Fuel Metering System....................................................................................................................3981 Fuel Pump Assembly......................................................................................................................3981 Fuel Pump Relay.........................................................................................................................3981 Fuel Rail Assembly......................................................................................................................3982 Fuel Tank...............................................................................................................................3983 Throttle Body (TB)......................................................................................................................3983 Electronic Ignition System..............................................................................................................3985 Catalytic Converter.....................................................................................................................3986 Air Conditioning Thermo Relay...........................................................................................................3986 EVAP Canister Hoses.....................................................................................................................3987 EVAP Canister...........................................................................................................................3987 EVAP Canister Vent Solenoid.............................................................................................................3989 Fuel Tank Pressure Sensor...............................................................................................................3990 EVAP Canister Purge Solenoid............................................................................................................3990 Fuel Tank Vent Valve....................................................................................................................3991 Linear Exhaust Gas Recirculation (EGR) Valve............................................................................................3992 Positive Crankcase Ventilation (PCV) Valve..............................................................................................3993 Wiring and Connectors...................................................................................................................3993 PCM Connectors and Terminals............................................................................................................3994 Wire Harness Repair: Twisted Shielded Cable.............................................................................................3994 Twisted Leads...........................................................................................................................3995 Weather-Pack Connector..................................................................................................................3996 Com-Pack III............................................................................................................................3997 Metri-Pack..............................................................................................................................3997 General Description (PCM and Sensors)...................................................................................................3999 58X Reference PCM Input.............................................................................................................3999 A/C Request Signal..................................................................................................................3999 Crankshaft Position (CKP) Sensor....................................................................................................3999 Camshaft Position (CMP) Sensor and Signal...........................................................................................3999 Engine Coolant Temperature (ECT) Sensor.............................................................................................3999 Electrically Erasable Programmable Read Only Memory (EEPROM)........................................................................4000 Fuel Control Heated Oxygen Sensors..................................................................................................4000 Catalyst Monitor Heated Oxygen Sensors..............................................................................................4000 Intake Air Temperature (IAT) Sensor.................................................................................................4001 Linear Exhaust Gas Recirculation (EGR) Control......................................................................................4001 Mass Air Flow (MAF) Sensor..........................................................................................................4001 Manifold Absolute Pressure (MAP) Sensor.............................................................................................4001 Powertrain Control Module (PCM).....................................................................................................4002 PCM Function........................................................................................................................4002 PCM Components......................................................................................................................4002 PCM Voltage Description.............................................................................................................4002 PCM Input/Outputs...................................................................................................................4003 PCM Service Precautions.............................................................................................................4003 Reprogramming The PCM...............................................................................................................4003 Throttle Position (TP) Sensor.......................................................................................................4003 Transmission Fluid Temperature (TFT) Sensor.........................................................................................4003 Transmission Range Switch...........................................................................................................4003 Vehicle Speed Sensor (VSS)..........................................................................................................4004 Use of Circuit Testing Tools........................................................................................................4004 Aftermarket Electrical and Vacuum Equipment.........................................................................................4004 Electrostatic Discharge Damage......................................................................................................4004 Upshift Lamp........................................................................................................................4004 General Description (Air Induction).....................................................................................................4004 Air Induction System................................................................................................................4004 General Description (Fuel Metering).....................................................................................................4005 Acceleration Mode...................................................................................................................4005 Battery Voltage Correction Mode.....................................................................................................4005 CMP Signal..........................................................................................................................4005 Clear Flood Mode....................................................................................................................4005 Deceleration Mode...................................................................................................................4005 Engine Speed/Vehicle Speed/Fuel Disable Mode........................................................................................4005 Fuel Cutoff Mode....................................................................................................................4005 Fuel Injector.......................................................................................................................4005 Fuel Metering System Components.....................................................................................................4005 Fuel Metering System Purpose........................................................................................................4006 Fuel Pressure Regulator.............................................................................................................4006 Fuel Pump Electrical Circuit........................................................................................................4006 Fuel Rail...........................................................................................................................4006 Run Mode............................................................................................................................4007 Starting Mode.......................................................................................................................4007 Throttle Body Unit..................................................................................................................4007 General Description (Electronic Ignition System)........................................................................................4007 Camshaft Position (CMP) Sensor......................................................................................................4007 Crankshaft Position (CKP) Sensor....................................................................................................4007 Electronic Ignition.................................................................................................................4008 Ignition Coils......................................................................................................................4008 Ignition Control....................................................................................................................4008 Ignition Control PCM Output.........................................................................................................4009 Powertrain Control Module (PCM).....................................................................................................4009 Spark Plug..........................................................................................................................4010 A/C Clutch Diagnosis....................................................................................................................4011 A/C Clutch Circuit Operation........................................................................................................4011 A/C Clutch Circuit Purpose..........................................................................................................4011 A/C Request Signal..................................................................................................................4011 General Description (Evaporative (EVAP) Emission System)................................................................................4012 EVAP Emission Control System Purpose................................................................................................4012 EVAP Emission Control System Operation..............................................................................................4012 Enhanced Evaporative Emission Control System........................................................................................4012 General Description (Exhaust Gas Recirculation (EGR) System)............................................................................4015 EGR Purpose.........................................................................................................................4015 Linear EGR Valve....................................................................................................................4016 Linear EGR Control..................................................................................................................4016 Linear EGR Valve Operation and Results of Incorrect Operation.......................................................................4016 EGR Pintle Position Sensor..........................................................................................................4016 General Description (Positive Crankcase Ventilation (PCV) System).......................................................................4016 Crankcase Ventilation System Purpose................................................................................................4016 Crankcase Ventilation System Operation..............................................................................................4016 Special Tools...........................................................................................................................4018 6F ENGINE EXHAUST (6VD1 3.2L).............................................................................................................4020 Service Precaution......................................................................................................................4020 General Description.....................................................................................................................4021 Three Way Catalytic Converter RH and Forked Exhaust Pipe................................................................................4022 Three Way Catalytic Converter RH and Forked Exhaust Pipe and Associated Parts.......................................................4022 Removal.............................................................................................................................4022 Installation........................................................................................................................4022 Three Way Catalytic Converter LH and Forked Exhaust Pipe................................................................................4023 Three Way Catalytic Converter LH and Forked Exhaust Pipe and Associated Parts.......................................................4023 Removal.............................................................................................................................4023 Installation........................................................................................................................4023 Forked Exhaust Pipe.....................................................................................................................4024 Forked Exhaust Pipe and Associated Parts............................................................................................4024 Removal.............................................................................................................................4024 Installation........................................................................................................................4024 Exhaust Silencer........................................................................................................................4025 Exhaust Silencer and Associated Parts...............................................................................................4025 Removal.............................................................................................................................4025 Installation........................................................................................................................4025 Rear Exhaust pipe.......................................................................................................................4026 Rear Exhaust pipe and Associated Parts..............................................................................................4026 Removal.............................................................................................................................4026 Installation........................................................................................................................4026 Main Data and Specifications............................................................................................................4027 6G ENGINE LUBRICATION (6VD1 3.2L).........................................................................................................4028 Service Precaution......................................................................................................................4028 General Description.....................................................................................................................4029 Oil Pump................................................................................................................................4030 Oil Pump and Associated Parts.......................................................................................................4030 Disassembly.........................................................................................................................4031 Inspection and Repair...............................................................................................................4031 Reassembly..........................................................................................................................4032 Oil Pan and Crankcase...................................................................................................................4034 Removal.............................................................................................................................4034 Installation........................................................................................................................4034 Oil Pump................................................................................................................................4036 Removal.............................................................................................................................4036 Installation........................................................................................................................4036 Oil Pump Oil Seal.......................................................................................................................4038 Removal.............................................................................................................................4038 Installation........................................................................................................................4038 Oil Filter..............................................................................................................................4039 Removal.............................................................................................................................4039 Installation........................................................................................................................4039 Main Data and Specification.............................................................................................................4040 6H ENGINE SPEED CONTROL SYSTEM (6VD1 3.2L)................................................................................................4041 Service Precaution......................................................................................................................4041 Accelerator Pedal.......................................................................................................................4042 Accelerator Pedal and Associated Parts..............................................................................................4042 Removal.............................................................................................................................4042 Installation........................................................................................................................4042 6J INDUCTION (6VD1 3.2L)..................................................................................................................4043 Service Precaution......................................................................................................................4043 Air Cleaner Element.....................................................................................................................4044 Removal.............................................................................................................................4044 Inspection..........................................................................................................................4044 Installation........................................................................................................................4044 