Ranger Drifter Repair Manual F161!10!99a

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RANG.DRFT.REPAIR MANUAL
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Ranger / Drifter Repair Manual

FOREWORD
This Manual has been prepared to provide information covering normal service repairs and maintenance for the RANGER / DRIFTER SERIES. As all information in this manual was the best available at the time of printing, vehicle specification and other information will be updated in Service Information.
Ford/Mazda Motor Company
WARNING
Servicing a vehicle can be dangerous. If you have not received service-related training, the risks of injury, property damage, and failure of servicing increase. The recommended servicing procedures for the vehicle in this workshop manual were developed with Ford/Mazda-trained technicians in mind. This manual may be useful to non-Ford/Mazda trained technicians, but a technician with our service-related training and experience will be at less risk when performing service operations. However, all users of this manual are excepted at least to know general safety procedures. This manual contains "Warnings" and "Cautions" applicable to risks not normally encountered in a general technician's experience. They should be followed to reduce the risk of injury and the risk that improper service or repair may damage the vehicle or render it unsafe. It is also important to understand that the "Warnings" and "Cautions" are not exhaustive. It is impossible to warn of all the hazardous consequences that might result from failure to follow the procedures. The procedures recommended and described in this manual are effective methods of performing service and repair. Some require tools specifically designed for a specific purpose. Persons using procedures and tools, which are not recommended by Ford/Mazda Motor Corporation, must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. The contents of this manual, including drawings and specifications, are the latest available at the time of printing, and Ford/Mazda Motor Corporation reserves the right to change the vehicle designs and alter the contents of this manual without notice and without incurring obligation. Parts should be replaced with genuine Ford/Mazda replacement parts or with parts, which match the quality of genuine Ford/Mazda replacement parts. Persons using replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts must satisfy themselves thoroughly that neither personal safety nor safety of the vehicle will be jeopardized. Ford/Mazda Motor Corporation is not responsible for any problems, which may arise from the use of this manual. The cause of such problems includes but is not limited to insufficient service related training, use of improper tools, use of replacement parts of lesser quality than that of genuine Ford/Mazda replacement parts, or not being aware of any revision of this manual.
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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL
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CONTENTS
Title General Information Section GI GI G6 Engine F8/FE WL, WL Turbo F2 Lubrication System Cooling System G6 Fuel and Emission Control Systems WL, WL Turbo F2 CIS F2 CARB Engine Electrical System Clutch M15MD M15MXD R15MD R15MXD Transfer Propeller Shaft Front and Rear Axles Steering System Braking System Suspension Body Body Electrical System Heater and Air Conditioner Systems Technical Data Special Tools B2 B3 D E F1 F2 F3 F4 G H J1 J2 J3 L M N P R S T U TD
ST ST
Ranger / Drifter Repair Manual
B1
APPLICATION: This manual is applicable to vehicles beginning with the Vehicle Identification Numbers (VIN), and related materials shown on the following page.
Manual Transmission
1999 Ford/Mazda Motor Company All rights reserved. Reproduction by any means, electronic or mechanical including photocopying, recording or by any information storage and retrieval system or translation in whole or part is not permitted without written authorization from Ford/Mazda Motor Company. PRINTED IN JAPAN, JAN.1999 F1611099A
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VEHICLE IDENTIFICATION NUMBERS (VIN)

U.K. specs.
JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ JMZ UN1B320W UN8B320W UN8F420W UN1*620W UN1*62WW UN1*320W UN1*32WW UN8*720W UN8*72WW UN8*320W UN8*32WW 100001 100001 100001 100001 100001 100001 100001 100001 100001 100001 100001
European specs.
General specs. (L.H.D.)

MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 MM7 UNY02100 UNY021WW UNYOW100 UNYOW1 WW UN2*6*00 UN2*6*WW UN3*6*00 UN3*6*WW UN2*2*00 UN2*2*WW 100001 100001 100001 100001 100001 100001 100001 100001 100001 100001 100001 100001
General specs. (R.H.D.)

MM6 UNY02100 MM6 UNYOW100
RELATED MATERIALS
B Series Training Manual .......................................... 3333-10-99A Engine Workshop Manual WL, WL Turbo ................ 1532-10-96C Engine Workshop Manual G6 .................................... 1640-10-99A Engine Workshop Manual F2 .................................... 1641-10-99A Manual Transmission Workshop Manual
M15M-D M15MX-D .............................................................. 1645-10-99A
Manual Transmission Workshop Manual R15M-D R15MX-D.................................................... 1642-10-99A B Series Wiring Diagrams (European, General specs. (L.H.D.)) ..................... 5449-10-99A B Series Wiring Diagrams (European, General specs. (R.H.D.)) .................... 5450-10-99A
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GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . . SERVICING PROCEDURE . . . . . . . . . . . . . . . SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADVISORY MESSAGES . . . . . . . . . . . . . . . . . . TROUBLESHOOTING PROCEDURE . . . . . . TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUNDAMENTAL PROCEDURES . . . . . . . . . . . . PROTECTION OF THE VEHICLE . . . . . . . . . . PREPARATION OF TOOLS AND MEASURING EQUIPMENT . . . . . . . . . . . . . . SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . DISCONNECTION OF THE NEGATIVE BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . INSPECTION DURING REMOVAL, DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF PARTS . . . . . . . . . . . . . . CLEANING OF PARTS . . . . . . . . . . . . . . . . . . . REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . RUBBER PARTS AND TUBING . . . . . . . . . . . HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . . VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI-1 GI-1 GI-1/2 GI-3 GI-3 GI-3/6 GI-6 GI-7 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8 GI-8/9 GI-9 GI-9 GI-9 GI1 9 GI1 9 GI10 GI10 DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . GI10 INSTALLATION OF RADIO SYSTEM . . . . . . . . GI10 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . GI11 ELECTRICAL PARTS . . . . . . . . . . . . . . . . . . . . GI11 CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . GI11/13 ELECTRICAL TROUBLESHOOTING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI13 JACKING POSITIONS . . . . . . . . . . . . . . . . . . . . . . GI14 VEHICLE LIFT (2 SUPPORTS) POSITIONS . . . GI14 SAFETY STAND POSITIONS . . . . . . . . . . . . . . . GI14 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GI15 TOWING HOOKS . . . . . . . . . . . . . . . . . . . . . . . . GI16 TIEDOWN HOOKS . . . . . . . . . . . . . . . . . . . . . . . GI16 IDENTIFICATION NUMBER LOCATIONS . . . . . GI16 VEHICLE IDENTIFICATION NUMBER . . . . . . GI16 ENGINE IDENTIFICATION NUMBER . . . . . . . GI16 NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . GI17/19 ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . GI19 PRE-DELIVERY INSPECTION. . . . . . . . . . . . . .GI-20 PRE-DELIVERY INSPECTION TABLE . . . . . . GI-20
HOW TO USE THIS MANUAL

RANGE OF TOPICS D This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment D Simple operations which can be performed easily just by looking at the vehicle, such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
SERVICING PROCEDURE Inspection, Adjustment D The procedures for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
SHOWS PROCEDURE ORDER FOR SERVICE
SHOWS TIGHTENING TORQUE SPECIFICATIONS
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Repair procedure 1. Most repair operations begin with an overview illustration. It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions. 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
Procedure SHOWS SERVICE ITEM (S) Indicates any relevant references which need to be followed during installation.
Removal/Installation Portion Inspection After Installation Portion SHOWS PROCEDURE ORDER FOR SERVICE Install the parts by performing Steps 13 in reverse order SHOWS SPECIAL SERVICE TOOL (SST) FOR SERVICE OPERATION SHOWS APPLICATION POINTS OF GREASE, ETC. SHOWS TIGHTENING TORQUE SPECIFICATIONS
SHOWS EXPENDABLE PARTS
SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS
SHOWS THERE ARE REFERRAL NOTES FOR SERVICE
SHOWS SPECIAL SERVICE TOOL (SST) NO.
SHOWS REFERRAL NOTES FOR SERVICE
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SYMBOLS D There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such materials during service.
Symbol Meaning Apply oil Kind
SECTION F ONLY
TROUBLESHOOTING PROCEDURE Basic Flow of Troubleshooting
Appropriate new engine oil or gear oil Appropriate new brake fluid Appropriate new automatic transaxle/ transmission fluid Appropriate grease Appropriate sealant Appropriate petroleum jelly O-ring, gasket, etc.
ACTUAL TROUBLESHOOTING PROCEDURES SECTION K ONLY
Apply brake fluid Apply automatic transaxle/ transmission fluid Apply grease
IF MENTIONED
Apply sealant
SECTION F ONLY
Apply petroleum jelly
Replace part
SST
Use SST
Appropriate SST
On-board diagnosis D The service codes are important hints for repairing malfunctions that are difficult to simulate. By following the service code, perform the inspection to quickly and accurately diagnose the malfunction. D The self-diagnostic function is used during inspection. When a service code is shown, specifying the cause of a malfunction, continue the inspection according to the items indicated by the self-diagnostic function. Engine tune-up (Section F) D Any necessary adjustments are made after starting the engine. Basic inspection (Section K) D The basic inspection is performed to quickly narrow down the possible causes after a malfunction occurs regardless of the symptoms. ST The basic inspection is performed to also locate the region of many malfunction symptoms. Diagnostic index D The diagnostic index lists the symptoms of the malfunctions. Select the symptoms pertaining or most closely pertaining to the actual malfunction. Quick diagnosis chart (If mentioned) D The quick diagnosis chart lists the diagnosis and inspection procedures to be performed specifically relating to the cause of the malfunction. Symptom troubleshooting D Symptom troubleshooting quickly determines the location of the malfunction according to the type of symptoms.
ADVISORY MESSAGES Youll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual. Warning D A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution D A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note D A Note provides added information that will help you to complete a particular procedure. Specification D The values indicate the allowable range when performing inspections or adjustments. Upper and lower limits D The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
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Procedures For Use Using the basic inspection
D D D D
Perform the basic inspection before the symptom troubleshooting. Perform each step in the order shown. The reference column lists the location of the detailed procedure for each basic inspection. Although inspection and adjustment are performed as according to the procedures referred to in the reference column, if the cause of the malfunction is discovered during the basic inspection, continue the procedures as indicated in the remarks column.
SHOWS INSPECTION ORDER SHOWS ITEM NAMES FOR THE DETAILED PROCEDURES
SHOW POINTS REQUIRING ATTENTION IN REGARD TO INSPECTION RESULTS
Perform malfunction diagnosis according to No. 26 HOLD INDICATOR LIGHT DOES NOT ILLUMINATE WHEN HOLD SWITCH IS TURNED ON or No. 27 HOLD INDICATOR LIGHT ILLUMINATES WHEN HOLD SWITCH IS NOT TURNED ON
Using the diagnostic index D The symptoms of the malfunctions are listed in the diagnostic index for system troubleshooting. D The exact malfunction symptoms can be selected using the details.
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Using the quick diagnosis chart D The chart lists the relation between the symptoms and cause of the malfunction. D The chart is effective in quickly narrowing down the relation between the symptoms and cause of the malfunction and specifying the region of the common cause when multiple malfunction symptoms occur. D The appropriate diagnostic inspection relating to the cause of the malfunction as specified by the symptoms can be selected by looking down the diagnostic inspection column of the chart.
PARTS WHICH MAY BE THE CAUSE OF PROBLEMS

ENGINE QUICK DIAGNOSTIC CHART
PART WHICH MAY BE THE SYMPTOM
CHOOSE THE ACTUAL SYMPTOM
ST
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Using the symptom troubleshooting
D Symptom troubleshooting shows diagnosis procedure, inspection method, and proper action to take for each
trouble symptom.
TROUBLESHOOTING HINTS describes possible point of malfunction.
TROUBLE SYMPTOM
STEP shows the order of troubleshooting. INSPECTION describes an inspection (method) to quickly determine the failed part.
ACTION describes the appropriate action to take as a result (Yes/No) of INSPECTION.
Reference page(s) for the detailed procedure to perform INSPECTION is shown. How to perform ACTION is described in the relative material shown.
TEXT SEQUENCE D The text sequence is as indicated by the arrows shown below. Example:
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UNITS
UNITS
Electric current Electric power Electric resistance Electric voltage Length A (ampere) W (watt) W (ohm) V (volt) mm (millimeter) in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) Positive pressure kgf/cm2 (kilogram force per square centimeter) psi (pounds per square inch) Number of revolutions rpm (revolutions per minute) Nm (Newton meter) kgfm (kilogram force per meter) Torque kgfcm (kilogram force per centimeter) ftlbf (foot pound) force inlbf (inch pound) force L (liter) US qt (U.S. quart) Imp qt (Imperial quart) Volume ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) Weight g (gram) oz (ounce)
D The actual converted values for 2.7 kgf/cm2 are
264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2.7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
Conversion to SI Units (Systme International dUnits) D All numerical values in this manual are based on SI units. Numbers shown in conventional units are converted from these values. Rounding off D Converted values are rounded off to the same number of places as the SI unit value. For example, if the SI unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits D When the data indicates upper and lower limits, the converted values are rounded down if the SI unit value is an upper limit and rounded up if the SI unit value is a lower limit. Therefore, converted values for the same SI unit value may differ after conversion. For example, consider 2.7 kgf/cm2 in the following specifications: 210260 kPa {2.12.7 kgf/cm2, 3038 psi} 270310 kPa {2.73.2 kgf/cm2, 3945 psi}
ST
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FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE D Always be sure to cover fenders, seats, and floor areas before starting work.
REMOVAL OF PARTS D While correcting a problem, try also to determine its cause. Begin work only after first learning which parts and subassemblies must be removed and disassembled for replacement or repair. After removing the part, plug all holes and ports to prevent foreign material from entering.
PREPARATION OF TOOLS AND MEASURING EQUIPMENT D Be sure that all necessary tools and measuring equipment are available before starting any work.
DISASSEMBLY D If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be marked in a place that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
SPECIAL SERVICE TOOLS D Use special tools when they are required.
INSPECTION DURING REMOVAL, DISASSEMBLY D When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
DISCONNECTION OF THE NEGATIVE BATTERY CABLE D Before beginning any work, turn the ignition switch to LOCK, then disconnect the negative battery cable and wait for more than 1 minute to allow the backup power supply of the SAS unit to deplete its stored power. Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is neccessary to verify those memories before disconnecting the cable.
ARRANGEMENT OF PARTS D All disassembled parts should be carefully arranged for reassembly. D Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
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D Oil should be applied to the moving components of
parts.
D Specified oil or grease should be applied at the
prescribed locations (such as oil seals) before reassembly.
CLEANING OF PARTS D All parts to be reused should be carefully and thoroughly cleaned using the appropriate method. Warning D Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear whenever using compressed air.
SXU00012
ADJUSTMENT D Use suitable gauges and/or testers when making adjustments.
SXU00013
REASSEMBLY D Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones:
1 3 5 Oil seals O-rings Cotter pins 2 4 6 Gaskets Lockwashers Nylon nuts
RUBBER PARTS AND TUBING D Prevent gasoline or oil from spilling on rubber parts or tubing.
ST
SXU00014
HOSE CLAMPS D When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
SXU00011
D Sealant, a gasket, or both should be applied to the
specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks.
CONTINUED
SXU00015
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FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM

TORQUE FORMULAS D When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque using the following formulas. Choose the formula that applies to you.
Torque Unit kgfm kgfcm ftlbf inlbf Formula kgfm kgfcm ftlbf inlbf [L/(L+A) ] [L/(L+A) ] [L/(L+A) ] [L/(L+A) ]
INSTALLATION OF RADIO SYSTEM

If a radio system is installed improprerly or if a highpowered type is used, the CIS and other systems may be affected. When the vehicle is to be equipped with a radio, observe the following precautions. 1. Install the antenna at the farthest point from control modules. 2. Install the antenna feeder as far as possible from the control modules harness, and perpendicular to wiring harnesses. 3. Do not install a high-powered radio system. 4. After installing the radio system, start and idle the engine, then confirm that the engine is not influenced by output waves from the system.
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
SXU00016
VISE D When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
SXU00017
DYNAMOMETER When test-running a vehicle on dynamometer : D Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle. D Connect an exhaust gas ventilation unit. D Cool the exhaust pipes with a fan. D Keep the area around the vehicle uncluttered. D Watch the water temperature gauge.
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ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
ELECTRICAL PARTS Battery Cable D Before disconnecting connectors or removing electrical parts, disconnect the negative battery cable.
Disconnecting Connectors D When disconnecting two connectors, grasp the connectors, not the wires.
SXU00020
D Connectors can be disconnected by pressing or
pulling the lock lever as shown.

SXU00018
Wiring Harness D To remove the wiring harness from the clip in the engine room, pry up the hook of the clip using a flathead screwdriver.
SXU00021
Locking Connector D When locking connectors, listen for a click that will indicate they are securely locked.
CONNECTORS Data Link Connector D Insert the probe into the service hole when connecting a jumper wire to the data link connector. Caution D Inserting a jumper wire probe into the data link connector terminal may damage the terminal.
SXU00022
Inspection 1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
SXU00019
SXU00023
2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
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ELECTRICAL SYSTEM
Caution D To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
SXU00027
SXU00024
Terminals Inspection D Pull lightly on individual wires to check that they are secured in the terminal.
Wiring Harness Wiring color codes D Two-color wires are indicated by a two-color code symbol. D The first letter indicates the base color of the wire and the second the color of the stripe.
CODE B BR G GY L LB LG
B/R
COLOR Black Brown Green Gray Blue Light Blue Light Green
CODE O P R V W Y
COLOR Orange Pink Red Violet White Yellow
BR/Y BLACK BROWN
SXU00025
Replacement D Use the appropriate tools to remove a terminal as shown. When installing a terminal, be sure to insert it until it locks securely. D Insert a thin piece of metal from the terminal side of the connector, and then, with the terminal locking tab pressed down, pull the terminal out from the connector.
TYPE A TYPE B
RED
YELLOW
SXU00028
Fuse Replacement 1. When replacing a fuse, be sure to replace it with one of the specified capacity. If a fuse again fails after it has been replaced, the circuit probably has a short and the wiring should be checked. 2. Be sure the negative battery terminal is disconnected before replacing a main fuse.
SXU00026
Sensors, Switches, and Relays D Handle sensors, switches, and relays carefully. Do not drop them or strike them against other objects.
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SXU00029
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ELECTRICAL SYSTEM
3. When replacing a pullout fuse, use the fuse puller.
PULLER
Ohmmeter D The ohmmeter is used to measure the resistance between two points in a circuit, and to check for continuity and short circuits. Caution D Do not connect the ohmmeter to any circuit to which voltage is applied. This will damage the ohmmeter.
POWER SOURCE LINE
FUSE
SXU00030
ELECTRICAL TROUBLESHOOTING TOOLS Jumper Wire D A jumper wire is used to create a temporary circuit. Connect the jumper wire between the terminals of a circuit to bypass a switch. Caution D Do not connect a jumper wire from the power source line to a body ground; this may cause burning or other damage to wiring harnesses or electronic components.
OHMMETER
GROUND LINE
SXU00034
SXU00032
Voltmeter D The DC voltmeter is used to measure circuit voltage. A voltmeter with a range of 15 V or more is used by connecting the positive (+) probe (red lead wire) to the point where voltage is to be measured and the negative () probe (black lead wire) to a body ground.
VOLTMETER POWER SOURCE LINE
BLACK LEAD
RED LEAD GROUND
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JACKING POSITIONS, VEHICLE LIFT (2 SUPPORTS) POSITIONS, SAFETY STAND POSITIONS
JACKING POSITIONS
Warning D Improperly jacking a vehicle is dangerous. The vehicle can slip off the jack and cause serious injury. Use only the correct front and rear jacking positions and block the wheels. Use safety stands to support the vehicle after it has been lifted. FRONT
REAR
SAFETY STAND POSITIONS

FRONT
REAR
REAR
VEHICLE LIFT (2 SUPPORTS) POSITIONS

FRONT
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TOWING
TOWING
Proper lifting and towing are necessary to prevent damage to the vehicle. Government and local laws must be followed.
(With Manual Transmission) If the transmission, rear axle, and steering system are not damaged, the vehicle may be towed on all four wheels. If any of these components are damaged, use wheel dollies. (With Automatic Transmission) If excessive damage or other conditions prevent towing the vehicle with the driving wheels off the ground, use wheel dollies.
Wheel dollies
If all four wheels are on the ground, the vehicle may be towed only forward. Do not exceed 45 km/h (28 mph) and a distance of 15 km (9.3 miles); you could damage the transmission. If speed must exceed 45 km/h (28 mph) or a towing distance of 15 km (9.3 miles), use one of these methods:
D Place the rear wheels on dollies. D Tow with the rear wheels off the ground.
Wheel dollies
D Disconnect the propeller shaft.
If the transmission or rear axle is inoperative, tow with the rear wheels off the ground. Caution D Follow these instructions when towing the vehicle with all wheels on the ground or with the front wheels on the ground and the rear wheels raised. (4 4 Model) 1. Put the transfer case in 2H. 2. Set the transfer case at 2H and the hubs at FREE. (All Models) 1. Set the transmission in neutral. 2. Turn the engine switch to ACC position. 3. Release the parking brake.
D Remember that power assist for the brakes
Caution D Do not tow with sling-type equipment. This could damage your vehicle. Use wheel-lift or flatbed equipment.
and steering will not be available when the engine is not running. If your Ford/Mazda has 4 4, change to 2-wheel drive before having the vehicle towed. If this is not possible, tow with all four wheels raised.
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TOWING, IDENTIFICATION NUMBER LOCATIONS

TOWING HOOKS Caution D The towing hooks should be used only in an emergency (e.g. to get the vehicle out of a ditch or a snow bank). D When using the towing hooks, always pull the cable or chain in a straight direction with respect to the hook. Apply no sideways force. FRONT 4 4
IDENTIFICATION NUMBER LOCATIONS

VEHICLE IDENTIFICATION NUMBER
ENGINE IDENTIFICATION NUMBER G6
TIEDOWN HOOKS Caution D Do not use the hook loops under the front for towing. They are designed ONLY for tying down the vehicle when it is being transported. Using them for towing will damage the bumper. FRONT 4 2
WL, WL Turbo
F2 CIS F2 CARB 4 4
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NEW STANDARDS
NEW STANDARDS
D Following is a comparison of the previous standard and the new standard. New Standard Abbreviation AP ACL A/C BARO B) CMP sensor CAC CLS CTP CPP CIS CS sensor CKP sensor DLC DTM DTC DI DLI EI ECT EM EVAP EGR FC FF 4GR FSO solenoid GEN GND HO2S IAC Name Accelerator Pedal Air Cleaner Air Conditioning Barometric Pressure Battery Positive Voltage Brake Switch Calibration Resistor Camshaft Position Sensor Charge Air Cooler Closed Loop System Closed Throttle Position Closed Throttle Position Switch Clutch Pedal Position Continuous Fuel Injection System Control Sleeve Sensor Crankshaft Position Sensor Data Link Connector Diagnostic Test Mode Diagnostic Trouble Code(s) Distributor Ignition Distributorless Ignition Electronic Ignition Engine Coolant Temperature Engine Modification Engine Speed Input Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Fourth Gear Fuel Pump Relay Fuel Shut Off Solenoid Generator Ground Heated Oxygen Sensor Idle Air Control Incorrect Gear Ratio Abbreviation VB EGI CSP sensor FCV Previous Standard Name Accelerator Pedal Air Cleaner Air Conditioning Atmospheric Pressure Battery Voltage Stoplight Switch Corrected Resistance Crank Angle Sensor Intercooler Feedback System Fully Closed Idle Switch Clutch Position Electronic Gasoline Injection System Control Sleeve Position Sensor Crank Angle Sensor 2 Diagnosis Connector Test Mode Service Code(s) Spark Ignition Direct Ignition Electronic Spark Ignition Water Thermo Engine Modification Engine RPM Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Flexible Fuel Overdrive Circuit Opening Relay Fuel Cut Valve Alternator Ground/Earth Oxygen Sensor Idle Speed Control With heater #3 #6 #2 #1 #6 #6 Remark
#1: Diagnostic trouble codes depend on the diagnostic test mode #2: Controlled by the PCM #3: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #6: Part name of diesel engine
CONTINUED
GI17
TO. MODEL .INDEX
NEW STANDARDS
New Standard Abbreviation IAT KS MIL MAP MAF sensor MFL OBD OL OC O2S PNP PSP PCM PAIR AIR SAPV SFI 3GR TWC TB TP sensor TCV TCC TCM TR TC VSS VR Injection Pump Input/Turbine Speed Sensor Intake Air Temperature Knock Sensor Malfunction Indicator Lamp Manifold Absolute Pressure Mass Air Flow Sensor Multiport Fuel Injection On-Board Diagnostic Open Loop Output Speed Sensor Oxidation Catalytic Converter Oxygen Sensor Park/Neutral Position PCM Control Relay Power Steering Pressure Powertrain Control Module Pressure Control Solenoid Pulsed Secondary Air Injection Pump Speed Sensor Secondary Air Injection Secondary Air Pulse Valve Sequential Multipoint Fuel Injection Shift Solenoid A Shift Solenoid B Shift Solenoid C Third Gear Three Way Catalytic Converter Throttle Body Throttle Position Sensor Timer Control Valve Torque Converter Clutch Transmission (Transaxle) Control Module Transmission (Transaxle) Fluid Temperature Sensor Transmission (Transaxle) Range Turbocharger Vehicle Speed Sensor Voltage Regulator Name Abbreviation FIP ECU TCV
Previous Standard Name Fuel Injection Pump Pulse Generator Intake Air Thermo Knock Sensor Malfunction Indicator Light Intake Air Pressure Airflow Sensor Multiport Fuel Injection Diagnosis/Self-Diagnosis Open Loop Vehicle Speed Sensor 1 Catalytic Converter Oxygen Sensor Park/Neutral Range Main Relay Power Steering Pressure Engine Control Unit Line Pressure Solenoid Valve Secondary Air Injection System NE Sensor Secondary Air Injection System Reed Valve Sequential Fuel Injection 12 Shift Solenoid Valve Shift A Solenoid Valve 23 Shift Solenoid Valve Shift B Solenoid Valve 34 Shift Solenoid Valve 3rd Gear Catalytic Converter Throttle Body Throttle Sensor Timing Control Valve Lock-up Position EC-AT Control Unit ATF Thermosensor Inhibitor Position Turbocharger Vehicle Speed Sensor IC Regulator #6 Pulsed injection #6 Injection with air pump #4 #6 #6 Remark
#4: Device that controls engine and powertrain #6: Part name of diesel engine
CONTINUED
GI18
TO. MODEL .INDEX
NEW STANDARDS, ABBREVIATIONS
New Standard Abbreviation VAF sensor WU-TWC WOT Name Volume Air Flow Sensor Warm Up Three Way Catalytic Converter Wide Open Throttle Abbreviation
Previous Standard Name Air flow Sensor Catalytic Converter Fully Open #5 Remark
#5: Directly connected to exhaust manifold
ABBREVIATIONS
ACC . . . . . . . . . . . . . . ATDC . . . . . . . . . . . . . ATF . . . . . . . . . . . . . . . BTDC . . . . . . . . . . . . . CARB . . . . . . . . . . . . . ELR . . . . . . . . . . . . . . EX . . . . . . . . . . . . . . . FIP . . . . . . . . . . . . . . . HI . . . . . . . . . . . . . . . . HLA . . . . . . . . . . . . . . IG . . . . . . . . . . . . . . . . IN . . . . . . . . . . . . . . . . INT . . . . . . . . . . . . . . . LH . . . . . . . . . . . . . . . . L.H.D. . . . . . . . . . . . . . LO . . . . . . . . . . . . . . . LSD . . . . . . . . . . . . . . LSPV . . . . . . . . . . . . . M ................ MAX . . . . . . . . . . . . . . MFW . . . . . . . . . . . . . MIN . . . . . . . . . . . . . . P/S . . . . . . . . . . . . . . . RFW . . . . . . . . . . . . . . RH . . . . . . . . . . . . . . . R.H.D. . . . . . . . . . . . . SAS . . . . . . . . . . . . . . SST . . . . . . . . . . . . . . TNS . . . . . . . . . . . . . . 2WD . . . . . . . . . . . . . . 4WD . . . . . . . . . . . . . . 4 2 .............. 4 4 .............. Accessories After top dead center Automatic transmission fluid Before top dead center Carburetor Emergency locking retractor Exhaust Fuel injection pump High Hydraulic lash adjuster Ignition Intake Intermittent Left hand Left hand drive Low Limited slip differential Load sensing proportioning valve Motor Maximum Manual freewheel Minimum Power steering Remote freewheel Right hand Right hand drive Sophisticated air bag sensor Special service tool Tail number side lights 2 wheel drive 4 wheel drive 4 wheel 2 drive 4 wheel 4 drive
CONTINUED
GI19
TO. MODEL .INDEX
PRE-DELIVERY INSPECTION PRE-DELIVERY INSPECTION

PRE-DELIVERY INSPECTION TABLE Following items may be done at any time prior to delivery to your customer. EXTERIOR INSPECT and ADJUST, if necessary, the following items to the specifications: Glass, exterior bright metal and paint for damage Wheel lug nuts Tire pressures All weatherstrips for damage or detachment Operation of bonnet release and lock Door operation and alignment Headlight aiming INSTALL the following parts: Wheel caps UNDER BONNET-ENGINE OFF INSPECT and ADJUST , if necessary, the following items to the specifications: Fuel, coolant and hydraulic lines, fittings, connections and components for leaks Engine oil level Power steering fluid level (if equipped) Brake and clutch master cylinder fluid levels Windshield washer reservoir fluid level Radiator coolant and specific gravity Tightness of water hose clamps Tightness of battery terminals, electrolyte level and specific gravity Drive belt tensions Accelerator cable and linkage for free movement CLEAN the spark plugs INTERIOR INSTALL the following parts Fuse for accessories CHECK the operation of the following items: Seat controls (sliding and reclining) and headrest Door locks Ignition switch (Engine switch) and steering lock All lights including warning and indicator lights Horn, windshield wipers and washers (if equipped) Wiper blades performance Clean the wiper blades and windshield Antenna Cigarette lighter and clock Tilt steering (if equipped) Air conditioner at various modes (if equipped) CHECK the following items: Presence of spare fuse Upholstery and interior finish CHECK and ADJUST , if necessary, the following items: Operation and fit of windows Pedal height and free play of brake and clutch pedals Parking brake UNDER BONNET-ENGINE RUNNING AT OPERATING TEMPERATURE CHECK the following items: Operation of dashpot Initial ignition timing Injection timing Idle speed Operation of throttle position sensor ON HOIST CHECK the following items: Operation of freewheel hubs Manual transmission oil level Transfer oil level Front differential oil level Rear differential oil level Underside fuel, coolant and hydraulic lines, fittings, connections and components for leaks Tires for cuts or bruises Steering linkage, suspension, exhaust system and all underside hardware for looseness or damage ROAD TEST CHECK the following items: Brake operation Clutch operation Steering control Operation of meters and gauges 3 Squeaks, rattles or unusual noise Engine general performance Emergency locking retractors Operation of transfer AFTER ROAD TEST REMOVE seat and floor mat protective covers CHECK for necessary owner's information material, tools and spare tire in vehicle
CONTINUED
Gl-20
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
ENGINE (G6)
DRIVE BELT ................................................................B1-1 DRIVE BELT INSPECTION ................................B1-1/2 DRIVE BELT ADJUSTMENT .............................B1-2 COMPRESSION INSPECTION ..................................B1-2 TIMING CHAIN .............................................................B1-3 TIMING CHAIN REMOVAL/ INSTALLATION .................................................... B1-3/5 CYLINDER HEAD GASKET ..................................B1-6 CYLINDER HEAD GASKET REPLACEMENT .................................................B1-6/9 HYDRAULIC LASH ADJUSTER (HLA).................B1-10 DRIVE BELT DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has been stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys. HLA REMOVAL/INSTALLATION .....................B1-10/11 HLA TROUBLESHOOTING .............................B1-12 FRONT OIL SEAL.......................................................B1-13 FRONT OIL SEAL REPLACEMENT .................B1-13 REAR OIL SEAL .........................................................B1-14 REAR OIL SEAL REPLACEMENT ..................B1-14 ENGINE .......................................................................B1-15 ENGINE REMOVAL/INSTALLATION ..............B1-15/16 ENGINE DISASSEMBLY/ASSEMBLY ..............B1-17
Deflection
Drive belt Generator P/S A/C *New 10.012.0 {0.400.47} 6.67.2 {0.260.28} 8.510.0 {0.340.39} Used
mm {in}
12.014.0 {0.480.55} 7.28.0 {0.290.31} 10.011.5 {0.400.45}
*: A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has been stopped. Using the SST, check the belt tension between any two pulleys.
N {kgf, Ibf}
Drive belt Generator P/S *New 491-588 {50-60,110-132} 412470 {42-48,93105} 557641 {56.765.4, 125143} Used 393-490 {40-50,88-110} 354402 {36-41, 8090} 471556 {48.056.7, 106124}
A/C
* A belt that has been on a running engine for less than five minutes.
CONTINUED
B1-1
TO. MODEL .INDEX
DRIVE BELT, COMPRESSION INSPECTION

2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B and locknut C. COMPRESSION INSPECTION Warning When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. 4. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 5. Disconnect the igniter connector. (Refer to section G, IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) 6. Remove the spark plugs. 7. Connect a compression gauge into the No.1 spark plug hole. 8. Fully depress the accelerator pedal and crank the engine. 9. Note the maximum gauge reading. 10. Inspect compression of each cylinder. Compression Item Standard Minimum Maximum difference between kPa {kgf/cm2, psi} [rpm] Engine type G6 1255 {12.8, 182} [270] 882.6 {9.0, 128} [270] 196 kPa {2.0 kgf/cm 2, 28 psi}
11. If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. (3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 12. Disconnect the compression gauge. 13. Install the spark plugs. Tightening torque 1522 N.m {1.52.3 kgf.m, 11l6ft.lbf} 14. Connect the igniter connector. 15. Install the fuel pump relay.
CONTINUED B1-2
TO. MODEL .INDEX
TIMING CHAIN
TIMING CHAIN
TIMING CHAIN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 4. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 5. Remove the cylinder head. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 6. Remove the water pump. (Refer to section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 7. Remove the oil pan. (Refer to section D, OIL PAN, OIL PAN REMOVAL/INSTALLATION.) 8. Disconnect the oil strainer stay. 9. Remove in the order indicated in the table. 10. Install in the reverse order of removal. 11. Start the engine and check for engine oil and engine coolant leakage.
1 2 3 4 5 6 7 8 9
A/C compressor bracket Generator strap P/S oil pump bracket Generator bracket Pulley lock bolt Removal/Installation Note Crankshaft pulley Chain cover Spacer Balancer chain guide Installation Note
10 11 12 13 14 15
Balancer chain, idler sprocket, crankshaft sprocket Installation Note Timing chain, timing sprocket, camshaft sprocket Installation Note Chain adjuster Installation Note Key Timing chain lever Installation Note Timing chain guide
CONTINUED B1-3
TO. MODEL .INDEX
TIMING CHAIN
Pulley Lock Bolt Removal/Installation Note Hold the crankshaft using the SST . 2. Assemble the camshaft sprocket to the timing chain so that the timing mark of camshaft sprocket is aligned with the white link of timing chain as shown.
Timing Chain Lever Installation Note Install the chain lever and verify that it moves smoothly in the direction indicated.
3. Secure the camshaft sprocket and the timing chain with a wire to prevent disengagement. Balancer Chain, Idler Sprocket, Crankshaft Sprocket Installation Note 1. Install the crankshaft sprocket as shown.
2. Assemble the idler sprocket on to the idler shaft. Chain Adjuster Installation Note Push the chain adjuster sleeve in (toward the left) and insert the pin as shown into the lever to hold the sleeve.
3. Set the balancer chain on the idler sprocket so that the timing mark of the idler sprocket is aligned with the brown link of the balancer chain as shown. Timing Chain, Timing Sprocket, Camshaft Sprocket Installation Note 1. Install the timing chain and timing sprocket so that the white link of the timing chain is aligned with the timing mark of the timing sprocket as shown.
CONTINUED B1-4
BACK.TO.CHAPTER.INDEX TIMING CHAIN

4. Install the balancer chain so that the five alignment marks on the chain, sprocket and cylinder block align, and attach the idler sprocket to the cylinder block.
TO. MODEL .INDEX
4. Loosen the chain guide C by adjusting bolt E. 5. Push the chain guide C with a force of 49 N {5.0 kgf, 11 Ibf} in the direction of the arrow, then pull back the chain guide 3.23.8 mm {0.130.14 in] and tighten the adjusting bolt E.
5. Hand-tighten the idler sprocket lock bolt. Balancer Chain Guide Installation Note 1. Install the chain guide A and B.
Note The balancer chain must be replaced if chain guide C bottoms when adjusting. 6. Measure the timing chain slack. Specification Approx. 3.0 mm {0.12 in}
2. Install the chain guide C, and tighten the bolt D and hand-tighten the adjusting bolt E.
3. Tighten the idler sprocket lock bolt.
CONTINUED
B1-5
TO. MODEL .INDEX
CYLINDER HEAD GASKET

CYLINDER HEAD GASKET REPLACEMENT Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan. 5. Remove the front pipe. 6. Remove the air intake pipe and resonance chamber. 7. Disconnect the accelerator cable and bracket. 8. S. Disconnect the vacuum hoses, water hoses, and engine harness connectors. 9. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the intake manifold bracket. 11. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 12. Remove the high-tension lead. (Refer to section G, IGNITION SYSTEM, HIGH-TENSION LEAD REMOVAL/INSTALLATION.) 13. Remove the spark plug. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Inspect for fuel leakage. 17. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 18. Start the engine and (1) check the pulleys and drive belt for runout and contact. (2) check the ignition timing and idle speed. (Refer to section F1, ENGINE TUNE-UP.)
CONTINUED
B1-6
TO. MODEL .INDEX
1 2 3
Upper radiator hose Cylinder head cover Installation Note Distributor drive gear Removal Note Installation Note Camshaft sprocket Removal Note Installation Note
Cylinder head Removal Note Installation Note Cylinder head gasket Installation Note
CONTINUED
B1-7
TO. MODEL .INDEX

Distributor Drive Gear Removal Note 1. Turn the crankshaft clockwise so that the No.1 piston is at TDC of the compression stroke.
2. Verify that the camshaft sprocket mark is aligned with the horizontal surface on the cylinder head.
3. Secure the camshaft sprocket and the chain with a wire as shown.
3. Remove the seal cover. 4. Hold the crankshaft using the SST .
4. Remove the camshaft sprocket off the camshaft dowel pin. Cylinder Head Removal Note 1. Remove the bolts A. 2. Loosen the cylinder head bolts a few turns in the order shown.
5. Remove the lock bolt. Camshaft Sprocket Removal Note 1. Remove the service cover on the chain cover.
Cylinder Head Gasket Installation Note Apply silicone sealant to the areas shown. Thickness 3.0 mm {0.12 in}
2. Push the chain adjuster sleeve in (toward the left) and insert a pin as shown into the lever hole to hold the sleeve.
CONTINUED B1-8
TO. MODEL .INDEX

Cylinder Head Installation Note 1. Tighten the cylinder head bolts a few turns in the order shown. Distributor Drive Gear Installation Note 1. Install the distributor drive gear with a new washer and lock bolt. 2. Hold the camshaft with a screwdriver as shown.
2. Tighten the bolts A. Camshaft Sprocket Installation Note 1. Install the camshaft sprocket onto the camshaft dowel pin. 2. Remove the wire securing the camshaft sprocket and chain.
3. Tighten the lock bolt. 4. Apply silicone sealant to the areas shown.
3. Remove the retaining pin from the chain adjuster. 4. Install the service cover with a new gasket. Tightening torque 7.910.7 N.m {80110 kgf.cm, 69.595.4 in.lbf}
5. Install the new seal cover. Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water, and other foreign material. 2. Coat a new gasket with silicone sealant, and install it onto the cylinder head cover. 3. Apply silicone sealant to the cylinder head as shown.
4. Install the cylinder head cover.
CONTINUED
B1-9
TO. MODEL .INDEX
HYDRAULIC LASH ADJUSTER (HLA)

HLA REMOVAL / INSTALLATION Caution Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
1. Disconnect the negative battery cable. 2. Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 3. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Check the engine oil level, (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) 7. Start the engine and (1) check the engine oil. (2) check the idle speed, (Refer to section F1, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 8. Check the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
Distributor drive gear CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Removal Note CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Distributor Drive Gear Installation Note
Rocker arm Removal Note & Installation Note HLA Installation Note
CONTINUED B1-10
TO. MODEL .INDEX

Rocker Arm Removal Note 1. Loosen the bolts a few turns in the order shown. Rocker Arm Installation Note Note The intake side shaft has twice as many oil holes as the exhaust side shaft. 1. Assemble the rocker arm and shaft assembly as shown in the figure according to the cap number and mark.
2.
Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts. HLA Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
2. Install the rocker arm and shaft. 3. Tighten the bolts a few turns in the order shown.
3. Pour engine oil into the oil reservoir in the rocker arm.
4. Apply clean engine oil to HLA O-ring
CONTINUED
B1-11
TO. MODEL .INDEX

HLA TROUBLESHOOTING
Problem 1. Noise when engine is started immediately after oil is changed. Noise when engine is started after sitting one day or more. Noise when engine is started after new HLA is installed. Noise continues more than 10 minutes. Oil leakage in HLA Possible Cause Oil leakage in oil passage or in HLA Action Run engine at 2,0003,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. Time required for engine oil to circulate within HLA includes tolerance for engine oil condition and ambient temperature. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.) Check oil pressure. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION) Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HLA, HLA TROUBLESHOOTING, Valve Clearance Inspection.) Check oil level. (Refer to section D, ENGINE OIL, ENGINE OIL INSPECTION.) Replace new engine oil. (Refer to section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
2.
3.
4.
Insufficient oil pressure
Faulty HLA
5.
Noise during idle after high speed running.
Incorrect oil amount
Deteriorated oil
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
CONTINUED
B1-12
BACK.TO.CHAPTER.INDEX FRONT OIL SEAL FRONT OIL SEAL

FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and water pump pulley. 5. Remove the radiator cowling. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
TO. MODEL .INDEX
2 3
Pulley lock bolt TIMING CHAIN, TIMING CHAIN REMOVAL/INSTALLATION, Pulley Lock Bolt Removal/Installation Note Crankshaft pulley Front oil seal Removal Note Installation Note
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED B1-13
TO. MODEL .INDEX
REAR OIL SEAL REAR OIL SEAL

REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
Rear oil seal Removal Note Installation Note Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
B1-14
BACK.TO.CHAPTER.INDEX ENGINE ENGINE

ENGINE REMOVAL/INSTALLATION
TO. MODEL .INDEX
Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F1. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and fresh-air duct. 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket, heater hoses, and vacuum hoses. 6. Remove the radiator. (Refer to section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 8. Disconnect the fuel hoses. (Refer to section F1, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to section F1, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Remove the transmission. (Refer to section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 10. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 11. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 12. Remove in the order indicated in the table. 13. Install in the reverse order of removal. 14. Start the engine and (1) check the engine oil, engine coolant, transmission oil, and fuel leakage. (2) check the ignition timing, idle speed and idle mixture. (Refer to section F1, ENGINE TUNE-UP.) 15. Perform a road test.
CONTINUED
B1-15
BACK.TO.CHAPTER.INDEX ENGINE
TO. MODEL .INDEX
Engine mount nut
Engine
CONTINUED
B1-16
ENGINE DISASSEMBLY/ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
TO. MODEL .INDEX
Remove the oil cooler. (Refer to section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) Remove the thermostat. (Refer to section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) Remove the spark plug. Remove the oil pressure switch. (Refer to section D, OIL PRESSURE INSPECTION.) Remove the intake-air system. (Refer to section F1, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) Remove the exhaust system. (Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Remove the oil filter. (Refer to section D, OIL FILTER, OIL FILTER REPLACEMENT) Remove the distributor. (Refer to section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) Remove the generator. Disassemble in the order indicated in the table. Assemble in the reverse order of disassembly.
1 2 3 4 5
Water bypass pipe Water inlet pipe A/C compressor bracket Generator bracket P/S oil pump bracket
6 7 8 9 10
A/C idler P/S idler Oil cooler bypass pipe Generator strap Engine mount
CONTINUED B1-17
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TO. MODEL .INDEX
Engine Workshop Manual F8 FE

FOREWORD This manual explains the disassembly, inspection, repair, and reassembly procedures for the above-indicated engines. In order to do these procedures safely, quickly, and correctly, you must first read this manual and any other relevant service materials carefully. The information in this manual is current up to April, 1997. Any changes that occur after that time will not be reflected in this particular manual. Therefore, the contents of this manual may not exactly match the mechanism that you are currently servicing. Mazda Motor Corporation HIROSHIMA, JAPAN
CONTENTS
Title General Information Engine Technical Data Special Tools 2001 Ford/Mazda Motor Corporation PRINTED IN JAPAN, APR. 1997 1570-10-97D Section GI B TD ST
CONTINUED
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GENERAL INFORMATION
HOW TO USE THIS MANUAL .............. ................ Gl- 1 RANGE OF TOPICS .................... .................... Gl- 1 SERVICING PROCEDURE .............. ................ Gl- 1/2 SYMBOLS ............................. .......................... Gl- 3 ADVISORY MESSAGES .................................. Gl- 3 TEXT SEQUENCE ........................................... Gl- 3 UNITS ................................................................... Gl- 4 NEW STANDARDS ............................................... Gl- 5 FUNDAMENTAL PROCEDURES ........... .............. Gl- 7 PREPARATION OF TOOLS AND MEASURING EQUIPMENT .......................... Gl- 7 SPECIAL TOOLS ............................................. Gl- 7 DISASSEMBLY ................................................ Gl- 7 INSPECTION DURING REMOVAL, DISASSEMBLY ............................................. Gl- 7 ARRANGEMENT OF PARTS ........................... Gl- 7 CLEANING OF PARTS .................................... Gl- 7 REASSEMBLY ................................................. Gl- 7 ADJUSTMENT ................................................. Gl- 8 RUBBER PARTS AND TUBING ....................... Gl- 8 HOSE CLAMPS ............................................... Gl- 8 TORQUE FORMULAS ...................................... Gl- 8 VISE ................................................................ Gl- 8 ELECTRICAL SYSTEM ........................................ Gl- 9 CONNECTORS ................................................ Gl- 9 ABBREVIATIONS.................................................. Gl- 10

RANGE OF TOPICS This manual contains the procedures for performing all of the required service operations. The procedures are divided into the following five basic operations. (1) Removal/Installation (2) Disassembly/Assembly (3) Replacement (4) Inspection (5) Adjustment Simple operations which can be performed easily just by looking at the vehicle such as removal/installation of parts, jacking, vehicle lift, cleaning of parts, and visual inspection, have been omitted.
SERVICING PROCEDURE Inspection, Adjustment The procedures .for inspections and adjustments are divided into steps. Important points in regard to the location and contents of the procedures are explained in detail and are shown in the illustrations.
CONTINUED
Gl-1
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Repair procedure 1. Most repair operations begin with an overview illustration, It identifies the components, shows how the parts fit together, and describes visual part inspection. However, only the removal/installation procedures which need to be performed methodically have written instructions, 2. Expendable parts, tightening torques, and symbols for oil, grease, and sealant are shown in the overview illustration. In addition, symbols indicating parts which require the use of special service tools for removal/installation are also shown. 3. The procedures are numbered and the part that is the main point of that procedure is shown in the illustration with the corresponding number. Occasionally, there are important points or information concerning a procedure. Refer to this information when servicing the related part.
CONTINUED
Gl-2
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SYMBOLS There are eight symbols indicating oil, grease, sealant, and the use of SSTs. These symbols show the points of applying or using such
Symbol Meaning Apply oil Kind New appropriate engine oil or gear oil New appropriate brake fluid New appropriate automatic transaxle/transmi ssion fluid Appropriate grease
TEXT SEQUENCE The text sequence is as indicated by the arrows shown below. Example:
Apply brake fluid
Apply automatic transaxle / transmission fluid
Apply grease
Apply sealant
Appropriate sealant
Apply petroleum jelly
Appropriate petroleum jelly
Replace part
O-ring, gasket, etc.
Use SST
Appropriate SST
ADVISORY MESSAGES You'll find several Warnings, Cautions, Notes, Specifications and Upper and lower limits in this manual. Warning A Warning indicates a situation in which serious injury or death could result if the warning is ignored. Caution A Caution indicates a situation in which damage to the vehicle could result if the caution is ignored. Note A Note provides added information that will help you to complete a particular procedure. Specification The values indicates the allowable range when performing inspections or adjustments. Upper and lower limits The values indicate the upper and lower limits that must not be exceeded when performing inspections or adjustments.
Gl-3
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UNITS
Electrical current Electric potential Electric power Length A (ampere) V (volt) W (watt) mm (millimeter) in (inch) kPa (kilo pascal) Negative pressure mmHg (millimeters of mercury) inHg (inches of mercury) kPa (kilo pascal) kgf/cm 2 (kilogram force per square centimeter) psi (pounds per square inch) Resistance Speed (ohm) rpm (revolution per minute) Nm (Newton meter) kgfm (kilogram force per meter) Torque kgfcm (kilogram force per centimeter) ftlbf (foot pound) inlbf (inch pound) L (liter) US qt (U.S. quart) Imp qt (Imperial quart) Volume ml (milliliter) cc (cubic centimeter) cu in (cubic inch) fl oz (fluid ounce) Weight 9 (gram) oz (ounce)
2 The actual converted values for 2.7 kgf/cm are 264 kPa and 38.4 psi. In the top specification, 2.7 is used as an upper limit, so its converted values are rounded down to 260 and 38. In the bottom specification, 2,7 is used as a lower limit, so its converted values are rounded up to 270 and 39.
Positive pressure
Conversion to Sl Units (Systme International d'Units) All numerical values in this manual are based on 81 units. Numbers shown In conventional units are converted from these values, Rounding off Converted values are rounded off to the same number of places are the Sl unit value. For example, if the 81 unit value is 17.2 and the value after conversion is 37.84, the converted value will be rounded off to 37.8. Upper and lower limits When the data indicates upper and lower limits, the converted values are rounded down if the Sl unit value is an upper limit and rounded up if the Sl unit value is a lower limit. Therefore, converted values for the same Sl unit value may differ after 2 conversion. For example, consider 2.7 kgf/cm in the following specifications: 210260 kPa { 2.12.7 kgf/cm2 , 3038 psi } 270310 kPa { 2.73.2 kgf/cm2 , 3945 psi }
CONTINUED
Gl-4
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NEW STANDARDS
NEW STANDARDS
Following is a comparison of the previous standard and the new standard.
Previous Standard Abbreviation VB Air Cleaner Air Conditioning Airflow Meter Airflow Sensor Alternator ATF Thermosensor Atmospheric Pressure Battery Voltage Name Accelerator Pedal Abbreviation AP ACL A/C VAF MAF GEN BARO B+ OC TWC WU-TWC EGI ECU Circuit Opening Relay Clutch Position Crank Angle Sensor Crank Angle Sensor 2 Diagnosis Connector Diagnosis/Self-Diagnosis Direct Ignition EC-AT Control Unit Electronic Gasoline Injection System Electronic Spark Ignition Engine Control Unit Engine Modification Engine RPM Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Feedback System Flexible Fuel Fuel Pump Fully Closed Fully Open Ground/Earth 1C Regulator FPR CPP CMP CKP DLC OBD DLI TCM CIS El PCM ECM EM EVAP EGR FC CLS FF FP CTP WOT GND VR Air Cleaner Air Conditioning Volume Air Flow Sensor Mass Air Flow Sensor Generator Transmission (Transaxle) Fluid Temperature Sensor Barometric Pressure Battery Positive Voltage Oxidation Catalytic Converter Three Way Catalytic Converter Warm Up Three Way Catalytic Converter Fuel Pump Relay Clutch Pedal Position Camshaft Position Sensor Crankshaft Position Sensor Data Link Connector On-Board Diagnostic Distributorless Ignition Transmission (Transaxle) Control Module Continuous Fuel Injection System Electronic Ignition Powertrain Control Module Engine Control Module Engine Modification Engine Speed Input Signal Evaporative Emission Exhaust Gas Recirculation Fan Control Closed Loop System Flexible Fuel Fuel Pump Closed Throttle Position Wide Open Throttle Ground Voltage Regulator #3 #4 #1 #2 New Standard Name Accelerator Pedal Remark
Catalytic Converter
#1: Directly connected to exhaust manifold #2: In some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump relay (speed). #3: Controlled by the ECM/PCM #4: Device that controls engine and powertrain
CONTINUED
Gl-5
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NEW STANDARDS
Previous Standard Abbreviation Idle Switch Igniter Inhibitor Position Intake Air Pressure Intake Air Thermo Intercooler Knock Sensor Line Pressure Solenoid Valve Lock-up Position Malfunction Indicator Light Multiport Fuel Injection Open Loop Overdrive Oxygen Sensor Park/Neutral Range Power Steering Pressure Pulse Generator Reed Valve Secondary Air Injection System Sequential Fuel Injection Service Code(s) Spark Ignition Stoplight Switch Test Mode Throttle Body Throttle Sensor Turbocharger Vehicle Speed Sensor Vehicle Speed Sensor 1 Water Thermo 12 Shift Solenoid Valve Shift+A Solenoid Valve 23 Shift Solenoid Valve Shift+B Solenoid Valve 34 Shift Solenoid Valve 3rd Gear 3GR Name Idle Speed Control Abbreviation IAC ICM TR MAP IAT CAC KS TCC MIL MFI OL 4GR HO2S O2S PNP PSP SAPV PAIR AIR SFI DTC Dl DTM TB TP TC VSS ECT New Standard Name Idle Air Control Closed Throttle Position Switch Ignition Control Module Transmission (Transaxle) Range Manifold Absolute Pressure Intake Air Temperature Charge Air Cooler Knock Sensor Pressure Control Solenoid Torque Converter Clutch Malfunction Indicator Lamp Multiport Fuel Injection Open Loop Fourth Gear Heated Oxygen Sensor Oxygen Sensor Park/Neutral Position Power Steering Pressure Input/Turbine Speed Sensor Secondary Air Pulse Valve Pulsed Secondary Air Injection Secondary Air Injection Sequential Multipoint Fuel Injection Diagnostic Trouble Code(s) Distributor Ignition Brake Switch Diagnostic Test Mode Throttle Body Throttle Position Sensor Turbocharger Vehicle Speed Sensor Output Speed Sensor Engine Coolant Temperature Shift Solenoid A Shift Solenoid B Shift Solenoid C Third Gear Incorrect Gear Ratio #5 Pulsed injection Inject with compressor With heater Remark
#5: Diagnostic trouble codes depend on the diagnostic test mode
CONTINUED
Gl-6
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PREPARATION OF TOOLS AND MESURING EQUIPMENT
Be sure that all necessary tools and measuring equipment are available before starting any work.
ARRANGEMENT OF PARTS All disassembled parts should be carefully arranged for reassembly. Be sure to separate or otherwise identify the parts to be replaced from those that will be reused.
SPECIAL TOOLS
Use special tools when they are required.
CLEANING OF PARTS DISASSEMBLY

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in a way that will not affect their performance or external appearance and identified so that reassembly can be performed easily and efficiently.
All parts to be reused should be carefully and thoroughly cleaned in the appropriate method.
Warning
Using compressed air can cause dirt and other particles to fly out, causing injury to the eyes. Wear protective eye wear " whenever using compressed air.
INSPECTION DURING REMOVAL, DISASSEMBLY

When removed, each part should be carefully inspected for malfunctioning, deformation, damage, and other problems.
Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts. If removed, these parts should be replaced with new ones:
1 3 5 Oil seals O-rings Cotter pins 2 4 6 Gaskets Lockwashers Nylon nuts
REASSEMBLY
CONTINUED
GI-7
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HOSE CLAMPS
When reinstalling, position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.
1. Sealant, gasket, or both should be applied to the specified locations. When sealant is applied, parts should be installed before sealant hardens. Hardened sealant causes leaks. 2. Oil should be applied to the moving components of parts. 3. Specified oil or grease should be applied at the prescribed locations (such as oil seals) before reassembly.
TORQUE FORMULAS
When using a torque wrench-SST combination, the written torque must be recalculated due to the extra length that the SST adds to the torque wrench. Recalculate the torque by using the following formulas. Choose the formula that applies to you. Torque Unit Nm kgf m kgfcm ftlbf inlbf Formula Nm x [L/(L+A) ] kgfm x [L/(L+A) ] kgfcm x [L/(L+A) ] ftlbf x [L/(L+A) ] inlbf x [L/(L+A) ]
ADJUSTMENT
Use suitable gauges and testers when making adjustments.
A: The length of the SST past the torque wrench drive. L: The length of the torque wrench.
VISE RUBBER PARTS AND TUBING

Prevent gasoline or oil from getting on rubber parts or tubing.
When using a vise, put protective plates in the jaws of the vise to prevent damage to parts.
GI-8
CONTINUED
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ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
CONNECTORS Disconnecting Connectors
When disconnecting two connectors, grasp the connectors, not the wires. 2. Check the terminals of waterproof connectors from the connector side, as they cannot be accessed from the wiring harness side.
Caution
To prevent damage to the terminal, wrap a thin wire around the lead before inserting it into the terminal.
Connectors can be disconnected by pressing or pulling the lock lever as shown.
Locking Connector
When locking connectors, listen for a click that will indicate they are securely locked.
Inspection
1. When a tester is used to check for continuity or to measure voltage, insert the tester probe from the wiring harness side.
GI-9
CONTINUED
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ABBREVIATIONS
ABBREVIATIONS
EX ............................................ HLA ......................................... IN ............................................. MAX ......................................... SST ......................................... Exhaust Hydraulic lash adjuster lntake Maximum Special service tool
CONTINUED
GI-10
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ENGINE
ENGINE OVERHAUL SERVICE WARNING .......... ENGINE MOUNTING/DISMOUNTING ................... MOUNTING ....................................................... DISMOUNTING .................................................. ENGINE DISASSEMBLY/ASSEMBLY .................. TIMING BELT DISASSEMBLY/ASSEMBLY ......... CYLINDER HEAD (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER HEAD (II) DISASSEMBLY/ ASSEMBLY .................................................... TIMING CHAIN DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (I) DISASSEMBLY/ ASSEMBLY .................................................... CYLINDER BLOCK (II) DISASSEMBLY/ ASSEMBLY .................................................... ENGINE INSPECTION/REPAIR ............................ CYLINDER HEAD INSPECTION/REPAIR ........... VALVE INSPECTION ......................................... VALVE GUIDE INSPECTION ............................. VALVE GUIDE REPLACEMENT ......................... VALVE SEAT INSPECTION/REPAIR ................. VALVE SPRING INSPECTION ........................... CAMSHAFT INSPECTION ................................. CAMSHAFT OIL CLEARANCE INSPECTION .................................................. B- 1 B- 1 B- 1/2 B- 2 B- 3 B- 3/5 B- 6/12 B-12/13 B-14/16 B-17/19 B-20/22 B-23 B-23 B-23/24 B-24 B-24 B-25 B-25 B-26 B-26 CAMSHAFT END PLAY INSPECTION ................... B-26 ROCKER ARM AND ROCKER ARM SHAFT INSPECTION ..................................................... B-26/27 CYLINDER BLOCK INSPECTION/ REPAIR ............................................................. B-27 PISTON INSPECTION ........................................... B-27 PISTON CLEARANCE INSPECTION/ REPAIR ............................................................. B-28 PISTON RING CLEARANCE INSPECTION ........... B-28 PISTON PIN CLEARANCE INSPECTION .............. B-28/29 CRANKSHAFT INSPECTION ................................. B-29 CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR ........................................ B-29/30 CRANKSHAFT END PLAY INSPECTION/REPAIR ........................................ B-30 CONNECTING ROD INSPECTION ........................ B-30 CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR ........................................ B-31 CONNECTING ROD SIDE CLEARANCE INSPECTION ..................................................... B-31 PISTON AND CONNECTING ROD INSPECTION ..................................................... B-31 TENSIONER SPRING INSPECTION ..................... B-31 GEAR CLEARANCE INSPECTION ........................ B-31/32 ROTOR CLEARANCE INSPECTION ..................... B-32/33 PLUNGER SPRING INSPECTION ......................... B-33
ENGINE OVERHAUL SERVICE WARNING

Warning Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work.
ENGINE MOUNTING/DISMOUNTING
MOUNTING 1. Install the SST (arms and attachment) to the cylinder block holes as shown, and hand-tighten the SST (bolts).
2. Assemble the SST (bolts, nuts, and plate) to the specified positions.
CONTINUED B-1
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3. Adjust the SST (bolts) so that less than 20 mm {0.79 in } of thread is exposed. 4. Make the SST (plate and arms) parallel by adjusting the SST (bolts and nuts). 5. Tighten the SST (bolts and nuts) to affix the SST firmly.
Warning
The self-locking brake system of the engine stand may not be effective when the engine is held In an unbalanced position. This could lead to sudden, rapid movement of the engine and mounting stand handle and cause serious injury. Never keep the engine in an unbalanced position, and always hold the rotating handle firmly when turning the engine.
6. Mount the engine on the SST (engine stand).
7. Drain the engine oil. 8. Install the oil drain plug. Tightening torque 3041 N.m {3.04.2 kgf.m, 2230 ft.lbf }
DISMOUNTING
Dismount in the reverse order of mounting.
CONTINUED
B-2
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ENGINE DISASSEMBLY/ASSEMBLY
TIMING BELT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2 3 4 5
Crankshaft pulley Refer to Disassembly Note Refer to Assembly Note Upper timing belt cover Lower timing belt cover Guide plate Spark plug
7 8
Timing belt Refer to Disassembly Note Refer to Assembly Note Tensioner, tensioner spring Refer to Assembly Note Idler
CONTINUED
B-3
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Crankshaft Pulley Disassembly Note Hold the crankshaft by using the SST.
Timing Belt Disassembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown. Camshaft pulley timing mark F8: 4 FE: 2
Timing Belt Assembly Note 1. Turn the crankshaft clockwise and align the timing marks as shown. Camshaft pulley timing mark F8: 4 FE: 2
2. Remove the spark plug. Caution The following will damage the belt and shorten its life; forcefully twisting it. Turning it inside out, or allowing oil or grease on It. 3. Mark the timing belt rotation on the belt for proper reinstallation.
2. Install the timing belt. 3. Turn the crankshaft clockwise twice and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Assembly Note step 1. 4. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 5. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 6. Turn the crankshaft clockwise twice and check the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf , 22 Ibf } If it is incorrect repeat from Timing Belt Disassembly Note. Timing belt deflection New : 4.05.0 mm {0.160.19 In } Used : 5.56.5 mm {0.220.25 in }
Tensioner, Tensioner Spring Assembly Note 1. Install the tensioner and tensioner spring. 2. Position the tensioner all the way to the intake side and temporarily secure it by tightening the lock bolt.
B-4
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Crankshaft Pulley Assembly note Hold the crankshaft by using the SST.
CONTINUED
B-5
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CYLINDER HEAD(I) DISASSEMBLY/ASSEMBLY Timing belt drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
Cylinder head cover Refer to Assembly Note Rocker arm Refer to Disassembly Note Refer to Assembly Note Camshaft pulley Refer to Disassembly Note Refer to Assembly Note
4 5 6
Front housing Refer to Assembly Note Camshaft Refer to Assembly Note Cylinder head Refer to Disassembly Note Refer to Assembly Note Cylinder head gasket
CONTINUED
B-6
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Rocker Arm Disassembly Note Loosen the bolts in two or three steps in the order shown.
Camshaft pulley Disassembly Note Hold the camshaft by using a screwdriver.
Front Housing Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Cylinder Head Disassembly Note Loosen the cylinder head bolts in two or three steps in the order shown.
Camshaft Pulley Assembly Note Install the camshaft pulley on the camshaft with the knock pin fit into the hole at the timing mark. Camshaft pulley timing mark F8: 4 FE: 2
Cylinder Head Assembly Note Tighten the bolts in two or three steps in the order shown. Rocker Arm Assembly Note 1. Assemble the rocker arms, rocker arm shafts, and camshaft bearing cap as shown in the figure.
Camshaft Assembly Note Be certain that the knock pin of the camshaft faces straight up. 2. Tighten the bolts in two or three steps in the order shown.
CONTINUED
B-7
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3. Tap in the seal cap by using a plastic hammer.
Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the shaded areas. Thickness 1.52.0 mm {0.0600.078 in }
2. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
CONTINUED
B-8
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Timing chain drive type 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
3 4
Cylinder head cover Refer to Assembly Note Chain adjuster Refer to Disassembly Note Refer to Assembly Note Camshaft gear Refer to Disassembly Note Rocker arm Refer to Disassembly Note Refer to Assembly Note Camshaft
Camshaft sprocket Refer to Disassembly Note Refer to Assembly Note Cylinder head Refer to Disassembly Note Refer to Assembly Note Cylinder head gasket Refer to Assembly Note
B-9
CONTINUED
TO. MODEL .INDEX
Chain Adjuster Disassembly Note 1. Turn the crankshaft until the FE mark of the camshaft pulley is at the top as shown. 2. Check that the crankshaft pulley timing mark is aligned with the indicator pin. Cylinder Head Disassembly Note 1. Remove the bolt A. 2. Loosen the remaining cylinder head bolts in two or three steps in the order shown.
3. Remove the chain adjuster. Camshaft Gear Disassembly Note 1. Pry up the washer tab.
Cylinder Head Gasket Assembly Note 1. Apply silicone sealant to the shaded area.
2. Install the cylinder head gasket. 3. Apply silicone sealant to the shaded area of the cylinder head gasket. 2. Hold the camshaft with a screwdriver as shown.
Rocker Arm Disassembly Note Loosen the rocker arm shaft bolts in two or three steps in the order shown.
Cylinder Head Assembly Note 1. Tighten the cylinder head bolts in two or three steps in the order shown.
2. Tighten the remaining small cylinder head bolts.
B-10
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TO. MODEL .INDEX
Rocker Arm Assembly Note 1. Apply silicone sealant to the shaded area.
Camshaft Sproket Assembly Note 1. Install the camshaft sprocket to the camshaft, aligning mark on the camshaft sprocket and timing chain.
2. Tighten the bolt in two or three steps in the order shown.
2. Hold the camshaft with a screwdriver as shown.
3. Tap in the new seal cap by using a plastic hammer.
3. Bent the washer tab to lock the locknut.
Chain Adjuster Assembly Note 1. Lift the ratchet pawl and compress the chain adjuster sleeve fully, then lock it with the pin lock.
CONTINUED
B-11
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Cylinder Head Cover Assembly Note 1. Apply silicone sealant to the seal cap as shown. CYLINDER HEAD (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2. Apply silicone sealant to the shaded areas.
1 3. Install the cylinder head cover and tighten the bolts in two or three steps in the order shown.
2 3 4 5 6
Valve keeper Refer to Disassembly Note Refer to Assembly Note Upper valve spring seat Valve spring (FE CIS: Single spring type) Refer to Assembly Note Lower valve spring seat Valve Valve seal Refer to Disassembly Note Refer to Assembly Note
Valve Keeper Disassembly Note Remove the valve keeper by using the SST.
Valve Seal Disassembly Note Remove the valve seal by using the SST.
CONTINUED
B-12
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Valve Spring Assembly Note Install the valve spring with the closer pitch toward the cylinder head.
Valve Seal Assembly Note 1. Assemble the SST so that depth L is as specified.
Depth L F8, FE CARB: 19.219.6 mm {0.7560.771 in } FE CIS: 21.422.2 mm {0.8430.874 in }
Valve Keeper Assembly Note Install the valve keeper by using the SST.
2. Press the valve seal onto the valve guide by hand. 3. Tap the SST by using a plastic hammer until its lower end touches the cylinder head.
CONTINUED
B-13
TO. MODEL .INDEX
TIMING CHAIN DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the order of disassembly.
1 2
4 5 6 7
Water pump Crankshaft pulley Refer to Disassembly Note Refer to Assembly Note Timing chain cover Refer to Disassembly Note Refer to Assembly Note Timing chain Refer to Assembly Note Timing gear Crankshaft key Timing chain lever
8 9 10
11 12 13 14 15 16
Timing chain guide Oil strainer Oil pan Refer to Disassembly Note Refer to Assembly Note Oil pump cover Inner rotor Outer rotor Spring seat Pressure spring Control plunger
CONTINUED
B-14
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Crankshaft Pulley Disassembly Note Hold the crankshaft by using the SST. Timing Chain Assembly Note 1. Install the timing chain as shown in the figure.
Oil Pan Disassembly Note Remove the oil pan by using the separator tool.
2. Support the timing chain by using a magnetic base. Timing Chain Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
Oil Pan Assembly Note Apply silicone sealant to the oil pan as shown. Thickness 2.53.5 mm {0.0990.137 in }
4. Apply silicone sealant to the mounting surface along the inside of the bolt holes as shown.
Timing Chain Cover Disassembly Note Remove the oil seal by using a screwdriver protected with a rag.
5. Tighten the timing chain cover installation bolt.
Tightening torque A: 1925 N.m {1.92.6 kgf.m , 1418 ft.lbf } B: 3851 N.m {3.85.3 kgf.m , 2838 ft.lbf }
B-15
CONTINUED
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Crankshaft Pulley Assembly Note Hold the crankshaft by using the SST.
CONTINUED
B-16
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CYLINDER BLOCK (I) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Oil pan (Timing belt drive type) Refer to Disassembly Note Refer to Assembly Note Oil strainer (Timing belt drive type) Oil baffle (FE CIS) Refer to Disassembly Note Refer to Assembly Note Timing belt pulley (Timing belt drive type) Refer to Disassembly Note Refer to Assembly Note Flywheel Refer to Disassembly Note Refer to Assembly Note End plate Oil pump (Timing belt drive type) Refer to Disassembly Note Refer to Assembly Note
8 9 10 11 12 13 14 15
Oil pump body (Timing belt drive type) Outer gear (Timing belt drive type) Inner gear (Timing belt drive type) Oil pump cover (Timing belt drive type) Spring seat (Timing belt drive type) . Pressure spring (Timing belt drive type) Control plunger (Timing belt drive type) Rear cover Refer to Disassembly Note Refer to Assembly Note Water pump Refer to Assembly Note
2 3
16
6 7
CONTINUED
B-17
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Oil Pan Disassembly Note
Note Do not insert the separator tool between the oil baffle and cylinder block. Remove the oil pan by using the separator tool.
Oil Pump Disassembly Note Remove the oil seal by using a screwdriver protected with a rag.
Oil Baffle Disassembly Note Remove the oil baffle by using the separator tool.
Rear Cover Disassembly Note Remove the oil seal by using a screwdriver protected with a rag.
Timing Belt Pulley Disassembly Note Hold the crankshaft by using the SST.
Water Pump Assembly Note 1. Verify that the rubber seal is securely fixed onto the water pump. 2. If not, replace the rubber seal and reapply the bonding agent. 3. Install the water pump.
Flywheel Disassembly Note Hold the crankshaft by using the SST.
Rear Cover Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST.
CONTINUED
B-18
TO. MODEL .INDEX
Oil Pump Assembly Note 1. Apply clean engine oil to the oil seal. 2. Push the oil seal slightly in by hand. 3. Press the oil seal in evenly by using the SST. Oil Pan Assembly Note Apply Silicone sealant to the oil pan as shown. Thickness 2.03.0 mm {0.0790.118 in }
Flywheel Assembly Note 1. Hold the crankshaft by using the SST. 2. Tighten the flywheel bolt in the order shown.
Timing Belt Pulley Assembly Note Hold the crankshaft by using the SST.
Oil Baffle Assembly Note Apply silicone sealant to the oil baffle as shown. Thickness 2.03.0 mm {0.0790.118 in }
CONTINUED
B-19
TO. MODEL .INDEX
CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3
Connecting rod cap Lower connecting rod bearing Piston and connecting rod Refer to Disassembly Note Refer to Assembly Note Upper connecting rod bearing Piston ring Piston pin Piston Connecting rod
10 11
4 5 6 7 8
Main bearing cap Refer to Disassembly Note Refer to Assembly Note Lower main bearing Pilot bearing Refer to Disassembly Note Refer to Assembly Note Crankshaft Upper main bearing Cylinder block
12 13 14
CONTINUED
B-20
TO. MODEL .INDEX
Piston and Connecting Rod Disassembly Note 1. Assemble the SST as shown. Pilot Bearing Disassembly Note Remove the pilot bearing by using the SST.
2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
Pilot Bearing Assembly Note Install the pilot bearing by using a suitable pipe.
3. Set the piston and connecting rod on the SST as shown.
Main Bearing Cap Assembly Note 1. Tighten the bolts in two or three steps in the order shown.
4. Press out the piston pin. Main Bearing Cap Disassembly Note Loosen the main bearing cap bolts in two or three steps in the order shown.
Piston and Connecting Rod Assembly Note 1. Assemble the SST as shown.
CONTINUED
B-21
TO. MODEL .INDEX
2. Insert SST No.2 into the piston pin as shown and fully screw in SST No.1.
3. Set the SST (stopper bolt) so that dimension L is as specified. Dimension L 60.0 mm {2.36 in }
8. Verify that the second ring is installed with the scraper face downward. 9. Position the end gap of the oil ring as shown.
10. F mark facing the front of the engine.
4. Apply clean engine oil to the piston pin. 5. Insert the piston pin and the SST assembled in step 2 into the piston and connecting rod.
6. Press the piston pin into the piston and connecting rod until the SST (guide) contacts the SST (stopper bolt). 7. While inserting the piston pin, check the pressure force. If it is less than the specification, replace the piston pin or the connecting rod. Pressure force 2.9414.70 KN {3001500 kgf , 6603300 Ibf }
CONTINUED
B-22
TO. MODEL .INDEX
ENGINE INSPECTION/REPAIR
CYLINDER HEAD INSPECTION/REPAIR 1. Carry out cooling flaw detection on the cylinder head surface. Replace the cylinder head if necessary. 2. Inspect for the following and repair or replace if necessary. (1) Sunken valve seats (2) Excessive camshaft oil clearance and end play 3. Measure the cylinder head for distortion in the six directions as shown. Distortion 0.15 mm {0.006 in} max. VALVE INSPECTION 1. Measure the valve head margin thickness of each valve. Replace the valve if necessary. Margin thickness FE CIS IN: 1.802.20 mm {0.0710.086 in } EX: 1.301.70 mm {0.0520.006 in } F8, FE CARB IN: 0.81.2 mm {0.0320.047 in } EX: 1.31.7 mm {0.0520.066 in }
2. Measure the length of each valve. Replace the valve if necessary. 4. If the cylinder head distortion exceeds the maximum, repair by grinding the height or replace the cylinder head. If the cylinder head height is not within the specification, replace it. Standard height 91.9592.05 mm {3.6213.624 in } Grinding 0.20 mm {0.008 in } max. 5. Measure the manifold contact surface distortion as shown. Distortion 0.15 mm {0.006 in } max. 6. If the distortion exceeds the specification, grind the surface or replace the cylinder head . Grinding 0.20 mm {0.008 in } max. Standard length FE CIS IN: 115.61116.01 mm {4.5524.567 in } EX: 116.01116.41mm {4.5684.583 in } F8, FE CARB IN: 111.69112.09 mm {4.3984.412} EX: 111.49111.89 mm {4.3904.405 in } Minimum length
FE CIS
IN: 115.51 mm {4.548 in} EX: 115.71 mm {4.556 in} F8, FE CARB IN: 111.39 mm {4.386 in} EX: 111.19 mm {4.378 in}
3. Measure the stem diameter of each valve in X and Y directions at the three points (A, B, and C) shown. Replace the valve if necessary. Standard diameter FE CIS IN: 6.9706.985 mm {0.27450.2749 in } EX: 6.9656.980 mm {0.27430.2748 in } F8, FE CARB IN: 8.0308.045 mm {0.31620.3167 in } EX: 8.0258.040 mm {0.31600.3165 in } Minimum diameter FE CIS IN: 6.920 mm {0.2724 in } EX: 6.915 mm {0.2722 in } F8, FE CARB IN: 7.980 mm {0.3142 in } EX: 7.975 mm {0.3140 in }
CONTINUED
B-23
TO. MODEL .INDEX
VALVE GUIDE INSPECTION 1. Measure the inner diameter of each valve guide in X and Y directions at the three points (A, B, and C) shown. Replace the valve guide if necessary. Standard inner diameter FE CIS IN: 7.0107.030 mm {0.27600.2767 in } EX: 7.0107.030 mm {0.27600.2767 in } F8, FE CARB IN: 8.0308.045 mm {0.31620.3167 in } EX: 8.0258.040 mm {0.31600.3165 in }
Valve Guide Installation 1. Assemble the SSTs so that depth L is as specified. Depth L FE CIS: 19.820.3 mm {0.7800.799 in } F8, FE CARB: 19.119.6 mm {0.7520.771 in }
2. Tap the valve guide in from the side opposite the combustion chamber until! the SST contacts the cylinder head. 3. Verify that the valve guide projection height (dimension) is within the specification. Standard height FE CIS: 19.820.3 mm {0.7800.799 in } FB, FE CARB: 19.119.6mm {0.7520.771 in }
2. Measure the protrusion height (dimension A) of each valve guide without lower valve spring seat. Replace the valve guide if necessary. Standard height FE CIS: 19.820.3 mm {0.7800.799 in } F8, FE CARB: 19.119.6mm {0.7520.711 in }
VALVE GUIDE REPLACEMENT Valve Guide Removal Remove the valve guide from the combustion chamber side by using the SST.
CONTINUED
B-24
TO. MODEL .INDEX
VALVE SEAT INSPECTION/REPAIR 1. Measure the seat contact width. If necessary, resurface the valve seat by using a 45 valve seat cutter and/or resurface the valve face. Standard width IN: 1.21.6 mm {0.0480.062 in } EX: 1.21.6 mm {0.0480.062 in } VALVE SPRING INSPECTION 1. Apply pressing force to the pressure spring and check the spring height. Replace the valve spring if necessary. Pressing force FE CIS IN: 203.10229.86 N {20.7123.44 kgf , 45.57 51.56 Ibf } EX: 240.37272.03 N {24.5127.74 kgf , 53.9361.02 Ibf } F8, FE CARB Inner: 117.19136.01 N {11.9513.87 kgf , 26.2930.51 Ibf } Outer: 243.70267.03 N {24.8527.23 kgf , 54.6759.90 Ibf } Standard height FE CIS IN: 41 mm {1.614 in } EX: 41 mm {1.614 in } F8, FE CARB Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in }
2. Verify that the valve seating position is at the center of the valve face. (1) If the seating position is too high, correct the valve seat by using a 75 (FE CIS) or 60 (F8, FE CARB) cutter, and a 45 cutter. (2) If the seating position is too low, correct the valve seat by using a 35 (IN) or 15 (EX) cutter and a 45 cutter.
2. Measure the out-of-square of the valve spring. Replace the valve spring if necessary. Valve spring out-or-square FE CIS IN: 1.70 mm {0.067 in } EX: 1.76 mm {0.069 in } FB, FE CARB Inner: 1.5 mm {0.059 in } Outer: 1.8 mm {0.071 in }
3. Check the sinking of the valve seat. Measure the protruding length (dimension L) of the valve stem. Replace the cylinder head if necessary. Standard dimension L F8, FE CARB: 46.5 mm {1.831 in } FE CIS: 49.7 mm {1.957 in } Maximum dimension L F8, FE CARB: 47.0 mm {1.850 in } FE CIS: 51.2 mm {2.016 in }
CONTINUED
B-25
TO. MODEL .INDEX
CAMSHAFT INSPECTION 1. Set the No.1 and No.5 journals on V-blocks. Measure the camshaft runout. Replace the camshaft if necessary. Runout 0.03 mm {0.0012 in } max. 2. Measure the cam lobe height at the two points as shown. Replace the camshaft if necessary. Standard height FE CIS IN: 41.340 mm {1.6276 in } EX: 41.847 mm {1.6475 in } F8, FE CARB IN: 38.202 mm {1.5040 in } EX: 38.202 mm {1.5040 in } Fuel pump cam: 39.900 mm {1.5709 in } 2. Install the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 3. Remove the camshaft cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER HEAD (II) Camshaft Cap Assembly Note.) 4. Measure the oil clearance. Replace the cylinder head if necessary. Standard clearance No.1, 5: 0.0350.085 mm {0.001380.00334 in } No.2, 3, 4: 0.0650.115 mm {0.002560.00453 in } Maximum clearance 0.15 mm {0.006 in }
3. Measure the journal diameters in X and Y directions at the two points (A and B) as shown. Replace the camshaft if necessary. Standard diameter No.1, 5: 31.94031.965 mm {1.25751.2585 in } No.2, 3, 4: 31.91031.935 mm {1 .25631.2572 in } Minimum diameter No.1, 5: 31.910 mm {1.2563 in } No.2, 3, 4: 31.880 mm {1.2551 in }
CAMSHAFT END PLAY INSPECTION 1. Install the camshaft and thrust plate. 2. Measure the camshaft end play. Replace the camshaft and/or thrust plate if necessary. Standard end play 0.080.16 mm {0.003150.00629 in } Maximum end play 0.20 mm {0.008 in } ROCKER ARM AND ROCKER ARM SHAFT INSPECTION 1. Measure the rocker arm inner diameter. Diameter FE CIS: 19.00019.033 mm {0.74810.7493 in } F8, FE CARB: 15.96615.984 mm {0.62860.6292 in }
CAMSHAFT OIL CLEARANCE INSPECTION 1. Position a plastigage atop the journals in the axial direction. 2. Measure the rocker arm shaft diameter.
CONTINUED
B-26
TO. MODEL .INDEX
Diameter FE CIS: 18.95918.980 mm {0.74650.7472 in } F8, FE CARB: 15.96615.984 mm {0.62860.6292 in }
3. If the cylinder bore exceeds the wear limit, replace the cylinder block or rebore the cylinder and install the oversize pistons so that the specified piston-to-cylinder clearance is obtained. 3. Calculate the rocker arm-to-shaft clearance. Replace the rocker arm and/or rocker arm shaft if necessary. Standard clearance FE CIS: 0.0200.074 mm {0.000790.00291 in } F8, FE CARB: 0.0160.061 mm {0.000630.00240 in } CYLINDER BLOCK INSPECTION/REPAIR 1. Measure the distortion of the cylinder block top surface in the six directions as shown. Repair by grinding or replace if necessary. Cylinder block distortion 0.15 mm {0.006 in } max. Cylinder block height FE: 288.93289.07 mm {11.37611.380 in } F8: 268.43268.57 mm {10.56910.573 in } Grinding 0.20 mm {0.008 in } max. Note Base the boring diameter on the diameter of an oversize piston. All cylinders must be the same diameter. Cylinder bore
Size Standard 0.25 {0.01} oversize 0.50 {0.02} oversize Diameter 86.00086.019 {3.38593.3865} 86.25086.269 {3.39573.3964} 86.50086.519 {3.40563.4062}
mm { in }
Wear limit 0.15 mm {0.006 in } PISTON INSPECTION Measure the outer diameter of each piston at a right angle (90) to the piston pin, 18.0 mm {0.709 in } below oil ring groove. Piston diameter mm { in }
Size Standard 0.25 {0.01} oversize 0.50 {0.02} oversize Diameter 85.94385.965 {3.383583.38444} 86.19386.215 {3.393423.39428} 86.44386.465 {3.403273.40412}
2. Measure the cylinder bores in X and Y directions at 65 mm {2.56 in } (F8), 70 mm {2.76 in } (FE) below the top surface.
CONTINUED
B-27
TO. MODEL .INDEX
PISTON CLEARANCE INSPECTION/REPAIR 1. Calculate the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit an oversized piston if necessary. Standard clearance 0.0350.076 mm {0.00140.0029 in } Maximum clearance 0.15 mm {0.006 in } 2. If the piston is replaced, the piston rings must also be replaced. PISTON RING CLEARANCE INSPECTION 1. Measure the piston ring-to-ring land clearance around the entire circumference. Replace the piston and piston ring if necessary. Standard clearance Top : 0.030.07 mm {0.00120.0027 in } Second : 0.030.07 mm {0.00120.0027 in } Oil : 0.030.07 mm {0.00120.0027 in } Maximum clearance 0.15 mm {0.006 in } PISTON PIN CLEARANCE INSPECTION 1. Measure each piston pin hole diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.98821.998 mm {0.86570.8660 in }
2. Measure each connecting rod small end inner diameter in X and Y directions as shown. Standard diameter 21.94321.961 mm {0.86390.8646 in }
2. Insert the piston ring into the cylinder by hand and use the piston to push it to the bottom of the ring travel. 3. Measure each piston ring end gap by using a feeler gauge. Replace the piston ring if necessary. Standard end gap Top : 0.200.35 mm {0.0080.013 in } Second : 0.150.30 mm {0.0060.011 in } Oil rail : 0.200.70 mm {0.0080.027 in } Maximum end gap 1.0 mm {0.039 in }
3. Measure each piston pin diameter in X and Y directions at the four points (A, B, C, and D) as shown. Standard diameter 21.97421.980 mm {0.86520.8653 in }
4. Calculate the piston pin-to-piston pin bore clearance. Replace the piston and/or piston pin if necessary.
CONTINUED
B-28
TO. MODEL .INDEX
Standard clearance 0.0080.024 mm {0.000320.00094 in } 5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin. Standard clearance - 0.0370.013 mm {-0.00140.0006 in } CRANKSHAFT INSPECTION 1. Measure the crankshaft runout. Replace the crankshaft if necessary. Runout 0.03 mm {0.0012 in } Crank pin
Bearing size Standard 0.25 {0.01} undersize 0.50 {0.02} undersize 0.75 {0.03} undersize Diameter 50.94050.955 {2.00562.0060} 50.69050.705 {1.99571.9962} 50.44050.455 {1.98591.9864} 50.19050.205 {1.97601.9765}
mm { in }
Out-of-round 0.05 mm {0.002 in } max.
2. Measure the journal diameter in X and Y direction at the two points (A and B) as shown. Replace the crankshaft or grind the journal and install the undersize bearing if necessary. Main journal
Bearing size Standard Diameter No.1, 2, 4, 5 : 59.93759.955 {2.35982.3604} No.3 : 59.93759.955 {2.35982.3604} No.1, 2, 4, 5 : 59.68759.697 {2.34992.3502} No.3 : 59.68759.691 {2.34992.3500} No.1, 2, 4, 5 : 59.43759.447 {2.34012.3404} No.3 : 59.43759.455 {2.34012.3407} No.1, 2, 4, 5 : 59.18759.197 {2.33022.3305} No.3 : 59.18759.205 {2.33022.3309}
mm { in }
0.25 {0.01} undersize
CRANKSHAFT OIL CLEARANCE INSPECTION/ REPAIR . 1. Position a plastigauge atop the journals in the axial direction. 2. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) 4. Measure the main journal oil clearance. If the clearance exceeds the maximum, replace the main bearing or grind the main journal and install the undersize bearings so that the specified oil clearance is obtained. Standard oil clearance No.1, 2, 4, 5: 0.0250.074 mm {0.000990.00291 in } No.3: 0.0310.074 mm {0.001230.00291 in } Maximum oil clearance 0.10 mm {0.004 in }
Out-of-round 0.05 mm {0.002 in } max.
CONTINUED
B-29
TO. MODEL .INDEX
mm { in }
Bearing size Standard 0.25 {0.01} undersize Bearing thickness 2.0042.007 {0.078900.07901} 2.1292.139 {0.083820.08421} No.1, 2, 4, 5 : 2.2542.264 {0.088740.08913} No.3 : 2.2542.257 {0.088740.08885} No.1, 2, 4, 5 : 2.3792.389 {0.093670.09405} No.3 : 2.3792.382 {0.093670.09377}
CRANKSHAFT END PLAY INSPECTION/REPAIR 1. Install the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Assembly Note.) 2. Measure the crankshaft end play. If the end play exceeds the maximum, replace the crankshaft bearing or grind the crankshaft and Install an undersize bearing so that the specified end play is obtained. Standard end play 0.080.18 mm {0.003150.00708 in } Maximum end play 0.30 mm {0.012 in } Note When replacing the No.3 crankshaft bearing replace all of the bearing as a set. mm { in }
Bearing size Standard 0.25 {0.01} undersize 0.50 {0.02} undersize 0.75 {0.03} undersize Bearing thickness 27.9427.99 {1.10001.1019} 28.0428.09 {1.1 0401.1 060} 28.1228.17 {1.10711.1090} 28.2028.25 {1.11031.1122}
3. Remove the main bearing cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY, Main Bearing Cap Disassembly Note.) CONNECTING ROD INSPECTION Measure each connecting rod for bending and distortion. Replace the connecting rod if necessary. Bending 0.15 mm {0.006 in } max. /100 mm {3.937 in } Distortion 0.180 mm {0.0071 in } max. /50 mm {1.97 in } Center-to-center distance FE: 151.95152.05 {5.9835.986 in } F8: 135.95136.05 {5.3535.356 in }
CONTINUED
B-30
TO. MODEL .INDEX
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR 1. Position a plastigauge atop the journals in the axial direction. 2. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY. CYLINDER BlOCK(II) DISASSEMBLY/ASSEMBLY, Piston and Connecting Rod Assembly Note.) 3. Remove the connecting rod cap. 4. Measure the crankpin oil clearance. If the clearance exceeds the maximum, replace the connecting rod bearing or grind the crankpin and use undersize bearings so that the specified clearance is obtained. Standard oil clearance 0.0270.067 mm {0.00110.0026 in } Maximum oil clearance 0.10 mm {0.004 in }
Bearing size Standard 0.25 {0.01} undersize 0.50 {0.02} undersize 0.75 {0.03} undersize
3. Remove the connecting rod cap. PISTON AND CONNECTING ROD INSPECTION Check the oscillation torque as shown. If the large end does not drop by its own weight, replace the piston or the piston pin.
mm { in }
Bearing thickness 1.5051.510 {0.05930.0594} 1.6301.635 {0.06420.0643} 1.7551.760 {0.06910.0692} 1.8801.885 {0.07410.0742}
TENSIONER SPRING INSPECTION Measure the free length of the tensioner spring. Replace the tensioner spring if necessary. Free length F8: 63.0 mm {2.48 in } FE CARB: 56.9 mm {2.24 in } FE CIS: 53.9 mm {2.12 in }
CONNECTING ROD SIDE CLEARANCE INSPECTION 1. Install the connecting rod cap. (Refer to ENGINE DISASSEMBLY/ASSEMBLY, CYLINDER BLOCK (II) DISASSEMBLY/ASSEMBLY. Piston and Connecting Rod Assembly Note.) 2. Measure the connecting rod large end side clearance. Replace the connecting rod and cap if necessary. Standard clearance 0.1100.262 mm {0.0050.010 in } Maximum clearance 0.30 mm {0.012 in }
GEAR CLEARANCE INSPECTION F8, FE CARB Timing Belt Drive Type Measure the following clearance. Replace the gear and/or pump body if necessary. Standard innergear tooth tip to cresent clearance 0.2670.380 mm {0.01060.0149 in } Maximum innergear tooth tip to cresent crearance 0.400 mm {0.0157 in }
B-31
CONTINUED
TO. MODEL .INDEX
Standard outer gear tooth tip to cresent clearance 0.2000.320 mm {0.00790.0125 in } Maximum outer gear tooth tip to cresent clearance 0.350 mm {0.0138 in }
ROTOR CLEARANCE INSPECTION FE CIS Measure the following clearance. Replace the rotor and/or pump body if necessary. Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
Standard side clearance 0.0300.063 mm {0.001190.00248 in } Maximum side clearance 0.10 mm {0.004 in }
Standard outer gear to pump body clearance 0.0900.176 mm {0.00360.0069 in } Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
Standard outer rotor to body clearance 0.0300.063 mm {0.001190.00248 in } Maximum body clearance 0.10 mm {0.004 in }
CONTINUED
B-32
TO. MODEL .INDEX
FE CARB Timing Chain Drive Type Measure the following clearance. Replace the rotor and/or pump body if necessary. Standard Inner rotor tooth tip to outer rotor clearance 0.0440.084 mm {0.00170.0033 in } Maximum Inner rotor tooth tip to outer rotor clearance 0.18 mm {0.007 in }
PLUNGER SPRING INSPECTION Measure the free length of the plunger spring. Replace the plunger spring if necessary. Free length 46.4 mm {1.827 in }
Standard outer gear to pump body clearance 0.0900.176 mm {0.00350.0069 in } Maximum outer gear to pump body clearance 0.20 mm {0.008 in }
CONTINUED
B-33
TO. MODEL .INDEX
TECHNICAL DATA
TECHNICAL DATA ......................................... TD-1/4
TECHNICAL DATA
Item Cylinder head Height mm Distortion mm Grinding mm Valve clearance (F8, FE CARB) mm { in } Valve and valve guide
Margin thickness mm { in } IN EX Standard Minimum mm { in } EX Standard Minimum IN Valve stem diameter mm { in } EX Minimum IN Guide inner diameter EX IN Valve guide protrusion height mm { in } EX Standard Minimum Standard FE CIS: 1.802.20 {0.0710.086} F8, FE CARB: 0.81.2 {0.0320.047} FE CIS: 1.301.70 {0.0520.066} F8, FE CARB: 1.31.7 {0.0520.066} FE CIS: 115.61116.01 {4.5524.567} F8, FE CARB: 111.69112.09 {4.3984.412} FE CIS: 115.51 {4.548}, F8, FE CARB: 111.39 {4.386} FE CIS: 116.01116.41 {4.5684.583} F8, FE CARB: 111.49111.89 {4.3904.405} FE CIS: 115.71 {4.556}, F8, FE CARB: 111.19{4.378} FE CIS: 6.9706.985 {0.27450.2749} F8, FE CARB: 8.0308.045 {0.31620.3167} FE CIS: 6.920 {0.2724} F8, FE CARB: 7.980 {0.3142} FE CIS: 6.9656.980 {0.27430.2748} F8, FE CARB: 8.0258.040 {0.31600.3165} FE CIS: 6.915 {0.2722} F8, FE CARB: 7.975 {0.3140} FE CIS: 7.0107.030 {0.27600.2767} F8, FE CARB: 8.0308.045 {0.31620.3167} FE CIS: 7.0107.030 {0.27600.2767} F8, FE CARB: 8.0258.040 {0.31600.3165} FE CIS: 19.820.3 {0.7800.799} F8, FE CARB: 19.119.6 {0.7520.771} FE CIS: 19.820.3 {0.7800.799} F8, FE CARB: 19.119.6 {0.7520.771} 1.21.6 {0.0480.062} 1.21.6 {0.0480.062} 45 45 F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957} F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016} F8, FE CARB: 46.5 {1.831} FE CIS: 49.7 {1.957} F8, FE CARB: 47.0 {1.850} FE CIS: 51.2 {2.016} { in } { in } { in } IN EX
Specification
91.9592.05 {3.6213.624} 0.15 {0.006} max. 0.20 {0.008} max. 0.30 {0.012} (Engine hot) 0.30 {0.012} (Engine hot)
IN Valve length
Valve seat
Seat contact width mm { in } Seat angle IN Seat sinking mm { in } (Valve protrusion height) EX IN EX IN EX Standard Maximum Standard Maximum
CONTINUED
TD-1
TO. MODEL .INDEX
TECHNICAL DATA
Item Valve spring
H: 41.0 mm {1.614 in } (FE CIS) IN H Inner: 36.5 mm {1.437 in } Outer: 41.0 mm {1.614 in } (F8, FE CARB) H: 41.0 mm {1.614 in } (FE CIS) EX H Inner: 36.5 mm {1.437 in} Outer: 41.0 mm {1.614 in } (F8, FE CARB) IN mm { in } EX 203.10229.86 {20.7123.44, 45.5751.56}
Specification
Inner: 117.19136,01 {11,9513.87, 26.2930,51} Outer: 243.70267.03 {24.8527.23, 54.6759.90}
Pressing force at Valve spring height H N { kgf, lbf }
240.37272.03 {24.5127.74, 53.9361.02}
Inner: 117.19136.01 {11.9513.87, 26,2930.51} Outer: 243.70267.03 {24.8527.23, 54.6759.90}
Out-of-square
FE CIS: 1.70 {0.067} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071} FE CIS: 1.76 {0.069} F8, FE CARB: Inner 1.5 {0.059} outer 1.8 {0.071} mm { in } 0.03 {0.0012} max. FE CIS: 41,340 {1.6276} F8, FE CARB: 38.202 {1.5040} FE CIS: 41.847 {1.6475} F8, FE CARB: 38.202 {1.5040} 31.94031.965 {1.25751.2585} 31.910 {1.2563} 31.91031.935 {1.25631.2572} 31.880 {1.2551} 0.0350.085 {0.001380,00334} 0.0650.115 {0.002560.00453} 0.15 {0.006} 0.080.16 {0.003150.00629} 0.20 {0.008} FE CIS: 19.00019.033 {0.74810.7493} F8, FE CARB: 15.96615.984 {0.62860.6292} FE CIS: 18.95918.980 {0.74650.7472} F8, FE CARB: 15.96615.984 {0.62860.6292} FE CIS: 0.0200.074 {0.000790.00291} F8, FE CARB: 0.0160.061 {0,000630.00240} FE; 288.93289.07 {11.37611.380} F8: 268.43268.57 {10.56910.573} 0.15 {0.006} max. 0.20 {0.008} max. 86.00086.019 {3.38593,3865} 86.25086.269 {3.39573.3964} 86.50086.519 {3.40563.4062} mm { in } 0.15 {0,006}
Camshaft Camshaft runout