Section.7 TRANSMISSION.......................................................................................................................4045 7A AUTOMATIC TRANSMISSION (4L30-E).......................................................................................................4045 Service Precaution......................................................................................................................4046 Construction............................................................................................................................4047 Range Reference Chart...................................................................................................................4048 Normal Operation of 2000 4L30-E Transmission............................................................................................4049 Diagnosis...............................................................................................................................4049 Driver Information......................................................................................................................4049 General Diagnosis Procedure.............................................................................................................4052 Preliminary Inspection Chart............................................................................................................4053 Checking Transmission Fluid Level and Condition.........................................................................................4054 Test Driving............................................................................................................................4055 Mechanical / Hydraulic Diagnosis Check Trans Indicator Chart............................................................................4056 Mechanical / Hydraulic Diagnosis Symptoms Index.........................................................................................4057 Stall Test..............................................................................................................................4066 Line Pressure Test......................................................................................................................4067 Shift Speed Chart.......................................................................................................................4068 Lockup Speed Chart......................................................................................................................4069 Changing Transmission Fluid.............................................................................................................4070 Selector Lever..........................................................................................................................4070 Inspection..........................................................................................................................4070 Removal.............................................................................................................................4070 Installation........................................................................................................................4072 Select Cable............................................................................................................................4072 Removal.............................................................................................................................4072 Installation........................................................................................................................4075 Shift Lock Cable........................................................................................................................4077 Removal.............................................................................................................................4077 Installation........................................................................................................................4077 Mode Switch.............................................................................................................................4078 Removal.............................................................................................................................4078 Installation........................................................................................................................4079 Transmission (With Transfer Case).......................................................................................................4080 Transmission and Associated Parts...................................................................................................4080 Removal.............................................................................................................................4081 Installation........................................................................................................................4086 Solenoid (Main Case Valve Body).........................................................................................................4090 Removal.............................................................................................................................4090 Installation........................................................................................................................4090 Solenoid (Adapter Case Valve Body)......................................................................................................4091 Removal.............................................................................................................................4091 Installation........................................................................................................................4091 Valve Body Assembly (Main Case).........................................................................................................4092 Removal.............................................................................................................................4092 Installation........................................................................................................................4092 Valve Body Assembly (Adapter Case)......................................................................................................4093 Removal.............................................................................................................................4093 Installation........................................................................................................................4093 Powertrain Control Module (PCM).........................................................................................................4093 Removal.............................................................................................................................4093 Installation........................................................................................................................4093 Speed Sensor (Extension Housing)........................................................................................................4094 Removal.............................................................................................................................4094 Installation........................................................................................................................4094 Transmission Oil Temperature Sensor (Main Case).........................................................................................4095 Removal.............................................................................................................................4095 Installation........................................................................................................................4095 Front Oil Seal (Converter Housing)......................................................................................................4096 Removal.............................................................................................................................4096 Installation........................................................................................................................4096 Rear Oil Seal (Extension Housing).......................................................................................................4096 Removal.............................................................................................................................4096 Installation........................................................................................................................4096 Transmission (4L30-E)...................................................................................................................4097 Disassembly.........................................................................................................................4097 Reassembly..........................................................................................................................4101 Converter Housing and Oil Pump Assembly.................................................................................................4111 Disassembled View...................................................................................................................4111 Disassembly.........................................................................................................................4111 Inspection and Repair...............................................................................................................4111 Reassembly..........................................................................................................................4111 Oil Pump................................................................................................................................4112 Disassembled View...................................................................................................................4112 Disassembly.........................................................................................................................4112 Inspection and Repair...............................................................................................................4112 Reassembly..........................................................................................................................4112 Main Case Valve Body....................................................................................................................4113 Disassembled View...................................................................................................................4113 Disassembly.........................................................................................................................4114 Inspection and Repair...............................................................................................................4114 Reassembly..........................................................................................................................4114 Adapter Case Valve Body.................................................................................................................4115 Disassembled View...................................................................................................................4115 Disassembly.........................................................................................................................4115 Inspection and Repair...............................................................................................................4115 Reassembly..........................................................................................................................4115 Third Clutch and Sprag Unit.............................................................................................................4116 Disassembled View...................................................................................................................4116 Disassembly.........................................................................................................................4116 Inspection and Repair...............................................................................................................4117 Reassembly..........................................................................................................................4117 Third Clutch............................................................................................................................4117 Disassembled View...................................................................................................................4117 Disassemble.........................................................................................................................4118 Inspection and Repair...............................................................................................................4118 Reassembly..........................................................................................................................4118 Sprag Unit..............................................................................................................................4119 Disassembled View...................................................................................................................4119 Disassembly.........................................................................................................................4119 Inspection and Repair...............................................................................................................4119 Reassembly..........................................................................................................................4119 Second Clutch...........................................................................................................................4120 Disassembled View...................................................................................................................4120 Disassembly.........................................................................................................................4120 Inspection and Repair...............................................................................................................4121 Reassembly..........................................................................................................................4121 3-4 Accumulator Piston..................................................................................................................4122 Disassembled View...................................................................................................................4122 Disassembly.........................................................................................................................4122 Inspection and Repair...............................................................................................................4123 Reassembly..........................................................................................................................4123 Reverse Clutch Piston and Center Support................................................................................................4124 Disassembled View...................................................................................................................4124 Disassembly.........................................................................................................................4125 Inspection and Repair...............................................................................................................4125 Reassembly..........................................................................................................................4125 Overrun Clutch and Turbine Shaft........................................................................................................4126 Disassembled View...................................................................................................................4126 Disassembly.........................................................................................................................4127 Inspection and Repair...............................................................................................................4127 Reassembly..........................................................................................................................4127 Main Data and Specification.............................................................................................................4129 Special Tools...........................................................................................................................4133 4L30-E Parts List.......................................................................................................................4136 7A1 TRANSMISSION CONTROL SYSTEM (4L30-E)...................................................................................................4143 Service Precaution......................................................................................................................4144 General Description.....................................................................................................................4144 Electronic Control Diagram..........................................................................................................4145 Powertrain Control Module (PCM).....................................................................................................4146 Control System Diagram..............................................................................................................4147 Shift Control.......................................................................................................................4148 Band Apply Control..................................................................................................................4148 Torque Converter Clutch Control.....................................................................................................4148 Line Pressure Control...............................................................................................................4148 On-Board Diagnostic System..........................................................................................................4148 Fail-Safe Mechanism.................................................................................................................4148 Torque Management Control...........................................................................................................4148 ATF Warning Control.................................................................................................................4148 Reverse Lock Out Control............................................................................................................4148 Downhill Control....................................................................................................................4148 Uphill Control......................................................................................................................4148 Shift Mode Control..................................................................................................................4149 Gear Shift Control..................................................................................................................4150 Winter Drive Mode...................................................................................................................4151 Backup Mode.........................................................................................................................4151 Functions of Input / Output Components..............................................................................................4152 Diagnosis...............................................................................................................................4153 Electronic Diagnosis................................................................................................................4153 Check Trans Indicator...............................................................................................................4153 Diagnostic Check....................................................................................................................4153 "Check Trans" Check.................................................................................................................4154 Tech 2 OBD II Connection............................................................................................................4155 Transmission Data...................................................................................................................4160 OBD II Diagnostic Management System.................................................................................................4161 16 - Terminal Data Link Connector (DLC).............................................................................................4162 