Lobe height mm { in } No.1, 5 Journal diameter mm { in } No.2, 3, 4 IN EX Standard Minimum Standard Minimum No.1, 5 No.2, 3, 4 Maximum Camshaft end play mm { in } Standard Maximum
Camshaft bearing oil clearance mm { in }
Rocker arm and rocker arm shaft Rocker arm inner diameter Rocker arm shaft diameter Rocker arm to shaft clearance mm { in } mm { in } mm { in }
Cylinder block
Height Distortion Grinding Cylinder bore diameter mm { in } Wear limit Standard 0.25 {0.01} oversize 0.50 {0.02} oversize mm { in } mm { in } mm { in }
CONTINUED
TD-2
TO. MODEL .INDEX
TECHNICAL DATA
Item Piston
Piston diameter Measured at 90 to pin bore axis and 18.0 mm {0.709 in } below oil ring groove mm { in } Standard 0.25 {0.01} oversize 0.50 {0.02} oversize Standard Maximum Top Piston ring-to-ring groove clearance mm { in } Second Oil Maximum Top End gap (Measured in cylinder) mm { in } Second Oil (rail) Maximum 85.94385.965 {3.383583.38444} 86.19386.215 {3.393423.39428} 86.44386.465 {3.403273.40412} 0.0350.076 {0.00140.0029} 0.15 {0.006} 0.030.07 {0.00120.0027} 0.030.07 {0.00120.0027} 0.030.07 {0.00120.0027} 0.15 {0.006} 0.200.35 {0.0080.013} 0.150.30 {0.0060.011} 0.200.70 {0.0080.027} 1.0 {0.039} mm { in } mm { in } mm { in } mm { in } Standard 0.25 {0.01} undersize 0.50 {0.02} undersize 0.75 {0.03} undersize Out-of-round Standard Crankpin diameter mm { in } Out-of-round Main journal oil clearance mm { in } Crankshaft end play mm { in } Standard Maximum Standard Maximum 0.25 {0.01} undersize 0.50 {0.02} undersize 0.75 {0.03} undersize mm { in } mm { in } 21.97421.980 {0.86520.8653} - 0.037 - 0.013 { -0.0014 - 0.0006} 0.0080.024 {0.000320.00094} 0.03 {0.0012} max. No.1, 2, 4, 5: 59.93759.955 {2.35982.3604} No.3: 59.93759.955 {2.35982.3604} No.1, 2, 4, 5: 59.68759.697 {2.34992.3502} No.3: 59.68759.691 {2.34992.3500} No.1, 2, 4. 5: 59.43759.447 {2.34012.3404} No.3: 59.43759.455 {2.34012.3407} No.1, 2, 4, 5: 59,18759.197 {2.33022.3305} No.3: 59.18759.205 {2.33022.3309} 0.05 {0.002} max. 50.94050.955 {2.00562.0060} 50.69050.705 {1.99571.9962} 50.44050.455 {1.98591.9864} 50.19050.205 {1.97601.9765} 0.05 {0.002} max. No.1, 2, 4, 5: 0.0250.074 {0.000990.00291} No.3: 0.0310.074 {0.001230.00291} 0.10 {0.004} 0.080.18 {0.003150.00708} 0.30 {0.012}
Specification
Piston-to-cylinder clearance mm { in }
Piston ring
Piston pin Diameter Connecting rod small end-to-piston pin clearance Piston-to-piston pin clearance Crankshaft
Crankshaft runout
Main journal diameter mm { in }
CONTINUED
TD-3
TO. MODEL .INDEX
TECHNICAL DATA
Item Connecting rod and connecting rod bearing
Length (Center to center) Bending Distortion Connecting rod side clearance mm { in } Connecting rod bearing oil clearance mm { in } Standard Maximum Standard Maximum mm { in } mm { in } mm { in }
Specification
F8: 135.95136.05 {5,3535.356} FE: 151.95152.05 {5.9835.986} 0.15 {0.006} max./100 mm {3.937 in} 0.180 {0.0071} max./50 mm {1.97 in } 0.1100.262 {0.0050.010} 0.30 {0.012} 0.0270.067 {0.00110.0026} 0.10 {0.004} F8: 63.0 {2.48}, FE CARB: 56.9 {2.24}, FE CIS: 53.9 {2.12} FE CARB Timing chain drive type: 0.0440.084 {0.00170.0033} 0.18 {0.007} (FE CIS, FE CARB Timing chain type) FE CIS, CARB Timing chain type: 0.0900.176 {0.00350.0069} FE CIS, CARB Timing chain type: 0.20 {0.008} F8, FE CARB Timing belt drive type: 0.2670.380 {0.01060.0149} F8, FE CARB Timing belt drive type: 0.400 {0.0157} P8, FE CARB Timing belt drive type: 0.2000.320 {0.00790.0125} F8, FE CARB Timing belt drive type: 0.350 {0.0138} 0.0300.063 {0.001190.00248} 0.10 {0.004} F8, FE CARB Timing belt drive type: 0.0300.063 {0.001200.0024} FE CIS, FE CARB Timing chain drive type: 0.030.09 {0.00120.0035} 0.10 {0.004} mm { in } 46.4 {1.827}
Tensioner spring
Free length mm { in }
Oil pump
Inner rotor tooth tip to outer rotor clearance mm { in } Outer rotor to body clearance mm { in } Standard Maximum Standard Maximum Standard Maximum Standard Maximum Standard Maximum Standard Maximum
Inner gear tooth tip to crescent clearance mm { in }
Outer gear tooth tip to crescent clearance mm { in } Outer gear to pump body clearance mm { in }
Side clearance
mm { in }
Plunger spring
Free length
CONTINUED
TD-4
TO. MODEL .INDEX
SPECIAL TOOLS
SPECIAL TOOLS ........................................... ST-1
SPECIAL TOOLS
49 0107 680A Engine stand 49 L010 1A0 Engine hanger set 49 0636 100B Valve spring lifter arm
49 B012 0A2 Pivot
49 0221 251A Valve guide remover and installer
49 S120 170 Valve seal remover
49 L012 0A2 Valve seal and guide installer
49 L011 0A0B Piston pin setting tool set
49 E011 1A0 Ring gear brake set
49 1285 071 Needle bearing puller
49 P005 204 Oil seal installer
49 S011 103 Oil seal installer
CONTINUED
ST-1
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
ENGINE (WL, WL Turbo)

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B21 DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B21/2 DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B22 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B22 VALVE CLEARANCE INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B22 COMPRESSION INSPECTION . . . . . . . . . . . . . . . B23 TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B24 TIMING BELT REMOVAL/INSTALLATION . . . . B24/5 CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B26 CYLINDER HEAD GASKET REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B26/8 ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 9 ROCKER ARM REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . B2 9/11 FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . B211 FRONT OIL SEAL REPLACEMEN T . . . . . . . . B211/12 REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B212 REAR OIL SEAL REPLACEMENT . . . . . . . . B212 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B213 ENGINE REMOVAL/INSTALLATION . . . . . . B213/14 ENGINE DISASSEMBLY/ASSEMBLY . . . . . B214
DRIVE BELT
DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 lbf} midway between the specified pulleys.
GENERATOR
MEASURING POINT
Deflection
Drive belt Generator a A/C b *New 7.09.0 {0.280.35} 5.06.2 {0.200.24} 9.511.8 {0.380.46} Used 8.010.0 {0.320.39} 6.06.5 {0.240.25} 11.012.5 {0.440.49}
(mm {in}) Limit 16.0 {0.63} 11.3 {0.44} 18.0 {0.71}
WATER PUMP GENERATOR CRANKSHAFT PULLEY MEASURING POINT a
2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
A/C
CRANKSHAFT PULLEY
A/C COMPRESSOR
49 9200 020A
MEASURING POINT b WHEN MEASURED
WHEN SET
CONTINUED
B21
TO. MODEL .INDEX
DRIVE BELT, VALVE CLEARANCE

Tension
Drive belt Generator *New 442637 {4565, 99143} 403519 {4153, 91116} Used 383539 {3955, 86121} 354431 {3644, 8096}
(N {kgf, lbf}) Limit 177 {18, 40} 181 {18.5, 41}
VALVE CLEARANCE
VALVE CLEARANCE INSPECTION/ADJUSTMENT 1. Remove the cylinder head cover. 2. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TDC of compression. 3. Measure the valve clearances A with the No.1 cylinder at TDC of compression, and those of B with the No.4 cylinder at TDC of compression. Valve clearance IN: 0.050.15 mm {0.00200.0059 in} [Engine cold] 0.15 mm {0.0059 in} [Engine hot (Reference)] EX:0.150.25 mm {0.00600.0098 in} [Engine cold] 0.25 mm {0.0098 in} [Engine hot (Reference)]
A A A
A/C
2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen the mounting bolt and locknut A. 2. Adjust the belt deflection or tension by turning adjusting bolt B. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten the mounting bolt and locknut A.
GENERATOR
B A 1925 WATER PUMP
{1.92.6, 1418}
ENGINE FRONT
B GENERATOR
CRANKSHAFT PULLEY B a
A {3.24.7,
2433}
3246
4. If not within the specification, adjust and recheck the valve clearance. 5. Turn the crankshaft one full turn and measure the remaining valve clearances. Adjust if necessary. Tightening torque (locknut) 1620 Nm {1.62.1 kgfm, 1215 ftlbf}
A/C
3851 {3.85.3, A 2838}
CRANKSHAFT PULLEY
A/C COMPRESSOR
FEELER GAUGE
ADJUST SCREW
LOCKNUT b
Nm {kgfm, ftlbf}
4. Inspect the belt deflection or tension. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.)
6. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note.)
CONTINUED
B22
TO. MODEL .INDEX
COMPRESSION INSPECTION
Warning D When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool. 1. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) 2. Warm up the engine to the normal operating temperature. 3. Stop the engine and allow it to cool off for about 10 minutes. Warning D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent fuel from spurting out of the injection nozzle hole, do not ground the FCV (fuel cut valve) terminal. 4. Disconnect the FCV (fuel cut valve) connector. 5. Remove all the glow plugs. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 6. Install the SSTs into the glow plug hole.
49 S010 1A0 49 S013 102
(3) If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. 10. Remove the SST. 11. Install the glow plug. (Refer to Section F2, INTAKE AIR SYSTEM, GLOW PLUG REMOVAL/INSTALLATION.) 12. Connect the FCV (fuel cut valve) connector.
7. Crank the engine and note the maximum gauge reading. 8. Check each cylinder as above. Compression
(kPa {kgf/cm2, psi} [rpm]) Item Standard Minimum Engine WL, WL Turbo 2942 {30, 427} [200] 2648 {27, 384} [200]
9. If the compression in one or more cylinders is low, pour a small amount of clean engine oil into the cylinder and recheck the compression. (1) If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. (2) If the compression stays low, a valve may be stuck or improperly seated and overhaul is required.
CONTINUED
B23
TO. MODEL .INDEX
TIMING BELT
TIMING BELT
TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
3. Remove the tensioner and tensioner spring. Timing Belt Installation Note 1. Measure the tensioner spring free length. Replace the tensioner spring if necessary. Free length 63.0 mm {2.48 in}
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
3851 {3.85.3, 2838} Nm {kgfm, ftlbf}
FREE LENGTH
1 2 3
Timing belt cover + Installation Note Tensioner, tensioner spring Timing belt + Removal Note + Installation Note
2. Turn the crankshaft clockwise and align the timing marks as shown.
TIMING MARK TENSIONER LOCK BOLT CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK FIP PULLEY
Timing Belt Removal Note Caution D Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life.
FAULTY
FAULTY ROTATION ARROW
FAULTY
Caution D Overtensioning of the timing belt can cause breakage of the belt and the camshaft. 3. Verify that the FIP attaching bolts and nuts are tightened to the specified torque. This must be done to prevent overtensioning of the timing belt after it has been installed. 4. Install the timing belt. 5. Install the tensioner, tensioner spring, and hand-tighten the lock bolt. 6. Turn the crankshaft clockwise twice, and align the timing marks. If they are not aligned, remove the timing belt and repeat from Timing Belt Installation Note Step 2. 7. Loosen the tensioner lock bolt to apply tension to the belt. Do not apply tension other than that of the tensioner spring. 8. Tighten the tensioner lock bolt. Be sure the tensioner does not move together with the bolt rotation. 9. Turn the crankshaft clockwise twice, and check the timing belt deflection as shown. If it is incorrect, repeat from Timing Belt Removal Note.
25 mm {1.0 in} MIN.
FAULTY
1. Mark the timing belt rotation on the belt for proper reinstallation. 2. Turn the crankshaft clockwise and align the timing marks as shown.
TIMING MARK
CAMSHAFT PULLEY TENSIONER SPRING TENSIONER TIMING MARK FIP PULLEY
CONTINUED
B24
TO. MODEL .INDEX
TIMING BELT
Timing belt deflection 9.010.0 mm {0.360.39 in} at 98 N {10 kgf, 22 lbf}
TENSIONER LOCK BOLT CAMSHAFT PULLEY TENSIONER SPRING TENSIONER FIP PULLEY
DEFLECTION CHECKING POINT
Timing Belt Cover Installation Note D Tighten the timing belt cover bolts in the order shown.
CONTINUED
ST
B25
TO. MODEL .INDEX

CYLINDER HEAD GASKET REPLACEMENT Warning D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety Procedures. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E,ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the intake manifold, air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove the injection nozzle. (Refer to Section F2, FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove the turbocharger. (WL Turbo) (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 7. Remove in the order indicated in the table. 8. Install in the reverse order of removal. 9. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 10. Check the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 11. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 12. Start the engine and (1) Inspect for engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, PREPARATION, Idle Speed Adjustment.) 13. Inspect the compression. (Refer to COMPRESSION INSPECTION.)
5.08.8 Nm {5090 kgfcm, 4478 inlbf} 7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
1819 {1.82.0, 13.114.4} 29 {3.0, 22} + (90105) + (90105)
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
3851 {3.85.3, 2838}
CONTINUED
Nm {kgfm, ftlbf}
B26
TO. MODEL .INDEX
1 2 3
Drive belt Cylinder head cover + Installation Note Cylinder head bolt + Removal Note + Installation Note Cylinder head Cylinder head gasket + Installation Note
LENGTH
4 5
Cylinder Head Bolt Removal Note 1. Remove bolts A. 2. Loosen the cylinder head bolts in two or three steps in the order shown.
A
2. Apply clean engine oil to the threads and the seat face of each bolt and install them. 3. Tighten the bolts in two or three steps in the order shown in the figure. Tightening torque 29 Nm {3.0 kgfm, 22 ftlbf}
A
Cylinder Head Gasket Installation Note D Apply silicone sealant to the cylinder head as shown. Thickness 2.03.0 mm {0.080.11 in}
16.0 mm {0.63 in} 40.5 mm {1.59 in} 48.5 mm {1.91 in} 9.0 mm {0.35 in} ENGINE FRONT
4. Put a paint mark on each bolt head. 5. Using the marks as a reference, tighten the bolts by turning each 90105 in the sequence shown. 6. Further tighten each bolt by turning another 90105.
PAINT MARK
90105
90105
ST
Cylinder Head Bolt Installation Note 1. Measure the length of each bolt. Replace the bolt if necessary. Cylinder head bolt
Bolt head mark W N Standard length 101.2101.8 {3.9854.007} 113.2113.8 {4.4574.480}
PAINT MARK
7. Tighten bolts A.
(mm {in}) Maximum length 102.5 {4.035} 114.5 {4.508}
Tightening torque 1819 Nm {1.82.0 kgfm, 13.114.4 ftlbf}
CONTINUED
B27
TO. MODEL .INDEX

Cylinder Head Cover Installation Note 1. Apply silicone sealant to the cylinder head as shown. Thickness 1.52.5 mm {0.0600.098 in}
2. Tighten cylinder head cover bolts A and B. Tightening torque 1.52.9 Nm {1530 kgfcm, 1426 inlbf}
A ENGINE FRONT B
3. Tighten the cylinder head cover bolts in the order shown. Tightening torque 5.08.8 Nm {5090 kgfcm, 4478 inlbf}
CONTINUED
B28
TO. MODEL .INDEX
ROCKER ARM
ROCKER ARM
ROCKER ARM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
5.08.8 Nm {5090 kgfcm, 4478 inlbf}
11.314.2 Nm {115145 kgfcm, 100125 inlbf} 1620 {1.62.1, 1215}
R SST
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 3041 {3.04.2, 2230}
123140 {12.514.3, 91103}
Nm {kgfm, ftlbf}
Cylinder head cover + VALVE CLEARANCE, VALVE CLEARANCE INSPECTION/ADJUSTMENT + CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT, Cylinder Head Cover Installation Note Camshaft pulley + Removal Note + Installation Note
3 4
Seal plate + Installation Note Camshaft + Removal Note + Installation Note Rocker arm + Installation Note Pivot
ST
5 6
CONTINUED
B29
TO. MODEL .INDEX
ROCKER ARM
Camshaft Pulley Removal Note D Hold the camshaft by using a wrench on the cast hexagon.
2. Tighten the camshaft cap bolts gradually in three or four steps in the order shown. Camshaft Removal Note Note D Mark the camshaft caps so that they can be reinstalled in the position from which they were removed.
D Loosen the camshaft cap bolts in three or four
ENGINE FRONT
steps in the order shown.
ENGINE FRONT
3. Apply clean engine oil to the new oil seal. 4. Push the oil seal slightly in by hand. 5. Tap the oil seal into the cylinder head by using the SST and a hammer. 6. To ensure that the oil seal is installed accurately, measure distance between the end of the cylinder head and the face of the oil seal.
49 S010 001
Rocker Arm Installation Note D If a new rocker arm is used, set dimension follows. Dimension A 04 mm {00.1 in}
as
0.51.0 mm {0.020.03 in}
HAMMER
CYLINDER HEAD
OIL SEAL
Seal Plate Installation Note D Tighten the seal plate bolts in the order shown.
A
Camshaft Installation Note 1. Apply silicone sealant to the front camshaft cap mounting surfaces as shown. Prevent sealant from getting onto the camshaft journal, oil seal surface, and camshaft thrust surface.
CONTINUED
B210
TO. MODEL .INDEX
ROCKER ARM, FRONT OIL SEAL

Camshaft Pulley Installation Note D Hold the camshaft by using a wrench on the cast hexagon and tighten the pulley lock bolt.
FRONT OIL SEAL

FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the upper radiator hose. 4. Remove the radiator cowling and cooling fan. (Refer to Section E, WATER PUMP, WATER PUMP REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Inspect the engine oil level. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
SST R SST
350390 {3540, 260280}
Nm {kgfm, ftlbf}
1 2
Drive belt Crankshaft pulley + Removal Note + Installation Note Front oil seal + Removal Note + Installation Note
Crankshaft Pulley Removal Note D Hold the crankshaft by using the SST. Caution D Turning the crankshaft after the crankshaft pulley is removed can cause the timing gear to become dislocated. D Removing the key can cause the key groove to become misaligned.
49 S011 102A
CONTINUED
B211
TO. MODEL .INDEX
FRONT OIL SEAL, REAR OIL SEAL

Front Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
REAR OIL SEAL

REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
RAG
Front Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the gear case cover and the face of the front oil seal.
GEAR CASE COVER
SST
49 S010 301
Rear oil seal + Removal Note + Installation Note
00.4 mm {00.01 in}
Rear Oil Seal Removal Note 1. Cut the oil seal lip by using a razor knife. 2. Remove the oil seal by using a screwdriver protected with a rag.
HAMMER
FRONT OIL SEAL
Crankshaft Pulley Installation Note D Hold the crankshaft by using the SST.
RAG
49 S011 102A
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly by using the SST and a hammer. 4. To ensure that the oil seal is installed accurately, measure the distance between the end of the rear cover and the face of the rear oil seal.
49 S011 103
REAR COVER
00.5 mm {00.01 in}
HAMMER
REAR OIL SEAL
CONTINUED
B212
TO. MODEL .INDEX
ENGINE
ENGINE
ENGINE REMOVAL/INSTALLATION Warning D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety Procedures. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL SYSTEM.) 1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the transmission. (Refer to section J2, TRANSMISSION, TRANSMISSION REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 10. Start the engine and (1) Inspect the engine oil, engine coolant, and fuel leakage. (2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed Adjustment.) 11. Perform a road test.
1925 {1.92.6, 1418}
9.914.7 Nm {100150 kgfcm, 86.8130 inlbf}
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
3246 {3.24.7, 2433}
2030 {2.03.1, 1522} Nm {kgfm, ftlbf}
1 2 3 4
Cooling fan Drive belt Accelerator cable A/C compressor + Removal Note
5 6 7
P/S oil pump + Removal Note Engine mount nut Engine + Removal/Installation Note
CONTINUED
B213
TO. MODEL .INDEX
ENGINE
A/C Compressor Removal Note D Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. P/S Oil Pump Removal Note D Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. Engine Removal/Installation Note D Install the engine hanger (JE48 10 561C) to the cylinder head by using bolt (99794 0820) or (M8 1.25, 6T, length 20 mm {0.79 in}) as shown. Tightening torque 1925 Nm {1.92.6 kgfm, 1418 ftlbf}
3851 {3.85.3, 2838}
ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the intake-air system. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the exhaust system. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Remove the oil cooler. (Refer to Section D, OIL COOLER, OIL COOLER REMOVAL/INSTALLATION.) 4. Disassemble in the ordre indicated in the table. 5. Assemble in the reverse order of disassembly.
1217 {1.21.8, 913}
ENGINE FRONT
3246 {3.24.7, 2433}
1925 {1.92.6, 1418}
3851 {3.85.3, 2838}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7
Drive belt Generator Idler A/C compressor bracket Engine mount bracket Oil pressure switch + Section D, OIL PRESSURE INSPECTION Water pump pulley
CONTINUED
B214
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
ENGINE (F2)
DRIVE BELT .................................................... B3- 1 DRIVE BELT INSPECTION .......................... B3- 1 DRIVE BELT ADJUSTMENT ........................ B3- 2 COMPRESSION INSPECTION ........................ B3- 2/3 TIMING BELT .................................................. B3- 4 TIMING BELT REMOVAL/INSTALLATION ... B3-4/6 CYLINDER HEAD GASKET ............................. B3- 7 CYLINDER HEAD GASKET REPLACEMENT ......................................... B3- 7/9 HYDRAULIC LASH ADJUSTER (HLA) ............ B3-10 HLA REMOVAL/INSTALLATION ................ B3-10/12 HLA TROUBLESHOOTING ........................ B3-13 FRONT OIL SEAL ......................................... B3-14 FRONT OIL SEAL REPLACEMENT ........... B3-14 REAR OIL SEAL ............................................. B3-15 REAR OIL SEAL REPLACEMENT ............. B3-15 ENGINE .......................................................... B3-16 ENGINE REMOVAL/INSTALLATION ......... B3-16/17 ENGINE DISASSEMBLY/ASSEMBLY ........ B3-18
DRIVE BELT
DRIVE BELT INSPECTION Drive Belt Deflection Check 1. Check the drive belt deflection when the engine is cold, or at least 30 minutes after the engine has stopped. Apply pressure 98 N {10 kgf, 22 Ibf} midway between the specified pulleys.
Deflection Drive belt Generator P/S A/C
*New 7.08.0 {0.280.31} 5.06.0 {0.200.23} 10.012.0 {0.400.47}
mm {in} Used 8.09.0 {0.320.35} 5.56.5 {0.220.25} 12.014.0 {0.480.55}
* A belt that has been on a running engine for less than five minutes. 2. If the deflection is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) Drive Belt Tension Check 1. Belt tension can be checked in place of belt deflection. Check the drive belt tension when the engine is cold, or at least 30 minutes after the engine has stopped. Using the SST, check the belt tension between any two pulleys.
CONTINUED
B3-1
TO. MODEL .INDEX
DRIVE BELT, COMPRESSION INSPECTION

Tension Drive belt Generator *New 510588 {5260, 115132} 393490 {4050, 88110} 373490 {3850, 84110} N {kgf, Ibf} Used 432509 4452, 97114} 344441 {3545, 7799} 275372 {2838, 6283}
Warning When the engine and the oil are hot, they can badly burn. Be careful not to burn yourself during removal/installation of each component. Verify that the battery is fully charged. Recharge it if necessary. (Refer to Section G, CHARGING SYSTEM, BATTERY INSPECTION, Battery.) Warm up the engine to the normal operating temperature. Stop the engine and allow it to cool off for about 10 minutes. Perform "Fuel Line Safety Procedure". Leave the fuel pump relay removed. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Remove the spark plugs. Connect a compression gauge into the No.1 spark plug hole. Fully depress the accelerator pedal and crank the engine. Note the maximum gauge reading. Inspect compression of each cylinder. kPa {kgf/cm2, psi} [rpm] Engine type F2 CARB F2CIS 1196 {12.2, 173} 1226 {12.5, 178} [300] [300] 837 {8.54, 121} [300] 858 {8.75, 124} [300]
P/S
A/C
* A belt that has been on a running engine for less than five minutes. 2. If the tension is not within the specification, adjust it. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) DRIVE BELT ADJUSTMENT 1. Loosen mounting bolts A and B, and locknut C. 2. Adjust the belt deflection or tension by turning the generator or adjusting bolt D. (Refer to DRIVE BELT, DRIVE BELT INSPECTION.) 3. Tighten mounting bolts A and B, and locknut C.
Compression Item Standard Minimum Maximum difference between cylinders
2 196 kPa {2.0 kgf/cm , 28 psi}
If the compression in one or more cylinders is low or the compression difference between cylinders exceeds the maximum, pour a small amount of clean engine oil into the cylinder and recheck the compression. If the compression increases, the piston, the piston rings, or cylinder wall may be worn and overhaul is required. If the compression stays low, a valve may be stuck or improperly seated and overhaul is required. If the compression in adjacent cylinders stays low, the cylinder head gasket may be damaged or the cylinder head distorted and overhaul is required. Disconnect the compression gauge. Install the spark plugs. Tightening torque 1522 N-m {1.52.3 kgf-m, 1116 ft-lbf}
B3-2
CONTINUED
TO. MODEL .INDEX
Connect the igniter connector (F2 CIS) or ignition coil primary wire connector (F2 CARB). Install the fuel pump relay.
CONTINUED
B3-3
BACK.TO.CHAPTER.INDEX TIMING BELT TIMING BELT
TO. MODEL .INDEX
TIMING BELT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the spark plugs. 3. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 4. Remove the cooling fan and cooling fan pulley. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Start the engine and (1) Inspect the pulleys and drive belt for runout and contact. (2) Inspect the ignition timing. (Refer to Section F3-F4, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
1 2 3 4 5
Generator strap Cooling fan bracket Timing belt cover Installation Note Crankshaft pulley Guide plate
Timing belt Removal Note Installation Note Tensioner, tensioner spring Installation Note
CONTINUED
B3-4
BACK.TO.CHAPTER.INDEX TIMING BELT Timing Belt

Removal Note 1. Turn the crankshaft clockwise and align the timing marks. Camshaft pulley timing mark 1
TO. MODEL .INDEX
2. Install the tensioner. 3. Temporarily secure the tensioner with the spring fully extended.
2. Loosen the tensioner lock bolt. 3. Push the tensioner in the direction of the ar reduce tension of the timing belt and handrow to tighten the tensioner lock bolt. Timing Belt Installation Note 1. Verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks as shown. Camshaft pulley timing mark 1
Caution Forcefully twisting the belt, turning it inside out, or allowing oil or grease on it will damage the belt and shorten its life. Note Mark the timing belt rotation on the belt for proper reinstallation. 2. Install the timing belt so that there is no looseness at the tension side.
Tensioner, Tensioner Spring Installation Note 1. Measure the tensioner spring free length. If not as specified, replace the tensioner spring. Free length 63.0 mm {2.48 in}
CONTINUED
B3-5
TO. MODEL .INDEX
TIMING BELT
Caution Applying excessive tension can break the timing belt. Be sure not to apply tension other than that of the tensioner spring. 3. Loosen the tensioner lock bolt to apply tension to the timing belt. 4. Turn the crankshaft clockwise twice and verify that the timing belt pulley mark and camshaft pulley mark are aligned with the timing marks. 5. If not, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Caution Prevent the tensioner from moving with the tensioner lock bolt as it is turned. Otherwise tension will become very high and the timing belt may break. 6. Tighten the tensioner lock bolt. 7. Inspect the timing belt deflection at the point indicated by applying moderate pressure 98 N {10 kgf, 22 Ibf}. Timing belt deflection New : 8.09.0 mm {0.320.35 in} Used : 9.010.0 mm {0.360.39 in}
8. If not as specified, repeat from Timing Belt Removal Note. (Refer to Timing Belt Removal Note.) Timing Belt Cover Installation Note Tighten the timing belt cover bolts in the order shown.
CONTINUED
B3-6
TO. MODEL .INDEX
CYLINDER HEAD GASKET CYLINDER HEAD GASKET

CYLINDER HEAD GASKET REPLACEMENT Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the timing belt, (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the air cleaner. (F2 CARB) 6. Remove the air hose. (F2 CIS) 7. Disconnect the PCV hose. 8. Disconnect the accelerator cable and bracket (F2 CIS). 9. Disconnect the vacuum hoses, and engine harness connector. 10. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, AFTER REPAIR PROCEDURE.) 11. Remove the dynamic chamber bracket. (F2 CIS) 12. Disconnect the heater hoses. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Inspect for fuel leakage. 16. Inspect the compression. (Refer to COMPRESSION INSPECTION.) 17. Start the engine and inspect the idle speed. (Refer to Section F3-F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.)
CONTINUED B3-7
TO. MODEL .INDEX
1 2
Cylinder head cover Installation Note Cylinder head Removal Note Installation Note
Cylinder head gasket
CONTINUED
B3-8
TO. MODEL .INDEX

Cylinder Head Bolt Removal Note Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Bolt Installation Note Tighten the cylinder head bolts a few turns in the order shown.
Cylinder Head Cover Installation Note 1. Verify that the grooves on the cylinder head cover are free of oil, water and other foreign material. 2. Apply sealant all around the cylinder head cover side of the cylinder head cover gasket surface. 3. Install the cylinder head cover gasket into the cylinder head cover. 4. Apply silicone sealant to the shaded area as shown.
CONTINUED
B3-9
TO. MODEL .INDEX
HYDRAULIC LASH ADJUSTER (HLA) HYDRAULIC LASH ADJUSTER (HLA)

HLA REMOVAL/INSTALLATION Caution Removal and installation of the HLA must be carried out only when the problem cannot be solved by the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.) 1. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 2. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) 6. Start the engine and (1) inspect the engine oil (2) inspect the idle speed. (Refer to Section F3F4, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 7. Inspect the HLA troubleshooting. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING.)
Rocker arm component Removal Note Installation Note Camshaft cap (F2 CARB) Installation Note
Hydraulic lash adjuster (HLA) Installation Note
CONTINUED
B3-10
TO. MODEL .INDEX

Rocker Arm Component Removal Note 1. Loosen the bolts a few turns in the order shown.
4. Apply clean engine oil to HLA 0-ring. Camshaft Cap (F2 CARS) Installation Note Apply silicone sealant to the shaded areas of the cylinder head as shown.
2. Identify the rocker arm and shaft assembly parts so that they can be reinstalled in the same locations from which they were removed. 3. Remove the rocker arm and shaft assembly together with the bolts. Hydraulic Lash Adjuster (HLA) Installation Note 1. Place each HLA in a container filled with clean engine oil. Caution Do not push the pin too hard. It may damage the HLA. 2. Bleed the air from the HLA by inserting a pin into the plunger hole and pressing the plunger until it no longer moves.
Rocker Arm Component Installation Note Note The intake side shaft has twice as many oil holes as the exhaust side shaft. (F2 CARB) 1. Assemble the rocker arms and shaft assembly as shown in the figure.
3. Pour engine oil into the oil reservoir in the rocker arm.
CONTINUED
B3-11
TO. MODEL .INDEX
2. Apply silicone sealant to the shaded areas of the cylinder head as shown.
3. Install the rocker arm component. 4. Tighten the bolts a few turns in the order shown.
CONTINUED
B3-12
TO. MODEL .INDEX

HLA TROUBLESHOOTING Problem Possible Cause 1. Noise when engine is started Oil leakage in oil immediately after oil is passage or in HLA changed. 2. 3. Action Run engine at 2,0003,000 rpm. If noise stops within 20 minutes*, HLA is normal. If not, replace HLA. * Time required for engine oil to circulate within HLA Noise when engine is started includes tolerance for engine oil condition and after sitting one day or more. ambient temperature. Noise when engine is started Oil leakage in HLA (Refer to HYDRAULIC LASH ADJUSTER (HLA), after new HLA is installed. HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise continues more than Insufficient oil pressure Check oil pressure. 10 minutes. If lower than specification, check for cause. (Refer to section D, OIL PRESSURE INSPECTION.) Faulty HLA Press down HLA by hand. If it does not move, HLA is normal. If it moves, replace HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) Measure valve clearance. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA TROUBLESHOOTING, Valve Clearance Inspection.) Noise during idle after high Incorrect oil amount Check oil level. speed running. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.) Deteriorated oil Replace new engine oil. (Refer to Section D, ENGINE OIL, ENGINE OIL REPLACEMENT.)
4.
5.
Valve Clearance Inspection 1. Remove the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.) 2. Measure valve clearance. Valve clearance 0.15 mm {0.0059 in} max.
3. If valve clearance is more than 0.15 mm {0.0059 in}, replace the HLA. (Refer to HYDRAULIC LASH ADJUSTER (HLA), HLA REMOVAL/INSTALLATION.) 4. Install the cylinder head cover. (Refer to CYLINDER HEAD GASKET, CYLINDER HEAD GASKET REPLACEMENT.)
CONTINUED
B3-13
TO. MODEL .INDEX
FRONT OIL SEAL FRONT OIL SEAL

FRONT OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the engine oil level. (Refer to Section D, ENGINE OIL, ENGINE OIL INSPECTION.)
Front Oil Seal Installation Note 1. Apply clean engine oil to the oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
1 2 3
Timing belt pulley Removal/Installation Note Key Front oil seal Removal Note Installation Note
Timing Belt Pulley Removal/Installation Note Hold the crankshaft using the SST.
Front Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
CONTINUED B3-14
TO. MODEL .INDEX
REAR OIL SEAL REAR OIL SEAL

REAR OIL SEAL REPLACEMENT 1. Disconnect the negative battery cable. 2. Remove the flywheel. (Refer to Section H, CLUTCH UNIT, CLUTCH UNIT REMOVAL/ INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
Rear oil seal Refer to Removal Note Refer to Installation Note
Rear Oil Seal Removal Note 1. Cut the oil seal lip using a razor knife. 2. Remove the oil seal using a screwdriver protected with a rag.
Rear Oil Seal Installation Note 1. Apply clean engine oil to the new oil seal lip. 2. Push the oil seal slightly in by hand. 3. Tap the oil seal in evenly using the SST and a hammer.
CONTINUED
B3-15
BACK.TO.CHAPTER.INDEX ENGINE ENGINE
TO. MODEL .INDEX
ENGINE REMOVAL/INSTALLATION Warning Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" in section F3, F4. (Refer to section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the air cleaner and air hose (F2, CIS). 4. Remove the front pipe. 5. Disconnect the accelerator cable, bracket (F2 CIS), heater hoses, high-tension leads, and vacuum hoses. 6. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.) 7. Remove the cooling fan and cooling fan pulley. 8. Remove the drive belt. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Disconnect the fuel hoses. (Refer to Section F3-F4, FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to Section F3-F4, FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 10. Remove the transmission. (Refer to Section J1-J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION.) 11. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. (Refer to Section N, ENGINE SPEED SENSING POWER STEERING, POWER STEERING OIL PUMP REMOVAL/INSTALLATION.) 12. Remove the A/C compressor with the pipe still connected. Position the A/C compressor so that it is out of the way. 13. Remove in the order indicated in the table. 14. Install in the reverse order of removal. 15. Start the engine and (1) Inspect the engine oil, engine coolant, transmission oil, and fuel leakage. (2) Inspect the ignition timing, idle speed and idle mixture. (Refer to Section F3-F4, ENGINE TUNE-UP.) 16. Perform a road test.
CONTINUED
B3-16
TO. MODEL .INDEX
Engine mount nut
Engine
CONTINUED
B3-17
TO. MODEL .INDEX
ENGINE DISASSEMBLY/ASSEMBLY 1. Remove the distributor. (Refer to Section G, IGNITION SYSTEM, DISTRIBUTOR REMOVAL/INSTALLATION.) 2. Remove the generator. 3. Remove the thermostat. (Refer to Section E, THERMOSTAT, THERMOSTAT REMOVAL/INSTALLATION.) 4. Remove the intake-air system. (Refer to Section F3-F4, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Remove the exhaust system. (Refer to Section F3-F4, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 6. Remove the oil filter. (Refer to Section D, OIL FILTER, OIL FILTER REPLACEMENT.) 7. Remove the oil pressure switch. (Refer to Section D, OIL PRESSURE INSPECTION.) 8. Disassemble in the order indicated in the table. 9. Assemble in the reverse order of disassembly.
1 2 3 4 5
Generator strap Cooling fan bracket Generator bracket Water inlet pipe Water bypass pipe
6 7 8 9
Dipstick P/S oil pump bracket Gusset plate Engine mount
CONTINUED
B3-18
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
LUBRICATION SYSTEM
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . . ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . . ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . . OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . . D1 D2 D2 D2 D2 D2 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL COOLER REMOVAL/INSTALLATION . . . . . OIL COOLER BODY INSPECTION . . . . . . . . . . OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN REMOVAL/INSTALLATION . . . . . . . . . D3 D3/4 D4 D4 D4/5
OIL PRESSURE INSPECTION

Warning D Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. D When the engine and the oil are hot, they can badly burn. Turn off the engine and wait until they are cool. 1. Remove the oil pressure switch. 2. Screw the SST into the oil pressure switch installation hole.
F2, G6
G6
: 305402 kPa {3.14.1 kgf/cm2, 4558 psi} [3,000 rpm] WL : 452529 kPa {4.65.4 kgf/cm2, 6676 psi} [3,000 rpm] WL Turbo : 402480 kPa {4.14.9 kgf/cm2, 5969 psi} [3,000 rpm]
5. If the pressure is not as specified, inspect for the cause and repair or replace as necessary. 6. Stop the engine and wait until it becomes cool. 7. Remove the SST. 8. Apply silicone sealant to the oil pressure switch threads as shown.
1.02.0 mm {0.0400.078 in}
49 0187 280
4.06.0 mm {0.160.23 in} WL, WL TURBO
9. Install the oil pressure switch before the sealant hardens. Tightening torque 1217 Nm {1.21.8 kgfm, 913 ftlbf} 10. Start the engine and inspect for oil leakage.
49 0187 280
3. Warm up the engine to normal operating temperature. 4. Run the engine at the specified speed, and note the gauge readings. Note D The oil pressure can vary with viscosity and temperature. Oil pressure F2 : 295392 kPa {3.04.0 kgf/cm2, 4356 psi} [3,000 rpm]
CONTINUED
D1
TO. MODEL .INDEX
ENGINE OIL, OIL FILTER
ENGINE OIL
ENGINE OIL INSPECTION 1. Position the vehicle on level ground. 2. Warm up the engine to normal operating temperature and stop it. 3. Wait for five minutes. 4. Remove the dipstick and inspect for oil level and condition. Verify that the oil level is within the F and L marks on the dipstick. 5. Add or replace oil if necessary. ENGINE OIL REPLACEMENT Warning D When the engine and the engine oil are hot, they can badly burn. Dont burn yourself with either. D A vehicle that is lifted but not securely supported on safety stands is dangerous. It can slip or fall, causing death or serious injury. Never work around or under a lifted vehicle if it is not securely supported on safety stands. D Continuous exposure with USED engine oil has caused skin cancer in laboratory mice. Protect your skin by washing with soap and water immediately after this work. 1. Position the vehicle on level ground. 2. Remove the oil filler cap and the oil pan drain plug. 3. Drain the oil into a container. 4. Install the drain plug by using a new washer. Tightening torque 3041 Nm {3.04.2 kgfm, 2230 ftlbf} 5. Refill the engine oil with the specified type and amount of engine oil. 6. Refit the oil filler cap. 7. Run the engine and inspect for oil leakage. 8. Inspect the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) Note D The actual oil level may vary from the specified capacity in some cases. Oil capacity
Item
OIL FILTER
OIL FILTER REPLACEMENT 1. Remove the oil filter by using the SST or the filter wrench.
49 9014 001
2. Use a clean rag to wipe off the mounting surface on the oil filter body. 3. Apply engine oil to the O-ring and tighten the filter according to the installation directions on the side of the oil filter using the SST or the filter wrench. 4. Start the engine and inspect for oil leakage. 5. Inspect for the oil level and add oil if necessary. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
(L {US qt, Imp qt})

Engine F2 3.9 {4.1, 3.4} 4.2 {4.4, 3.7} 4.6 {4.9, 4.0} G6 4.5 {4.8, 4.0} 4.7 {5.0, 4.4} 5.5 {5.8, 4.8} WL, WL Turbo 5.6 {5.9, 4.9} 6.3 {6.7, 5.5} 6.7 {7.1, 5.9}
Oil replacement Oil and oil filter replacement Total (dry engine)
CONTINUED
D2
TO. MODEL .INDEX
OIL COOLER
OIL COOLER
OIL COOLER REMOVAL/INSTALLATION G6, WL, WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) (WL Turbo model.) 4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.) 5. Remove in the order shown in the figure. 6. Install in the reverse order of removal. 7. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E, ENGINE COOLANT,ENGINE COOLANT REPLACEMENT.) 8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.) 9. Start the engine and inspect for engine coolant leakage.
G6
3039 {3.04.0, 2228} Nm {kgfm, ftlbf}
1 2
Water hose Nut
Oil cooler
WL, WL TURBO R
3049 {3.05.0, 2236}
7.910.7 Nm {80110 kgfcm, 7095 inlbf} 1925 {1.92.6, 1418}
R
1925 {1.92.6, 1418}
R
Nm {kgfm, ftlbf}
1 2 3 4
Dipstick pipe Radiator hose Thermostat case Insulator
5 6
Oil cooler body + Installation Note Oil cooler
CONTINUED
D3
TO. MODEL .INDEX
OIL COOLER, OIL PAN

Oil Cooler Body Installation Note WL, WL Turbo D Tighten the mounting bolts and nuts in the order shown.
OIL PAN
OIL PAN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 3. Remove in the order shown in the figure. 4. Install in the reverse order of removal. 5. Fill with the specified amount and type of engine oil. (Refer to ENGINE OIL, ENGINE OIL REPLACEMENT.) 6. Start the engine and inspect for engine oil leakage.
F2, G6
OIL COOLER BODY INSPECTION WL, WL Turbo D Measure the spring free length. Replace the spring if necessary. Standard free length Bypass valve spring: 36.7 mm {1.44 in} Pressure control valve spring: 54.7 mm {2.15 in}
BYPASS VALVE SPRING
3041 {3.04.2, 2230}
7.910.7 Nm {80110 kgfcm, 7095 inlbf} 3851 {3.85.3, 2838}
PRESSURE CONTROL VALVE SPRING
3851 {3.85.3, 2838}
Nm {kgfm, ftlbf}
1 2
Gusset plate Oil pan + Removal Note + Installation Note
CONTINUED
D4
TO. MODEL .INDEX
OIL PAN
Oil Pan Installation Note Caution D If the bolts are reused, remove the old sealant from the bolt threads. Tightening a bolt that has old sealant on it can cause bolt hole damage.
CRACKS
WL, WL TURBO
94115 {9.511.8, 6985}
OLD SEALANT
5580 {5.68.2, 4159}
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
1. Apply silicone sealant to the oil pan along the inside of the bolt holes and overlap the ends.
Nm {kgfm, ftlbf}
1 2
Crossmember (4WD) Oil pan + Removal Note + Installation Note
Thickness 2.03.0 mm {0.080.11 in}
OIL PAN
Oil Pan Removal Note 1. Remove the oil pan mounting bolts. Caution D Pry tools can easily scratch the cylinder block or oil baffle and oil pan contact surfaces. Prying off the oil pan can also easily bend the oil pan flange. 2. Use a separator tool to separate the oil pan.
SEPARATOR TOOL
2. Install the oil pan before the sealant hardens.
CONTINUED
D5
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
COOLING SYSTEM
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE COOLANT LEVEL INSPECTION . . . . ENGINE COOLANT REPLACEMENT . . . . . . . . ENGINE COOLANT LEAKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR CAP INSPECTION . . . . . . . . . . . . . . RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RADIATOR REMOVAL/INSTALLATION . . . . . . . E1 E1 E1/2 E2 E3 E3 E3 E3 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT REMOVAL/INSTALLATION . . . . THERMOSTAT INSPECTION . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP REMOVAL/INSTALLATION . . . . COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING FAN REMOVAL/INSTALLATION . . . COOLING FAN INSPECTION . . . . . . . . . . . . . . . E4 E4/5 E5 E6 E6 E7 E7 E7
ENGINE COOLANT
Warning D Removing the radiator cap or loosening the radiator drain plug while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. D Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. D When youre sure all the pressure is gone, press down on the cap still using a cloth turn it, and remove it. D When the engine and the engine coolant are hot, they can badly burn. Turn off the engine and wait until they are cool before draining the engine coolant. ENGINE COOLANT LEVEL INSPECTION 1. Remove the radiator cap. 2. Verify that the coolant level is near the radiator filler neck. 3. Verify that the coolant level in the radiator reservoir is between the FULL and LOW marks. 4. Add coolant if necessary. ENGINE COOLANT REPLACEMENT 1. Drain the coolant in the radiator reservoir. 2. Remove the radiator cap and loosen the radiator drain plug.
TYPE A
DRAIN PLUG TYPE B
3. Drain the coolant into a container. 4. Flush the cooling system with water until all traces of color are gone. 5. Let the system drain completely. 6. Tighten the radiator drain plug. Tightening torque Type A: 1.52.9 Nm {1530 kgfcm, 1426 inlbf} Type B: 0.91.1 Nm {9.012 kgfcm, 7.910 inlbf} Caution D The engine has aluminum parts that can be damaged by alcohol or methanol antifreeze. Do not use alcohol or methanol in the cooling system. Use only ethylene-glycol-based coolant. D Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut down on the coolants effectiveness. 7. Referring to the following graph and chart, select proper gravity of the coolant. Slowly pour the coolant into the radiator up to the coolant filler port. Filling pace 1.0 L {1.1 US qt, 0.88 Imp qt}/min. [max]
CONTINUED
E1
TO. MODEL .INDEX
ENGINE COOLANT
Caution D Applying more than 103 kPa {1.05 kgf/cm2, 14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7 psi} (G6, WL, WL Turbo) can damage the hoses, fittings, and other components, and cause leakage.
49 9200 147
50% 40% 30% 1,040 1,030 1,020 1,010 1,000 0 10 0 10 20 30 40 50 60 70 80 90 { 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 } COOLANT TEMPERATURE C { F }
SPECIFIC GRAVITY 1,100 1,090 1,080 1,070 1,060 1,050
COOLANT PROTECTION
49 9200 146
5. Verify that the pressure is held. If not, inspect the system for coolant leakage.
Antifreeze solution mixture percentage

Volume percentage Coolant protection Water Above 16C {3F} Above 26C {15F} Above 40C {40F} 65 55 45 Coolant 35 45 55 Gravity at 20C {68F} 1,054 1,066 1,078
8. Fill the coolant into the reservoir up to the FULL mark. 9. Fully install the radiator cap. 10. Start the engine and let it idle for approx. 10 minutes. If the coolant temperature becomes too high, stop the engine to prevent it from overheating. 11. After the engine warms up, run it at approx. 2,500 rpm for five minutes. 12. Increase the engine speed to approx. 3,000 rpm for five seconds, then return to idle. Repeat several times. 13. Stop the engine and wait until it is cool. 14. Inspect the coolant level. If it is low, repeat Steps 712. 15. Inspect for coolant leakage. ENGINE COOLANT LEAKAGE INSPECTION 1. Inspect the coolant level. (Refer to ENGINE COOLANT, ENGINE COOLANT LEVEL INSPECTION.) 2. Remove the radiator cap. 3. Connect a radiator cap tester and the SST to the radiator filler neck. 4. Apply pressure to the radiator. Pressure F2: 103 kPa {1.05 kgf/cm2, 14.9 psi} G6, WL, WL Turbo: 122 kPa {1.25 kgf/cm2, 17.7 psi}
CONTINUED
E2
TO. MODEL .INDEX
RADIATOR CAP, RADIATOR
RADIATOR CAP
RADIATOR CAP INSPECTION Warning D Removing the radiator cap while the engine is running, or when the engine and radiator are hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. It may also damage the engine and cooling system. D Turn off the engine and wait until it is cool. Even then, be very careful when removing the cap. Wrap a thick cloth around it and slowly turn it counterclockwise to the first stop. Step back while the pressure escapes. D When youre sure all the pressure is gone, press down on the cap still using a cloth turn it, and remove it. 1. Attach the radiator cap to a radiator cap tester with the SST. Apply pressure gradually. 2. Verify that the pressure becomes stable within the specification. Pressure F2: 74102 kPa {0.751.05 kgf/cm2, 10.714.9 psi} G6, WL, WL Turbo: 94122 kPa {0.951.25 kgf/cm2, 13.517.7 psi} 3. If the pressure is held for 10 seconds, the radiator cap is normal.
49 9200 147
RADIATOR
RADIATOR REMOVAL/INSTALLATION 1. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indiacted in the table. 3. Install in the reverse order of removal. 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 1826 {1.82.7, 1419} 1826 {1.82.7, 1419}
Nm {kgfm, ftlbf}
1 2 3 4
Radiator hose Lower radiator cowling Radiator cowling Radiator
CONTINUED
ST
E3
TO. MODEL .INDEX
THERMOSTAT
THERMOSTAT
1 2
Upper radiator hose
Thermostat cover THERMOSTAT REMOVAL/INSTALLATION 3 Thermostat 1. Drain the engine coolant. (Refer to ENGINE + Installation Note COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. WL, WL TURBO 4. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
F2
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
1925 {1.92.6, 1418}
R
1925 {1.92.6, 1418}
Nm {kgfm, ftlbf}
1
Nm {kgfm, ftlbf}
Dipstick pipe Lower radiator hose Thermostat cover Thermostat + Installation Note
2 3 4
1 2 3
Upper radiator hose Thermostat cover Thermostat + Installation Note
G6
Thermostat Installation Note F2, G6 1. Install the thermostat into the cylinder head with the jiggle pin at the top. 2. Install a new gasket with the seal print side facing the cylinder head.
JIGGLE PIN A
1925 {1.92.6, 1418}
AA A
1925 {1.92.6, 1418}
PRINT
WL, WL Turbo D Install the thermostat into the thermostat cover, aligning the projection on the gasket to the thermostat cover as shown.
Nm {kgfm, ftlbf}
CONTINUED
E4
TO. MODEL .INDEX
THERMOSTAT
GASKET PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION Warning D During inspection, the thermostat and water are extremely hot and they can badly burn. Do not touch the thermostat and water directly. Inspect the thermostat for the following and replace as necessary. D Open valve in room temperature D Opening temperature and lift of the valve Initial-opening temperature F2: 83.589.5 C {183193 F} G6: 86.589.5 C {188193 F} (Main valve) 83.586.5 C {183187 F} (Sub valve) WL, WL Turbo: 8084 C {176183 F} Full open temperature F2, G6 : 100 C {212 F} WL, WL Turbo : 95 C {203 F} Full open lift G6 : 8.0 mm {0.31 in} min. (Main valve) 1.5 mm {0.06 in} min. (Sub valve) F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
CONTINUED
ST
E5
TO. MODEL .INDEX
WATER PUMP
WATER PUMP
WL, WL TURBO
WATER PUMP REMOVAL/INSTALLATION 1. Remove the cooling fan. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) 1925 2. Remove the timing belt (F2). {1.92.6, 1418} (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.) 3. Drain the engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Fill the radiator with the specified amount and type of engine coolant. (Refer to ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
F2
1922 {1.92.3, 1416}
Nm {kgfm, ftlbf} 1925 {1.92.6, 1418}
1 2
Water pump Idler
3851 {3.85.3, 2838} Nm {kgfm, ftlbf}
G6
1922 {1.92.2, 1416} Nm {kgfm, ftlbf}
CONTINUED
E6
TO. MODEL .INDEX
COOLING FAN
COOLING FAN
COOLING FAN REMOVAL/INSTALLATION 1. Remove the drive belt. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the drive belt (generator) deflection. (Refer to Section B2,DRIVE BELT, DRIVE BELT ADJUSTMENT.)
F2, G6: 7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} WL, WL TURBO: 1925 {1.92.6, 1418} Nm {kgfm, ftlbf}
1 2
Cooling fan Water pump pulley
COOLING FAN INSPECTION 1. Rotate the cooling fan by hand and inspect for abnormal noise and looseness. Replace the cooling fan if necessary. (Refer to COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.)
CONTINUED
E7
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
Page 1 of 2
FUEL AND EMISSION CONTROL SYSTEMS (G6)

CHECK VALVE (TWO-WAY) INSPECTION ....................................................... F1-25/26 EVAPORATIVE CHAMBER INSPECTION ....................................................... F1-26 CHARCOAL CANISTER INSPECTION ................... F1-26 PURGE SOLENOID VALVE INSPECTION ....................................................... F1-26/27 POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION .............................. F1-27 CONTROL SYSTEM .......................................................... F1-28 CONTROL SYSTEM COMPONENT LOCATION............................................................ F1-28 PCM REMOVAL/INSTALLATION ............................. F1-29 PCM INSPECTION .............................................. F1-29/37 MASS AIR FLOW (MAF) SENSOR INSPECTION ........................................................ F1-37 THROTTLE POSITION (TP) SENSOR INSPECTION ....................................................... F1-37/38 THROTTLE POSITION (TP) SENSOR ADJUSTMENT .................................................... F1-38 THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION ................................ F1-38/39 CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION ....................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION ....................................................... F1-39 INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION ................................ F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION ............... F1-40 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION ...................................... F1-40/41 CAMSHAFT POSITION (CMP) SENSOR INSPECTION ....................................................... F1-41 OXYGEN SENSOR O2S ) INSPECTION ....................................................... F1-41/42 OXYGEN SENSOR O2S ) REMOVAL/INSTALLATION ................................. F1-42 VARIABLE RESISTOR INSPECTION ........................ F1-42 CLUTCH SWITCH INSPECTION .............................. F1-42/43 CLUTCH SWITCH REMOVAL/INSTALLATION ............................... F1-43 NEUTRAL SWITCH INSPECTION ............................ F1-43 NEUTRAL SWITCH REMOVAL/INSTALLATION ................................ F1-43/44 POWER STEERING PRESSURE (PSP) SWITCH INSPECTION ............................ F1-44 MAIN RELAY INSPECTION ....................................... F1-44/45 MAIN RELAY REMOVAL/INSTALLATION ................ F1-45 ON-BOARD DIAGNOSTIC SYSTEM ............................... F1-45 READ/CLEAR DIAGNOSTIC TEST RESULTS ............................................................. F1-45 PARAMETER IDENTIFICATION (PID) ACCESS ............................................................... F1-45 DIAGNOSTIC SUPPORT PROCEDURE .................. F1-45 SIMULATION TEST ..................................................... F1-45 ON-BOARD DIAGNOSTIC TEST .............................. F1-45/46 DTC READING PROCEDURE .................................. F1-46/48
ENGINE TUNE-UP ...............................................................F1-2 ENGINE TUNE-UP PREPARATION ............................F1-2 IGNITION TIMING ADJUSTMENT ...............................F1-2/3 IDLE SPEED ADJUSTMENT .......................................F1-4 IDLE-UP SPEED INSPECTION ..................................F1-4/5 IDLE MIXTURE INSPECTION .....................................F1-5 INTAKE-AIR SYSTEM ........................................................F1-6 VACUUM HOSE ROUTING DIAGRAM .......................F1-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .................................F1-6/7 BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION .................................F1-8 AIR VALVE INSPECTION ........................................... F1-8 IDLE AIR CONTROL (lAC) VALVE INSPECTION ........................................................F1-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ................................ F1-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT ..............................F1-9 FUEL SYSTEM .................................................................. F1-10 BEFORE REPAIR PROCEDURE ............................. F1-10 AFTER REPAIR PROCEDURE ................................. F1-10 FUEL TANK REMOVAL/INSTALLATION ............................... F1-11/13 NONRETURN VALVE INSPECTION ........................ F1-13 FUEL PUMP UNIT REMOVAL/INSTALLATION ............................... F1-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY .............................. F1-13/14 FUEL PUMP UNIT INSPECTION .............................. F1-14/16 FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION ............................... F1-16/17 FUEL INJECTOR REMOVAL/INSTALLATION ............................... F1-18/19 FUEL INJECTOR INSPECTION ................................ F1-19/21 PRESSURE REGULATOR REMOVAL/INSTALLATION ............................... F1-21 PRESSURE REGULATOR INSPECTION ...................................................... F1-21/22 PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION ................................................. F1-22 PULSATION DAMPER REMOVAL/INSTALLATION ............................... F1-22 PULSATION DAMPER INSPECTION ....................... F1-22 FUEL PUMP RELAY INSPECTION .......................... F1-23 EXHAUST SYSTEM .......................................................... F1-24 EXHAUST SYSTEM INSPECTION ........................... F1-24 EXHAUST SYSTEM REMOVAL/INSTALLATION ............................... F1-24 EMISSION SYSTEM .......................................................... F1-25 EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION .......................................................... F1-25 ROLLOVER VALVE INSPECTION ........................... F1-25 EVAPORATIVE GAS CHECK VALVE (TWO-WAY) INSPECTION ................................ F1-25
F1-1
CONTINUED
TO. MODEL .INDEX
FUEL AND EMISSION CONTROL SYSTEMS (G6 )