Malfunction Indicator Lamp (MIL)....................................................................................................4163 Types Of Diagnostic Trouble Codes (DTCs)............................................................................................4163 Clear DTC...........................................................................................................................4163 DTC Check...........................................................................................................................4164 PCM Precaution......................................................................................................................4164 Information On PCM..................................................................................................................4164 Intermittent Conditions.............................................................................................................4165 Transmission and PCM Identification.................................................................................................4166 Isuzu Rodeo.........................................................................................................................4166 Diagnostic Trouble Code (DTC) Identification........................................................................................4167 DTC P0218 Transmission Fluid Over Temperature...........................................................................................4168 DTC P0705 Transmission Range Switch (Mode Switch) Illegal Position......................................................................4170 DTC P0706 Transmission Range Switch (Mode Switch) Performance...........................................................................4173 DTC P0711 Transmission Fluid Temperature (TFT) Sensor Performance.......................................................................4176 DTC P0712 Transmission Fluid Temperature (TFT) Sensor Circuit Low Input.................................................................4179 DTC P0713 Transmission Fluid Temperature (TFT) Sensor Circuit High Input................................................................4182 DTC P0719 Brake Switch Circuit Low (Stuck On)...........................................................................................4185 DTC P0722 Automatic Transmission Output Speed Sensor (OSS) Low Input....................................................................4188 DTC P0723 Automatic Transmission Output Speed Sensor (OSS) Intermittent.................................................................4191 DTC P0724 Brake Switch Circuit High (Stuck Off).........................................................................................4194 DTC P0730 Gear Error Without Input Speed................................................................................................4196 DTC P0742 Torque Converter Clutch (TCC) System Stuck On.................................................................................4199 DTC P0748 Pressure Control Solenoid (PCS) (Force Motor) Circuit Electrical..............................................................4201 DTC P0751 Shift Solenoid A Performance (Stuck Off)......................................................................................4203 DTC P0752 Shift Solenoid A Performance (Stuck On).......................................................................................4205 DTC P0753 Shift Solenoid A Electrical...................................................................................................4207 DTC P0756 Shift Solenoid B Performance (Stuck Off)......................................................................................4210 DTC P0757 Shift Solenoid B Performance (Stuck On).......................................................................................4212 DTC P0758 Shift Solenoid B Electrical...................................................................................................4214 DTC P1850 Brake Band Apply Solenoid Malfunction.........................................................................................4218 DTC P1860 TCC Solenoid Electrical.......................................................................................................4222 DTC P1870 Transmission Component Slipping (TCC Stuck Off)...............................................................................4225 Connector List..........................................................................................................................4227 7B MANUAL TRANSMISSION MUA 5C............................................................................................................4228 Service Precaution......................................................................................................................4228 General Description.....................................................................................................................4229 Diagnosis...............................................................................................................................4231 Rear Oil Seal (4X2).....................................................................................................................4232 Disassembled View...................................................................................................................4232 Removal.............................................................................................................................4232 Installation........................................................................................................................4232 Transmission............................................................................................................................4233 Disassembled View...................................................................................................................4233 Removal.............................................................................................................................4234 Installation........................................................................................................................4238 Transmission Case.......................................................................................................................4243 Major Component (4X2)...............................................................................................................4243 Disassembly.........................................................................................................................4244 Reassembly..........................................................................................................................4245 Transmission Case and Transfer Case.....................................................................................................4248 Major Component (4X4)...............................................................................................................4248 Disassembly.........................................................................................................................4249 Reassembly..........................................................................................................................4252 Intermediate Plate with Gear Assembly, Detent, Shift Arm, and Interlock Pin.............................................................4258 Disassembled View...................................................................................................................4258 Disassembly.........................................................................................................................4259 Inspection and Repair...............................................................................................................4260 Reassembly..........................................................................................................................4261 Reverse Gear and 5th Gear...............................................................................................................4262 Disassembled View...................................................................................................................4262 Disassembly.........................................................................................................................4263 Inspection and Repair...............................................................................................................4265 Reassembly..........................................................................................................................4265 Top Gear Shaft, Main Gear Shaft, and Counter Gear Shaft.................................................................................4271 Disassmebled View...................................................................................................................4271 Disassembly.........................................................................................................................4272 Inspection and Repair...............................................................................................................4273 Reassembly..........................................................................................................................4276 Main Data and Specifications............................................................................................................4282 Special Tools (MUA).....................................................................................................................4286 7C CLUTCH................................................................................................................................4288 Service Precaution......................................................................................................................4288 General Description.....................................................................................................................4289 Diagnosis...............................................................................................................................4294 Clutch Assembly (X22SE).................................................................................................................4295 Clutch Assembly (X22SE) and Associated Parts........................................................................................4295 Removal.............................................................................................................................4295 Inspection and Repair...............................................................................................................4296 Installation........................................................................................................................4300 Clutch Assembly (6VD1)..................................................................................................................4302 Clutch Assembly (6VD1) and Associated Parts.........................................................................................4302 Removal.............................................................................................................................4302 Inspection and Repair...............................................................................................................4304 Installation........................................................................................................................4308 Clutch Control..........................................................................................................................4310 Parts Location View.................................................................................................................4310 Removal.............................................................................................................................4311 Inspection and Repair...............................................................................................................4311 Installation........................................................................................................................4311 Master Cylinder.........................................................................................................................4314 Slave Cylinder..........................................................................................................................4315 Disassembled View...................................................................................................................4315 Disassembly.........................................................................................................................4315 Inspection and Repair...............................................................................................................4315 Reassembly..........................................................................................................................4316 Main Data and Specifications............................................................................................................4317 Special Tools...........................................................................................................................4320 Section.8 BODY AND ACCESSORIES...............................................................................................................4321 8A LIGHTING SYSTEM........................................................................................................................4321 Service Precaution......................................................................................................................4321 Headlight Bulb..........................................................................................................................4322 Headlight Assembly......................................................................................................................4322 Headlight Adjustment................................................................................................................4323 Fog Light Bulb..........................................................................................................................4323 Fog Light Assembly......................................................................................................................4324 Fog Light Adjustment................................................................................................................4324 Side Marker Light Bulb..................................................................................................................4324 Taillight Bulb..........................................................................................................................4325 License Plate Light Bulb (Bumper Type)..................................................................................................4325 License Plate Light Bulb (Tailgate Type)................................................................................................4326 Stoplight Bulb..........................................................................................................................4326 High Mounted Stoplight Assembly.........................................................................................................4327 High Mounted Stoplight Bulb.............................................................................................................4327 Backup Light Bulb.......................................................................................................................4328 Front Turn Signal Light Bulb............................................................................................................4328 Rear Turn Signal Light Bulb.............................................................................................................4329 Dome Light Bulb.........................................................................................................................4329 Courtesy Light Bulb.....................................................................................................................4330 Spotlight Bulb..........................................................................................................................4330 Luggage Room Light Bulb.................................................................................................................4331 HVAC Bezel Illumination Light Bulb......................................................................................................4331 Shift Lever Illumination Light Bulb (A/T)...............................................................................................4332 Vanity Mirror Illumination Light Bulb...................................................................................................4332 Starter Switch..........................................................................................................................4333 Lighting Switch (Combination Switch)....................................................................................................4333 Dimmer-Passing Switch (Combination Switch)..............................................................................................4333 Door Switch.............................................................................................................................4333 Rear Defogger Switch....................................................................................................................4334 Key Remind Switch (Starter Switch)......................................................................................................4334 Hazard Warning Light Switch.............................................................................................................4335 Stoplight Switch........................................................................................................................4335 Backup Light Switch.....................................................................................................................4336 Turn Signal Light Switch (Combination Switch)...........................................................................................4336 Illumination Controller.................................................................................................................4337 Light and Bulb Specifications...........................................................................................................4338 8B WIPER / WASHER SYSTEM..................................................................................................................4340 Service Precaution......................................................................................................................4340 Windshield Wiper/Washer System..........................................................................................................4341 General Description.....................................................................................................................4341 Windshield Wiper And Washer Switch......................................................................................................4341 Removal and Installation............................................................................................................4341 Windshield Wiper Motor..................................................................................................................4341 Removal.............................................................................................................................4341 Installation........................................................................................................................4341 Windshield Washer Motor.................................................................................................................4342 Removal.............................................................................................................................4342 Installation........................................................................................................................4342 Windshield Washer Spray Pattern.........................................................................................................4343 Windshield Wiper Linkage................................................................................................................4344 Windshield Wiper Linkage and Associated Parts.......................................................................................4344 Removal.............................................................................................................................4344 Installation........................................................................................................................4344 Windshield Wiper Arm/Blade..............................................................................................................4345 Removal.............................................................................................................................4345 