Page 2 of 2
PID/DATA MONITOR AND RECORD PROCEDURE ...................................................... F1-48 PLAYBACK OF STORED PIDS PROCEDURE ...................................................... F1-48/49 DIAGNOSTIC SUPPORT PROCEDURE .......... F1-49 SIMULATION TEST PROCEDURE ........................ F1-50/51 AFTER REPAIR PROCEDURE ............................. F1-51 DTC INSPECTION .................................................. F1-52/69 TROUBLESHOOTING ...................................................F1-70 FOREWORD ............................................................F1-70 TROUBLESHOOTING ITEM TABLE .....................F1-70 QUICK DIAGNOSTIC CHART ...............................F1-71/74 SYMPTOM TROUBLESHOOTING .......................F1-75/114 DIAGNOSTIC INSPECTION..................................F1-115/120 ENGINE SYSTEM INSPECTION .........................F1-120/127
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION Using the SSTs (NGS Tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. A/C switch 4. Verify that the steering wheel is at straight ahead position. 5. Connect the SSTs (NQS tester) to the DLC and select "PID/DATA MONITOR AND RECORD". (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.)
Not Using the SSTs (NGS tester) 1. Warm up the engine to normal operating temperature. 2. Shift the transmission into neutral. 3. Turn off all electrical loads. A/C switch 4. Verify that the steering wheel is at straight ahead position. Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 5. Connect a dwell tachometer to the DLC terminal IG-.
6. Access RPM PID. Press the trigger key to enter this selection. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 7. Press SETUP (Key 8) and turn the test mode on. 8. Press CANCEL. 9. Press START.
IGNITION TIMING ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNEUP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730770 (750 20) rpm 3. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 4. Connect the timing light to the high-tension lead of the No. 1 cylinder. 5. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 46(5 1)
CONTINUED
F1-2
TO. MODEL .INDEX
ENGINE TUNE-UP
6. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 7. Tighten the distributor lock bolts to the specified torque. Tightening torque 1925 N.m {1.92.6 kgf.m, 1418 ft.lbf} 8. Press SETUP (Key 8) and turn the test mode off. 9. Press CANCEL. 10. Verify that the timing mark on the crankshaft pulley is within the specification.
4. Verify that the idle speed is within the specification. Specification 730770 (750 20) RPM 5. If not as specified, adjust the idle speed. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Connect the timing light to the high-tension lead of the No.1 cylinder. 7. Verify that the timing mark on the crankshaft pulley is within the specification.
Specification BTDC 130 Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
Specification BTDC 46 (5 1) 8. If not as specified, loosen the distributor lock bolts and turn the distributor to make the adjustment. 9. Tighten the distributor lock bolts to the specified torque. Tightening torque 1925 N.m {1.92.6 kgf.m, 1418 ft.lbf} 10. Disconnect the SST or jumper wire. 11. Verify that the timing mark on the crankshaft pulley is within the specification. Specification BTDC 130
3. If using a jumper wire to turn on the test mode, perform the following: Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. Use a jumper wire to short terminal TEN of the DLC to body GND.
CONTINUED F1-3
TO. MODEL .INDEX
ENGINE TUNE-UP
IDLE SPEED ADJUSTMENT Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the RPM PID is within the specification. Specification 730770 (750 20) RPM Caution The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 3. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT", then adjust the idle speed by turning the AAS. Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. Use a jumper wire to short terminal TEN of the DLC to body GND.
4. Verify that the idle speed is within the specification using the dwell tachometer. Specification 730770 (750 20) RPM Caution The TAS is set at the factory and must not be adjusted. Any adjustment will negatively affect the engine performance. 5. If not as specified, verify that the ignition timing is within specification according to the "IGNITION TIMING ADJUSTMENT', then adjust the idle speed by turning the AAS.
4. Press SETUP (Key 8) to turn the test mode off. 5. Press CLEAR to clear previously selected items. 6. Disconnect the SSTs. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. If using the SST (System selector) to turn on the test mode, perform the following: (1) Connect the SST to the DLC. (2) Set switch A to position 1. (3) Set the test switch to SELF TEST.
3. If using a jumper wire to turn on the test mode, perform the following:
6. Disconnect the SST or a jumper wire. 7. Disconnect the dwell tachometer. IDLE-UP SPEED INSPECTION Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Press SETUP (Key 8) and turn the test mode off. 3. Press CANCEL. 4. Press START. 5. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 6. Verify that the RPM PID is within the specification.
CONTINUED F1-4
TO. MODEL .INDEX
ENGINE TUNE-UP
Specification Load condition P/S ON*2 A/C ON*3
1
Idle-up speed (RPM)*1 700800 (750 50)
* : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. : A/C switch and fan switch are on. 7. If not as specified with all load conditions, inspect the IAC valve. 8. If not as specified with some load condition, inspect the related input switches, harnesses, and connectors. Not Using the SSTs (NGS Tester) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed is normal. (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Verify that the idle-up speed is within the specification. Specification 1 Load condition Idle-up speed (rpm)* P/S ON*2 700800 (750 50) A/C ON*3 1 * : Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. 4. If not as specified with all load conditions, inspect the IAC valve. 5. If not as specified with some load conditions, inspect the related input switches, harnesses, and connectors. IDLE MIXTURE INSPECTION Vehicles With Oxygen Sensor (O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". (Refer to ENGINE TUNE-UP, ENGINE TUNE-UP PREPARATION.) 2. Verify that the idle speed and ignition timing are within the specification. (Refer to ENGINE TUNE-UP, IGNITION TIMING INSPECTION.) (Refer to ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT.) 3. Turn the test mode off. 4. Warm up the engine by holding the engine speed at 25003000 rpm for approx. 3 minutes. 5. Insert an exhaust gas analyzer to the tailpipe. 6. Verify that the CO and HC concentrations are within the regulation. 7. If not within the regulation, inspect the following: On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) O2S (Refer to CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION.)
Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Intake Manifold Vacuum Inspection.) Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.) If the systems and devices are normal, replace the TWC. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
Vehicles Without Oxygen Sensor O2S) 1. Perform "ENGINE TUNE-UP PREPARATION". 2. Verify that the idle speed and ignition timing are within the specification. (Refer to IGNITION TIMING INSPECTION.) (Refer to IDLE SPEED ADJUSTMENT.) 3. Insert an exhaust gas analyzer to the tailpipe. 4. Verify that the CO and HC concentrations are within the regulation. 5. If not, turn the adjust screw to adjust CO and HC concentration using the SST.
6. If not adjusted, inspect the following: On-board diagnostic system (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ON-BOARD DIAGNOSTIC TROUBLE CODE INSPECTION.) Variable resistor (Refer to CONTROL SYSTEM, VARIABLE RESISTOR INSPECTION.) Intake manifold vacuum (Refer to TROUBLESHOOTING, ENGINE SYSTEM, INSPECTION, Intake Manifold Vacuum Inspection.) Fuel line pressure (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel line Pressure Inspection.) Ignition timing control (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Ignition Timing Control Inspection.)
F1-5
CONTINUED
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning When the engine and intake-air system are hot, they can badly burn. Turn off engine and wait until they are cool before removing the intake-air system. Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Disconnect the negative battery cable. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
CONTINUED
F1-6
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INTAKE-AIR SYSTEM
1 2 3 4
Air cleaner component Air intake hose MAP sensor Accelerator cable ACCELERATOR CABLE INSPECTION/ ADJUSTMENT
5 6 7
Throttle body component Dynamic chamber Fuel injector FUEL SYSTEM, FUEL INJECTOR REMOVAL/ INSTALLATION Intake manifold
CONTINUED
F1-7
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INTAKE-AIR SYSTEM
BYPASS AIR CONTROL (BAC) VALVE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAC valve connector. 3. Drain the engine coolant from the radiator. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 4. Remove the BAC valve.
6. If not as specified, replace the BAC valve. (Refer to BAC VALVE REMOVAL/INSTALLATION.) If as specified, but IAC valve is failed, inspect for the following: Open circuit Power circuit (IAC valve connector terminal A and main relay terminal D) 5. Install in the reverse order of removal. AIR VALVE INSPECTION Operation Inspection Note 1. Perform the following test only when directed. 1. Carry out the "Idle Air Control (IAC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. Remove the BAC valve. (Refer to INTAKE-AIR SYSTEM, BAC VALVE REMOVAL/INSTALLATION.) 3. Add cold water into the engine coolant passage of the BAC valve to reduce the air valve temperature. 4. Verify that the air valve operates when hot water is added into the engine coolant passage of the BAC valve. 5. If not as specified, replace the BAC valve, 6. Install the BAC valve. IDLE AIR CONTROL (IAC) VALVE INSPECTION Resistance Inspection Note 2. Perform the following test only when directed, 1. Carry out the "Idle Air Control (IAC) Inspection", (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Idle Air Control (IAC) Inspection.) 2. If not as specified, perform the further inspection for the IAC valve. 3. Disconnect the negative battery cable. 4. Disconnect the IAC valve connector. 5. Measure the resistance between the IAC valve terminals using an ohmmeter. Resistance 7.79.3 [23 C {73 F}]
GND circuit (IAC valve connector terminal B and PCM connector terminal 2W) Short circuit IAC valve connector terminal B and PCM connector terminal 2W to GND 7. Repair or replace faulty areas. 8. Connect the IAC valve connector. 9. Connect the negative battery cable.
CONTINUED F1-8
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Measure the free play of the accelerator cable.
Free play 13 mm {0.040.11 in} 2. If not as specified, adjust by turning the locknut,
CONTINUED
F1-9
TO. MODEL .INDEX
FUEL SYSTEM
FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Note Fuel in the fuel system is under high pressure when the engine is not running. Fuel Line Safety Procedures 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position. CLAMP INSTALLATION RANGE
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and "Fuel Leakage Inspection" described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
Fuel Leakage Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Caution Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 1. Short the DLC terminal F/P to body GND using a jumper wire.
2. Turn the ignition switch on to operate the fuel pump body. 3. Pressurize the system this way for at least 5 minutes to be sure of no leakage. 4. If there is fuel leakage, inspect for damaged fuel hoses, hose clamps, and fuel pipe sealing surface and replace as necessary. 5. After repair, assemble the system and repeat Steps 1 to 3.
F1-10
CONTINUED
TO. MODEL .INDEX
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Level the vehicle. 2. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disconnect the negative battery cable. 4. Drain the fuel from the drain plug. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) STRETCH CAB 2WD, DOUBLE CAB 2WD
CONTINUED F1-11
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FUEL SYSTEM
STRETCH CAB 4WD, DOUBLE CAB 4WD, REGULAR CAB
1 2 3 4 5 6 7
Joint hose Installation Note Breather hose Installation Note Under guard Fuel hose Fuel tank Evaporative hose Installation Note Rollover valve
8 Fuel pump unit 9 Fuel-filler pipe 10 Dust cover 11 Fuel inlet pipe 12 Nonreturn valve 13 Evaporative gas check valve (two-way) Installation Note 14 Check valve (two-way) 15 Evaporative chamber
CONTINUED
F1-12
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FUEL SYSTEM
Evaporative Gas Check Valve (Two-way) Installation Note Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 2530 mm {0.991.18 in}
Breather Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Breather hose: 2530 mm {0.991.18 in}
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 5056 when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Joint Hose Installation Note Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 3540 mm {1.41.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAL/INSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
CONTINUED F1-13
TO. MODEL .INDEX
FUEL SYSTEM
STRETCH CAB 2WD, DOUBLE CAB 2WD
2. If not as specified, perform the further inspection for the fuel pump unit. Continuity Inspection Note Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
5. If there is no continuity, replace the fuel pump body. If as specified but the "Simulation Test" is failed, inspect the following: Fuel pump relay malfunction Open circuit GND circuit (fuel pump unit connector terminal D and body GND) Power circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
1 2 3 4 5 6
Rubber mount Fuel filter (low-pressure) Clamp Fuel hose Fuel pump body Fuel gauge sender unit
FUEL PUMP UNIT INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.)
Short circuit Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 6. Repair or replace faulty areas. 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
CONTINUED F1-14
TO. MODEL .INDEX
FUEL SYSTEM
Fuel Pump Maximum Pressure Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Perform the following test only when directed. 8. If not as specified, inspect the following: Fuel pump relay Fuel filter (low-pressure, high-pressure) for clogging Fuel line for clogging or leakage 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Connect the negative battery cable. 13. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Fuel Pump Hold Pressure Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Perform the following test only when directed.
Note 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
Note 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 4. Connect the negative battery cable. Caution Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge to the fuel hose between the pulsation damper and fuel main hose, then plug the opening as shown.
5. Short the DLC terminal F/P to body GND using a jumper wire.
4. Connect the negative battery cable. Caution 6. Turn the ignition switch on to operate the fuel pump body. Measure the fuel pump maximum pressure. Fuel pump maximum pressure 500630 kPa {5.06.5 kgf/cm2, 7292 psi} 7. Turn the ignition switch off and disconnect the jumper wire. Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only.
5. Short the DLC terminal F/P to body GND using a jumper wire.
CONTINUED
F1-15
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FUEL SYSTEM
6. Turn the ignition switch on for 10 seconds to operate the fuel pump body. 7. Turn the ignition switch off. Measure the fuel pump hold pressure after 5 minutes. Fuel pump hold pressure More than 340 kPa {3.5 kgf/cm2, 50 psi} 8. Disconnect the jumper wire. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the negative battery cable. 13. If not as specified, carry out the "PRESSURE REGULATOR INSPECTION", "FUEL INJECTOR INSPECTION" (Refer to FUEL SYSTEM, PRESSURE REGULATOR INSPECTION.) (Refer to FUEL SYSTEM, FUEL INJECTOR INSPECTION.) 14. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order or removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 2 3
Fuel hose Protector Fuel filter (high-pressure) Removal Note Installation Note
Fuel Filter (High-pressure) Removal Note Before removing the fuel filter (high-pressure), paint marks on the fuel filter (high-pressure) and fuel filter bracket for correct reassembly.
Fuel Filter (High-pressure) Installation Note Replacing the fuel filter (high-pressure) 1. Paint a mark on the new fuel filter (high-pressure) at the same spot as the removed fuel filter (highpressure). 2. Align the paint marks and install the fuel filter (high-pressure) as shown.
CONTINUED
F1-16
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FUEL SYSTEM
Replacing the fuel filter bracket 1. Paint a mark on the new fuel filter bracket at the same spot as the removed fuel filter bracket. 2. Align the paint marks and install the fuel filter bracket as shown.
CONTINUED
F1-17
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FUEL SYSTEM
FUEL INJECTOR REMOVAL/INSTALLATION Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2. 3. 4. 5. 6. Complete the "BEFORE REPAIR PROCEDURE" (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Disconnect the fuel injector connectors and remove the harness from the fuel distributor. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE." (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 Dynamic chamber 2 Dynamic chamber gasket 3 Fuel injector connector 4 Fuel hose 5 Fuel distributor
6 Fuel injector Installation note 7 Grommet 8 Fuel injector insulator
CONTINUED F1-18
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FUEL SYSTEM
Fuel Injector Installation Note 1. Use new fuel injector O-rings. 2. Verify that the O-rings and the fuel injector sealing surfaces are free of foreign materials. Clean with gasoline if necessary. 3. Apply a small amount of engine oil to the O-rings and into the fuel distributor. 4. Install the fuel injectors in the fuel distributor with a light twisting motion so that the O-rings will not be folded. Open circuit GND circuit (No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U) GND circuit (No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V) GND circuit (No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U) GND circuit (No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V) Power circuit (No.1 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) Power circuit (No.2 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) Power circuit (No.3 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector) Power circuit (No.4 cylinder fuel injector connector terminal A and main relay connector terminal D through common connector)
FUEL INJECTOR INSPECTION Simulation Test 1. Carry out the "Fuel Injector Operation Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Injector Operation Inspection.) 2. If not as specified, perform the further inspection for the fuel injectors. Resistance Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the fuel injector connectors. 3. Measure the resistance of the fuel injector using an ohmmeter.
Resistance 1216[20C {68F}] 4. If not as specified, replace the fuel injector. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) If as specified but "Simulation Test" is failed, inspect for the following:
Short circuit No.1 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND No.2 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND No.3 cylinder fuel injector connector terminal B and PCM connector terminal 2U to GND No.4 cylinder fuel injector connector terminal B and PCM connector terminal 2V to GND 5. Repair or replace faulty areas. 6. Reconnect the fuel injector connectors. 7. Reconnect the negative battery cable. Fuel Leakage Test Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note Perform the following test only when directed.
CONTINUED F1-19
TO. MODEL .INDEX
FUEL SYSTEM
1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) 4. Fasten the fuel injectors firmly to the fuel distributor with wire. 9. Turn the ignition switch off and remove the jumper wire. 10. If not as specified, replace the fuel injector. 11. Complete the "AFTER REPAIR PROCEDURE", (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) Volume Test Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Always carry out the following procedure with the engine stopped. Note Perform the following test only when directed. Complete the "BEFORE REPAIR PROCEDURE", (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Remove the fuel injectors together with the fuel distributor. (Refer to FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION.) Fasten the fuel injectors firmly to the fuel distributor with wire. Connect the SST as shown in the figure.
5. Connect the negative battery cable. Caution Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 6. Short the DLC terminal F/P to body GND using a jumper wire.
1.
2. 3.
4. 5.
7. Turn the ignition switch on to operate the fuel pump body. 8. Tilt the fuel injectors approx. 60 degrees and verify that fuel leakage from the fuel injector nozzles is within the specification.
6. Connect the negative battery cable. Caution Connecting the wrong DLC terminal may possibly cause a malfunction. Carefully connect the specified terminal only. 7. Short the DLC terminal F/P to body GND using a jumper wire.
Fuel leakage Less than 1 drop/2 minutes 8. Turn the ignition switch on to operate the fuel pump body. 9. Measure the injection volume of each fuel injector using a graduated container.
F1-20
CONTINUED
TO. MODEL .INDEX
FUEL SYSTEM
Injection volume 5571 ml {5571 cc, 1.92.3 fl oz}/15 sec. 10. Turn the ignition switch off and disconnect the jumper wire. 11. If not as specified, replace the fuel injector. 12. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR REMOVAL/INSTALLATION Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE".) 2. Disconnect the negative battery cable. 3. Connect a fuel pressure gauge between the pulsation damper and fuel main hose.
4. Connect the negative battery cable. 5. Start the engine and let it idle. 6. Measure the fuel line pressure after approx. 2 minutes. Fuel line pressure 2 210250 kPa {2.12.6 kgf/cm , 3036 psi} 7. Disconnect the vacuum hose from the pressure regulator and measure the fuel line pressure.
O 1 Vacuum hose 2 Fuel hose 3 Pressure regulator PRESSURE REGULATOR INSPECTION Simulation Test 1. Carry out the "Fuel Line Pressure Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection.) 2. If not as specified, perform the further inspection for the pressure regulator. Operation Inspection Note Perform the following test only when directed.
Fuel line pressure 270310 kPa {2.73.2 kgf/cm2, 3945 psi} 8. Turn the ignition switch off. 9. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.") 10. Disconnect the negative battery cable. 11. Disconnect the fuel pressure gauge. 12. Reconnect the fuel main hose to the fuel distributor. 13. Reconnect the negative battery cable. 14. If not as specified, inspect the following: Fuel pump maximum pressure Fuel pump hold pressure Fuel filter for clogging Fuel injector for leakage Fuel pump relay Fuel line for improper routing, clogging, kinks or leakage
CONTINUED F1-21
TO. MODEL .INDEX
FUEL SYSTEM
If all items above are okay, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) 15. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Pressure Regulator Control (PRC) Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Pressure Regulator Control (PRC) Inspection.) 2. If not as specified, perform the further inspection for the PRC solenoid valve, Airflow Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the PRC solenoid valve. (Refer to INTAKE-AIR SYSTEM, VACUUM HOSE ROUTING DIAGRAM.) 3. Inspect airflow between the ports under the following conditions.
Short circuit PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector to GND) 5. Repair or replace faulty areas. 6. Install the PRC solenoid valve. 7. Reconnect the negative battery cable. PULSATION DAMPER REMOVAL/INSTALLATION 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the pulsation damper. 4. Install in the reverse order of removal. 5. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
1 4. If not as spec tied, replace the PRC solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage Open circuit GND circuit (PRC solenoid valve connector terminal B and PCM connector terminal 2T through common connector) Power circuit (PRC solenoid valve connector terminal A and main relay connector terminal D through common connector) 2 3
Fuel hose Bolt Pulsation damper
PULSATION DAMPER INSPECTION 1. Remove the pulsation damper. (Refer to FUEL SYSTEM, PULSATION DAMPER REMOVAL/INSTALLATION.) 2. Visually inspect the pulsation damper for damage and cracks. Also inspect that there is no extreme rust, which will cause fuel leakage. 3. If either is observed, replace the pulsation damper.
CONTINUED
F1-22
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FUEL SYSTEM
FUEL PUMP RELAY INSPECTION Simulation Test 1. Carry out the "Fuel Pump Operation Inspection", "Fuel Pump Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Operation Inspection.) (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pump Control Inspection.) 2. If not as specified, perform the further inspection for the fuel pump relay. Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the fuel pump relay located under the passenger's side front side trim. Power circuit (fuel pump relay connector terminal A or C and IG switch connector terminal IG1 through common connector)
3. Inspect for continuity between the fuel pump relay terminals using an ohmmeter.
Short circuit Fuel pump relay connector terminal B and PCM connector terminal 1H through common connector to GND Fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector to GND 5. Repair or replace faulty areas. 6. Install the fuel pump relay. 7. Reconnect the negative battery cable.
4. If not as specified, replace the fuel pump relay. If as specified but the "Simulation Test" is failed, inspect for the following: Fuel pump unit malfunction Open circuit GND circuit (fuel pump relay connector terminal B and PCM connector terminal 1H through common connector) GND circuit (fuel pump relay connector terminal D and fuel pump unit connector terminal B through common connector)
CONTINUED
F1-23
TO. MODEL .INDEX
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 3
After silencer Main silencer TWO (Europe) Presilencer (Except Europe)
4 5 6
Front pipe Insulator Exhaust manifold
CONTINUED
F1-24
TO. MODEL .INDEX
EMISSION SYSTEM
EMISSION SYSTEM
EMISSION SYSTEM (ENGINE COMPARTMENT SIDE) COMPONENT LOCATION
4. If not as specified, replace the rollover valve. EVAPORATIVE GAS CHECK VALVE (TWOWAY) INSPECTION 1. Remove the evaporative gas check valve (twoway). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 kPa {-7.36 mmHg, -0.29 inHg} to port A No airflow Airflow Airflow
1 2 3
Charcoal canister Purge solenoid valve PCV valve
ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow. 3. If not as specified, replace the evaporative gas check valve (two-way). CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Inspect airflow of the valve under the following conditions. Apply pressure of -0.981-13.7 kPa {-7.31-102 mmHg, -0.28 + 4.0 inHg} to port A Apply pressure over +18.6 kPa {+140 mmHg, +5.5 inHg} to port A Apply pressure over -4.9 kPa {-36.8 mmHg, -1.4 inHg} to port B
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow.
No airflow Airflow Airflow
CONTINUED
F1-25
TO. MODEL .INDEX
EMISSION SYSTEM
PURGE SOLENOID VALVE INSPECTION Simulation Test 1. Carry out the "Purge Control Inspection". (Refer to TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection.) 2. If not as specified, perform the further inspection for the purge solenoid valve, Airflow Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the purge solenoid valve. 3. Inspect airflow between the ports under the following conditions.
3. If not as specified, replace the check valve (twoway). EVAPORATIVE CHAMBER INSPECTION 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow air into port A and verify that air flows out from the holes B on the evaporative chamber.
3. Visually inspect that there is no damage nor crack on the evaporative chamber. 4. If not as specified, replace the evaporative chamber. 5. Install the evaporative chamber. CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Plug the atmosphere side port and purge solenoid valve side port of the charcoal canister. 3. Blow air into the charcoal canister from the fuel tank side port and verify that there is no air leakage. 4. If not as specified, replace the purge solenoid valve. If as specified but the "Simulation Test" is failed, inspect for the following: Vacuum hose improper routing, kinks or leakage. Open circuit GND circuit (purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector) Power circuit (purge solenoid valve connector terminal A and main relay connector terminal D through common connector)
4. If there is air leakage, replace the charcoal canister.
CONTINUED
F1-26
TO. MODEL .INDEX
EMISSION SYSTEM
Short circuit Purge solenoid valve connector terminal B and PCM connector terminal 2X through common connector to GND 5. Repair or replace faulty areas. 6. Install the purge solenoid valve. 7. Reconnect the negative battery cable.
POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION
1. Remove the PCV valve. 2. Blow through the valve and verify that air flows as specified. Specification
Condition Air applied from port A Air applied from port B Airflow Yes No
3. If not as specified, replace the PCV valve.
CONTINUED
F1-27
TO. MODEL .INDEX
CONTROL SYSTEM
CONTROL SYSTEM
CONTROL SYSTEM COMPONENT LOCATION
1 2 3 4 5 6 7
PCM MAF sensor TP sensor CTP switch IAT sensor ECT sensor CMP sensor (In distributor)
8 9 10 11 12 13
O2S (Europe only) Variable resistor (Except Europe) Clutch switch Neutral switch PSP switch Main relay
CONTINUED
F1-28
TO. MODEL .INDEX
CONTROL SYSTEM
PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the cowl side panel (driver's side). 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM terminal voltage. When measuring the following PID value, perform the following: TP V PID (Refer to Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection.) (Refer to Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection.)
6. If PID value is not within the specification, follow the instruction in action column. Note Perform the SIMULATION TEST for the output device (A/C RLY, FP RLY, IACV, PRGV) after PID/DATA measurement is completed.
1 PCM 2 PCM connector PCM INSPECTION Using SSTs (NGS tester) Note PIDs for the following parts are not available on this model. Go to the appropriate part inspection page. 1. Water temperature sender unit (Integrated with ECT sensor) (Refer to CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION.) 2. CMP sensor (Refer to CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION.) 3. Main relay (Refer to CONTROL SYSTEM, MAIN RELAY INSPECTION.) 1. Connect the SSTs (NGS tester) to the DLC. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, ONBOARD DIAGNOSTIC TEST, NGS Tester Hook-up Procedure.) 2. Turn the ignition switch on. 3. Select the "PID/DATA MONITOR AND RECORD" function on the NGS tester display and press TRIGGER. (Refer to ON-BOARD DIAGNOSTIC SYSTEM, PID/DATA MONITOR AND RECORD PROCEDURE.) 4. Select the appropriate PID on the NGS tester display and press START. 5. Measure the PID value. Note The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the PCM. Therefore, an output device malfunction is not directly indicated as a malfunction of the monitored value for the output device. If a monitored value of an output device is out of specification, inspect the monitored value of the input device related to the output control.
F1-29
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
PID MONITOR Table
Monitor item (Definition) A/C RLY (A/C relay) A/C SW (A/C switch) Unit/ Condition ON/OFF Condition/Specification Ignition switch on: OFF A/C switch on and fan switch on at idle: ON Action Inspect following PIDs: RPM, TP V, ECT V, A/C SW. Inspect A/C relay. Section U PCM terminal 1J
ON/OFF
A/C switch and fan switch on at ignition Inspect A/C switch. switch on: ON Section U A/C switch off at ignition switch on: OFF Inspect main relay. CONTROL SYSTEM, MAIN RELAY INSPECTION Inspect battery. Section G DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION DTC P1195 is indicated. Follow DTC Troubleshooting ON-BOARD DIAGNOSTIC SYSTEM, DTC INSPECTION Inspect brake switch. Section P Inspect CTP switch CONTROL SYSTEM, CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Inspect engine coolant temperature sensor. w CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect engine coolant temperature sensor. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION
1Q
B+ (Battery positive voltage)
Constant: B+
1B
BARO*2 (Barometric pressure) BARO V*2 (Barometric pressure signal voltage) BRKSW (Brake switch) CTP SW (Idle switch)
kPa
Below 400 m {0.25 mile} above sea level: 100103 kPa {1.011.05 kgf/cm2}
Below 400 m {0.25 mile} above sea level: 3.94.0 V Brake pedal depressed: ON Brake pedal released: OFF Accelerator depressed: OFF Accelerator released: ON
ON/OFF
1O
ON/OFF
1N
ECT (Engine coolant temperature) ECT V (ECT signal voltage)
Engine coolant temperature 20 C {68F}: 20C {68F} Engine coolant temperature 60 C {140F}: 60C {140F} Engine coolant temperature 20 C {68 F}; 2.22.4V After warms up: Below 1.0 V Ignition switch on: 0,11.0 V After warm up: 0.11.0 V Acceleration (after warm up): 0.51.0 V Deceleration (after warm up): 00.5V Ignition switch on: OFF Idle: ON Cranking: ON
2Q
2Q
FHO2S*1 (Oxygen sensor)
Inspect O2S. CONTROL SYSTEM, OXYGEN SENSOR O2S) INSPECTION
2N
FPRLY (Fuel pump relay)
ON/OFF
Inspect following PID: RPM. Inspect fuel pump relay. FUEL SYSTEM, FUEL PUMP RELAY INSPECTION Inspect following PIDs: IATV, RPM, ECT V, MAF V, TP V, NL SW, CLT SW, PSP SW, A/C SW, TEN. Inspect idle air control valve. INTAKE-AIR SYSTEM, IDLE AIR CONTROL (IAC) VALVE INSPECTION
1H
IACV (Idle air control valve)
ms
Idle: 2.42.7 ms
2W
: Europe only *2: Except Europe
CONTINUED F1-30
TO. MODEL .INDEX
CONTROL SYSTEM
Monitor item (Definition) IATDC (Intake air temperature (Dynamic chamber)) IATDC V (IAT signal voltage (Dymanic chamber)) Unit/ Condition C Condition/Specification Action Inspect IAT sensor rar -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect IAT sensor -CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, PSP SW, NL SW, A/C SW, TEN, Inspect CMP sensor. -CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect idle speed and ignition timing. - ENGINE TUNE-UP. Inspect following PIDs: MAF V, IAT V, RPM, TP V, ECT V, NL SW, FHO2S, PSP SW, BRK SW, A/C SW, B+. Inspect CMP sensor. - CONTROL SYSTEM, CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect mass air flow sensor. CONTROL SYSTEM, MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect neutral switch. - CONTROL SYSTEM, NEUTRAL SWITCH INSPECTION Inspect clutch switch. -CONTROL SYSTEM, CLUTCH SWITCH INSPECTION PCM terminal
Intake air temperature 20 C {68 F}:20C{68 F}
2L
Intake air temperature 20 C {68 F}: 2.52.7 V
2L
IGT (Ignition timing)
Terminal TEN (DLC) BTC short to ground: A6 BTC Idle: 130 BTC
2F
INJ (Fuel injection duration) ms
Ignition switch on: 0.0 ms Idle: 3.05.0 ms
2U 2V
MAFV (Mass air flow signal voltage) MT/AT*1 (MT/AT distinction signal) NLSW (Load/no load condition signal) ON/OFF V
Ignition switch on: 1.02.0 V Idle: 1.92.8 V
20
ON/OFF
Constant: ON
1L
Neutral position and clutch pedal depressed: ON Others: OFF
1V
*1: Europe only
CONTINUED
F1-31
TO. MODEL .INDEX
CONTROL SYSTEM
Monitor item (Definition) PRCV (Pressure regulator control) PRGV (Purge solenoid valve duty value) % Ignition switch on: 0% Idle: 0% ON/OFF Unit/ Condition Condition/Specification Ignition switch on: OFF Idle: OFF Engine start at hot condition: ON Action Inspect following PIDs: ECTV, IAT V, RPM,TP V, B+. Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION Inspect following PIDs: IATV, RPM, ECT V, MAP V, TP V, FHO2S, B+. Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Inspect PSP switch. CONTROL SYSTEM, POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect CMP sensor. CONTROL SYSTEM, CRANKSHAFT POSITION SENSOR INSPECTION Inspect wiring from DLC terminal TEN to PCM terminal 1L Inspect TP sensor. CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR INSPECTION Inspect variable resistor VARIABLE RESISTOR INSPECTION Inspect vehicle speedometer sensor PGM terminal
2T
2X
PSP SW (PSP switch)
ON/OFF
Steering wheel fully turned: ON Steering wheel straight ahead position: OFF
1P
RPM (Engine speed) TEN (TEN terminal (DLC)) TP V (TP sensor signal voltage) VRV*2 (Variable resistor)
RPM
Idle: 700770 RPM
2E
ON/OFF
Terminal TEN (DLC) short to ground: ON Terminal TEN (DLC) open: OFF Closed throttle position: 0.40.6 V Wide open throttle: 3.44.7 V
1K
2M
Turned fully clockwise: below 1.0 V Turned fully counterclockwise: Approx 4.0 V Vehicle speed 20 km/h {mph}: 20 km/h {mph}
2N
Section T, WARNING AND

INDICATOR SYSTEM, INSTRUMENT CLUSTER INSPECTION Inspect vehicle speed sensor 1M
VS (Vehicle speed)
KPH
Vehicle speed 40 km/h {mph}: 40 km/h {mph}
*2: Except Europe
CONTINUED
F1 -32
TO. MODEL .INDEX
CONTROL SYSTEM
Not Using the SSTs (NGS tester) at Constant Voltage Terminal Inspection 1. 2. Turn the ignition switch on. Measure the voltage between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal A and body GND using a voltmeter. (1) When measurement voltage is 0 V. Turn the ignition switch off. Disconnect the TP sensor and variable resistor (Except Europe) connector (applied to constant voltage). 4. If there is no continuity, repair the related harnesses. Not Using the SSTs (NGS Tester) at Power Supply Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Measure the voltage between the PCM battery power terminal connectors and body GND using an ohmmeter. Power supply terminal 1A Power supply terminal voltage: B+ 4. If not as specified, repair the related harnesses and replace the faulty fuses. Not Using the SSTs (NGS Tester) at Serial Communication Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Verify there is continuity between PCM connector terminal 1 D and DLC KLN terminal.
(2)
Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and body GND using an ohmmeter. If there is continuity, repair the related harnesses. Using an ohmmeter, inspect for continuity between the PCM connector (vehicle side) terminal 2D and TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C which is applied to constant voltage. If there is continuity, repair the related harness.
4.
If there is no continuity, repair the related harnesses.
(3)
When measurement voltage is B+. Turn the ignition switch off. Disconnect the battery positive harness, then battery negative harness. Verify there is no continuity between the TP sensor and variable resistor (Except Europe) connector (vehicle side) terminal C and battery positive harness using an ohmmeter. If there is continuity, repair the related harnesses. When measurement voltage is approx. 5V. Constant voltage terminal of PCM is okay.
Not Using the SSTs (NGS Tester) at Instrument Cluster (Engine speed signal) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connector and instrument cluster connector (26 pin). 3. Verify there is continuity between PCM connector terminal 2F and instrument cluster connector (20 pin) terminal 3B.
Not Using the SSTs (NGS tester) at Ground (GND) Terminal Inspection 1. Turn the ignition switch off. 2. Disconnect the PCM connectors. 3. Inspect for continuity between the PCM GND terminals and body GND using an ohmmeter. PCM GND terminal 2A 2B 2C
4.
If there is no continuity, repair the related harnesses.
CONTINUED F1-33
TO. MODEL .INDEX
CONTROL SYSTEM
Using voltmeter Caution The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal.
PCM Terminal Voltage (Reference)
Note With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the action column in the terminal voltage list.
Terminal 1A 1B 1C
Signal Back-up power supply Power supply Serial communication
Connected to Battery Main relay Constant
Test condition
Voltage (V) B+ 0 B+
Action Inspect ROOM fuse. Inspect related harness. Inspect related harness.
Ignition switch off Ignition switch on
1D
Carry out inspection according to DTC. DTC output is a part of serial DLC communication. (Terminal KLN) Judgement by terminal voltage is not possible. Ignition switch on DLC and terminal TEN (Terminal FEN) (in DLC) short to chassis ground Ignition switch on No DTC stored DTC stored
Inspect related harness.
Below 1.0 0-B+ B+ Below 1.0 Below 1.0
1E 1F 1G
DTC output
1H
Fuel pump control Fuel pump relay
Cranking Idle
Inspect fuel pump relay. FUEL SYSTEM,FUEL PUMP INSPECTION Inspect related harness.
1I
A/C relay
Ignition switch on Ignition switch off A/C switch on A/C switch off A/C switch on A/C switch off Terminal TEN (DLC) open Terminal TEN (DLC) short to ground
B+ B+ Below 1.0 Below 1.0 B+ Below 1.0 0
1J
A/C control
Inspect A/C relay. section U Inspect related harness.
1K
Diagnostic test mode
DLC Ignition switch (Terminal TEN) on
1L*1
Transmission distinction
Ground
Constant
*1: Europe only
CONTINUED F1-34
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal 1M Signal Vehicle speed Connected to VSS Test condition Vehicle stopped Vehicle running Accelerator pedal depressed Accelerator pedal released Voltage (V) Action
Inspect VSS. 0 or Approx. 5.0 section T Approx. 5.0 Inspect related harness. B+ Below 1.0 B+ Inspect CTP switch. CLOSED THROTLE POSITION (CTP) SWITCH INSPECTION Inspect related harness.
1N
CTP
CTP switch
Ignition switch on
Brake pedal depressed 1O Brake Brake switch Brake pedal released Steering wheel straight ahead position Steering wheel fully turned A/C switch Ignition switch on A/C switch and fan switch on A/C switch off Transmission neutral position or clutch pedal depressed Other than transmission neutral or clutch pedal released
Inspect brake switch. section P Below 1.0 Inspect related harness. B+ Below 1.0 Below 1.0 B+ Below 1.0 B+ Below 1.0 Below 1.0 Below 1.0 Inspect PSP switch. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Inspect related harness. Inspect A/C switch. section U Inspect related harness. Inspect neutral switch. NEUTRAL SWITCH INSPECTION Inspect clutch switch. CLUTCH SWITCH INSPECTION Inspect related harness. Inspect related harness. Inspect related harness. Inspect related harness.
1P
Power steering pressure
PSP switch
Idle
1Q 1R 1S 1T 1U
A/C
1V
Load/no load distinction
Neutral/clutch Ignition switch switch on
2A 2B 2C
Fuel injector ground Power ground System ground
Ground Ground Ground MAF sensor, IAT sensor, ECT sensor, O2S,TP sensor
Constant Constant Constant
2D
Analog ground
Constant
Below 1.0
2E
SGT
Ignition switch on CMP sensor (integrated into distributor) Idle Ignition switch on Idle Ignition switch on
5.0 1.82.3 Below 1.0 0.350.5 4.55.5
Inspect CMP sensor. CAMSHAFT POSITION (CMP) SENSOR INSPECTION Inspect related harness. Inspect ignition control module. section G Inspect related harness.
2F 2G 2H 2I 2J 2K
IGT control
Ignition control module
Constant voltage TP sensor (Vref)
F1-35
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal Signal Connected to Test condition Voltage (V) 2L IAT IAT sensor Ignition switch on IAT 20 C {68F} 2.15 Ignition switch on Ignition switch on 2N*
1
Action Inspect IAT sensor. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Inspect related harness. Inspect TP sensor. THROTTLE POSITION (TP) SENSOR INSPECTION Inspect related harness. Inspect O2S. OXYGEN SENSOR (O2S) INSPECTION Inspect related harness. Inspect variable resistor. VARIABLE RESISTOR INSPECTION Inspect related harness. Inspect MAF sensor. MASS AIR FLOW (MAF) SENSOR INSPECTION Inspect related harness. Inspect ECT sensor. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Inspect related harness. Inspect PRC solenoid valve. FUEL SYSTEM, PRC SOLENOID VALVE INSPECTION Inspect related harness. Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect fuel injector. FUEL SYSTEM,FUEL INJECTOR INSPECTION Inspect related harness. Inspect IAC valve. INTAKE-AIR SYSTEM, IAC VALVE INSPECTION Inspect related harness.
2M
TP
TP sensor
Accelerator pedal released Accelerator pedal depressed Engine cold After warm up
0.40.6 3,44.7 0.55 0.01.0 0.01.0 0.51.0 0.00.5
O2S
O2S
Idle Acceleration Deceleration
2N*
Varies according to the variable Variable resistor Variable resistor resistor adjustment Ignition switch on
04 1.45 2.15 2.73 1.02
2O
Mass airflow
MAP sensor
Idle (after warm up) Engine speed 3000 rpm (after warm up)
2P
IAT 20C {68F}
2Q
ECT
ECT sensor
Ignition switch on After warm up 0.58 For 120 sec. after ignition switch on For 120 sec. after engine start Ignition switch on 0 0 B+ B+ B+ B+ B+ 0.2 Approx 1.0
2R 2S
ECT above 90C {194F} (Hot condition) Others
2T
Pressure PRC solenoid regulator control valve
2U Fuel injector control 2V
Fuel injector No.1,No.3
Ignition switch on Idle Ignition switch on Idle Ignition switch on
Fuel injector No.2, No.4
2W
IAC
IAC valve Idle (after warm up)
*1: Europe only *2: Except Europe
CONTINUED F1-36
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal Signal Connected to Test condition Ignition switch on 2X Purge control Purge solenoid valve Idle Driving in gear 2Y Engine speed output B+ 4.97.0 Voltage (V) B+ B+ Action Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Inspect related harness. Inspect instrument cluster. FUEL SYSTEM, FUEL INJECTOR INSPECTION Inspect related harness.
2Z
Tachometer Ignition switch on (integrated into instrument cluster) Idle
MASS AIR FLOW (MAF) SENSOR INSPECTION Note Perform the following test only when directed. MAF Sensor Inspection 1. Visually inspect for the following on the MAF sensor. Damage Cracks Terminal bends Terminal rust 2. If any of the above are found, replace the MAF sensor. If the MAF sensor PID value is out of specification, inspect as follows and repair or replace as necessary: 3. Disconnect the MAF sensor connector. Open circuit MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20) Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector) GND circuit (MAF sensor connector terminal A and PCM connector terminal 2D through common connector)
THROTTLE POSITION (TP) SENSOR INSPECTION Note Perform the following test only when directed. Resistance Inspection 1. Verify that the throttle valve is at closed throttle position. 2. Inspect that the accelerator cable free play is within the specification. (Refer to INTAKE-AIR SYSTEM, ACCELERATOR CABLE INSPECTION / ADJUSTMENT.) 3. If as specified but PID valve is out of specification, measure the resistance between TP sensor terminals A and C using an ohmmeter. Specification 46K
Short circuit MAF signal circuit (MAF sensor connector terminal B and PCM connector terminal 20 to GND) Power circuit (MAF sensor connector terminal C and main relay terminal D through common connector to GND) 4. Repair or replace faulty areas. 5. Reconnect the MAF sensor connector.
4. Disconnect the TP sensor connector. 5. If not as specified, replace the TP sensor. If as specified, inspect for the following: Open circuit Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M) GND circuit (TP sensor connector terminal C and PCM connector terminal 2D) Short circuit Reference voltage circuit (TP sensor connector terminal A and PCM connector terminal 2K) TP signal circuit (TP sensor connector terminal B and PCM connector terminal 2M)
CONTINUED F1-37
TO. MODEL .INDEX
CONTROL SYSTEM
6. Repair or replace faulty areas. 7. Reconnect the TP sensor connector. THROTTLE POSITION (TP) SENSOR ADJUSTMENT Caution Adjusting the TP sensor with the throttle adjusting screw (TAS) can adversely affect the engine. Do not adjust the TP sensor with the TAS. Since the TP sensor is adjusted by the manufacturer, adjusting the TP sensor excessively can adversely affect the engine. Do not adjust the TP sensor excessively. 1. Verify that the throttle valve is at closed throttle position. 2. Disconnect the TP sensor connector. 3. Turn ignition switch on. 4. Measure and record the voltage of the disconnected harness side connector terminal C using a voltmeter. Specification (CTP) TP sensor terminal C voltage (V) PCM terminal 2M voltage TP V (NGS tester) (V) 0.40.6 0.40.6 0.40.6
4.54.9 4.95.1 5.15.5 8. Tighten the TP sensor screw.
Tightening torque 1.62.3 N.m {1624 kgf.cm, 1420 in.lbf} 9. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to verify the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is wide open. Specification (WOT) TP sensor terminal C voltage (V) 4.54.7 4.74.8 4.84.9 4.95.0 5.05.1 5.15.3 5.35.4 5.45.5 PCM terminal 2M voltage TP V (NGS tester) (V) 3.44.4 3.64.5 3.74.6 3.74.8 3.84.9 4.05.0 4.15.1 4.25.2
Specification 4.55.5 V 5. Reconnect the TP sensor connector. 6. Loosen the TP sensor screw.
10. If not as specified, replace the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR REMOVAL / INSTALLATION.) THROTTLE POSITION (TP) SENSOR REMOVAL/INSTALLATION 1. Disconnect the TP sensor connector. 2. Remove the TP sensor screws. 3. Remove the TP sensor from the throttle body.
7. Use the NGS tester ("TP V" of PID/DATA MONITOR AND RECORD function) or voltmeter to adjust the TP sensor so that the voltage of PCM terminal 2M is within the specification below when the throttle valve is at the closed throttle position.
4. Verify that the throttle valve is fully closed. 5. Install the TP sensor to the throttle body. 6. tighten the TP sensor screws. Tightening torque 1.62.3 N.m {1624 kgf.cm, 1420 in.lbf } 7. Verify that the throttle valve moves smoothly. 8. Reconnect the TP sensor connector.
F1-38
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
9. Adjust the TP sensor. (Refer to CONTROL SYSTEM, THROTTLE POSITION (TP) SENSOR ADJUSTMENT.) CLOSED THROTTLE POSITION (CTP) SWITCH INSPECTION Caution The CTP switch is set at the factory. Do not try to adjust it. Removing the closed throttle position switch can negatively affect the engine. Note Perform the following test only when directed. 1. Disconnect the CTP switch connector. 2. Inspect for continuity between the CTP switch terminal and a GND using an ohmmeter. Short circuit CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1 N to GND) 4. Reconnect CTP switch connector. INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Resistance inspection Note Perform the following test only when directed. 1. Remove the IAT sensor. 2. Heat the IAT sensor using the lamp. 3. Measure the resistance of the IAT sensor using an ohmmeter
Specification Measuring condition Closed throttle position Others
Continuity Yes No
Specification Water temperature (C {F}) 20 {68} 80 {176}
Resistance (k ) 2.09 2.81 0.274 0.802
3. If not as specified, replace the throttle body. If the CTP switch is okay, but PI D value is out of specification, inspect as follows and repair or replace as necessary. Open circuit CTP signal circuit (CTP switch connector terminal and PCM connector terminal 1N) GND circuit (CTP switch body to GND)
4. If not as specified, replace the IAT sensor. If IAT sensor is okay, but PID value is out of specification, inspect as follows and repair or replace as necessary. Open circuit IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2L) GND circuit (IAT sensor connector terminal B and PCM connector terminal 2D)
Short circuit IAT signal circuit (IAT sensor connector terminal A and PCM connector terminal 2Lto GND) 5. Reconnect the IAT sensor connector.
CONTINUED
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CONTROL SYSTEM
INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the IAT sensor connector. 3. Remove the IAT sensor. 4. Install the IAT sensor. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note Perform the following test only when directed. ECT Sensor Resistance Inspection 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the ECT sensor. 3. Place the ECT sensor in water with a thermometer, and heat the water gradually.
Tightening torque 7.911.7 N.m {80120 kgf.cm, 70104 in.lbf} 5. Connect the IAT sensor connector. 6. Connect the negative battery cable. ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION Warning When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before removing or installing the ECT sensor. 1. Drain the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor.
4. Measure the resistance between the ECT sensor terminals A and B using an ohmmeter. Specification Water temperature (C {F}) Resistance (k ) 20 {68} 2.22.8 80 {176} 0.290.4 5. If not as specified, replace the ECT sensor. If the ECT sensor is okay, but PID value is out of specification, inspect for the following: Open circuit ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector) GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector) Short circuit ECT signal circuit (ECT sensor connector terminal A and PCM connector terminal 2Q through common connector to GND) GND circuit (ECT sensor connector terminal B and PCM connector terminal 2D through common connector to GND) 6. Repair or replace faulty areas.
4. Replace the gasket. 5. Install in the reverse order of removal, Tightening torque 2529 N.m {2.53.0 kgf.m, 1921 ft.lbf} 6. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
F1-40
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
7. Install the ECT sensor. 8. Refill the engine coolant. (Refer to Section E, COOLING SYSTEM SERVICE WARNINGS.) (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) CAMSHAFT POSITION (CMP) SENSOR INSPECTION Note Perform the following test only when directed. Voltage Inspection 1. Remove the distributor. 2. Disconnect the fuel injector connectors. 3. Disconnect the high-tension lead. 4. Connect the distributor connector. Warning Turning the ignition switch on with the fuel injector connector still connected will actuate the fuel injector. Turning the ignition switch on with the distributor connector still connected will generate sparks, which can cause electrical shock. Disconnect the connector and prevent it from grounding to the vehicle body. 5. Turn the ignition switch on. 6. Verify the following signal (voltage) from the PCM 2E terminal using a voltmeter when the distributor is rotated by hand. Specification Signal Terminal SGT 2E Voltage 4 pulses/rev. (Approx. 5.0 V)
Short circuit SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E to GND) Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D to GND) 9. If the harnesses are okay, replace the distributor and adjust the ignition timing. (Refer to ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.) OXYGEN SENSOR (O2S) INSPECTION O2S Voltage Inspection Note Perform the following test only when directed. 1. Warm up the engine and run it at idle. 2. Disconnect the O2S connector. 3. Connect the voltmeter test leads to the following O2S terminals: (+) lead-O2S terminal A (-) lead-O2S terminal B
7. If not as specified, inspect as follows and repair or replace as necessary. 8. Disconnect the distributor connector. Open circuit SGT signal circuit (Distributor harness side connector terminal C and PCM harness side connector terminal 2E) Power circuit (Distributor harness side connector terminal B and main relay harness side connector terminal D) GND circuit (Distributor harness side connector terminal A and engine GND)
4. Run the engine at 3000 rpm until the voltmeter increases 0.50.7 V. 5. Verify that the voltmeter needle moves when racing the engine several times. Specification Engine condition Voltage (V) Acceleration 0.51.0 Deceleration 00.5 6. If not as specified, replace the O2S. If the O2S is okay, but PID value is out of specification, inspect for following:
F1-41
CONTINUED
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CONTROL SYSTEM
Open circuit O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N) GND circuit (O2S connector terminal B and PCM connector terminal 2D)
Variable resistor condition Turned fully clockwise Turned fully counterclockwise
Resistance (k ) 4-6 Below 0.1
Short circuit O2S signal circuit (O2S connector terminal A and PCM connector terminal 2N to GND) 7. Repair or replace faulty areas. 8. Reconnect the O2S connector. OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION 1. Disconnect the battery negative terminal. 2. Disconnect the O2S connector. 3. Remove the O2S. 4. Install in the reverse order of removal. Tightening torque 29-49 N.m {35 kgf.m, 2236 ft.lbf} VARIABLE RESISTOR INSPECTION 1. Disconnect the connector from the variable resistor. 2. Connect an ohmmeter between the variable resistor terminal B and C.
3. Using the SST , verify that the resistance increases in relation to the turning amount of the variable resistor.
4. If not as specified, replace the variable resistor. 5. Adjust idle mixture. 6. If the variable resistor is okay, but PCM terminal 2N or 2K voltage is out of specification, inspect for the following: Open circuit Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) GND circuit (Variable resistor connector terminal C and PCM connector terminal 2D) Short circuit Reference voltage circuit (Variable resistor connector terminal A and PCM connector terminal 2K) Variable resistor signal circuit (Variable resistor connector terminal B and PCM connector terminal 2N) 7. If there is an open or short circuit, repair or replace wiring harness. 8. If there is no open or short circuit, replace variable resistor. 9. Reconnect the variable resistor connector. CLUTCH SWITCH INSPECTION Continuity Inspection Note Perform the following test only when directed. 1. Verify that the clutch switch is installed properly. 2. Disconnect the negative battery cable. 3. Remove the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLATION.) 4. Inspect the continuity between the clutch switch terminals A and B using an ohmmeter.
CONTINUED F1-42
TO. MODEL .INDEX
CONTROL SYSTEM
Specification Specification Transmission In neutral Others Continuity Yes No
5. If not as specified, replace the clutch switch. If the clutch switch is okay, but PID value is out of specification, inspect for the following: Open circuit Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V through common connector) GND circuit (Clutch switch connector terminal A and GND) Short circuit Power circuit (Clutch switch connector terminal B and PCM connector terminal 1V to GND) Neutral switch The neutral switch operation and related harnesses continuity (Refer to NEUTRAL SWITCH INSPECTION. 6. Repair or replace faulty areas. 7. Install the clutch switch. (Refer to CONTROL SYSTEM, CLUTCH SWITCH REMOVAL/INSTALLTION.) 8. Connect the negative battery cable. CLUTCH SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the clutch switch connector. 3. Loosen the nuts and remove the clutch switch. 4. Install the clutch switch. 5. Adjust the clutch pedal height referring to the above and the height specification. (Refer to Section H, CLUTCH PEDAL, CLUTCH PEDAL INSPECTION/ADJUSTMENT.) 6. Connect the clutch switch connector. 7. Connect the negative battery cable. NEUTRAL SWITCH INSPECTION Continuity inspection Note Perform the following test only when directed. 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Measure the continuity between the neutral switch terminals A and B using an ohmmeter.
4. If not as specified, replace the neutral switch. If the neutral switch is okay, but PID value is out of specification, inspect for the following: Open circuit Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector) GND circuit (neutral switch connector terminal B and GND)
Short circuit Load/no load distinction circuit (neutral switch connector terminal A and PCM connector terminal 1V through common connector to GND) Clutch switch The clutch switch operation and related harness continuity. (Refer to CONTROL SYSTEM, CLUTCH SWITCH INSPECTION.) 5. Repair or replace faulty areas. 6. Reconnect the neutral switch connector. NEUTRAL SWITCH REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Disconnect the neutral switch connector. 3. Remove the neutral switch. 4. Install the new washer and neutral switch.
F1-43
CONTINUED
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CONTROL SYSTEM
Tightening torque 2534 N.m {2.53.5 kgf.m, 1925 ft.lbf} 5. Connect the neutral switch connector. 6. Connect the battery negative cable. POWER STEERING PRESSURE (PSP) SWITCH INSPECTION Continuity inspection Note Perform the following test only when directed. 1. Disconnect the PSP switch connector. 2. Start the engine. 3. Inspect for continuity between the PSP switch terminal and GND using an ohmmeter.
Short circuit PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector to GND) Power steering fluid (Refer to Section N, engine speed sensing power steering system.) Fluid level Fluid leakage Fluid pressure 5. Repair or replace faulty areas. 6. Reconnect the PSP switch connector. MAIN RELAY INSPECTION Continuity Inspection Note Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the main relay connector. 3. Inspect for continuity between terminals of the relay using an ohmmeter.
Specification Condition Steering wheel in straight ahead Steering wheel fully turned
Continuity Yes No
Specification
4. If not as specified, replace the PSP switch. If the PSP switch is okay, but PID value is out of specification, inspect for the following: Open circuit PSP signal circuit (PSP switch connector terminal and PCM connector terminal 1P through common connector) GND circuit (PSP switch body and GND)
4. If not as specified, replace the main relay. If the main relay is okay, inspect for the following: Open circuit Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector) PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector)
CONTINUED F1-44
TO. MODEL .INDEX
CONTROL SYSTEM, ON-BOARD DIAGNOSTIC SYSTEM

GND circuit (Main relay connector terminal B and GND) Short circuit Main relay power supply circuit (Main relay connector terminal A and ignition switch (IG1) connector through common connector to GND) PCM power supply circuit (Main relay connector terminal C and battery positive terminal through common connector to GND) 5. Repair or replace faulty areas. 6. Reconnect the main relay. 7. Reconnect the negative battery cable. MAIN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the main relay connector. 3. Remove the main relay. 4. Install the reverse order of removal. Tightening torque 7.910.7 N.m {80110 kgf.cm, 69.595.4 in-Ibf} ON-BOARD DIAGNOSTIC SYSTEM READ/CLEAR DIAGNOSTIC TEST RESULTS This retrieves all stored DTCs in the PCM and clears the DTC. PARAMETER IDENTIFICATION (PID) ACCESS The PID mode allows access to certain data values, analog and digital inputs and outputs, calculated values and system status information. Since PID values for output devices are PCM internal data values, perform the Simulation Test to identify which output devices are malfunctioning. Note PID monitor item "PRCV" can be selected and "ON" or "OFF' is displayed for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. DIAGNOSTIC SUPPORT PROCEDURE These tests are the ability of the powertrain control system to detect a change in certain input devices by following the instructions on the NGS tester. There are two options: ALL TEST and SINGLE TEST. ALL TEST takes you through all diagnostic support tests. SINGLE TEST enables you to perform specific tests that relate to the particular diagnosis that you are conducting. This test MUST follow the instructions on the NGS tester. If not, a "TEST CONDITIONS NOT CORRECT' message will appear, or else the test result will be FAULTY. SIMULATION TEST Output devices can be turned on and off by sending simulation command signals from the NGS tester to the PCM. The "Idling Test" and "Ignition ON Test" are available in this test. These tests will verify the PCM status, output devices, and related circuit wiring harnesses. Note "PRCV" of the simulation item can be selected for vehicles without the PRC system, but is not used for the inspection because the corresponding part (PRC solenoid valve) is not equipped. ON-BOARD DIAGNOSTIC TEST NGS Tester Hook-up Procedure Note Make sure the ignition switch is at LOCK position. 1. Insert the vehicle interface module and latest program card into the hand-held NGS control unit.
CONTINUED F1-45
TO. MODEL .INDEX
ON-BOARD DIAGNOSTIC SYSTEM
3. Move the cursor to SELECT NEW VEHICLE YEAR & MODEL Press the TRIGGER key to enter this selection. 2. Plug the adapter harness connector into the vehicle interface module and the DLC located at the engine compartment. 3. Plug the NGS tester power connector into the cigarette lighter. Alternatively, use a battery hook-up adapter.
4. Listen to the double beep. The NGS tester is now initialized. Begin the powertrain control system functional test. DTC READING PROCEDURE Using the SSTs (NGS Tester) Note Start engine and keep it running. If the engine will not start, turn the ignition switch on during the procedure. 1. Perform the necessary vehicle preparation and visual inspection. Hook the NGS tester up to the vehicle.
4. Move the cursor to B-SERIES (UN). Press the TRIGGER key to enter this selection. EUROPE
2. Move the cursor to VEHICLE & ENGINE SELECTION. Press the TRIGGER key to enter this function.
CONTINUED
F1-46
TO. MODEL .INDEX

EXCEPT EUROPE 9. Move the cursor to READ/CLEAR DIAGNOSTIC TEST RESULTS. Press the TRIGGER key to enter this selection.
Note Make sure the selected vehicle is correct. 5. A vehicle selection screen showing the selected vehicle will be displayed. Move the cursor to the vehicle selected. Press the TRIGGER key. 6. Move the cursor to DIAGNOSTIC DATA LINK on the main menu screen. Press the TRIGGER key to enter into menu system diagnostics.
10. Press START. 11. Retrieve DTCs. Not Using the SSTs (NGS Tester) Using the SST (self-diagnosis checker) 1. Connect the SST s to the DLC located in the engine compartment and ground the black (negative) lead to the body.
7. Move the cursor to PCM-POWERTRAIN CONTROL MODULE. Press the TRIGGER key to enter this selection.
8. Move the cursor to DIAGNOSTIC TEST MODES. Press the TRIGGER key to enter this selection.
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the ignition switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code "88" flashes for 5 seconds. If DTC is not detected, "00" will then be indicated. Note If the "88" does not flash, inspect +B terminal of the DLC, and the related harnesses and connectors. If the "88" flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs is indicated, inspect the appropriate area and repair as necessary. Note A DTC consists of four numbers. They are flashed one by one in the right window on the display. ("1" is always shown on the left window.)
CONTINUED
F1-47
TO. MODEL .INDEX

7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SST s (NGS tester).) 8. Remove the SST s. 7. If any DTCs is indicated, inspect the appropriate area and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE, Not Using the SST s (NGS Tester).) 9. Remove the voltmeter and jumper wire PID/DATA MONITOR AND RECORD PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 7 from the DTC READING PROCEDURE. 3. Turn the ignition switch on or run the engine. 4. Move the cursor to PID/DATA MONITOR AND RECORD. Press the TRIGGER key to enter this selection. Using the Voltmeter 1. Turn the ignition switch off. Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 2. Using a jumper wire to short terminal TEN of the DLC to body GND. 3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.
5. Move the cursor to PID values to view. Press the TRIGGER key. A star symbol will appear next to the item when it is selected. Note Press the TRIGGER key once again to deselect a PID. Press the CLEAR to deselect all PIDs. 6. Press START to begin. 7. When ready to capture and store the selected PIDs, press the TRIGGER key. 8. Press the TRIGGER key again when ready to save information. 9. Move the cursor to STORE RECORDING AREA 1. Press the TRIGGER key.
4. Turn the ignition switch on. 5. The voltmeter indicates B+ for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeter's needle. If DTC is not detected, the needle does not move. Note The DTC will be output as shown. 10. Follow the instructions displayed on the NGS tester to save the recording data. PLAYBACK OF STORED PIDS PROCEDURE Note Look for abnormal behavior or values that are clearly incorrect. Inspect the signals for abrupt or unexpected changes.
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CONTINUED
TO. MODEL .INDEX

Look for agreement in related signals. Make sure signals act in proper sequence.
1. Select VIEW RECORDER AREAS.
2. Select up to four PIDs to review in the table format or two PIDs to review in the graph mode. (1) Table format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the values.
4. Move the cursor to ALL TEST or SINGLE TEST . Press the TRIGGER key. Note ALL TEST inspects each item according to an established programmed order. With SINGLE TEST , enable to select and inspect any test item in any order, one at a time.
5. Follow the instructions displayed on the NGS tester and press the TRIGGER key. Note To skip a test item, press OMIT. Before performing the test, the basic condition on the test vehicle must be set up in order to get exact data. Press BASIC to view the basic condition instruction screen. If the screen shows PASSED, the system operates correctly. If the screen shows FAULTY, the system operates incorrectly.
(2) Graph format: Scroll through the PID data while analyzing the information. Look for sudden drops or peaks in the linear lines showing the transformation of values to the line graph.
DIAGNOSTIC SUPPORT PROCEDURE 1. Perform the NGS Tester Hook-up Procedure. 2. Perform Steps 1 through 8 from the DTC READING PROCEDURE. 3. Move the cursor to DIAGNOSTIC SUPPORT PROCEDURE. Press the TRIGGER key to enter this selection.
CONTINUED
F1-49
TO. MODEL .INDEX

SIMULATION TEST PROCEDURE Idling Test 1. Perform the NGS tester hook-up procedure. 2. Perform the Steps 1 through 7 from the DTC READING PROCEDURE. 3. Start the engine and run it at idle. 4. Move the cursor to SIMULATION TEST . Press the TRIGGER key to enter this selection. 8. Press the TRIGGER key.
9. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
5. Move the cursor to IDLING TEST . Press the TRIGGER key to enter this selection. 10. To perform the simulation again, press the TRIGGER key. To exit the idling test, press the CANCEL key. Ignition ON Test 1. Perform Steps 1 through 7 from the DTCs READING PROCEDURE. 2. Turn the ignition switch on. Move the cursor to SIMULATION TEST . Press the TRIGGER key to enter this selection.
6. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key. Note Only one simulation item can be selected at a time.
3. Move the cursor to IGNITION ON TEST . Press the TRIGGER key to enter this selection. 7. Press START . Note If the screen displays "TEST CONDITION NOT CORRECT ", inspect the following signal conditions and determine whether or not they are normal: NLSW: ON RPM; above 550
CONTINUED
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TO. MODEL .INDEX

AFTER REPAIR PROCEDURE Using the SSTs (NGS Tester) 1. After repairs have been made, perform the DTCs READING PROCEDURE. 2. Press CLEAR. 3. Press the TRIGGER key. 4. Press the CANCEL key. 5. Ensure that the customer's concern has been resolved. Not Using the SSTs (NGS Tester) 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note If the engine will not start, continue to operate the starter for 5-6 seconds. 3. Perform the "DTC READING PROCEDURE" again. 4. Verify that the DTC is not detected.
4. The screen will display a list of simulation items. Select the appropriate simulation item for testing, then press the TRIGGER key.
5. Press START . 6. Press the TRIGGER key.
7. The simulation is performed for 3 seconds, and a "SIMULATION ACTIVATED PLEASE WAIT" message is displayed during those 3 seconds.
8. To perform the simulation again, press the TRIGGER key. To exit the ignition on test, press the CANCEL key.
CONTINUED
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TO. MODEL .INDEX

DTC INSPECTION DTC Table DTC No. P0100 P0115 P0120 P0134 P0340 P0443 P0505 P1110 P1170 P1195 P1250 P1608 Output pattern Display on the NGS tester MAF/VAF-CIRCUIT MALFUNCTION ECT-CIRCUIT MALFUNCTION Condition MAF sensor circuit malfunction ECT sensor circuit malfunction
TP-CIRCUIT MALFUNCTION TP sensor circuit malfunction O2S 11-CIRCUITNO ACTIVITY DETECTED CAMSHAFT POS SENSORCKT MALFUNCTION EVAP SYSTEM-PURGE CTRL VALVE CKT MALF IDLE CONTROL SYSTEMMALFUNCTION O2S circuit no activity detected SGT signal is not detected Purge solenoid valve circuit malfunction IAC valve circuit malfunction
IATS (D/C)-OPEN OR SHORT IAT sensor circuit malfunction HO2S 11-INVERSION EGRBS-OPEN OR SHORT PRC-OPEN OR SHORT PCM (CPU)-MALFUNCTION O2S is stuck Barometric pressure sensor (in PCM) malfunction PRC solenoid valve circuit malfunction PCM internal circuit malfunction
CONTINUED
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TO. MODEL .INDEX

DTC Troubleshooting
DTC P0100 DETECTION CONDITION Mass air flow (MAP) sensor circuit malfunction Input voltage from MAF sensor is below 0.7 V or above 5.4 V when ignition switch is turned on. MAF sensor malfunction Blockage at MAP sensor Poor connection of connectors at MAF sensor and/or PCM Leakage in intake-air system Short to power supply circuit in wiring from MAF sensor terminal B to PCM terminal 20 Short to ground in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal B to PCM terminal 20 Open circuit in wiring from MAF sensor terminal C to main relay terminal D Open circuit in wiring from MAF sensor terminal A to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground. Yes ACTION Inspect for open circuit in following wiring harnesses, then go to Step 12. Main relay terminal D-purge solenoid valve, PRC solenoid valve, IAC valve CMP sensor PCM terminal 2D-throttle position sensor, intake-air temperature sensor, engine coolant temperature sensor, oxygen sensor Between PCM terminal 2C and engine ground Go to next step Go to next step. Go to next step Repair or replace faulty parts, then go to Step 12. Go to next step. Inspect for open or short circuit in wiring harness (between main relay terminal D and MAF sensor terminal C), then go to Step 12. Go to next step. Repair open circuit, then go to Step 12. Go to next step Repair open circuit, then go to Step 12.
POSSIBLE CAUSE
STEP INSPECTION 1 Verify stored DTC. Have DTCs P0115, P0120, P0134, P0340, P0443, P0505, P1110, P1170, and/or P1250 been stored?
No 2 3 4 Does MAP sensor connector or PCM connector have poor connection? Is intake-air system okay? Disconnect MAF sensor connector. Turn ignition switch on. Is there battery positive voltage at MAF sensor harness side connector terminal C? No Yes No Yes No
Yes Repair or replace connector, then go to Step 12.
Disconnect PCM connector. MAF sensor connector is Yes disconnected. Is there continuity between MAF sensor harness side No connector terminal A and PCM harness side connector terminal 2D? Is there continuity between MAF sensor harness side connector terminal B and PCM harness side connector terminal 20 Is there continuity from PCM harness side connector terminals 20 to 1B? Is there continuity from PCM harness side connector terminals 20 to body ground. Remove MAF sensor. Is there any foreign material at MAF sensor screen? Connect MAF sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access MAF V PID. Does MAF V PID change when air is blown into mass airflow sensor? Note If NGS tester is not used, measure PCM 20 terminal voltage with circuit tester. Yes No
7 8 9 10
Yes Repair short to power circuit, then go to Step 12. No No Go to next step Go to next step. Yes Repair short to ground circuit, then go to Step 12. Yes Clean MAF sensor screen, then go to Step 12. No Yes Go to next step. Go to next step.
No
Replace MAF sensor, then go to Step 12.
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STEP 11 INSPECTION Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Go to Step 1. Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection. Troubleshooting completed. ACTION
12
Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes No
DTC P0115 DETECTION CONDITION
Engine coolant temperature (ECT) sensor circuit malfunction Input voltage from ECT sensor is below 0.07 V or above 4.58 V when ignition switch is turned on. ECT sensor malfunction Poor connection of connectors at ECT sensor terminal and/or PCM Short to power supply circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Short to ground in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal A to PCM terminal 2Q Open circuit in wiring from ECT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine ground INSPECTION ACTION Yes Inspect for open circuit in following wiring harnesses, then go to Step 9. PCM terminal 2D-MAF sensor, O2S, IAT sensor, and/or TP sensor PCM terminal 2C-engine ground Go to next step Repair or replace connector, then go to Step 9. Go to next step Go to next step Inspect for open or short circuit in wiring harness (between PCM terminal 2Q and ECT sensor terminal A), then go to Step 9. Go to next step. Repair open circuit, then go to Step 9 Repair short to power circuit, then go to Step 9 Go to next step. Repair short to ground circuit, then go to Step 9. Go to next step Go to next step Replace ECT sensor, then go to Step 9. CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL/INSTALLATION.
POSSIBLE CAUSE
STEP 1
Verify stored DTC. Have DTCs P0100, P0120, P0134, P1110, and/or P1170 been stored?
No 2 3 Does ECT sensor connector or PCM connector have poor connection? Disconnect ECT sensor connector. Turn ignition switch on. Is there 5V at engine coolant temperature sensor harness side connector terminal A Disconnect PCM connector. ECT sensor connector is disconnected. Is there continuity between ECT sensor harness side connector terminal B and PCM harness side connector terminal 2D Is there continuity from PCM harness side connector terminals 2Q to 1B? Is there continuity from PCM harness side connector terminals 2Q to body ground? Is ECT sensor okay? CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Yes No Yes No
Yes No Yes No Yes No Yes No
5 6 7
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STEP 8 INSPECTION Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Go to Step 1. Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection. Troubleshooting completed. ACTION
Yes No
DTC P0120
DETECTION CONDITION
Throttle position (TP) sensor circuit malfunction Input voltage from TP sensor is below 0.09 V or above 4.78 V when ignition switch is turned on. TP sensor malfunction Poor connection of connectors at TP sensor and/or PCM Short to power supply circuit in wiring from TP sensor terminal A to PCM terminal 2K Short to power supply circuit in wiring from TP sensor terminal C to PCM terminal 2D Short to power supply circuit in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal B to PCM terminal 2M Short to ground in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal A to PCM terminal 2K Open circuit in wiring from TP sensor terminal C to PCM terminal 2D Open circuit in wiring from TP sensor terminal B to PCM terminal 2M Open circuit in wiring from TP sensor terminal 2C to engine ground INSPECTION ACTION Yes Inspect for open or short circuit in following wiring harnesses, then go to Step 11. PCM terminal 2D -MAP sensor, O2S, IAT sensor, and/or ECT sensor Between PCM terminal 2C and engine ground Go to next step Repair or replace connector, then go to Step 11 Go to next step. Go to next step. Inspect for open or short circuit in wiring harness (between PCM terminal 2K and TP sensor terminal A), then go to Step 11 Go to next step. Repair open circuit, then go to Step 11. Go to next step. Repair or replace wiring harness, then go to Step 11.
POSSIBLE CAUSE
STEP 1
Verify stored DTC. Have DTC P0100, P0115, P0134, P1110 and/or P1170 been stored.
No 2 3 Does TP sensor connector or PCM connector have poor connection? Disconnect TP sensor connector. Turn ignition switch on. Is there 5V at TP sensor harness side connector terminal A? Yes No Yes No
Disconnect PCM connector. Yes TP sensor is disconnected. Is there continuity between TP sensor harness side connector terminal No C and PCM harness side connector terminal 2D. Is there continuity between TP sensor harness side connector terminal B and PCM harness side connector terminal 2M. Yes No
CONTINUED
F1-55
TO. MODEL .INDEX

STEP 6 INSPECTION Is there continuity from PCM harness side connector terminals 2D to 1B? Is there continuity from PCM harness side connector terminal 2M to 1B Is there continuity from PCM harness side connector terminals 2M to body ground? Connect TP sensor and PCM connectors. Connect NGS tester to DLC. Turn ignition switch on. Access TP V PID. Does TP V increase linear according to throttle valve opening angle? Note If NGS tester is not used, measure PCM 2M terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No 7 Yes No 8 9 Yes No Yes ACTION Repair short to power supply circuit, then go to Step 11 Go to next step. Repair short to power supply circuit, then go to Step 11. Go to next step. Repair short to ground circuit, then go to Step 11. Go to next step. Go to next step.
No
Verify TP sensor, then go to Step 11.
10
Yes No
Go to Step 1. Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection Troubleshooting completed.
11
Yes No
CONTINUED
F1-56
TO. MODEL .INDEX

DTC P0134 DETECTION CONDITION Oxygen sensor (O2S) circuit no activity detected O2S signal does not exceed 0.45 V after the engine is started, or stays below 0.45 V for 180 seconds after the engine has reached normal operating temperature. O2S malfunction Open or short circuit in wiring harness Open or short circuit in wiring harness Poor connection of connector Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose and/or fuel filter clogging or leakage Leakage in intake-air system Leakage in exhaust system Ignition coil and/or igniter malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Vacuum hose damage or looseness
POSSIBLE CAUSE
Warning Following troubleshooting flow chart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify stored DTC. Have DTC P0100 P0120, P0115 and/or P1110 been stored? Clear DTC. Verify RPM, ECT and VS PIDs. Drive in normal mode for approx. 2 minutes under same condition. Is DTC P0134 stored? Note If NGS tester is not used, measure follow PCM terminal voltages with circuit tester. SGT (terminal 2E) ECT sensor (terminal 2Q) Vehicle speed (terminal 1M) Implement PID/DATA MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK by using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle? Note If NGS tester is not used, measure following PCM terminal voltages with circuit tester. ECT sensor (terminal 2Q) SGT (terminal 2E) TP sensor (terminal 2M) Yes No Yes ACTION Inspect and repair DTC P0100, P0115, P0120 or P1110 then go to Step 22. Go to next step Trouble is in process. Go to next step.
No
Go to 'TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent concerns".
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22.
No
Go to next step.
CONTINUED F1-57
TO. MODEL .INDEX

STEP 4 INSPECTION Continue monitoring items in previous step. Is there any input signal, which causes drastic changes when it is set to be in trouble condition? Yes ACTION Implement 'TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure" and repair or replace, then go to Step 22. Go to next step. Repair or replace faulty exhaust parts, then go to Step 22. EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION. Go to next step Go to next step. Install O2S properly, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION. Go to next step.
No 5 Inspect exhaust system upstream from oxygen sensor. Is there any gas leakage? Yes
No 6 Inspect installation of O2S. Is it okay? Yes No
Implement PID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on oxygen sensor as follows while racing engine (in neutral)? More than 0.45V when accelerator pedal is suddenly pressed: rich condition Less than 0.45V during fuel cut: lean condition Note If NGS tester is not used, measure PCM 2N terminal voltage with circuit tester. Inspect for open, poor connection, and other problems on following harnesses, connectors and terminals (for fuel injector at each cylinder): Front main relay to fuel injector Are there any problems? Inspect injection amount of each fuel injector. FUEL SYSTEM, FUEL INJECTOR INSPECTION, Fuel Injection Volume Test. Are there any fuel injectors in abnormal condition for amount or condition of injection? Inspect for air suction: From air cleaner to throttle body From throttle body to dynamic chamber From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction be confirmed? Inspect for suction in vacuum hose which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay? Inspect for clogging in fuel filter (high-pressure). Are there foreign materials on fuel side of fuel filter?
Yes
No
Inspect and repair or replace faulty oxygen sensor harness, connector or terminal, then go to Step 22. CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 22. Go to next step. Replace faulty fuel injectors, then go to Step 22. FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION. Go to next step. Repair or replace source of air suction, then go to Step 22.
No Yes
No Yes
10
No
Go to next step.
11
Yes No Yes No Yes No
Repair or replace source of air suction, then go to Step 22. Go to next step. Go to Step 17. Go to next step. Go to next step Replace fuel pump, then go to Step 22. FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION. Go to next step. Go to Step 16.
12
13
14
Yes No
F1-58
CONTINUED
TO. MODEL .INDEX

STEP 15 INSPECTION Inspect inside of fuel tank for foreign materials and stains. Is inside of fuel tank okay? Yes ACTION Replace fuel filter (high-pressure), then go to Step 22. - FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION. Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter (high-pressure), then go to Step 22. -FUEL SYSTEM, FUEL FILTER (HIGH-PRESSURE) REMOVAL/INSTALLATION.
No
16
Inspect for leakage and clogging in fuel line from fuel Yes distributor to fuel pump. No Is it okay? Inspect for leakage in fuel line fuel filter (highpressure) to fuel tank (return side). Is it okay? Yes
Go to next step. Repair or replace necessary, then go to Step 22. Replace pressure regulator, then go to Step 22. -FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION. Repair or replace as necessary, the go to Step 22. Go to Step 19. Go to next step. Go to next step. Replace ignition coil, then go to Step 22. Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 22.
17
No 18 Verify blinking condition on each cylinder by setting Yes timing light on high-tension lead under trouble condition. No Does it blink regularly and stably? Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? Warning Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles which make engine coolant white at filling opening? Note Large bubbles are normal since they are remaining air coming out from engine coolant passage. Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? Yes No Yes
19
20
No
Go to next step.
21
Yes No Yes No
Go to next step Implement engine overhaul, the go to next step. Go to applicable DTC inspection. Troubleshooting completed.
22
CONTINUED F1-59
TO. MODEL .INDEX

DTC P0340 DETECTION CONDITION SGT signal is not detected No SGT signal input from CMP sensor when engine is started and 2.1 seconds have passed CMP sensor malfunction CMP sensor air gap incorrect Short to power supply circuit in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal C to PCM terminal 2E Short to ground in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal C to PCM terminal 2E Open circuit in wiring from CMP sensor terminal B to main relay terminal D Open circuit in wiring from CMP sensor terminal A to body ground INSPECTION Verify stored DTC. Have DTC PP0100, P0443, P0505, and/or P1250 been stored? Yes ACTION Inspect for open circuit in following wiring harnesses, then go to Step 11. Main relay terminal D-purg solenoid valve, PRC solenoid valve, IAC solenoid valve, MAF sensor Go to next step. Repair or replace connector, then go to Step 11. Go to next step Go to next step. Inspect for open or short circuit in wiring harness (between main relay terminal D and CMP sensor terminal B), then go to Step 11. Go to next step. Inspect for open or short circuit in wiring harness (between PCM terminal 2E and CMP terminal C), then go to Step 11. Go to next step. Repair open circuit, then go to Step 11. Repair short to power circuit, then go to Step 11. Go to next step. Repair short to ground circuit, then go to Step 11. Go to next step. Go to next step. Repair open circuit, then go to Step 11. Go to next step.
POSSIBLE CAUSE
STEP 1
No 2 3 Does CMP sensor or PCM connector have poor connection? Disconnect CMP sensor connector. Turn ignition switch on. Is there battery positive voltage at CMP sensor harness side connector terminal B? Disconnect CMP sensor connector. Turn ignition switch on. Is there 5 V at CMP sensor harness side connector terminal C? Disconnect PCM connector and CMP sensor connector. Is there continuity between CMP sensor harness side connector terminal C and PCM harness side connector terminal 2E? Yes No Yes No
Yes No
Yes No
6 7 8 9
Is there continuity from PCM harness side connector Yes terminal 2E to 1B? No Is there continuity from PCM harness side connector Yes terminal 2E to body ground? No Is there continuity from CMP sensor harness side terminal A to body ground? Connect CMP sensor connector. Connect NGS tester to DLC. Turn ignition switch on. Access RPM PID. Does RPM PID change when engine is running? Note If NGS tester is not used, measure PCM 2E terminal voltage with circuit tester. Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes
No
Replace distributor and adjust ignition timing, then go to Step 11.
10
Yes No
Go to Step 1 Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
11
Yes No
CONTINUED
F1-60
TO. MODEL .INDEX
Purge solenoid valve circuit malfunction Open or short circuit is observed in purge solenoid valve system when ignition switch is turned on. Purge solenoid valve malfunction Poor connection of connectors at purge solenoid valve and/or PCM Short to power supply circuit in wiring from purge solenoid valve B to PCM terminal 2X Short to ground in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from purge solenoid valve terminal B to PCM terminal 2X Open circuit in wiring from purge solenoid valve terminal A to main relay terminal D INSPECTION ACTION Yes Inspect for open circuit following wiring harnesses, then go to Step 9. Main relay terminal D-PRC solenoid valve, IAC solenoid valve, MAF sensor, CMP sensor Between PCM terminal 2C and engine ground Go to next step Repair or replace connector, then go to Step 9. Go to next step. Go to next step. Inspect for open or short circuit in wiring harness (between main relay terminal D and purge solenoid valve terminal A), then go to Step 9. Go to next step. Repair open circuit, then go to step 9. Repair short to power supply circuit, then go to Step 9. Go to next step. Repair short to ground circuit, then go to Step 9. Go to next step. Go to next step Replace purge solenoid valve, then go to Step 9. Go to Step 1. Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
POSSIBLE CAUSE
STEP 1
Verify stored DTC. Have DTC P0100, P0505, P0340, and/or P1250 been stored?
No 2 3 Does purge solenoid valve connector or PCM connector have poor connection? Disconnect purge solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at purge solenoid valve harness side connector terminal A? Disconnect PCM connector Purge solenoid valve is disconnected. Is there continuity between purge solenoid valve harness side connector terminal B and PCM harness side connector terminal 2X? Is there continuity from PCM harness side connector terminal 2X to 1B? Is there continuity from PCM harness side connector terminal 2X to body ground? Is purge solenoid valve okay? EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No
Yes No Yes No
6 7
Yes No
F1-61
CONTINUED
TO. MODEL .INDEX
Idle air control (IAC) valve circuit malfunction Open or short circuit is observed in idle air control, system IAC valve malfunction Poor connection of connectors at IAC valve and/or PCM Short to ground in wiring from IAC valve terminal B to PCM terminal 2W Short to power supply circuit in wiring from IAC valve terminal B to PCM terminal 2W Short to ground in wiring from IAC valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2B and/or 2C to engine ground Open circuit in wiring from IAC valve terminal B to PCM terminal 2W Open circuit in wiring from IAC valve terminal A to main relay terminal D
POSSIBLE CAUSE
STEP 1
INSPECTION Verify stored DTC. Have DTC P0100, P0340, P0443, and/or P1250 been stored. Yes
ACTION Inspect for open circuit following wiring harnesses, then go to Step 9. Main relay terminal D-PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve Between PCM terminal 2C and engine ground Go to next step Repair or replace connector, then go to Step 9. Go to next step Go to next step. Inspect for open or short circuit in wiring harness (between main relay terminal D and IAC valve terminal A), then go to Step 9. Go to next step. Repair open circuit, then go to step 9. Repair short to power supply circuit, then go to Step 9. Go to next step. Repair short to ground circuit, then go to Step 9, Go to next step Go to next step. Replace IAC valve, then go to Step 9. Go to Step 1 Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection Troubleshooting completed
No 2 3 Does IAC valve connector or PCM connector have poor connection? Yes No
Disconnect IAC valve connector. Yes Turn ignition switch on. No Is there battery positive voltage at IAC valve harness side connector terminal A? Disconnect PCM connector IAC valve is disconnected. Is there continuity between IAC valve harness side connector terminal B and PCM harness side connector terminal 2W? Yes No
Is there continuity from PCM harness side connector Yes terminal 2W to 1B? No Is there continuity from PCM harness side connector Yes terminal 2W to body ground? No Is resistance between IAC valve component side connector A and B as specified? Specification 8.710.5 [23 C {73.4 F}] Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No
6 7
Yes No
F1-62
CONTINUED
TO. MODEL .INDEX
Intake air temperature (IAT) sensor circuit malfunction Input from IAT sensor is below 0.1 V or above 4.9 V when ignition switch is turned on IAT sensor malfunction Poor connection of connectors at IAT sensor terminal and/or PCM Short to power supply circuit in wiring from IAT sensor terminal A to PCM terminal 2L Short to GND in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal A to PCM terminal 2L Open circuit in wiring from IAT sensor terminal B to PCM terminal 2D Open circuit in wiring from PCM terminal 2C to engine GND INSPECTION ACTION Yes Inspect for open circuit in following wiring harnesses, then go to Step 7. PCM terminal 2D-ECT sensor, MAP sensor, O2S, CMP sensor and/or TP sensor PCM terminal 2C-engine GND Go to next step. Repair or replace connector, then go to Step 9. Go to next step. Go to next step. Inspect for open or short circuit in wiring harness (between PCM terminal 2L and IAT sensor terminal A), then go to Step 9. Go to next step. Repair open circuit, then go to Step 9. Repair short to power circuit, then go to Step 9. Go to next step. Repair short to ground circuit, then go to Step 9. Go to next step. Go to next step. Replace IAT sensor, then go to Step 9. CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR REMOVAL/INSTALLATION Go to Step 1. Intermittent poor connection in wiring harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
POSSIBLE CAUSE
STEP 1
Verify stored DTC. Have DTC P0100, P0115, P0120, P0134, P0335, and/or P1170 been stored?
No 2 3 Does IAT sensor connector or PCM connector have poor connection? Disconnect IAT sensor connector. Turn ignition switch on. Is there 5V at IAT sensor harness side connector terminal A? Disconnect PCM connector. IAT sensor connector is disconnected. Is there continuity between IAT sensor harness side connector terminal B and PCM harness side connector terminal 2D? Is there continuity from PCM harness side connector terminals 2L to 1B? Is there continuity from PCM harness side connector terminal 2D to body GND? Is IAT sensor okay? CONTROL SYSTEM, INTAKE AIR TEMPERATURE (IAT) SENSOR INSPECTION Yes No Yes No
5 6 7
Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Clear DTC from memory. Is there any DTC present after performing "AFTER REPAIR PROCEDURE"?
Yes No
Yes No
CONTINUED F1-63
TO. MODEL .INDEX
DTCP1170 DETECTION CONDITION
Oxygen sensor (O2S) is stuck When O2S signal stays above 0.45V for 20 seconds after engine has reached normal operating temperature. O2S deterioration Fuel injector malfunction Pressure regulator malfunction Fuel pump malfunction Fuel delivery hose clogging or leakage Fuel return hose and/or fuel filter clogging Leakage in intake-air system or exhaust system PCV valve malfunction Purge solenoid valve malfunction or purge solenoid hoses are hooked up incorrectly Ignition coil malfunction Insufficient compression MAF sensor malfunction ECT sensor malfunction TP sensor malfunction Open or short circuit in wiring harness Poor connection of connector Vacuum hose damage or looseness
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify stored DTC. Have DTCs P0100, P0110 P0115, and/or P0120 been stored? Yes ACTION Inspect and repair DTC P0100, P0110, P0115, or P0120. Go to Step 26. Go to next step.
No
CONTINUED
F1-64
TO. MODEL .INDEX

STEP 2 INSPECTION Clear DTC. Verify RPM, ECT and VS PIDS. Drive vehicle approx. 1 minute under same condition. Is DTC P1170 stored? Note If NGS tester is not used, measure following PCM terminal voltage with voltmeter. SGT (terminal 2E) ECT sensor (terminal 2Q) Vehicle speed (terminal 1 M) Implement PID/DATA.MONITOR AND RECORD (ECT, RPM, TP V) from DIAGNOSTIC DATA LINK using NGS tester. Is there any signal that is far out of specification when ignition switch is on, and engine is run at idle? Note If NGS tester is not used, measure following PCM terminal voltage with voltmeter. ECT sensor (terminal 2Q) SGT (terminal 2E) TP sensor (terminal 2K) 4 Continue monitoring items on previous PIDs. Is there any input signal which causes drastic changes when it is set to be in trouble condition? Yes ACTION Trouble is in process. Go to next step.
No
Go to TROUBLESHOOTING, ENGINE SYMPTOM TROUBLESHOOTING, Intermittent Concerns.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace then go to Step 26.
No
Go to next step.
Yes
Implement TROUBLESHOOTING, ENGINE DIAGNOSTIC INSPECTION, Input Signal System Investigation Procedure and repair or replace, then go to Step 26. Go to next step. Repair or replace faulty exhaust parts, then go to Step 26. EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION. Go to next step. Go to next step. Install heated oxygen sensor properly, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S) REMOVAL/INSTALLATION. Go to next step.
No 5 Inspect exhaust system, upstream from O2S. Is there any gas leakage? Yes
No 6 Is O2S installed properly? Yes No
Implement FID/DATA MONITOR AND RECORD (O2S) from DIAGNOSTIC DATA LINK using NGS tester. Is voltage on O2S as follows while racing engine (in neutral)? More than 0.45V when accelerator pedal is suddenly pressed: rich condition Less than 0.45V during fuel cut: lean condition Note If NGS tester is not used, measure PCM 2N voltages with voltmeter. Inspect for open, poor connection and other problems on the following harnesses, connectors, and terminals (for fuel injector at each cylinder): From main relay to fuel injector From fuel injector to PCM Is there any trouble?
Yes
No
Inspect and repair or replace faulty O2S, harnesses, connector or terminals, then go to Step 26. CONTROL SYSTEM, OXYGEN SENSOR (O2S) INSPECTION.
Yes
Repair or replace faulty harness, connector or terminal, then go to Step 26. Go to next step.
No
F1-65
CONTINUED
TO. MODEL .INDEX

STEP 9 INSPECTION Inspect injection amount of each injector. FUEL SYSTEM, FUEL INJECTOR INSPECTION, Volume Test. Are there any injectors operating abnormally? (e.g. injection amount, injection condition) Inspect purge control system. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Purge Control Inspection. Is it okay? Inspect PCV valve operation. EMISSION SYSTEM, POSITIVE CRANKCASE VENTILATION (PCV) VALVE INSPECTION. Is it okay? Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? Inspect pressure regulator. FUEL SYSTEM, PRESSURE REGULATOR INSPECTION. Is it okay? Inspect air suction: From air cleaner to throttle body From throttle body to dynamic chamber From dynamic chamber to intake manifold Visually inspect for cracks and damage, and inspect fluctuation after spraying rust penetrating agent, then select air suction area. Can air suction confirmed? Inspect for air suction in vacuum hose, which has negative pressure on intake manifold, in the same manner as previous step. Can air suction be confirmed? Inspect fuel line pressure under trouble condition. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection. Is fuel line pressure okay? Inspect fuel pump maximum pressure. FUEL SYSTEM, FUEL PUMP UNIT INSPECTION, Fuel Pump Maximum Pressure Inspection. Is it okay? Inspect for clogging in fuel filter (high-pressure). Is there foreign material in fuel on fuel pump side of filter? Inspect inside of fuel tank for foreign material and stains. Is inside of fuel tank okay? Yes ACTION Replace faulty fuel injectors, then go to Step 26. FUEL SYSTEM, FUEL INJECTOR REMOVAL/INSTALLATION. Go to next step. Go to next step. By following system inspection, repair or replace faulty parts, then go to Step 26. Go to next step. Replace PCV valve, then go to Step 26, Inspect for leakage and injection amount. FUEL SYSTEM, FUEL INJECTOR INSPECTION. Replace faulty fuel injector, then go to Step 26. Go to next step. Go to next step. Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION, Repair or replace source of air suction, then go to Step 26.
No Yes No Yes No Yes
10
11
12
No Yes No
13
14
Yes
No
Go to next step.
15
Repair or replace source of air suction, then go to Step 26. Go to next step, Go to Step 22. Go to next step. Go to next step. Replace fuel pump body, then go to Step 26. FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/ INSTALLATION. Go to next step. Go to Step 20. Replace fuel filter (high-pressure), then go to Step 26. FUEL SYSTEM, FUEL FILTER (HIGHPRESSURE) REMOVAL/INSTALLATION. Clean inside of fuel tank and fuel filter (low-pressure). Replace fuel filter, then go to Step 26. Go to next step. Repair or replace source of fuel leakage or clogging, then go to Step 26.
16
17
18
Yes No Yes
19
No 20 Inspect for leakage and clogging in fuel line from distributor to fuel pump. Is it okay? Yes No
CONTINUED F1-66
TO. MODEL .INDEX

STEP 21 INSPECTION Inspect for leakage in fuel line from fuel filter (highpressure) to fuel tank (return side). Is it okay? Yes ACTION Replace pressure regulator, then go to Step 26. FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION. Repair or replace source of fuel leakage, then go to Step 26 Go to Step 24 Go to next step. Go to next step. Replace ignition coil, then go to Step 26. Air gets in from poor sealing on head gasket or other areas between combustion chamber and engine coolant passage. Repair or replace faulty parts, then go to Step 26.
No 22 Verify blinking condition on each cylinder by setting timing light on high-tension lead under trouble condition. Does it blink regularly and stably? Inspect resistance of ignition coil. Section G, IGNITION COIL INSPECTION. Is it okay? Warning Removing the radiator cap when the radiator is hot is dangerous. Scalding coolant and steam may shoot out and cause serious injury. When removing the radiator cap, wrap a thick cloth around and turn it slowly. Remove radiator cap. Implement procedure to bleed air from engine coolant, then run engine at idle. Are there any small bubbles, which make engine coolant white at filling opening? Note Large bubbles are normal since they are remaining air coming out from engine coolant passage. 25 Inspect engine compression. Section B1, COMPRESSION INSPECTION. Is it okay? Clear DTC. Verify DTC after running vehicle. Is there any DTC stored? Yes No Yes No Yes No Yes No Yes
23
24
No
Go to next step.
Go to next step. Implement engine overhaul, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
26
DTC P1195 DETECTION CONDITION POSSIBLE CAUSE STEP _
Barometric pressure (BARO) sensor (in PCM) Input voltage from barometric pressure sensor is below 1.5 V or above 4.5 V when ignition switch is turned on. Barometric pressure sensor (in PCM) malfunction. INSPECTION _ _ ACTION Replace PCM CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
CONTINUED
F1-67
TO. MODEL .INDEX