Installation........................................................................................................................4345 Windshield Wiper Blade Rubber...........................................................................................................4346 Removal.............................................................................................................................4346 Installation........................................................................................................................4346 Rear Wiper/Washer System................................................................................................................4347 General Description.....................................................................................................................4347 Rear Wiper and Washer Switch............................................................................................................4347 Removal.............................................................................................................................4347 Installation........................................................................................................................4347 Rear Wiper Motor........................................................................................................................4348 Removal.............................................................................................................................4348 Installation........................................................................................................................4348 Rear Washer Motor.......................................................................................................................4349 Removal.............................................................................................................................4349 Installation........................................................................................................................4349 Alarm and Relay Control Unit............................................................................................................4349 Removal.............................................................................................................................4349 Installation........................................................................................................................4349 Rear Wiper Arm/Blade....................................................................................................................4350 Removal.............................................................................................................................4350 Installation........................................................................................................................4350 Rear Washer Nozzle......................................................................................................................4350 Removal.............................................................................................................................4350 Installation........................................................................................................................4350 Rear Washer Spray Pattern...........................................................................................................4350 Rear Wiper Blade Rubber.................................................................................................................4351 Removal.............................................................................................................................4351 Installation........................................................................................................................4351 Main Data and Specifications............................................................................................................4352 8C ENTERTAINMENT..........................................................................................................................4353 Service Precaution......................................................................................................................4353 Cigarette Lighter.......................................................................................................................4354 General Description.................................................................................................................4354 Removal.............................................................................................................................4354 Installation........................................................................................................................4354 Digital Clock...........................................................................................................................4354 Removal.............................................................................................................................4354 Installation........................................................................................................................4355 Rod Type Antenna........................................................................................................................4355 Removal.............................................................................................................................4355 Installation........................................................................................................................4355 Accessory Socket........................................................................................................................4356 Front Accessory Socket..............................................................................................................4356 Rear Accessory Socket...............................................................................................................4356 Radio...................................................................................................................................4357 Removal.............................................................................................................................4357 Installation........................................................................................................................4357 Speaker.................................................................................................................................4358 Front Speaker.......................................................................................................................4358 Tweeter Assembly....................................................................................................................4358 Rear Speaker........................................................................................................................4358 Horn....................................................................................................................................4359 Removal.............................................................................................................................4359 Installation........................................................................................................................4359 8D WIRING SYSTEM..........................................................................................................................4360 Fuse, Relay and Diode...................................................................................................................4361 Relay / Fuse Box Location...........................................................................................................4361 Relay / Fuse Box (Instrument Panel).................................................................................................4362 Relay / Fuse Box (L4 Engine Room)...................................................................................................4363 Relay / Fuse Box (V6 Engine Room)...................................................................................................4364 Circuit Diagram.........................................................................................................................4365 8E METER AND GAUGE........................................................................................................................4392 Service Precaution......................................................................................................................4392 General Description.....................................................................................................................4392 Meter Assembly..........................................................................................................................4393 General Description.................................................................................................................4393 Layout for Meters/Gauges, Warning Lights, Indicator Lights and Illumination Lights..................................................4393 Table for Meter/Gauge Connector Terminal Connections................................................................................4395 Removal.............................................................................................................................4397 Installation........................................................................................................................4397 Warning Light Bulb and Indicator Light Bulb.............................................................................................4397 Removal.............................................................................................................................4397 Installation........................................................................................................................4397 A/T Shift Indicator Light Bulb..........................................................................................................4398 Removal.............................................................................................................................4398 Installation........................................................................................................................4399 Vehicle Speed Sensor....................................................................................................................4399 Removal.............................................................................................................................4399 Installation........................................................................................................................4399 Fuel Tank Unit..........................................................................................................................4400 Removal.............................................................................................................................4400 Installation........................................................................................................................4400 Main Data and Specifications............................................................................................................4401 8F BODY STRUCTURE.........................................................................................................................4402 Service Precaution......................................................................................................................4403 Frame...................................................................................................................................4403 General Description.................................................................................................................4403 Frame Dimensions (LWB)..............................................................................................................4404 Frame Dimensions (SWB)..............................................................................................................4405 General Description (Bumper)............................................................................................................4406 Front Bumper............................................................................................................................4406 Parts Location......................................................................................................................4406 Removal.............................................................................................................................4407 Installation........................................................................................................................4407 Front Bumper Slider Bracket.............................................................................................................4408 Removal.............................................................................................................................4408 Installation........................................................................................................................4408 Rear Bumper.............................................................................................................................4409 Parts Location (Spare tire mounted tailgate model)..................................................................................4409 Removal.............................................................................................................................4410 Installation........................................................................................................................4410 Parts Location (Spare tire mounted under floor model)...............................................................................4412 Removal.............................................................................................................................4413 Installation........................................................................................................................4413 Rear Bumper Slider......................................................................................................................4414 Removal.............................................................................................................................4414 Installation........................................................................................................................4414 General Description (Sheet Metal).......................................................................................................4415 Engine Hood.............................................................................................................................4415 Parts Location......................................................................................................................4415 Removal.............................................................................................................................4416 Installation........................................................................................................................4416 Engine Hood Lock........................................................................................................................4418 Parts Location......................................................................................................................4418 Removal.............................................................................................................................4418 Installation........................................................................................................................4419 Radiator Grille.........................................................................................................................4420 Parts Location......................................................................................................................4420 Removal.............................................................................................................................4420 Installation........................................................................................................................4421 Front Fender Panel......................................................................................................................4422 Parts Location......................................................................................................................4422 Removal.............................................................................................................................4422 Installation........................................................................................................................4423 Body Mounting...........................................................................................................................4425 Parts Location......................................................................................................................4425 Tightening Torque...................................................................................................................4425 Body Dimension..........................................................................................................................4426 General Description (Body)..............................................................................................................4441 Instrument Panel Assembly...............................................................................................................4441 Parts Location......................................................................................................................4441 Removal.............................................................................................................................4442 Installation........................................................................................................................4444 Front Door Assembly.....................................................................................................................4445 Parts Location......................................................................................................................4445 Removal.............................................................................................................................4445 Installation........................................................................................................................4446 Rear Door Assembly......................................................................................................................4447 Parts Location......................................................................................................................4447 Removal.............................................................................................................................4447 Installation........................................................................................................................4448 Front Window Regulator, Glass and Glass Run.............................................................................................4449 Parts Location......................................................................................................................4449 Removal.............................................................................................................................4450 Installation........................................................................................................................4452 Rear Window Regulator, Glass and Glass Run..............................................................................................4453 Parts Location......................................................................................................................4453 Removal.............................................................................................................................4454 Installation........................................................................................................................4456 Tailgate (LWB)..........................................................................................................................4457 Parts Location......................................................................................................................4457 Removal.............................................................................................................................4458 Installation........................................................................................................................4458 Tailgate (SWB)..........................................................................................................................4460 Parts Location......................................................................................................................4460 Removal.............................................................................................................................4460 Installation........................................................................................................................4461 Rear Hatchgate (LWB)....................................................................................................................4462 Parts Location......................................................................................................................4462 Removal.............................................................................................................................4463 Installation........................................................................................................................4463 Adjustment..........................................................................................................................4465 Tailgate Glass (Resin Top)..............................................................................................................4466 Parts Location......................................................................................................................4466 Removal.............................................................................................................................4466 Installation........................................................................................................................4467 Spare Tire Carrier......................................................................................................................4468 Parts Location......................................................................................................................4468 Removal.............................................................................................................................4468 Installation........................................................................................................................4468 Spare Tire Hanger.......................................................................................................................4469 Parts Location......................................................................................................................4469 Removal.............................................................................................................................4470 Installation........................................................................................................................4470 Windshield..............................................................................................................................4471 Parts Location......................................................................................................................4471 Removal.............................................................................................................................4471 Installation........................................................................................................................4472 Rear Quarter Glass (LWB)................................................................................................................4475 Parts Location......................................................................................................................4475 Removal.............................................................................................................................4475 Installation........................................................................................................................4476 Rear Quarter Glass (Resin Top)..........................................................................................................4477 Parts Location......................................................................................................................4477 Removal.............................................................................................................................4477 Installation........................................................................................................................4477 Side Window Glass (SWB).................................................................................................................4479 Parts Location......................................................................................................................4479 Removal.............................................................................................................................4479 Installation........................................................................................................................4479 Main Data and Specifications............................................................................................................4481 Special Tools...........................................................................................................................4484 8G SEATS..................................................................................................................................4485 Service Precaution......................................................................................................................4485 Front Seat Assembly.....................................................................................................................4486 Front Seat Assembly and Associated Parts............................................................................................4486 Removal.............................................................................................................................4486 Installation........................................................................................................................4488 Rear Seat Assembly (LWB)................................................................................................................4489 Rear Seat Cushion Assembly and Associated Parts.....................................................................................4489 Removal.............................................................................................................................4489 Installation........................................................................................................................4490 Rear Seat Back Assembly and Associated Parts........................................................................................4491 Removal.............................................................................................................................4491 Installation........................................................................................................................4492 Rear Seat Assembly (SWB)................................................................................................................4493 Rear Seat Assembly and Associated Parts.............................................................................................4493 Removal.............................................................................................................................4494 Installation........................................................................................................................4494 Main Data and Specifications............................................................................................................4495 8H SECURITY AND LOCKS.....................................................................................................................4497 Service Precaution......................................................................................................................4497 Front Door Lock Assembly................................................................................................................4498 Front Door Lock Assembly and Associated Parts.......................................................................................4498 Removal.............................................................................................................................4499 Installation........................................................................................................................4500 Front Outside Handle....................................................................................................................4501 Front Outside Handle and Associated Parts...........................................................................................4501 Removal.............................................................................................................................4501 Installation........................................................................................................................4501 Rear Door Lock Assembly.................................................................................................................4502 Rear Door Lock Assembly and Associated Parts........................................................................................4502 Removal.............................................................................................................................4503 Installation........................................................................................................................4503 Rear Outside Handle.....................................................................................................................4505 Rear Outside Handle and Associated Parts............................................................................................4505 Removal.............................................................................................................................4505 Installation........................................................................................................................4505 Tailgate Lock and Hatchgate Lock (LWB)..................................................................................................4506 Tailgate Lock, Hatchgate Lock and Associated Parts..................................................................................4506 Removal.............................................................................................................................4507 Installation........................................................................................................................4507 Tailgate Lock (SWB).....................................................................................................................4508 Tailgate Lock and Associated Parts..................................................................................................4508 Removal.............................................................................................................................4508 Installation........................................................................................................................4509 Key.....................................................................................................................................4510 Key Coding..........................................................................................................................4510 Key Styles..........................................................................................................................4510 Power Door Lock System..................................................................................................................4511 General Description.................................................................................................................4511 Door Lock Key Switch................................................................................................................4511 Front Door Lock Actuator............................................................................................................4511 Rear Door Lock Actuator.............................................................................................................4511 Tailgate Lock Actuator..............................................................................................................4511 Anti-Theft System.......................................................................................................................4511 General Description.................................................................................................................4511 Anti-Theft & Keyless Entry Controller...............................................................................................4511 Anti-Theft Indicator................................................................................................................4512 Anti-Theft Horn.....................................................................................................................4512 Engine Hood Switch..................................................................................................................4513 Anti-theft & Keyless Entry Control Unit/Transmitter Replacement.....................................................................4513 Main Data and Specifications............................................................................................................4514 8I SUNROOF/CONVERTIBLE TOP...............................................................................................................4515 Service Precaution......................................................................................................................4515 Sunroof Glass (LWB).....................................................................................................................4516 Sunroof Glass and Associated Parts..................................................................................................4516 Removal.............................................................................................................................4516 Installation........................................................................................................................4517 Sunroof Glass (SWB).....................................................................................................................4517 Sunroof Glass and Associated Parts..................................................................................................4517 Removal.............................................................................................................................4518 Installation........................................................................................................................4518 Sunroof Deflector (LWB).................................................................................................................4519 Removal.............................................................................................................................4519 Installation........................................................................................................................4519 Sunroof Deflector (SWB).................................................................................................................4520 Parts Location......................................................................................................................4520 Removal.............................................................................................................................4520 Installation........................................................................................................................4520 Sunshade (LWB)..........................................................................................................................4521 Disassembled View...................................................................................................................4521 Removal.............................................................................................................................4521 Installation........................................................................................................................4522 Sunroof Frame Complete Assembly (LWB)...................................................................................................4523 Sunroof Frame Complete Assembly and Associated Parts................................................................................4523 Removal.............................................................................................................................4523 Installation........................................................................................................................4524 Sunroof Switch..........................................................................................................................4524 Removal.............................................................................................................................4524 Installation........................................................................................................................4524 Sunroof Control Unit....................................................................................................................4525 Removal.............................................................................................................................4525 Installation........................................................................................................................4525 Safety Stop Switch......................................................................................................................4525 Removal.............................................................................................................................4525 Installation........................................................................................................................4525 Limit Switch............................................................................................................................4526 Removal.............................................................................................................................4526 Installation........................................................................................................................4526 Sunroof Motor...........................................................................................................................4526 Removal.............................................................................................................................4526 Installation........................................................................................................................4526 Soft Top Assembly.......................................................................................................................4527 Soft Top Assembly and Associated Parts..............................................................................................4527 Removal.............................................................................................................................4528 Installation........................................................................................................................4528 Resin Top Assembly......................................................................................................................4529 Resin Top Assembly and Associated Parts.............................................................................................4529 Removal.............................................................................................................................4529 Installation........................................................................................................................4530 Seat Belt Cross Bar Assembly............................................................................................................4531 Seat Belt Cross Bar Assembly and Associated Parts...................................................................................4531 Removal.............................................................................................................................4531 Installation........................................................................................................................4532 Main Data and Specifications............................................................................................................4533 8J EXTERIOR / INTERIOR TRIM...............................................................................................................4534 Service Precaution......................................................................................................................4535 Consoles................................................................................................................................4536 Consoles and Associated Parts.......................................................................................................4536 