DTC P1250 DETECTION CONDITION PRESSURE REGULATOR CONTROL (PRC) solenoid valve circuit malfunction Open or short circuit is observed in PRC solenoid valve when Ignition switch is turned on PRC solenoid valve malfunction Poor connection of connectors at PRC solenoid valve and/or PCM Short to power supply circuit in wiring from PRC solenoid valve B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal B to PCM terminal 2T Short to GND in wiring from PRC solenoid valve terminal A to main relay terminal D Open circuit in wiring from PCM terminal 2T and/or 2C to engine GND Open circuit in wiring from PRC solenoid valve terminal B to PCM terminal 2T Open circuit in wiring from PRC solenoid valve terminal A to man relay terminal D INSPECTION Verify stored DTC. Have DTCs P0100, P0335, P0443 and/or P0505 been stored? Yes ACTION Inspect for open circuit in following wiring harnesses, then go to Step 9. Main relay terminal D-IAC valve, PRC solenoid valve, MAF sensor, CMP sensor, purge solenoid valve Between PCM terminal 2C and engine ground. Go to next step. Repair or replace connector, then go to Step 9. Go to next step. Go to next step. Inspect for open or short circuit in wiring harness. (between main relay terminal D and PRC solenoid valve terminal A), then go to Step 9. Go to next step. Repair open circuit, then go to Step 9. Repair short to power supply circuit, then go to Step 9. Go to next step. Repair short to GND circuit, then go to Step 9. Go to next step. Go to next step. Replace PRC solenoid valve, then go to Step 9. Go to Step 1. Intermittent poor connection in wiring harnesses or connectors. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
POSSIBLE CAUSE
STEP 1
No 2 3 Does PRC solenoid valve connector or PCM connector have poor connection? Disconnect PRC solenoid valve connector. Turn ignition switch on. Is there battery positive voltage at harness side connector terminal A? Disconnect PCM connector. PRC solenoid valve is disconnected. Is there continuity between PRC solenoid valve harness side connector terminal B and PCM harness side connector terminal 2T? Is there continuity between PCM harness side connector terminals 2T and 1B? Is there continuity from PCM harness side connector terminal 2T to body GND? Is PRC solenoid valve okay? FUEL SYSTEM, PRESSURE REGULATOR CONTROL (PRC) SOLENOID VALVE INSPECTION Clear DTC from memory. Is same DTC present after performing "AFTER REPAIR PROCEDURE"? Yes No Yes No
Yes No Yes No
6 7
Yes No
CONTINUED
F1-68
TO. MODEL .INDEX

DTCP1608 DETECTION CONDITION POSSIBLE CAUSE PCM internal circuit malfunction PCM does not read DTC from output devices. PCM does not read DTC from output devices. Short to power supply circuit in wiring from output devices (purge solenoid valve, PRC solenoid valve, IAC solenoid valve and/or fuel injectors) to PCM Yes ACTION Repair short to power supply circuit. Replace PCM. CONTROL SYSTEM, PCM REMOVAL/INSTALLATION Replace PCM CONTROL SYSTEM, PCM REMOVAL/INSTALLATION
STEP INSPECTION 1 Disconnect output devices and PCM connector. Is there continuity between the following connectors? PCM harness side connector terminal 2X-1B PCM harness side connector terminal 2E-1B PCM harness side connector terminal 2W-1B PCM harness side connector terminal 2U-1B PCM harness side connector terminal 2V-1B
No
CONTINUED
F1-69
TO. MODEL .INDEX
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD Before proceeding with the following troubleshooting. (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If the diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE Confirm trouble symptom using the following diagnostic index, then go to appropriate troubleshooting chart.
No. 1 2 3 4 5 6 7 8 9 TROUBLESHOOTING ITEM Melting of main or other fuses Will not crank Hard to start/long crank/erratic start/erratic crank Engine stalls After start/at idle Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Lack/loss of power Knocking/pinging Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Starter does not work. Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Engine stops unexpectedly at idle and/or after start. Starter cranks engine at normal speed but engine will not run. Engine takes more time than normal to return to idle speed. Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off. Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. Performance is poor under load (e.g. power down when climbing hills). Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber). Fuel economy is unsatisfactory. Emission compliance test is failed. Oil consumption is excessive. Engine runs at higher than normal temperature/overheats. Engine takes excessive period for reaching normal operating temperature. Blue, black, or white smoke from exhaust system Gasoline fuel smell or visible leakage Engine noise from under hood Vibration from under hood or driveline A/C compressor magnetic clutch does not engage when A/C is turned on. A/C compressor magnetic clutch does not disengage. A/C compressor magnetic clutch does not disengage under WOT. Rotten egg smell (sulphur) from exhaust. Symptom occurs randomly and is difficult to diagnose. Incorrect constant voltage. DESCRIPTION
10
11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Poor fuel economy Emissions compliance High oil consumption/leakage Cooling system concerns Cooling system concerns Exhaust smoke Fuel odor (in engine compartment) Engine noise Vibration concerns (engine) A/C does not work sufficiently A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions Exhaust sulphur smell Intermittent concerns Constant voltage Overheating Runs cold
CONTINUED F1-70
TO. MODEL .INDEX
TROUBLESHOOTING
QUICK DIAGNOSTIC CHART
Possible factor Starter motor malfunction (Mechanical or electrical) Engine or transmission mounts improperly installed x
Cooling system malfunction (Radiator, hoses, overflow system, thermostat, etc.)
Starter circuit including ignition switch open
Improper tension or damaged drive belts
Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise
x X X x x x x
x x x
x x x x x x x x x x
x x x x x x x x x x x x x x x x x X x x x x x x x x
Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns Overheating 17 Cooling system concerns Runs cold 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently. 23 A/C is always on/A/C compressor runs continuously x
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage x
F1-71
CONTINUED
Water and anti-freeze mixed improperly
Charging system malfunction
Improper engine compression
Improper engine coolant level
Improper engine oil viscosity
Improper engine oil level
Improper valve timing
Low or dead battery
Hydrolocked engine
Improper dipstick
Base engine malfunction
Flywheel seized
TO. MODEL .INDEX
TROUBLESHOOTING
Possible factor Vacuum leakage (Vacuum hose damaged, mis-routing) Air leakage from intake-air system (Tubes looseness, crack, gaskets broken)
Initial ignition timing misadjustment (CMP & crankshaft pulley misadjustment
Ignition coil malfunction (e.g. open short or cracks)
High-tension leads malfunction (Cracks , open, low resistance) x x x x x x x x
Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic star/erratic crank 4 Engine stalls After start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise
x x x x x x x x
x x
x x x x x x x x x x x x x x x x x
x x x x x x x x x
x x x x
x x x x x x x x
x x x x x x x x
x x x x x x x x x
x x x x x x x
x x x x x x
x x x x x x x x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns 17 Cooling system concerns 18 Exhaust smoke 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently. A/C is always on/A/C compressor runs 23 continuously 24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage x x Overheating Runs cold
x x x
19 Fuel odor (in engine compartment)
F1-72
CONTINUED
CMP sensor damaged (e.g. open or short circuits) x x x x x x x x x x x x
Accelerator cable free play misadjustment
Air cleaner element clogged or restriction
Cooling fan seated improperly
IAC valve improper operation
Throttle body malfunction
Spark plug malfunction
Engine overheating
Fuel quality
TO. MODEL .INDEX
TROUBLESHOOTING
Fuel pump body malfunction (Mechanical or electrical Possible factor Fuel leakage from fuel system (Including insulator, injector O-ring) Evaporative emission control system malfunction Main relay malfunction (Mechanical or electrical)
Injectors malfunction (Leakage or clogging, inoperative)
PRC solenoid valve improper operation
V-reference supply circuit malfunction
Improper air/fuel mixture ratio control
Exhaust system restricted or clogged
Fuel hoses restricted or clogged
Fuel filters restricted or clogged
Catalytic converter malfunction
Pressure regulator malfunction
ECT sensor malfunction
PCV valve malfunction
Troubleshooting item Melting of main or other fuses Will not crank 1 2
x x x x
x x x x
x x x x
x x x x x x x
x x x x x
x x x x
x x x x x
x x x x x
x x x x
Hard to start/long crank/erratic start/erratic crank 3 After start/at idle Engine stalls 4 Cranks normally but will not start Slow return to idle Engine runs rough/rolling idle Fast idle/runs on Low idle/stalls during deceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise Acceleration/cruise Poor fuel economy Emissions compliance High oil consumption/leakage Overheating Runs cold Cooling system concerns Cooling system concerns Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Lack/loss of power Knocking/pinging 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 10 5 6 7 8 9
x x x x x x x x x x
x x x x x x x x x x
x x x x x x x x x
x x x x x x x
x x x x x x
x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x x
x x x x x x
x x x x x x
x x
x x
x x x x
x x
x x
x x
x x
Exhaust smoke Fuel odor (in engine compartment) Engine noise Vibration concerns (engine) A/C does not work sufficiently. A/C is always on/A/C compressor runs continuously A/C is not cut off under WOT conditions
x x
Exhaust sulphur smell Intermittent concerns Constant voltage
CONTINUED F1-73
TO. MODEL .INDEX
TROUBLESHOOTING
Neutral or clutch switch and related circuit malfunction Possible factor
TP sensor misadjustment (Including looseness)
Variable resistor and related circuit malfunction (Except Europe)
A/C relay (A/C control signal) circuit malfunction
Brake switch and related circuit malfunction
MAF sensor and related circuit malfunction
PSP switch and related circuit malfunction
TP sensor and related circuit malfunction
Improper refrigerant charging amount
VSS and related circuit malfunction
Wheels and tires improper balance
Improper ATF level
Troubleshooting item 1 Melting of main or other fuses 2 Will not crank 3 Hard to start/long crank/erratic start/erratic crank 4 Engine stalls after start/at idle 5 Cranks normally but will not start 6 Slow return to idle 7 Engine runs rough/rolling idle 8 Fast idle/runs on 9 Low idle/stalls during deceleration Engine stalls/quits Engine runs rough Misses 10 Buck/jerk Hesitation/stumble Surges 11 Lack/loss of power 12 Knocking/pinging 13 Poor fuel economy acceleration/cruise acceleration/cruise acceleration/cruise acceleration/cruise/ deceleration acceleration acceleration/cruise acceleration/cruise acceleration/cruise
x x x
x x x x x x x x x x x x x x x x x x x x x x x x x
x x
x x x x x x x
x x x x x x x
x x x x x x x
x x x x x x x x x x
14 Emissions compliance 15 High oil consumption/leakage 16 Cooling system concerns 17 Cooling system concerns 18 Exhaust smoke 19 Fuel odor (in engine compartment) 20 Engine noise 21 Vibration concerns (engine) 22 A/C does not work sufficiently. 23 A/C is always on/A/C compressor runs continuously x x x x x x x x x x x x x x x x x overheating runs cold x x
24 A/C is not cut off under WOT conditions 25 Exhaust sulphur smell 26 Intermittent concerns 27 Constant voltage
CONTINUED F1-74
Suspension malfunction
Drive line malfunction
Clutch slippage
Brake dragging
Loose parts
TO. MODEL .INDEX
SYMPTOM TROUBLESHOOTING:
Symptom 1-Melting of main or other fuses Symptom 2-Will not crank Symptom 3-Hard to start/long crank/erratic crank Symptom 4-Engine stalls-after start/at idle Symptom 5-Cranks normally but will not start Symptom 6-Slow return to idle Symptom 7-Engine runs rough/rolling idle Symptom 8-Fast idle/runs on Symptom 9-Low idle/stalls during deceleration Symptom 10-Engie stalls/quits-acceleration/cruise - Engine runs rough acceleration/cruise - Misses-acceleration/cruise - Buck/jerk acceleration/cruise/deceleration - Hesitation/stumble acceleration - Surges acceleration/cruise Symptom 11-Lack/loss of power-acceleration/cruise Symptom 12-Knocking/pinging-acceleration/cruise Symptom 13-Poor fuel economy Symptom 14-Emission compliance Symptom 15-High oil consumption/leakage Symptom 16-Cooling system concerns-overheating Symptom 17-Cooling system concerns-runs cold Symptom 18-Exhaust smoke Symptom 19-Fuel odor (in engine compartment) Symptom 20-Engine noise Symptom 21-Vibration concerns (engine) Symptom 22-A/C does not work sufficiently Symptom 23-A/C is always on (a/c compressor runs continuously Symptom 24-A/C does not cut off under wide open throttle (wot) conditions Symptom 25-Exhaust sulphur smell Symptom 26-Intermittent concerns Symptom 27-Constant voltage FI-91-93 FI-94-96 FI-97 FI-98-99 FI-100-101 FI-101 FI-102-103 FI-103 FI-104-105 FI-106 FI-107 FI-107 FI-108 FI-109 FI-110 FI-111 FI-112 FI-113-114 FI-75 FI-76 FI-77-78 FI-79-81 FI-82-84 FI-85 FI-86-88 FI-89 FI-90
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING SYMPTOM 1 MELTING OF MAIN OR OTHER FUSES
Damaged Fuse MAIN (80 A)
HEAD (30 A) A/C (10A) WIPER (15 A)
STOP (15 A) FUEL INJ (30 A)
ROOM (10 A) ENGINE (15 A)
Related Wiring Harness MAIN fuse Generator Ignition switch Starter Ignition coil Condenser HEAD fuse Generator A/C relay Generator WIPER fuse A/C relay A/C switch STOP fuse Brake switch Main relay Fuel injector PCM PRC solenoid valve Purge solenoid valve IAC valve MAF sensor CMP sensor ROOM fuse PCM ENGINE fuse Main relay Fuel pump relay Fuel pump relay Fuel pump METER fuse PCM
METER (15 A)
CONTINUED
F1-75
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 2 WILL NOT CRANK DESCRIPTION Starter does not work. Open circuit between ignition switch and starter POSSIBLE Starter malfunction CAUSE Seized/hydrolocked engine or flywheel STEP INSPECTION RESULTS ACTION 1 Inspect for following: Yes Go to next step. Battery connection No Service as necessary. Battery condition Repeat Step 1. Fuses Are all items okay? 2 3 Is clicking sound heard from starter when ignition switch is turned to START? Inspect starting system. Section G, STARTING SYSTEM, STARTER INSPECTION Is starting system okay? Do any other electrical accessories work? Yes No Yes Go to next step. Go to Step 4. Inspect for seized/hydrolocked engine or flywheel. Section H, FLYWHEEL, FLYWHEEL INSPECTION Repair or replace components as required. Go to next step. Inspect charging system. Section G, CHARGING SYSTEM, GENERATOR INSPECTION No DTC is displayed: Inspect following: START circuit in ignition switch Open circuit between ignition switch and starter DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: Open circuit between main relay and PCM terminal 1B Open main relay GND circuit Main relay is stuck open. Open or poor GND circuit at PCM Poor connection of vehicle body GND
No Yes No
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Yes
No
Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-76
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 3 DESCRIPTION HARD TO START/LONG CRANK/ERRATIC START/ERRATIC CRANK Starter cranks engine at normal speed but engine requires excessive cranking time before starting. Battery in normal condition. Spark leakage from high-tension leads Vacuum leakage Poor fuel quality Starting system malfunction Spark plug malfunction Air leakage from intake-air system Erratic signal from CMP sensor Air cleaner restriction PCV valve malfunction Inadequate fuel pressure Purge solenoid valve malfunction MAF sensor contamination Restriction in exhaust system Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Inspect for following: Vacuum leakage Fuel quality (e.g. proper octane, contamination, winter/summer blend) Loose bands on intake-air system Cracks on intake-air system parts Air cleaner restriction Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes Go to next step. ACTION
No
Service as necessary.
Yes No Yes No
No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to symptom troubleshooting No.16 for "Cooling system concerns - Overheating". Go to next step. Repair suspected high-tension leads. Go to next step. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Replace malfunctioning parts. Go to next step. Replace PCV valve.
4 5
Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white?
Yes No Yes
No 6 7 Visually inspect CMP sensor. Is CMP sensor okay? Remove PCV valve and inspect PCV valve. Does PCV valve rattle? Yes No Yes No
F1-77
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION 8 Install fuel pressure gauge between fuel filter Yes Go to next step. and fuel distributor. No Zero or low: Connect a jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. TROUBLESHOOTING, ENGINE SYSTEM Inspect for fuel leakage inside pressure regulator. INSPECTION, Fuel Line Pressure Inspect for clogged main fuel line. Inspection Inspect PRC solenoid valve and related vacuum hose Turn ignition switch on. and harnesses. Is fuel line pressure correct? High: Fuel line pressure 270310 kPa {2.73.2 kgf/cm 2, 3945 psi} Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. 9 Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min. Disconnect vacuum hose from pressure regulator and plug hose. Start engine. Does fuel line pressure remain within 20 kPa 2 {0.21 kgf/cm , 3 psi} while driving vehicle? Connect vacuum hose to pressure regulator. Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or fuel pressure gauge reading decrease as vacuum gauge reading increases? Disconnect a vacuum hose from purge solenoid valve and plug opening end of vacuum hose. Start engine. Is starting condition improved? Inspect for contaminated MAP sensor. Is there any contamination? Is there restriction in exhaust system? Yes No Go to next step. Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator. Go to next step.
10
Yes
No
Inspect for clogged fuel filter.
11
Yes No
Go to next step. Connect vacuum hose to pressure regulator. Start engine. Verify fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator. Inspect if purge solenoid valve sticks to open. Go to next step. Replace MAP sensor. Go to next step. Inspect exhaust system. Go to next step.
12
13 14 15
16
Inspect starting system. Yes Inspect for loose connectors or poor terminal contact. Section G, STARTING SYSTEM, STARTER INSPECTION No Repair or replace components as required. Is starting system normal? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-78
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 4 DESCRIPTION ENGINE STALLS - AFTER START / AT IDLE Engine stops unexpectedly at idle and/or after start. A/C system operation is improper. Air leakage from intake-air system parts Purge solenoid valve malfunction Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or wrong installation Vacuum leakage Low engine compression Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Electrical connector disconnection Open or short circuit in fuel pump body and related harness No battery power supply to PCM or poor GND Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION Verify following: 1 Vacuum connection Air cleaner element No air leakage from intake-air system No restriction of intake-air system Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) Ignition wiring Fuel quality (e.g. proper octane, contamination, winter/summer blend) Electrical connections Smooth operation of throttle valve Are all items okay? 2 Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.55.5 V Is voltage okay? RESULTS Yes Go to next step. ACTION
No
Service as necessary. Repeat Step 11.
Yes
Go to next step.
No
Go to symptom troubleshooting No.27 "Constant voltage".
CONTINUED F1-79
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 3 INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or SYSTEM PASSED" displayed? RESULTS Yes No No DTC is displayed: Go to next step. DTC Is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: Open circuit between main relay and PCM terminal 1B Open main relay GND circuit Main relay stuck open Open PCM GND circuit (terminal 2A, 2B or 2C) Poor connection of vehicle body GND Inspect IAC valve and wiring harness. Go to next step. Go to next step. Inspect for following: Open or short circuit In CMP sensor Open or short circuit between CMP sensor and PCM terminal 2E Open or short circuit in CMP sensor harnesses If CMP sensor and harness okay, go to next step. Go to next step. Replace malfunctioning parts. Repair suspected high-tension lead. Go to next step. Go to next step. If symptom occurs with A/C on, go to Step 14. Inspect for following: Open or short circuit in ignition coil Open circuit in high-tension leads Open circuit between igniter connector GND terminal and body GND Open circuit between ignition switch and ignition coil Open circuit between ignition coil and condenser Open circuit between condenser and igniter Open circuit between ignition coil and igniter Open circuit between igniter and PCM terminal 2F Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Replace PCV valve. Inspect exhaust system. Go to next step. ACTION
4 5
Attempt to start engine at part throttle. Does engine run smoothly at part throttle? Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed during cranking of engine?
Yes No Yes No
6 7 8
Visually inspect CMP sensor. Is CMP sensor okay? Inspect for cracks on high-tension leads Are there any cracks on high-tension leads? Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes
No 10 11 Remove and shake PCV valve. Does PCV valve rattle? Is there any restriction in the exhaust system? Yes No Yes No
CONTINUED
F1-80
TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION 12 Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270310kPa {2.73.2 kgf/cm 2, 3945 psi} RESULTS Yes Go to next step. No ACTION
Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. Inspect PRC solenoid valve, related vacuum hose and related harnesses. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step.
13
14
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2,21 psi} for 5 min. Note The following test is for stall concerns with A/C on. If other symptoms exist, go to next step. Connect pressure gauges to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Is pressure within specifications? Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid side. Plug opening end of vacuum hose. Start engine. Is engine stall now eliminated? Is air leakage felt or heard at intake-air system components while racing engine to higher speed? Is engine compression correct?
Yes
No
Inspect pressure regulator diaphragm condition. If condition is okay, inspect fuel injector. If condition is not okay, replace pressure regulator.
Yes
Go to next step.
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". For other symptoms, inspect following: Refrigerant charging amount
15
Yes
Inspect if purge solenoid valve sticks to open. Inspect evaporative emission control system. Go to next step. Repair or replace. Go to next step. Inspect valve timing. Inspect for cause.
No Yes No Yes No
16
17 18
CONTINUED
F1-81
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 5 CRANKS NORMALLY BUT WILL NOT START Starter cranks engine at normal speed but engine will not run. Refer to "Engine stalls" if this symptom appears after engine stall. Fuel in tank. Battery in normal condition. No battery power supply to PCM Air leakage from intake-air system Open PCM GND or vehicle body GND Improper operation of IAC valve No signal from CMP sensor due to sensor related wire or incorrect installation Low engine compression Vacuum leakage Spark leakage from high-tension leads Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connector Open or short circuit in fuel pump body and related harness Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from injector Fuel injector is clogged. Purge solenoid valve malfunction Pressure regulator control (PRO) system malfunction
DESCRIPTION
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: STEP 1 Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Verify following: Vacuum connection External fuel shut off or accessory (kill switch, alarm etc.) Fuel quality (e.g. proper octane, contamination, winter/summer blend) No air leakage from intake-air system Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) Ignition wiring Electrical connections Fuses Smooth operation of throttle valve Are all items okay? RESULTS Yes Go to next step. ACTION
No
CONTINUED
F1-82
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 2 INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? RESULTS Yes No No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Communication error message is displayed: Inspect for following: Open circuit between main relay and PCM terminal 1B Open main relay GND circuit Main relay stuck open Open PCM GND circuit (PCM terminal 2A, 2B or 2C) Poor connection of vehicle body GND Go to next step. ACTION
Turn ignition switch on. Disconnect TP sensor connector. Measure voltage at TP sensor connector VREF terminal with ignition switch on. Voltage 4.55.5 V Is voltage okay? Does engine start with throttle closed? Will engine start and run smoothly at part throttle? Connect NGS tester to DLC. Access RPM PID. Is RPM PID indicating engine speed when cranking engine?
Yes
No
Go to symptom troubleshooting No.27 "Constant voltage",
4 5 6
Go to Step 18. Go to next step. Inspect IAC valve and wiring harness. Go to next step. Go to next step. Inspect for following: Open or short circuit in CMP sensor Open or short circuit between CMP sensor and PCM terminal 2E Open or short circuit in CMP sensor harnesses If CMP sensor and harness are okay, go to next step. Go to next step. Replace malfunctioning parts. Repair suspected high-tension leads. Go to next step. Go to next step. Inspect for following: Open or short circuit in ignition coil Open circuit in high-tension leads Open circuit between igniter connector GND terminal and body GND Open circuit between ignition switch and ignition coil Open circuit between ignition coil and condenser Open circuit between condenser and igniter Open circuit between ignition coil and igniter Open circuit between igniter and PCM terminal 2F If spark plug is wet or covered with carbon, inspect for fuel leakage from injector. If spark plug is grayish white, inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Replace PCV valve. Inspect exhaust system. Go to next step.
7 8 9
Visually inspect CMP sensor. Is CMP sensor okay? Inspect for cracks on high-tension leads. Is there any cracks on high-tension leads? Is strong blue spark visible at each disconnected high-tension lead while cranking engine?
10
Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white?
Yes
No 11 12 Remove and shake PCV valve. Does PCV valve rattle? Is there any restriction in exhaust system? Yes No Yes No
F1-83
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TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION 13 Install fuel pressure gauge between fuel main Yes Go to next step. pipe and fuel distributor. No Zero or low: Connect jumper wire between F/P terminal at Inspect fuel pump circuit. DLC in engine compartment and GND. Inspect for open fuel pump relief valve. Turn ignition switch on. Inspect for fuel leakage inside pressure regulator. Is fuel line pressure correct when ignition switch Inspect for clogged main fuel line. is cycled on/off five times? Inspect PRC solenoid, related vacuum hose, and harFuel line pressure nesses. High: 2703-10 kPa Inspect pressure regulator for high pressure cause. {2.73.2 kgf/cm 2, 3945 psi} Inspect for clogged fuel return line. 14 Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Is fuel line pressure held after ignition switch is turned off? Fuel line pressure More than 150 kPa {1.5 kgf/cm 2, 21 psi} for 5 min. Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Is starting condition improved? Is air leakage felt or heard at intake-air system components while racing engine to higher speed? Is engine compression correct? Yes Go to next step.
No
15
Yes
Inspect if purge solenoid valve sticks to open mechanically. Inspect evaporative emission control system.
No Yes No Yes No
Go to next step. Repair or replace. Go to next step. Inspect valve timing. Inspect for causes.
16
17 18
CONTINUED
F1-84
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 6 DESCRIPTION POSSIBLE CAUSE STEP 1 SLOW RETURN TO IDLE Engine takes more time than normal to return to idle speed. ECT sensor malfunction Thermostat is stuck open. Throttle body malfunction Air leakage from intake-air system INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Remove thermostat and inspect operation. Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay? RESULTS Yes No Yes No No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Engine coolant temperature and thermostat are okay. Go to next step. Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT V PID is normal, inspect temperature gauge and heat gauge unit. Inspect for air leakage from intake-air system components while racing engine to higher speed. Clean or replace throttle body. ACTION
Is throttle body free of contamination?
Yes No
CONTINUED
F1-85
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 7 DESCRIPTION ENGINE RUNS ROUGH/ROLLING IDLE Engine speed fluctuates between specified idle speed and lower speed and engine shakes excessively. Idle speed is too slow and engine shakes excessively. Air leakage from intake-air system parts A/C system operation is improper. Spark leakage from high-tension leads Purge solenoid valve malfunction (if equipped) Improper operation of IAC valve Low engine compression Erratic signal from CMP sensor Poor fuel quality PCV valve malfunction Air cleaner restriction Restriction in exhaust system Disconnected electrical connectors Inadequate fuel pressure Fuel pump body mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Engine overheating Vacuum leakage Pressure regulator control (PRC) system malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify following: External fuel shut off or accessory Fuel quality (e.g. proper octane, contamination, winter/summer blend) No air leakage from intake-air system Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) Ignition wiring Electrical connections Fuses Smooth operation of throttle valve. Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" display? Is engine overheating? RESULTS Yes Go to next step. ACTION
No
Yes
No DTC is displayed: Go to next step.
No Yes No
DTC is displayed: Go to appropriate DTC test. Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". Go to next step.
F1-86
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TROUBLESHOOTING
STEP 4 INSPECTION Note Following test is for engine running rough idle with A/C on concerns. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high pressure side lines. Start engine and run it at idle. Turn A/C switch on. Measure low side and high side pressures. Section U, REFRIGERANT SYSTEM SERVICE PROCEDURE, REFRIGERANT PRESSURE CHECK Are reading pressures within specification? Note Following test is for engine running rough with P/S on. If other symptoms exist, go to next step. Start engine and run it at idle. Access PSP SW PID. Inspect if PSP SW PID is on while turning steering wheel right to left. Is PSP SW PID okay? Visually inspect CMP sensor. Is CMP sensor okay? Inspect for cracks on high-tension leads. Are there any cracks on high-tension leads? Inspect spark plug conditions. Is spark plug wet, covered with carbon, or grayish white? RESULTS Yes Go to next step. ACTION
No
Yes
Inspect power steering pressure switch operation and wiring harness between power steering pressure switch connector and PCM connector terminal 1P.
No
Go to next step.
6 7 8
Yes No Yes No Yes
Go to next step. Replace malfunctioning parts. Repair suspected high-tension leads. Go to next step. Spark plug is wet or covered with carbon: Inspect for fuel leakage from injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Inspect IAC valve and wiring harness. Go to next step. Zero or low Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line Inspect PRC solenoid valve, related vacuum hose and harnesses High Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line Go to next step.
No 9 Start engine and disconnect IAC valve connector. Does rpm drop or engine stall? Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250 kPa {2.12.6 kgf/cm 2, 3036 psi} Yes No Yes No
10
11
Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm ,21 psi} for 5 min.
Yes
No
CONTINUED
F1-87
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 12 INSPECTION Connect NGS tester to DLC, Start the engine and run it at idle. Access FHO2S PID. Is FHO2S PID okay? More than 0.45 V when accelerator pedal is suddenly depressed: rich condition Less than 0.45 V during fuel cut: lean condition Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Start engine. Does engine condition improve? Remove and shake PCV valve. Does PCV valve rattle? Is there restriction in exhaust system? Is engine compression correct? RESULTS Yes Go to next step. ACTION
No
Inspect and repair or replace faulty O2S, harness, connector or terminal, then go to next step.
13
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No Yes No Yes No Yes No
Go to next step. Go to next step. Replace PCV valve. Inspect exhaust system. Go to next step. Inspect valve timing. Inspect for causes.
14 15 16 17
CONTINUED
F1-88
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 8 DESCRIPTION POSSIBLE CAUSE FAST IDLE/RUNS ON Engine speed continues at fast idle after warm-up. Engine runs after ignition switch is turned off.
ECT malfunction Air leakage from intake-air system Throttle body malfunction STEP INSPECTION RESULTS 1 Connect NGS tester to DLC. Yes Access ECT PID. No Start and warm up engine to normal operating temperature. Is ECT PID reading between 112C {234F} and 82C {180F}?
ACTION Go to next step. ECT PID is higher than 112C {234F}: Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". ECT PID is less than 82C {180F}: Go to symptom troubleshooting No.17 "Cooling system concerns - Runs cold". No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Repair or replace parts as necessary. Verify accelerator cable free play.
Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is there air leakage felt or heard at intake-air system components while racing engine to higher speed?
Yes No Yes No
CONTINUED
F1-89
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 9 DESCRIPTION LOW IDLE/STALLS DURING DECELERATION Engine stops unexpectedly at beginning of deceleration or recovery from deceleration. Vacuum leakage IAC valve malfunction Air leakage from intake-air system MAF sensor or related circuit malfunction TP sensor or related circuit malfunction Brake switch or related circuit malfunction Neutral/clutch switch or related circuit malfunction INSPECTION Does engine idle roughly? RESULTS Yes No 2 Verify following: Proper routing and no damage of vacuum lines IAC valve is connected properly. No air leakage from intake-air system Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Does idle speed drop or stall when disconnecting IAC valve? Yes No ACTION Go to symptom troubleshooting No.7 for "Engine runs rough/Rolling idle". Go to next step. Go to next step. Service as necessary. Repeat Step 2. No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to next step. Inspect following: Circuit from IAC valve to PCM connector terminal 2W for open and short IAC valve for sticking If okay, go to next step. Inspect evaporative emission control system.
POSSIBLE CAUSE
STEP 1
Yes No Yes No
Disconnect vacuum hose between purge Yes solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. No Drive vehicle. Does engine condition improve? Connect NGS tester to DLC. Yes Access TP V, MAP V, VS, BRK SW and NL SW PIDs. Monitor each PID while driving vehicle. No TP V PID MAF V PID VS PID BRK SW PID NL SW PID Are PIDs okay? CONTROL SYSTEM, PCM INSPECTION
Go to next step. Go to symptom troubleshooting No.26 for "Intermittent concerns".
TP V PID: Inspect TP sensor. MAF V PID: Inspect MAF sensor. VS PID: Inspect VSS. BRK SW PID: Inspect brake switch. NL SW PID: Inspect neutral switch and clutch switch.
CONTINUED
F1-90
TO. MODEL .INDEX
TROUBLESHOOTING
ENGINE STALLS/QUITS - ACCELERATION/CRUISE ENGINE RUNS ROUGH - ACCELERATION/CRUISE MISSES - ACCELERATION/CRUISE BUCK/JERK - ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE - ACCELERATION SURGES - ACCELERATION/CRUISE Engine stops unexpectedly at beginning of acceleration or during acceleration. Engine stops unexpectedly while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. A/C system operation is improper. Air leakage from intake-air system parts Purge solenoid valve malfunction Improper operation of IAC valve Erratic signal from CMP sensor Low engine compression Vacuum leakage Poor fuel quality Spark leakage from high-tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out of timing belt Restriction in exhaust system Intermittent open or short in fuel pump circuit Inadequate fuel pressure Fuel pump mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Intermittent open or short of MAF sensor, TP sensor and VSS Clutch slippage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual.
SYMPTOM 10
DESCRIPTION
POSSIBLE CAUSE
FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS Verify following: Go to next step. 1 Yes Vacuum connection Air cleaner element No air leakage from intake-air system No restriction of intake-air system Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) No Service as necessary. Ignition wiring Repeat Step 1. Fuel quality (e.g. proper octane, contamination, winter/summer blend) Electrical connections Smooth operation of throttle valve Are all items okay?
ACTION
F1-91
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TROUBLESHOOTING
STEP 2 INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes No No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to symptom troubleshooting No.16 "Cooling system concerns - Overheating". Go to next step. Go to next step. RPM PID: Inspect CMP sensor and related harness for vibration, intermittent open/short circuit. B+ PID: Inspect for open circuit intermittently. MAF V PID: Inspect for open circuit of MAF sensor and related wire harness intermittently. TP V PID: Inspect if output signal from TP sensor changes smoothly. VS PID: Inspect for open circuit of VSS and related wire harness intermittently. Go to next step. Replace malfunctioning parts. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Replace PCV valve. Go to next step. Adjust as necessary. Inspect exhaust system. Go to next step. Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step. ACTION
Yes No
Connect NGS tester to DLC. Access RPM PID, B+ PID, TP V PID, MAF V PID, and VS PID. RPM PID B+PID TP V PID MAF V PID VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION
Yes No
5 6
Visually inspect CMP sensor. Is CMP sensor okay? Inspect spark plug condition. Is spark plug wet, covered with carbon, or grayish white?
Yes No Yes
No 7 8 Remove and shake PCV valve. Does PCV valve rattle? Verify that throttle lever is resting on throttle valve stop screw and/or throttle valve orifice plug. Is lever in correct position? Are there restrictions in the exhaust system? Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270310kPa {2.73.2 kgf/cm 2, 3945 psi} Visually inspect for fuel leakage at fuel injector, O-ring, and fuel line. Service as necessary. Does fuel line pressure hold after ignition switch is turned off? Fuel line pressure 2 More than 150 kPa {1.5 kgf/cm , 21 psi} for 5 min. Yes No Yes No Yes No 10 Yes No
11
Yes
No
CONTINUED F1-92
TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION RESULTS ACTION 12 Install vacuum gauge to intake manifold. Yes Go to next step. Start engine. No Connect vacuum hose to pressure regulator. Does fuel pressure gauge reading increase as Start engine. vacuum gauge reading decreases and/or does Verify that fuel pressure gauge reading changes as vacuum fuel pressure gauge reading decrease as changes. vacuum reading increases? If it changes, inspect vacuum line. If it does not change, replace pressure regulator. 13 Note The following test is for engine stalling with A/C on. If other symptoms exist, go to next step. Connect a pressure gauge to A/C low and high pressure side lines. Turn A/C on and measure low side and high side pressure. Is pressure within specifications? Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct? Yes Go to next step.
No
14
Yes
Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system.
No Yes
Go to next step. Inspect following: Valve timing Clutch Inspect for cause.
15
No 16
CONTINUED
F1-93
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 11 DESCRIPTION LACK/LOSS OF POWER - ACCELERATION/CRUISE
Performance is poor under load e.g. power down when climbing hills). Improper A/C system operation Air leakage from intake-air system parts Purge control solenoid malfunction Brake dragging Erratic signal from CMP sensor Low engine compression Vacuum leakage Poor fuel quality Spark leakage from high-tension leads Air cleaner restriction PCV valve malfunction Improper valve timing due to jumping out of timing belt Restriction in exhaust system Intermittent open or short in fuel pump circuit Inadequate fuel pressure Fuel pump mechanical malfunction Fuel leakage from fuel injector Fuel injector clogging Intermittent open or short of MAP sensor, TP sensor and VSS Clutch slippage
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Verify following: Vacuum connection Air cleaner element No air leakage from intake-air system No restriction of intake-air system Proper sealing of intake manifold and components attached to intake manifold (e.g. IAC valve) Fuel quality (e.g. proper octane, contamination, winter/summer blend) Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTCs. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine overheating? RESULTS Yes Go to next step. ACTION
No
Yes No Yes No
No DTC Is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to symptom troubleshooting No. 16 "Cooling system concerns - Overheating". Go to next step.
CONTINUED F1-94
TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION 4 Connect NGS tester to DLC. Access RPM PID, MAF V PID, TP V PID, and VS PID. RPM PID MAP V PID TP V PID VS PID Drive vehicle while monitoring PIDs. Are PIDs within specification? CONTROL SYSTEM, PCM INSPECTION 5 6 Visually inspect CMP sensor. Is CMP sensor okay? Inspect spark plug conditions. Is spark plug wet, covered with carbon or grayish white? Yes No Yes RESULTS Yes Go to next step. No ACTION
RPM PID: Inspect CMP sensor and related harness for vibration and/or intermittent open/short circuit. MAF V PID: Inspect for intermittent open circuit of MAF sensor and related wire harness. TP V PID: Inspect if TP sensor output increases smoothly. VS PID: Inspect for intermittent open circuit of VSS and related wire harness. Go to next step. Replace malfunctioning parts. Spark plug is wet or covered with carbon: Inspect for fuel leakage from fuel injector. Spark plug is grayish white: Inspect for clogged fuel injector. Install spark plugs on original cylinders. Go to next step. Go to next step. Replace PCV valve. Inspect exhaust system. Go to next step. Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step. Connect vacuum hose to pressure-regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator. Go to next step.
No 7 8 9 Remove and shake PCV valve. Does PCV valve rattle? Is there restriction in exhaust system? Install fuel pressure gauge between fuel main pipe and fuel distributor. Connect jumper wire between F/P terminal at DLC in engine compartment and GND. Turn ignition switch on. Is fuel line pressure correct with ignition switch on? Fuel line pressure 270310 kPa {2.73.2 kgf/cm 2, 3945 psi} Install vacuum gauge to intake manifold. Start engine. Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases? Note Following test is for engine stalling with A/C on concern. If other symptoms exist, go to next step. Connect pressure gauge to A/C low and high side pressure lines. Turn A/C on and measure low side and high side pressure. Is the pressure within specifications? Section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK Inspect for A/C cut off operation. Does A/C cut-off work properly? Yes No Yes No Yes No
10
Yes No
11
Yes
No
If A/C is always on, go to symptom troubleshooting No.23 "A/C always on/ A/C compressor runs continuously". For other symptoms, inspect following: Refrigerant charging amount
12
Yes No
Go to next step. Inspect A/C cut-off system components.
F1-95
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 13 INSPECTION Disconnect vacuum hose between purge solenoid valve and dynamic chamber from purge solenoid valve side. Plug opening end of vacuum hose. Drive vehicle. Does engine condition improve? Is engine compression correct? RESULTS Yes ACTION Inspect if purge solenoid valve sticks open mechanically. Inspect evaporative emission control system. Go to next step. Inspect following: Valve timing Clutch Brake system for dragging Inspect for cause.
No Yes
14
No 15
CONTINUED
F1-96
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 12 DESCRIPTION KNOCKING/PINGING - ACCELERATION/CRUISE Sound is produced when air/fuel mixture is ignited by something other than spark plug (e.g. hot spot in combustion chamber). Engine overheating due to cooling system malfunction Inadequate engine compression Inadequate fuel pressure
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Go to next step. Inspect cooling system for cause of overheating. ACTION
STEP 1
Connect NGS tester to DLC. Access ECT P1D. Verify ECT PID is less than 116C {241 F} while driving. Is ECT PID less than specification? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is engine compression correct? Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2, 3036 psi}
Yes No
No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to next step. Inspect for cause. Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Inspect ignition timing. Connect vacuum hose to pressure regulator. Start engine. Verify that fuel pressure gauge reading changes as vacuum changes. If it changes, inspect vacuum line. If it does not change, replace pressure regulator.
3 4
Yes No Yes No
Install vacuum gauge to intake manifold. Yes Start engine. No Does fuel pressure gauge reading increase as vacuum gauge reading decreases and/or does fuel pressure gauge reading decrease as vacuum reading increases?
CONTINUED
F1-97
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 13 DESCRIPTION POOR FUEL ECONOMY Fuel economy is unsatisfactory. Contaminated air cleaner element Engine cooling system malfunction Improper automatic transmission fluid level Weak spark Poor fuel quality Improper coolant level Inadequate fuel pressure Spark plug malfunction PCV valve malfunction Brake dragging Improper valve timing due to jumping out of timing belt Contaminated MAF sensor Improper engine compression Exhaust system clogging
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION RESULTS ACTION 1 Yes Go to next step. Inspect following: Air cleaner element for contamination Automatic transmission fluid level No Service as necessary. Fuel quality Coolant level Are all items okay? Repeat Step 1. Connect NGS tester to DLC. Yes No DTC is displayed: 2 Turn ignition switch on. Go to next step. Retrieve any DTCs. No DTC is displayed: Is "NO CODES RECEIVED" or "SYSTEM Go to appropriate DTC test. PASSED" display? 3 Connect NGS tester to DLC. Access ECT PID. Drive vehicle while monitoring PID. CONTROL SYSTEM, PCM INSPECTION Is PID within specification? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? Yes No Go to next step. Inspect for coolant leakage, cooling fan operation, or thermostat operation. Inspect for following: Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step. Inspect the following: High-tension leads Ignition coil and connector Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
Yes
No
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2, 3036 psi}
Yes No
CONTINUED F1-98
TO. MODEL .INDEX
TROUBLESHOOTING
STEP INSPECTION 6 Remove and shake PCV valve. Does PCV valve rattle? 7 8 9 10 11 Is there restriction in exhaust system? Is brake system functioning properly? Inspect for contaminated MAF sensor. Is there any contamination? Is engine compression correct? RESULTS Yes Go to next step. No Yes No Yes No Yes No Yes No Replace PCV valve. Inspect exhaust system. Go to next step. Go to next step. Inspect for cause. Replace MAP sensor. Go to next step. Inspect valve timing. Inspect for cause. ACTION
CONTINUED
F1-99
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 14 DESCRIPTION EMISSION COMPLIANCE Emission compliance test is failed. Vacuum line leakage or blockage Cooling system malfunction Spark plug malfunction Leakage from intake manifold Inadequate fuel pressure PCV valve malfunction or incorrect valve installation Exhaust system clogging Fuel tank ventilation system malfunction Charcoal canister damage Excessive carbon built up in combustion chamber Improper engine compression Improper valve timing
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Inspect following: Vacuum lines for leakage or blockage Electrical connections Proper maintenance schedule followed Intake-air system and air cleaner element concerns: obstructions, leakage or dirt Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Is any other drivability concern present? Connect NGS tester to DLC. Access ECT PID. Warm up engine and run it at idle. Is ECT PID correct? Is strong blue spark visible at each disconnected high-tension lead while cranking engine? RESULTS Yes Go to next step. ACTION
No
Yes No Yes No Yes No Yes
No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to appropriate symptom troubleshooting. Go to next step. Go to next step. Inspect for coolant leakage, cooling fan operation or thermostat operation. Inspect for following: Spark plug malfunction Repair or replace malfunctioning parts. If okay, go to next step. Inspect following: High-tension leads Ignition coil and connector Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
3 4
No
Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250 kPa { 2.12.6 kgf/cm2, 3036 psi}
Yes No
CONTINUED F1-100
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TROUBLESHOOTING
STEP 7 INSPECTION Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2, 3036 psi} Remove and shake PCV valve. Does PCV valve rattle? Is there restriction in the exhaust system? Inspect for fuel saturation inside charcoal canister. Is excessive amount of liquid fuel present in canister? RESULTS Yes Go to next step. ACTION
No
Inspect pressure regulator for high pressure cause.
8 9 10
Go to next step. Replace PCV valve. Inspect exhaust system. Go to next step. Replace charcoal canister. Inspect fuel tank vent system.
11
Verify test results. If okay, return to diagnostic index to service any additional symptoms. HIGH OIL CONSUMPTION/LEAKAGE Oil consumption is excessive. PCV valve malfunction Improper dipstick Improper engine oil viscosity Engine internal parts malfunction RESULTS Yes Go to next step. No Yes Replace PCV valve. Inspect internal engine parts such as valves, valve guides, valve stem seals, cylinder head drain passage, piston rings. Service as necessary. Repeat Step 2. ACTION
SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE
STEP INSPECTION 1 Remove and shake PCV valve. Does PCV valve rattle? 2 Inspect for following: External leakage Proper dipstick Proper engine oil viscosity Are all items okay?
No
CONTINUED
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TROUBLESHOOTING
SYMPTOM 16 DESCRIPTION COOLING SYSTEM CONCERNS - OVERHEATING Engine runs at higher than normal temperature/overheats. Improper coolant level Blown fuses Coolant leakage/Improper coolant level Excessive A/C system pressure Improper water/anti-freeze mixture Fans reverse rotation Poor radiator condition Thermostat malfunction Radiator hose damage Improper or damaged radiator cap Main cooling fan is inoperative. Coolant overflow system malfunction Improper tension of drive belt Drive belt damage INSPECTION RESULTS Yes Go to next step.
POSSIBLE CAUSE
STEP 1
ACTION
Inspect following: Engine coolant level Coolant leakage Water and anti-freeze mixture Radiator condition Collapsed or restricted radiator hoses Radiator pressure cap Overflow system Fan rotational direction Fuses Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle speed. Turn A/C switch on. Does A/C compressor engage?
No
Yes No Yes No
No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to Step 5. Inspect for following and repair or replace as necessary: Refrigerant charging amount Open circuit between A/C relay and PCM terminal 1J Seized A/C magnetic clutch A/C magnetic clutch malfunction If all Items are okay, go to next step. Go to next step. Inspect for following: Refrigerant pressure switch operation A/C switch stuck open Open or short circuit between refrigerant pressure switch and PCM terminal 1Q Open circuit of blower motor fan switch and resistor (if blower motor does not operate) Evaporator temperature sensor and A/C amplifier Go to next step. Replace drive belt. Inspect and service heater for leakage. Go to next step. Replace malfunctioning parts. Go to next step.
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine and run it at idle speed. Turn A/C switch on. Does A/C SW PID read ON?
Yes No
5 6 7
Is drive belt okay? Is there any leakage around heater unit in passenger compartment? Is there any leakage at coolant hoses and/or radiator?
CONTINUED
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TROUBLESHOOTING
STEP 8 INSPECTION Cool down engine. Remove thermostat and inspect operation. Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay? RESULTS Yes No ACTION Engine coolant temperature and thermostat are okay, inspect engine block for leakage or blockage. Access ECT V PID on NGS tester. Inspect for both ECT V and temperature gauge readings. If temperature gauge on instrument cluster indicates normal range but ECT V is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates overheating but ECT V is normal, inspect temperature gauge and heat gauge unit.
Verify test results. If okay, return to diagnostic index to service any additional symptoms. COOLING SYSTEM CONCERNS - RUNS COLD Engine takes excessive period for reaching normal operating temperature. Thermostat malfunction Cooling fan system malfunction INSPECTION RESULTS Yes No Yes No Yes Go to next step. Go to symptom troubleshooting No.8 "Fast idle/runs on". Go to next step. Access ECT V PID on NGS tester. Inspect for both ECT V PID and temperature gauge on instrument cluster readings. If temperature gauge on instrument cluster indicates normal range but ECT V PID is not same as temperature gauge reading, inspect ECT sensor. If temperature gauge on instrument cluster indicates cold range but ECT voltage is normal, inspect temperature gauge and heat gauge unit. Replace thermostat.
SYMPTOM 17 DESCRIPTION POSSIBLE CAUSE STEP 1 2 3
ACTION Inspect A/C and heater system.
Is customer complaint "Lack of passenger compartment heat" only? Does engine speed continue at fast idle? Remove thermostat and inspect operation. Section E, THERMOSTAT, THERMOSTAT INSPECTION Is thermostat okay?
No 4
CONTINUED
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TROUBLESHOOTING
SYMPTOM 18 DESCRIPTION EXHAUST SMOKE Blue, black, or white smoke from exhaust system. Blue smoke (Burning oil): PCV valve malfunction Engine internal oil leakage White smoke (Water in combustion): Cooling system (coolant loss) malfunction Engine internal coolant leakage Black smoke (Rich fuel mixture): Air cleaner restriction Intake-air system is collapsed or restricted. Fuel return line is restricted. Excessive fuel pressure Improper engine compression Injector fuel leakage Ignition system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION What color is smoke coming from exhaust system? RESULTS Blue White Black 2 Remove and shake PCV valve. Does PCV valve rattle? Yes ACTION Burning oil is indicated. Go to next step. Water in combustion is indicated. Go to Step 3. Rich fuel mixture is indicated. Go to Step 4. Inspect for following: Damaged valve guide, stems or valve seals Blocked oil drain passage in cylinder head Piston rings are not seated, seized or worn Damaged cylinder bore If other drivability symptoms are present, return to diagnostic index to service any additional symptoms. Replace PCV valve. Inspect for following: Cylinder head gasket leakage Intake manifold gasket leakage Cracked or porous engine block If other drivability symptoms are present, return to diagnostic index to service any additional symptoms. Inspect for cause. Go to next step. Service as necessary, Repeat Step 4. No DTC Is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test.
POSSIBLE CAUSE
No 3 Does cooling system hold pressure? Yes
No 4 Inspect for following: Air cleaner restriction Collapsed or restricted intake-air system Restricted fuel return line Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Yes No
Yes No
F1-104
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TROUBLESHOOTING
STEP INSPECTION 6 Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Measure fuel line pressure at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250 kPa {2.12.6 kgf/cm 2,3036 psi} 7 Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2,3036 psi} Is strong blue spark visible at each disconnected high-tension lead while cranking engine? RESULTS Yes Go to next step. No ACTION
Zero or low: Inspect fuel pump circuit Inspect for open fuel pump relief valve Inspect for fuel leakage inside pressure regulator Inspect for clogged main fuel line High: Inspect pressure regulator for high pressure cause Inspect for clogged fuel return line Go to next step.
Yes
No
Yes No
Inspect spark plugs. Inspect following: High-tension leads Ignition coil and connector
CONTINUED
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TROUBLESHOOTING
SYMPTOM 19 DESCRIPTION FUEL ODOR (IN ENGINE COMPARTMENT) Gasoline fuel smell or visible leakage, Excessive fuel pressure Fuel tank vent system blockage Charcoal canister malfunction
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes Go to next step, ACTION
STEP 1
Visually inspect for fuel leakage at fuel injector O-ring and fuel line. Service as necessary. Install fuel pressure gauge between fuel main pipe and fuel distributor. Start engine and run it at idle. Then stop engine. Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on and off? Fuel line pressure 210250 kPa {2.12.6 kgf/cm 2, 3036 psi} Inspect for blockage/restriction or open between engine vacuum port and charcoal canister. Inspect for blockage in fuel tank vent system. Is fault indicated? Inspect purge solenoid valve. EMISSION SYSTEM, PURGE SOLENOID VALVE INSPECTION Is solenoid operating properly? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
No
Yes
Replace vacuum hose.
No
Go to next step.
Yes No Yes
Go to next step. Replace purge solenoid valve.
No DTC is displayed: Inspect charcoal canister for fuel saturation. If excessive amount of liquid fuel is present, replace charcoal canister. No DTC is displayed: Go to appropriate DTC test. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
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TROUBLESHOOTING
SYMPTOM 20 DESCRIPTION ENGINE NOISE Engine noise from under hood Squealing, clicking or chirping noise: Improper engine oil level Improper drive belt tension Rattling noise: Loose parts Hissing sound noise: Vacuum leakage Loose spark plug Air leakage from intake-air system Rumbling or grinding noise: Improper drive belt tension Rapping or roar noise: Exhaust system looseness Other noise: Camshaft friction gear noise RESULTS ACTION Yes Inspect engine oil level or drive belts. No Yes No 3 4 Is rattling sound present? Is hissing sound present? Yes No Yes Go to next step. Inspect drive belt. Go to next step. Inspect location of rattle for loose parts. Go to next step. Inspect following: Vacuum leakage Spark plug looseness Intake-air system leakage Go to next step. Inspect exhaust system for loose parts. Go to next step. Go to symptom troubleshooting No.12 "Knocking/ pinging".
POSSIBLE CAUSE
STEP INSPECTION 1 Is squealing, clicking or chirping sound present? 2 Is rumbling or grinding sound present?
No 5 6 Is rapping or roaring sound present? Is knocking sound present? Yes No Yes No
If noise comes from inside engine, inspect for friction gear noise. Verify test results. If okay, return to diagnostic index to service any additional symptoms. VIBRATION CONCERNS (ENGINE) Vibration from under hood or driveline Loose attaching bolts or worn parts Component malfunctions such as worn parts INSPECTION Inspect following components for loose attaching bolts or worn parts: Cooling fan Drive belt and pulleys Engine mounts Are all items okay? RESULTS Yes ACTION Inspect following systems: Wheels Driveline Suspension
SYMPTOM 21 DESCRIPTION POSSIBLECAU SE STEP 1
Readjust or retighten engine mount installation position. Service as necessary for other parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
No
CONTINUED F1-107
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TROUBLESHOOTING
SYMPTOM 22 DESCRIPTION A/C DOES NOT WORK SUFFICIENTLY. A/C compressor magnetic clutch does not engage when A/C switch is turned on. Improper refrigerant charging amount Open A/C magnetic clutch Open circuit between A/C relay and A/C magnetic clutch Poor GND of A/C magnetic clutch Refrigerant pressure switch is struck open. A/C relay is stuck open. Seized A/C compressor Open circuit between A/C switch and PCM through both refrigerant pressure switch and A/C amplifier INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Disconnect A/C compressor connector. Start engine and turn A/C switch on. Is there correct voltage at terminal of A/C compressor magnetic clutch connector? Specification More than 10.5V Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start engine. Turn A/C switch on and set blower fan at any speed. Does A/C SW PI Dread ON? Disconnect refrigerant pressure switch connector. Connect a jumper wire between terminals of refrigerant pressure switch connector. Start engine and turn A/C switch on. Does A/C work? RESULTS Yes No Yes No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test, Inspect for GND condition of magnetic clutch on A/C compressor. If GND condition is okay, inspect for open circuit of magnetic clutch coil. Go to next step. Inspect for stuck open A/C relay. Replace as necessary. Go to next step. Inspect for following: Refrigerant charging amount Refrigerant pressure switch operation Inspect for following: A/C switch is stuck open. Open circuit between refrigerant pressure switch and PCM terminal 1Q Open circuit of blower motor fan switch and resistor (if blower motor does not operate) Evaporator temperature sensor and A/C amplifier Open circuit between A/C amplifier and refrigerant pressure switch ACTION
POSSIBLE CAUSE
STEP 1
No Yes
No Yes
No
CONTINUED
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TROUBLESHOOTING
SYMPTOM 23 DESCRIPTION A/C IS ALWAYS ON /A/C COMPRESSOR RUNS CONTINUOUSLY. A/C compressor magnetic clutch does not disengage. Stuck engagement A/C relay is stuck closed. Short to GND between A/C switch and PCM Short to GND circuit between A/C relay and PCM A/C relay to magnetic clutch circuit shorts to battery power INSPECTION Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Start engine and run it at idle. Turn A/C switch on. Remove A/C relay. Does A/C magnetic clutch disengage? RESULTS Yes No Yes No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Inspect for following: A/C relay is stuck closed. Short to GND circuit between A/C relay and PCM terminal 1J If both items okay, go to next step. Inspect if circuit between A/C relay and magnetic clutch shorts to battery power circuit. If circuit is okay, inspect magnetic clutch engagement or clearance. Inspect for short to GND circuit between refrigerant pressure switch and PCM terminal 10. ACTION
POSSIBLE CAUSE
STEP 1
No
Connect NGS tester to DLC. Access A/C SW PID on NGS tester. Start the engine and turn A/C switch on. Read A/C SW PID while disconnecting refrigerant pressure switch connector. Note A/C SW PID should read OFF when disconnecting connector. If A/C SW PID reading remains ON, short to GND circuit may be present. Does A/C SW PID reading remain ON?
Yes
No
Go to next step.
Reconnect refrigerant pressure switch Yes Inspect for following: connector. Short to GND circuit between A/C switch and A/C Read A/C SW PID while turning off A/C switch. amplifier Note Short to GND circuit between A/C amplifier and A/C SW PID should read OFF when turnrefrigerant pressure switch ing A/C switch off. If A/C SW PID reading remains ON, short to GND circuit may be No Inspect for stuck closed A/C switch. present. Does A/C SW PID reading remain ON? Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-109
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TROUBLESHOOTING
SYMPTOM 24 DESCRIPTION POSSIBLE CAUSE A/C DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE (WOT) CONDITIONS A/C compressor magnetic clutch does not disengage under WOT. TP sensor malfunction TP sensor misadjustment TP sensor is loosely installed. RESULTS Yes Go to next step. No Yes No ACTION
STEP INSPECTION 1 Does A/C compressor disengage when A/C switch is turned off? 2 Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed?
Go to symptom troubleshooting No.23 "A/C is always on / A/C compressor runs continuously". No DTC is displayed: Inspect TP sensor for proper adjustment. DTC is displayed: Go to appropriate DTC test.
Verify test results. If okay, return to diagnostic index to service any additional symptoms,
CONTINUED
F1-110
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TROUBLESHOOTING
SYMPTOM 25 EXHAUST SULPHUR SMELL Rotten egg smell (sulphur) from exhaust Electrical connectors are disconnected or connected poorly Charcoal canister malfunction Vacuum lines are disconnected or connected improperly. Improper fuel pressure
DESCRIPTION
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Yes No Go to next step. Go to next step. Service as necessary. Repeat Step 2. No DTC is displayed: Go to next step. DTC is displayed: Go to appropriate DTC test. Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for open fuel pump relief valve. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step. ACTION Go to appropriate flow chart.
STEP 1 2
Are any drivability or exhaust smoke concerns present? Inspect following: Electrical connections Vacuum lines Are all items okay? Connect NGS tester to DLC. Turn ignition switch on. Retrieve any DTC. Is "NO CODES RECEIVED" or "SYSTEM PASSED" displayed? Install fuel pressure gauge between fuel filter and fuel distributor. Start engine and run it at idle. Is fuel line pressure correct at idle? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2,3036 psi}
Does fuel line pressure remain at specification for 60 seconds when ignition switch is turned on? Fuel line pressure 210250kPa {2.12.6 kgf/cm 2, 3036 psi} Inspect charcoal canister for fuel saturation. Is excessive amount of liquid fuel present in canister?
Yes
No
Yes No
Replace charcoal canister.
Inspect fuel tank vent system. If fuel tank vent system is okay, since sulfur content can vary in different fuels, suggest trying a different brand. If fuel tank vent system is not okay, repair or replace malfunctioning parts. Verify test results. If okay, return to diagnostic index to service any additional symptoms.
CONTINUED
F1-111
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TROUBLESHOOTING
SYMPTOM 26 INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose. DESCRIPTION STEP 1 INSPECTION Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous repairs and components replaced for a certain symptom? Connect NGS tester to DLC. If input is switch-type component, turn on manually. Turn ignition switch on. Access PIDs for suspect component. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range? Start engine. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM. Are any PID values out of range, or do they suddenly change and go back into range? Start engine. Accurately spray water on suspect component wire, component or vacuum line related to possible fault area. Are any PID values out of range, or do they suddenly change and go back into range, or was there a noticeable engine misfire/ stumble? RESULTS Yes No Yes Go to next step. Go to Symptom Index. Inspect each wire for corrosion, bent or loose terminal crimps. ACTION
No
Go to next step.
Yes
Inspect each wire for corrosion, bent or loose terminal crimps. Go to next step. Fault occurred while spraying component: Replace part and verify repair. Fault occurred while spraying wiring: Inspect each wire for corrosion, bent or loose terminals and poor wire terminal crimps. Fault occurred while spraying vacuum line: Repair vacuum hoses. Inspect wire and connector at suspect component for corrosion, bent or loose terminals, poor wire terminal crimps and high tension of wire. Repair as necessary.
No Yes
No
CONTINUED
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TROUBLESHOOTING
SYMPTOM 27 CONSTANT VOLTAGE DESCRIPTION Incorrect constant voltage POSSIBLE CAUSE STEP 1 Constant voltage circuit malfunction Note TP sensor and variable resistor (Except Europe) use constant voltage. INSPECTION Disconnect TP sensor connector. Turn ignition switch on. Measure voltage between following TP sensor and variable resistor (Except Europe) connector terminals: Constant voltage terminal - GND terminal Is constant voltage greater than 6.0 volts? Is voltage across battery terminals greater than 10.5 volts? Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Measure voltage between battery positive terminal and GND circuit at TP sensor connector. Is voltage greater than 10.5 volts and within 1.0 volt of battery voltage? Note The purpose of this step is to determine if NGS tester is communicating with PCM. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed? Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Turn ignition switch on. Measure voltage between PCM connector terminals 1B and 2B. Is voltage greater than 10.5 volts? Leave TP sensor, variable resistor (Except Europe) and PCM connectors disconnected. Disconnect NGS tester from DLC. Measure resistance between PCM connector terminals 2K and 2B. Is resistance greater than 10,000 ohms? Turn ignition switch off. Leave TP sensor and variable resistor (Except Europe) connector disconnected. Disconnect PCM connector. Measure resistance between PCM connector terminal 2K and constant voltage circuit at appropriate sensor connector. Is resistance less than 5.0 ohms? Note The purpose of this step is to determine if NGS tester is communicating with PCM. Reconnect TP sensor and variable resistor (Except Europe) connector. Turn ignition switch on. Attempt to access ECT PID. Can ECT PID be accessed? RESULTS Yes ACTION Repair constant voltage circuit short to power in harness.
No
Go to next step.
2 3
Yes No Yes
Go to next step. Inspect charging system. Go to next step.
No
Go to Step 8.
Yes
Go to Step 7.
No
Go to next step.
Yes
Go to next step.
No
Repair open circuit between PCM terminal 1B and main relay.
Yes
Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM. Repair constant voltage circuit short to GND. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again. If constant voltage is still out of range, replace PCM.
No Yes
No
Repair open constant voltage circuit.
Yes
Go to next step.
No
Go to Step 10.
CONTINUED F1-113
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TROUBLESHOOTING
STEP 9 INSPECTION Turn ignition switch off. Disconnect NGS tester from DLC. Disconnect PCM connector. Measure resistance between GND circuit at appropriate sensor connector and PCM connector terminal 2D. Is resistance less than 5.0 ohms? Turn ignition switch off. Disconnect PCM connector. Measure resistance between battery negative terminal and PCM terminals 2A, 2B and 2C. Is each resistance less than 5.0 ohms? Turn ignition switch off. Measure resistance between GND circuit at following sensor connector and GND: ECT sensor O2S IAT sensor MAF sensor TP sensor Variable resistor (Except Europe) Is each resistance less than 5.0 ohms? RESULTS Yes ACTION Reconnect sensor connector. Go to appropriate DTC test.
No
Repair open GND circuit.
10
Yes
Go to next step.
No Yes
Repair open GND circuit. GND circuits are okay. Inspect for constant voltage at TP sensor and variable resistor (Except Europe) connector again.
11
No
Inspect for open GND circuit.
CONTINUED
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TROUBLESHOOTING
DIAGNOSTIC INSPECTION Spark Plug Condition Inspection Purpose Inspecting spark plugs condition can determine whether problem is related to a specific cylinder or to all cylinders. Spark plug condition Specific plug is wet or covered with carbon. Specific plug looks grayish white. All plugs are wet or covered with carbon. All plugs look grayish white. SYMPTOM 1 Wet/carbon stuck on specific plug SparkNo spark visible or spark weak Air/fuel mixtureExcessive fuel injection volume CompressionNo compression, low compression Faulty spark plug Procedure 1. Remove the spark plug. 2. Inspect spark plug condition. 3. Go to appropriate troubleshooting chart for further information. Troubleshooting chart Wet/carbon stuck on specific plug Grayish white with specific plug Wet/carbon stuck on all plugs Grayish white with all plugs
Symptom 1 Symptom 2 Symptom 3 Symptom 4
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Working up and down inspect all areas related to oil. No Yes Go to next step. Go to next step.
STEP INSPECTION 1 Is spark plug wet/covered with carbon by engine oil? 2 Inspect spark plug for following: Cracked insulator Heating value Air gap Worn electrode Is spark plug okay? Inspect compression pressure at suspected faulty cylinder. Section B1, COMPRESSION INSPECTION Is compression pressure correct? Install all spark plugs. Carry out spark test at suspected faulty cylinder. Is strong blue spark visible? (Compare with normal cylinder) Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270310 kPa {2.73.2 kgf/cm 2, 3945 psi}
No
Replace spark plug.
Yes No Yes No Yes
Go to next step. Repair or replace malfunctioning parts. Go to next step. Repair or replace malfunctioning parts. Inspect fuel injector for following: Open or short in injector Leakage Injection volume Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
No
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TROUBLESHOOTING
SYMPTOM 2 POSSIBLE CAUSE STEP 1 Grayish white with specific plug Air/fuel mixtureInsufficient fuel injection volume Faulty spark plug INSPECTION Inspect spark plug for following: Heating value Air gap Is spark plug okay? Remove suspected fuel injector. Inspect for following: FUEL SYSTEM, FUEL INJECTOR INSPECTION Resistance Fuel injection volume Are all above items okay? Wet/carbon stuck on all plugs SparkSpark weak Air/fuel mixtureToo rich CompressionLow compression Clogging in intake/exhaust system RESULTS Yes No Yes Go to next step. Replace spark plug. Inspect for open circuit between suspected fuel injector terminal and PCM connector terminal. ACTION
No
Replace fuel injector.
SYMPTOM 3
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also Irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Go to next step. Replace air cleaner element. Go to next step. Repair or replace malfunctioning parts. Go to next step. Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line. Go to next step. ACTION
STEP 1 2 3
Is air cleaner element free of restriction? Carry out spark test. Is strong blue spark visible at each cylinder? Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION. Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270310 kPa {2.73.2 kgf/cm 2, 3745 psi}
Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR INSPECTION MAF V ECT FHO2S (When engine can be started) Are PIDs okay? Carry out purge control inspection. (When engine can be started) Is purge control correct? Carry out compression inspection. Is compression correct?
Yes
No
Repair or replace malfunctioning parts.
Yes No Yes No
Go to next step. Repair or replace malfunctioning parts. Inspect for clogging in exhaust system. Repair or replace malfunctioning parts.
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TROUBLESHOOTING
SYMPTOM 4 Grayish white with all plugs Air/fuel mixtureToo lean
POSSIBLE CAUSE
Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes ACTION Repair or replace malfunctioning parts. Go to next step. Inspect following PIDs: CONTROL SYSTEM, PID/DATA MONITOR INSPECTION MAF V ECT FHO2S (When engine can be started) Inspect for PCM GND condition. Zero or low: Inspect fuel pump circuit. Inspect for fuel pump relief valve open. Inspect for fuel leakage inside pressure regulator. Inspect for clogged main fuel line. High: Inspect pressure regulator for high pressure cause. Inspect for clogged fuel return line.
STEP 1
When engine cannot be started, inspect intake-air system for air leakage. When engine can be started, carry out intake manifold vacuum inspection. Is air sucked in from intake-air system? Carry out fuel line pressure inspection. TROUBLESHOOTING, ENGINE SYSTEM INSPECTION, Fuel Line Pressure Inspection Is fuel line pressure correct? Fuel line pressure 270310 kPa {2.73.2 kgf/cm 2, 3745 psi}
No
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TROUBLESHOOTING
Inspection Using an Oscilloscope (Reference) Purpose Using an oscilloscope, inspection such as stuck solenoid valve is made possible without actually removing parts. Finding unusual signals While referring to the diagnostic trouble code inspection section of the on-board diagnostic system, use the PID/DATA MONITOR AND RECORD function to inspect the input signal system relating to the problem. 1. Turn the ignition on and run it at idle. You can assume that any signals that are out of specifications by a wide margin are unusual. 2. When recreating the problem, any sudden change in monitor input signals that is not consciously created by the driver can be judged as unusual. Locating the source of unusual signals Caution: When normal Counter electromotive voltage A, generated when the threeway solenoid valve or the fuel injector is turned off from on, shows irregular convergence because induced electromotive voltage B, generated by the plunger return operation, is added to it. Compare the NGS monitor voltage with the measurement voltage using the DIGITAL MEASUREMENT SYSTEM function. If you use another tester, misreading may occur. When measuring voltage, attach the tester GND to the GND of the PCM that is being tested, or to the engine itself. If this is not done, the measured voltage and actual voltage may differ. After connecting the pin to a waterproof coupler, confirming continuity and measuring the voltage, inspect the waterproof connector for cracks. If there are any, use sealant to fix them. Failure to do this may result in deterioration of the harness or terminal from water damage, leading to problems with the vehicle.
When plunger is stuck When the plunger is stuck, pulse convergence is smooth because no induced electromotive voltage B is generated.
Variable resistance type 1 (Throttle position (TP) sensor and variable resistor (Except Europe))
Input Signal System Investigation Procedure 1. Find an unusual signal. (Refer to procedures below) 2. Locate its source. (Refer to procedures below) 3. Repair or replace the defective part. 4. Confirm that the unusual signal has been erased.
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. 2. Female terminal opening loose Coupler (pin holder) damage Pin discoloration (blackness)
Harness/pin crimp is loose or disconnected. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING
(2) If the sensor and NGS voltages are the same, inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Investigate the standard power supply system (1) Confirm that the #3 terminal is at 5 V. (1) If the measured voltage on the #3 terminal is 5 V, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. (3) Female terminal opening looseness (4) Coupler (pin holder) damage (5) Pin discoloration (blackness) (2) If the #3 terminal measures other than 5 V, inspect for the following. Open or short circuit in harness Harness/pin crimp is loose or disconnected. Investigate the GND system 1. Confirm that terminal sensor #5 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open or short circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Variable resistance type 2 (Mass air flow (MAP) sensor)
(2) If the sensor and NGS voltages are the same,