Removal.............................................................................................................................4536 Installation........................................................................................................................4536 Front Door Trim Panel...................................................................................................................4537 Front Door Trim Panel and Associated Parts..........................................................................................4537 Removal.............................................................................................................................4538 Installation........................................................................................................................4538 Rear Door Trim Panel....................................................................................................................4539 Rear Door Trim Panel and Associated Parts...........................................................................................4539 Removal.............................................................................................................................4539 Installation........................................................................................................................4540 Door Mirror Assembly....................................................................................................................4541 Removal.............................................................................................................................4541 Installation........................................................................................................................4541 Interior Trim Panels (LWB)..............................................................................................................4542 Interior Trim Panels and Associated Parts...........................................................................................4542 Removal.............................................................................................................................4542 Installation........................................................................................................................4544 Interior Trim Panels (SWB)..............................................................................................................4545 Interior Trim Panels and Associated Parts...........................................................................................4545 Removal.............................................................................................................................4545 Installation........................................................................................................................4546 Headlining (LWB)........................................................................................................................4547 Parts Location......................................................................................................................4547 Removal.............................................................................................................................4547 Installation........................................................................................................................4548 Headlining (SWB)........................................................................................................................4549 Parts Location......................................................................................................................4549 Removal.............................................................................................................................4550 Installation........................................................................................................................4551 Wheel Arch Protector (LWB)..............................................................................................................4552 Wheel Arch Protector and Associated Parts...........................................................................................4552 Removal.............................................................................................................................4552 Installation........................................................................................................................4552 Wheel Arch Protector (SWB)..............................................................................................................4553 Wheel Arch Protector and Associated Parts...........................................................................................4553 Removal.............................................................................................................................4553 Installation........................................................................................................................4553 Wheel Arch Molding (SWB)................................................................................................................4554 Wheel Arch Molding and Associated Parts.............................................................................................4554 Removal.............................................................................................................................4554 Installation........................................................................................................................4555 Wheel Arch Molding (LWB)................................................................................................................4556 Wheel Arch Molding and Associated Parts.............................................................................................4556 Removal.............................................................................................................................4556 Installation........................................................................................................................4557 Fuel Filler Door........................................................................................................................4558 Parts Location......................................................................................................................4558 Removal.............................................................................................................................4558 Installation........................................................................................................................4558 Roof Rail...............................................................................................................................4559 Parts Location......................................................................................................................4559 Removal.............................................................................................................................4559 Installation........................................................................................................................4559 Power Door Mirror System................................................................................................................4560 General Description.................................................................................................................4560 Door Mirror Switch..................................................................................................................4560 Power Window System.....................................................................................................................4561 General Description.................................................................................................................4561 Power Window Switch Driver Seat Side................................................................................................4561 Power Window Motor..................................................................................................................4562 Main Data and Specifications............................................................................................................4563 Section.9 RESTRAINTS.........................................................................................................................4564 9A SEAT BELT SYSTEM......................................................................................................................4564 Service Precaution......................................................................................................................4564 Front Seat Belt (LWB)...................................................................................................................4565 Front Seat Belt and Associated Parts................................................................................................4565 Removal.............................................................................................................................4565 Inspection..........................................................................................................................4565 Installation........................................................................................................................4566 Front Seat Belt (SWB)...................................................................................................................4567 Front Seat Belt and Associated Parts................................................................................................4567 Removal.............................................................................................................................4567 Inspection..........................................................................................................................4568 Installation........................................................................................................................4568 Rear Seat Belt (LWB)....................................................................................................................4569 Rear Seat Belt and Associated Parts.................................................................................................4569 Removal.............................................................................................................................4569 Inspection..........................................................................................................................4570 Installation........................................................................................................................4570 Rear Seat Belt (SWB)....................................................................................................................4571 Rear Seat Belt and Associated Parts.................................................................................................4571 Removal.............................................................................................................................4571 Inspection..........................................................................................................................4573 Installation........................................................................................................................4573 Front Seat Buckle Assembly..............................................................................................................4574 Removal.............................................................................................................................4574 Installation........................................................................................................................4574 Rear Center Seat Belt / Buckle Assembly.................................................................................................4575 Rear Center Seat Belt / Buckle Assembly and Associated Parts........................................................................4575 Removal.............................................................................................................................4575 Installation........................................................................................................................4575 Child Seat Tether Anchor Bracket (Child Restraint)......................................................................................4576 General Description.................................................................................................................4576 Child Seat Tether Anchor Bracket and Associated Parts...............................................................................4576 Installation........................................................................................................................4576 Main Data and Specifications............................................................................................................4577 9J SEAT BELT SYSTEM......................................................................................................................4579 Service Precaution......................................................................................................................4580 General Description.....................................................................................................................4580 Restraint Devices...................................................................................................................4580 System Description..................................................................................................................4581 SRS Component and Wiring Location View..................................................................................................4582 Component Description...............................................................................................................4582 SDM (Sensing and Diagnostic Module).................................................................................................4582 "Air Bag" Warning Lamp..............................................................................................................4583 SRS Coil Assembly...................................................................................................................4583 Air Bag Assemblies..................................................................................................................4583 Steering Column.....................................................................................................................4584 Knee Bolster........................................................................................................................4584 Definition..............................................................................................................................4584 Diagnosis...............................................................................................................................4585 Diagnostic Trouble Codes............................................................................................................4585 Scan Tool Diagnostics...............................................................................................................4585 Use of Special Tools................................................................................................................4586 SRS Connector Body Face Views...........................................................................................................4586 Repairs and Inspections Required After an Accident......................................................................................4586 Accident With Deployment - Component Replacement and Inspections....................................................................4587 Accident With or Without Deployment佑omponent Inspection.............................................................................4587 SDM Replacement Guidelines..........................................................................................................4587 Wiring Damage.......................................................................................................................4587 SRS Connector (Plastic Body And Terminal Metal Pin) Damage..........................................................................4587 SRS Wire Pigtail Damage.............................................................................................................4587 On-Vehicle Service......................................................................................................................4587 Service Precautions.................................................................................................................4587 Disabling The SRS...................................................................................................................4587 Enabling The SRS....................................................................................................................4587 Handling / Installation / Diagnosis.................................................................................................4588 Air Bag Assembly Handling / Shipping / Scrapping........................................................................................4588 Live (Undeployed) Air Bag Assembly..................................................................................................4588 Air Bag Assembly Shipping Procedure For Live (Undeployed) Air Bag Assemblies........................................................4589 Deployed Air Bag Assembly...........................................................................................................4589 Air Bag Assembly Scrapping Procedure................................................................................................4589 Deployment Outside Vehicle (Driver Air Bag Assembly)................................................................................4589 Deployment Outside Vehicle (Passenger Air Bag Assembly).............................................................................4591 Deployment Inside Vehicle (Vehicle Scrapping Procedure).............................................................................4593 Deployed Air Bag Assembly Handling..................................................................................................4596 Special Tools...........................................................................................................................4596 J-41433 SRS Driver/Passenger Load Tool..............................................................................................4596 J-39200 DVM.........................................................................................................................4597 Scan Tool...........................................................................................................................4597 J-35616-A Connector Test Adapter Kit................................................................................................4597 J-42986 SRS Deployment Tool.........................................................................................................4597 J-42987 SRS Adapter For Load Tool...................................................................................................4598 J-41497 SRS Deployment Fixture......................................................................................................4598 Tech 2 Scan Tool....................................................................................................................4599 DTC Modes...........................................................................................................................4602 Plottong Snapshot Graph.................................................................................................................4602 Plotting Graph Flow Chart (Plotting graph after obtaining vehicle information)......................................................4603 Flow Chart for Snapshot Replay (Plotting Graph).....................................................................................4604 Service Precaution......................................................................................................................4605 Disabling The SRS...................................................................................................................4605 Enabling The SRS....................................................................................................................4605 Handling / Installation / Diagnosis.................................................................................................4605 Inspections Required After An Accident..............................................................................................4605 Sensing and Diagnostic Module (SDM).....................................................................................................4606 Service Precautions.................................................................................................................4606 Removal.............................................................................................................................4606 Installation........................................................................................................................4607 Driver Air Bag Assembly.................................................................................................................4607 Service Precautions.................................................................................................................4607 Removal.............................................................................................................................4607 Installation........................................................................................................................4608 Steering Wheel..........................................................................................................................4608 Service Precautions.................................................................................................................4608 Removal.............................................................................................................................4608 Installation........................................................................................................................4609 SRS Coil Assembly.......................................................................................................................4610 Service Precaution..................................................................................................................4610 Removal.............................................................................................................................4610 Installation........................................................................................................................4610 Steering Column.........................................................................................................................4612 Service Precaution..................................................................................................................4612 Removal.............................................................................................................................4612 Installation........................................................................................................................4613 Passenger Air Bag Assembly..............................................................................................................4614 Service Precaution..................................................................................................................4614 Removal.............................................................................................................................4614 Installation........................................................................................................................4614 9J1 SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...................................................................................................4615 Service Precaution......................................................................................................................4615 Diagnostic Information..................................................................................................................4616 Diagnostic Procedures...............................................................................................................4616 Diagnostic Codes....................................................................................................................4616 How To Read Trouble Codes...........................................................................................................4616 How To Clear Trouble Codes..........................................................................................................4616 Scan Tool Diagnostics...............................................................................................................4616 Basic Knowledge Required............................................................................................................4616 Basic Electrical Circuits...........................................................................................................4616 "Flash Code" Diagnostics............................................................................................................4616 System Schematic........................................................................................................................4617 SRS Diagnostic System Check.............................................................................................................4618 Chart A SDM Integrity Check.............................................................................................................4620 Chart B "AIR BAG" Warning Lamp Comes "ON" Steady........................................................................................4622 Chart C "AIR BAG" Warning Lamp Does Not Comes "ON" Steady...............................................................................4624 DTC 15 Passenger Deployment Loop Resistance High........................................................................................4627 DTC 16 Passenger Deployment Loop Resistance Low.........................................................................................4630 DTC 17 Passenger Deployment Loop Open...................................................................................................4633 DTC 18 Passenger Deployment Loop Short To Ground........................................................................................4635 DTC 19 Passenger Deployment Loop Short To Voltage.......................................................................................4637 DTC 21 Driver Deployment Loop Resistance High...........................................................................................4639 DTC 22 Driver Deployment Loop Resistance Low............................................................................................4642 DTC 24 Driver Deployment Loop Short To Ground...........................................................................................4645 DTC 25 Driver Deployment Loop Short To Voltage..........................................................................................4647 DTC 26 Driver Deployment Loop Open......................................................................................................4650 DTC 51 Deployment Event Commanded.......................................................................................................4653 DTC 53 Deployment Commanded With Deployment Loop Fault Or Energy Reserves Out Of Range..................................................4655 DTC 61 Warning Lamp Circuit Failure.....................................................................................................4657 DTC 71 Internal SDM Fault...............................................................................................................4659 Section.10 CONTROL SYSTEM......................................................................................................................4661 10A CRUISE CONTROL SYSTEM.................................................................................................................4661 Service Precaution......................................................................................................................4661 General Description.....................................................................................................................4661 Brake Switch............................................................................................................................4662 Removal and Installation............................................................................................................4662 Adjustment..........................................................................................................................4662 Clutch Switch...........................................................................................................................4663 Removal and Installation............................................................................................................4663 Adjustment..........................................................................................................................4663 Powertrain Control Module (PCM) Removal and Installation................................................................................4663 Mode Switch Removal and Installation................................................................................................4663 Cruise Control Main Switch..............................................................................................................4664 Removal.............................................................................................................................4664 Installation........................................................................................................................4664 Cruise Control Switch (Combination Switch)..............................................................................................4664 Removal and Installation............................................................................................................4664 Diagnosis...............................................................................................................................4665 AMIGO...............................................................................................................................................4666 Section.0 GENERAL INFORMATION.................................................................................................................4667 0A General Information....................................................................................................................4667 General Repair Instruction..............................................................................................................4667 Illustration Arrows.....................................................................................................................4668 Identification..........................................................................................................................4669 Theft Prevention Standard...............................................................................................................4672 Lifting Instructions....................................................................................................................4677 Standard Bolts Torque Specifications....................................................................................................4679 Abbreviations Charts....................................................................................................................4680 Service Parts Identification Plate......................................................................................................4681 0B Maintenance and Lubrication............................................................................................................4682 Maintenance Schedule List...............................................................................................................4682 Explanation of Complete Vehicle Maintenance Schedule....................................................................................4686 Recommended Fluids and Lubricants...................................................................................................4689 Lubricant Viscosity Chart...............................................................................................................4690 Recommended Liquid Gasket...........................................................................................................4692 Recommended Thread Locking Agents...................................................................................................4692 Maintenance Service Data................................................................................................................4693 Section.2 STEERING............................................................................................................................4694 2A POWER-ASSISTED STEERING SYSTEM.........................................................................................................4694 Service Precaution......................................................................................................................4695 Diagnosis...............................................................................................................................4695 General Description.....................................................................................................................4701 Power Steering System Test..............................................................................................................4703 Maintenance.............................................................................................................................4704 Fluid Level.............................................................................................................................4704 Bleeding The Power Steering System......................................................................................................4704 Bleeding Procedure......................................................................................................................4704 Flushing The Power Steering System......................................................................................................4704 Steering Wheel Free Play Inspection.....................................................................................................4705 Front End Alignment Inspection and Adjustment...........................................................................................4705 Main Data and Specifications............................................................................................................4709 Special Tools...........................................................................................................................4710 Power Steering Unit.....................................................................................................................4711 Power Steering Unit and Associated Parts............................................................................................4711 Removal.............................................................................................................................4711 Installation (4 × 2 Model)..........................................................................................................4712 Installation (4 × 4 Model)..........................................................................................................4712 Power Steering Unit Disassembled View...............................................................................................4713 Disassembly.........................................................................................................................4713 Inspection and Repair...............................................................................................................4713 Reassembly..........................................................................................................................4713 Main Data and Specifications........................................................................................................4714 Special Tools.......................................................................................................................4714 Power Steering Pump.....................................................................................................................4715 Power Steering Pump and Associated Parts............................................................................................4715 Removal.............................................................................................................................4715 Installation........................................................................................................................4715 Power Steering Pump Disassembled View...............................................................................................4716 Disassembly.........................................................................................................................4716 Inspection and Repair...............................................................................................................4717 Reassembly..........................................................................................................................4717 Main Data and Specifications........................................................................................................4719 Transfer Gear Assembly..................................................................................................................4720 Transfer Gear Assembly and Associated Parts.........................................................................................4720 Removal.............................................................................................................................4720 Inspection and Repair...............................................................................................................4720 Installation........................................................................................................................4720 Supplemental Restraint System Steering Wheel & Column...................................................................................4721 Service Precaution..................................................................................................................4721 Inflator Module.........................................................................................................................4722 Inflator Module and Associated Parts................................................................................................4722 Removal.............................................................................................................................4722 Inspection and Repair...............................................................................................................4723 Installation........................................................................................................................4723 Steering Wheel..........................................................................................................................4724 Steering Wheel and Associated Parts.................................................................................................4724 Removal.............................................................................................................................4724 Installation........................................................................................................................4726 Combination Switch......................................................................................................................4727 Combination Switch and Associated Parts.............................................................................................4727 Removal.............................................................................................................................4727 Installation........................................................................................................................4729 Lock Cylinder...........................................................................................................................4731 Lock Cylinder and Associated Parts..................................................................................................4731 Removal.............................................................................................................................4731 Installation........................................................................................................................4733 System Inspection...................................................................................................................4734 Steering Column.........................................................................................................................4735 Steering Column and Associated Parts................................................................................................4735 Removal.............................................................................................................................4735 Installation........................................................................................................................4737 System Inspection...................................................................................................................4738 Supplemental Restraint System Steering Wheel & Column and Associated Parts..............................................................4739 Main Data and Specifications........................................................................................................4739 Special Tools.......................................................................................................................4739 Section.3 SUSPENSION..........................................................................................................................4740 3C FRONT SUSPENSION.......................................................................................................................4740 Service Precaution......................................................................................................................4740 General Description.....................................................................................................................4741 Diagnosis...............................................................................................................................4741 Shock Absorber..........................................................................................................................4744 Shock Absorber and Associated Parts.................................................................................................4744 Removal.............................................................................................................................4744 Inspection and Repair...............................................................................................................4744 Installation........................................................................................................................4744 Stabilizer Bar..........................................................................................................................4745 Stabilizer Bar and Associated Parts.................................................................................................4745 Removal.............................................................................................................................4745 Inspection and Repair...............................................................................................................4745 Installation........................................................................................................................4745 Torsion Bar.............................................................................................................................4746 Torsion Bar and Associated Parts....................................................................................................4746 Removal.............................................................................................................................4746 Inspection and Repair...............................................................................................................4747 Installation........................................................................................................................4747 Knuckle.................................................................................................................................4749 Knuckle and Associated Parts........................................................................................................4749 Removal.............................................................................................................................4749 Inspection and Repair...............................................................................................................4750 Installation........................................................................................................................4750 Upper Control Arm.......................................................................................................................4752 Upper Control Arm and Associated Parts..............................................................................................4752 Removal.............................................................................................................................4752 Inspection and Repair...............................................................................................................4753 Installation........................................................................................................................4753 Lower Control Arm.......................................................................................................................4755 Lower Control Arm and Associated Parts..............................................................................................4755 Removal.............................................................................................................................4755 Inspection and Repair...............................................................................................................4756 Installation........................................................................................................................4757 Upper Ball Joint........................................................................................................................4758 Upper Ball Joint and Associated Parts...............................................................................................4758 Removal.............................................................................................................................4758 Inspection and Repair...............................................................................................................4759 Installation........................................................................................................................4759 Lower Ball Joint........................................................................................................................4760 Lower Ball Joint and Associated Parts...............................................................................................4760 Removal.............................................................................................................................4760 Inspection and Repair...............................................................................................................4761 Installation........................................................................................................................4761 Main Data and Specifications............................................................................................................4762 Special Tools...........................................................................................................................4763 3D REAR SUSPENSION........................................................................................................................4764 Service Precaution......................................................................................................................4764 General Description.....................................................................................................................4764 Diagnosis...............................................................................................................................4765 Coil Spring.............................................................................................................................4768 Coil Spring and Associated Parts....................................................................................................4768 Removal.............................................................................................................................4768 Inspection and Repair...............................................................................................................4769 Installation........................................................................................................................4769 Shock Absorber..........................................................................................................................4770 Shock Absorber and Associated Parts.................................................................................................4770 Removal.............................................................................................................................4770 Inspection and Repair...............................................................................................................4770 Installation........................................................................................................................4770 Trailing Link...........................................................................................................................4771 Trailing Link and Associated Parts..................................................................................................4771 Removal.............................................................................................................................4771 Inspection and Repair...............................................................................................................4771 Installation........................................................................................................................4772 Upper Link..............................................................................................................................4773 Upper Link and Associated Parts.....................................................................................................4773 Removal.............................................................................................................................4773 Inspection and Repair...............................................................................................................4773 Installation........................................................................................................................4774 Lateral Rod.............................................................................................................................4775 Lateral Rod and Associated Parts....................................................................................................4775 Removal.............................................................................................................................4775 Inspection and Repair...............................................................................................................4775 Installation........................................................................................................................4776 Stabilizer Bar..........................................................................................................................4777 Stabilizer Bar and Associated Parts.................................................................................................4777 Removal.............................................................................................................................4777 Inspection and Repair...............................................................................................................4777 Installation........................................................................................................................4778 Main Data and Specifications............................................................................................................4778 Special Tools...........................................................................................................................4780 3E WHEEL AND TIRE SYSTEM..................................................................................................................2354 3F INTELLIGENT SUSPENSION SYSTEM..........................................................................................................4781 Service Precaution......................................................................................................................4782 General Description.....................................................................................................................4782 PIN ASSIGNMENT TABLE................................................................................................................4784 System Components...................................................................................................................4784 Control Unit........................................................................................................................4784 Actuator............................................................................................................................4784 Adjustable Damping Force Shock Absorber.............................................................................................4784 Warning Lamp........................................................................................................................4784 Vertical G-Sensor...................................................................................................................4785 Horizontal G-Sensor.................................................................................................................4785 Acronyms and Abbreviations..........................................................................................................4785 General Diagnosis.......................................................................................................................4785 General Information.................................................................................................................4785 Service Precautions.................................................................................................................4785 Computer System Service Precautions.................................................................................................4785 General Service Precautions.........................................................................................................4785 Parts Handling......................................................................................................................4785 FLASHING CODES......................................................................................................................4786 CLEAR DTC...........................................................................................................................4787 INTERMITTENT CONDITIONS.............................................................................................................4788 BULB CHECK..........................................................................................................................4788 DTC CHECK...........................................................................................................................4788 Basic Diagnosis Flow................................................................................................................4789 Circuit Diagram.....................................................................................................................4790 Parts Location......................................................................................................................4793 Connector List......................................................................................................................4794 Diagnostic Trouble Code (DTC) Identification........................................................................................4796 DTC2 Actuator Coil Over Current.........................................................................................................4797 Circuit Description.................................................................................................................4797 Diagnostic Aids.....................................................................................................................4797 DTC3 Actuator Coil/Position Sensor Open Circuit or Short................................................................................4799 Circuit Description.................................................................................................................4799 Diagnostic Aids.....................................................................................................................4799 DTC4 G-Sensor Open Circuit or Short.....................................................................................................4802 Circuit Description.................................................................................................................4802 Diagnostic Aids.....................................................................................................................4802 DTC5 Vehicle Speed Sensor Open Circuit or Short.........................................................................................4803 Circuit Description.................................................................................................................4803 Diagnostic Aids.....................................................................................................................4803 DTC6 Stop Lamp Switch Open Circuit or Short.............................................................................................4805 Circuit Description.................................................................................................................4805 Diagnostic Aids.....................................................................................................................4805 DTC7 Engine Speed Signal Open Circuit or Short..........................................................................................4807 Circuit Description.................................................................................................................4807 Diagnostic Aids.....................................................................................................................4807 DTC9 Control Unit Abnormality.......................................................................................................4808 Control Unit............................................................................................................................4812 Control Unit and Associated Parts...................................................................................................4812 Removal.............................................................................................................................4812 Installation........................................................................................................................4813 Front Actuator..........................................................................................................................4814 Front Actuator and Associated Parts.................................................................................................4814 Removal.............................................................................................................................4815 Inspection and Repair...............................................................................................................4815 Installation........................................................................................................................4815 Rear Shock Absorber.....................................................................................................................4816 Rear Shock Absorber and Associated Parts............................................................................................4816 Removal.............................................................................................................................4817 Inspection and Repair...............................................................................................................4817 Installation........................................................................................................................4817 Section.4 DRIVELINE/AXLE......................................................................................................................4818 4A1 DIFFERENTIAL (FRONT)..................................................................................................................4818 Main Data And Specifications............................................................................................................4819 4A2 DIFFERENTIAL (REAR)...................................................................................................................4820 Main Data And Specifications............................................................................................................4821 4C DRIVE SHAFT SYSTEM.....................................................................................................................4822
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