inspect the following points concerning the sensor connector. If there are no problems, proceed to next investigation below. Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Investigate the electrical supply system 1. Confirm that the sensor #3 terminal is B+. (1) If the measured voltage on the #3 terminal is B+, inspect the following points on the sensor connector. If there is no problem, proceed to next investigation below. Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) (2) If the #3 terminal measures other than B+, inspect for the following. Open or short circuit in harness Harness/pin crimp is loose or disconnected. Investigate the GND system
1. Confirm that terminal sensor #4 is at 0 V.

(1) (2) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. If not at 0 V, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Thermistor type (Intake air temperature (IAT) and engine coolant temperature (ECT) sensors)
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (1) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (2) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (1) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
Investigate the input signal system 1. When you get an unusual signal, measure the #1 PCM terminal voltage. (2) If the #1 terminal voltage and the NGS monitor voltage are the same, proceed to the next step. (3) If there is a difference of 0.5 V or more, inspect the following points concerning the PCM connector. (1) Female terminal opening looseness (2) Coupler (pin holder) damage (3) Pin discoloration (blackness) (4) Harness/pin crimp is loose or disconnected. 2. When you get an unusual signal, measure the #2 sensor terminal voltage. (3) If there is a 0.5 V or more difference between the sensor and NGS voltages, inspect the harness for open or short circuits.
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TROUBLESHOOTING
(2) If the sensor and NGS voltages are the same, inspect for the following points concerning the sensor connector. If there are no problems, proceed to next investigation below, Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
Pin discoloration (blackness) Harness/pin crimp is loose or disconnected.
ENGINE SYSTEM INSPECTION Main Relay Operation Inspection 1. Verify that the main relay clicks when the ignition switch is turned to on and off.
Investigate the GND system 1. Confirm that terminal sensor #3 is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Vehicle speed sensor (VSS) 2. If there is no operating sound, inspect the following. Main relay Harness and connector between ignition switch and main relay
1.
Measure the #1 PCM terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine is at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the PCM connector. If there are no problem, proceed to next step. Female terminal opening loose Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Measure the #2 sensor terminal voltage and confirm that it is at 0 V or 5 V when the ignition switch is on and the engine at idle. (1) If it is at 0 V or 5 V, proceed to symptom troubleshooting No.26 "Intermittent Concerns". (2) If not, inspect the following points concerning the sensor connector. If there are no problems, proceed to next step. Female terminal opening looseness Coupler (pin holder) damage Pin discoloration (blackness) Harness/pin crimp is loose or disconnected. Confirm that the #3 terminal switch voltage is at 0 V. (1) If it is at 0 V, inspect the sensor. If necessary, replace the sensor. (2) If not, inspect for the following. Open circuit in harness Female terminal opening looseness Coupler (pin holder) damage
Intake Manifold Vacuum Inspection 1. Verify air intake hoses are installed properly. 2. Start the engine and run it at idle. 3. Disconnect the vacuum hose between the intake manifold and purge solenoid valve on the intake manifold side. 4. Connect a vacuum gauge to the intake manifold and measure the intake manifold vacuum.
2.
Specification More than 60 kPa {450 mmHg, 18 inHg} 5. If not as specified, inspect for the following: Air suction at throttle body, intake manifold and PCV valve installation points Fuel injector insulator Accelerator cable free play Engine compression (Refer to section B1.) Note
3.
Air suction can be located by engine speed change when lubricant is sprayed on the area where suction is occurring.
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TROUBLESHOOTING
Idle Air Control (IAC) Inspection Engine coolant temperature (ECT) compensation inspection 1. Connect the SSTs (NQS tester) to DLC. Verify that DTC P0505 is not displayed. If DTC P0505 is shown, carry out DTC inspection. (4) Select the SIMULATION TEST function on the NGS display. (5) Change the duty value of the IAC valve to 100% using the IACV PID. (6) Verify that the idle speed increases. If the idle speed increases, replace the PCM. If the idle speed does not change, inspect the following. IAC valve air passage Open or short circuit between IAC valve connector terminals and PCM connector terminal 2W Warm up the engine to normal operating temperature and run it at idle. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. A/C SW IAC V PSP SW RPM 7. Turn the electrical loads on and verify that the engine speed is within the specification. Load condition
2
(3)
4. 2. 3. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select the following PIDs. ECT IACV RPM Verify that the engine is cold, then start the engine. Verify that the engine speed decreases as the engine warms up. If the engine speed does not decrease or decreases slowly, carry out the following. ECT sensor inspection IAC valve inspection 5. 6.
4. 5. 6.
Engine speed (rpm) Idle-up speed (rpm)*

1
Load compensation inspection 1. Start the engine and run at idle. 2. Disconnect the IAC valve connector and verify that the engine rotation changes.
P/S ON* 700800 (750 50) A/CON*3 *1 Excludes temporary idle speed drop just after the electrical loads (E/L) are turned on. 2 * : Steering wheel is fully turned. 3 * : A/C switch and fan switch are on. Note Excludes temporary idle speed drop just after the electrical loads are turned on. 8. If not as specified, carry out the following. A/C switch inspection PSP switch inspection IAC valve inspection Fuel Line Pressure Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2. Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
3.
If the engine condition does not change, do as follows. (1) Connect the IAC valve connector. (2) Connect the SSTs (NGS tester) to DLC.
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TROUBLESHOOTING
If fuel line pressure gradually increases, inspect the fuel pump maximum pressure. If the fuel pump maximum pressure is normal, inspect for clogging between fuel pump body and pressure regulator.
3.
Connect the negative battery cable. Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. Short the DLC terminal F/P to body GND using a jumper wire.
Fuel Pressure Hold Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. 2. Disconnect the negative battery cable. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
4.
5.
Turn the ignition switch on and measure the fuel line pressure. Specification 2 270310 kPa {2.73.2 kgf/cm , 3945 psi}
3.
Connect the negative battery cable. Caution Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only.
6. 7.
8.
Turn off the ignition switch and disconnect the jumper wire. If the pressure is higher than specified, inspect the fuel pump maximum pressure. If normal, inspect fuel return hose or the pressure regulator for clogging. If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
4.
Short the DLC terminal F/P to body GND using a jumper wire.
5. 6. 7.
Turn the ignition switch on for approx. 10 sec. to operate the fuel pump body. Turn off the ignition switch and disconnect the jumper wire. Observe the fuel pressure after 5 min. Specification 2 More than 150 kPa {1.5 kgf/cm , 21 psi}
If the fuel line pressure quickly increases, inspect the pressure regulator and PRC solenoid valve.
8.
If the pressure is lower than specified, measure the fuel line pressure while pinching the return hose.
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TROUBLESHOOTING
Inspection 1 1. Connect the SSTs (NGS tester) to the DLC.
If the fuel line pressure holds, replace the pressure regulator. (Refer to FUEL SYSTEM, PRESSURE REGULATOR REMOVAL/INSTALLATION.) If fuel line pressure does not hold, inspect the fuel leakage from fuel line and fuel injector. Pressure Regulator Control Inspection Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death. Fuel can also irritate skin and eyes. To prevent this, always complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Connect a fuel pressure gauge between the fuel filter and fuel distributor.
2. 3.
Start the engine and let it idle. Select the SIMULATION TEST function on the NGS display. 4. Select IDLING TEST mode. 5. Select PRCV PID. 6. Press START. 7. Turn the PRC solenoid valve from off to on and inspect if the fuel pressure changes. (1) If the pressure changes, inspect the following. ECT, IATDC and TP V PIDs (Refer to CONTROL SYSTEM, PID/DATA MONITOR INSPECTION.) (2) If the pressure does not change, do as follows. Select the SIMULATION TEST function on the NGS display. Select IDLING TEST mode. Select PRCV PID. Press START. Turn the PRC solenoid valve from off to on and inspect if the operation sound of the valve is heard. If the operating sound is heard, inspect the pressure regulator. It the operating sound is not heard, inspect the PRC solenoid valve. Inspection 2 1. Connect the SSTs (NGS tester) to the DLC.
3. 4.
Connect the negative battery cable. Measure the fuel line pressure under the following conditions. Fuel pressure [kPa {kgf/cm 2, psi}] 210250 {2.12.6, 3036} 270310 {2.73.2, 3945} 210250 {2.12.6, 3036} Normal 210250 {2.12.6, 3036} 270310 {2.73.2, 3&45} 2. 3. 4. Not Normal (Perform Inspection 1) Not Normal (Perform Inspection 2) Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the PRC solenoid valve from off to on using the PRCV PID and inspect if the operating sound is heard. (1) If the operating sound is heard, inspect for a loose or damaged vacuum hose. (Pressure regulatorPRC solenoid valveintake manifold) (2) If the operating sound is not heard, inspect the PRC solenoid valve)
Specifications Condition Idling During 120 sec. of hot start After 120 sec. of hot start Judgment
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TROUBLESHOOTING
Fuel Injector Operation Inspection
STEP INSPECTION 1 While cranking engine, inspect for fuel injector operating sound at each cylinder using a soundscope. Is operating sound heard? RESULTS ACTION Yes Fuel injector operation is okay. Not heard at all cylinders: No Go to next step. Not heard at some cylinders: Go to Step 3. Yes Inspect following: Fuel injector power system related wiring harnesses and connectors PCM connectors Fuel injector GND and related wiring harnesses and connectors Repair or replace malfunctioning parts. Go to next step. Replace fuel injector. Inspect PCM terminal voltage of fuel injector signal. Repair or replace malfunctioning parts.
Carry out main relay operation inspection. Is main relay operation okay?
No 3 Change fuel injector connector of not operating fuel injector and operating fuel injector. Is operating sound heard? Are wiring harnesses and connectors of not operating fuel injector okay? (Open or short) Yes No Yes No
Fuel Cut Control Inspection 1. Warm up engine and let it idle. 2. Turn off the electrical loads and A/C switch. 3. Connect the SSTs (NGS tester) to the DLC.
Fuel Pump Operation Inspection 1. Connect the SSTs (NGS tester) to the DLC.
4. 5. 6. 7.
8.
Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select RPM and INJ PIDs. Press START. Monitor both PIDs while performing the following steps. (1) Depress the accelerator pedal and increase the engine speed to 4000 rpm. (2) Release the accelerator pedal (brake pedal is not depressed) and inspect that the fuel injector duration time is 0 msec., and 25 msec. when the engine speed drops below 1200 rpm. If not as specified, carry out the following. ECT sensor inspection Neutral/clutch switch inspection
2. 3. 4. 5. 6.
Remove the fuel-filler cap. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Turn the fuel pump relay from off to on using the FP RLY PID and inspect if the operating sound is heard. If no operating sound is heard, measure the voltage at harness side fuel pump unit connector terminal B. Specification Battery positive voltage (Ignition switch on)
CONTINUED
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TROUBLESHOOTING
7. If the voltage is as specified, inspect the following. Fuel pump continuity Fuel pump GND Wiring harness between fuel pump relay and PCM terminal 1 H If not as specified, inspect the following. 1. Fuel pump relay 2. Wiring harness and connector (Main relayfuel pump relayfuel pump unit) 4. 5. Increase the engine speed and verify the ignition timing is advanced. If the ignition timing is not advanced, carry out the following. CMP sensor inspection MAP sensor inspection
8.
Fuel Pump Control Inspection 1. Connect the SSTs (NGS tester) to the DLC.
2. 3. 4. 5. 6. 7.
Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. Select IG ON TEST mode. Select FP RLY PID. Press START. Turn the fuel pump relay from off to on and inspect if the operating sound of the fuel pump relay is heard.
8. 9.
If no operating sound is heard, inspect the fuel pump relay. If the fuel pump relay is normal, inspect the following. Wiring harnesses and connectors (Main relayfuel pump relayPCM)
Ignition Timing Control Inspection 1. Connect a timing light to the engine. 2. Crank the engine. 3. Verify that the timing mark (yellow) on the crankshaft pulley is within the specification. Specification BTDC 911(10 1)
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TROUBLESHOOTING
Spark Test 1. Remove the fuel pump relay. 2. Verify that each high-tension lead and connector is connected properly. 3. Inspect the ignition system in the following procedure. Warning High voltage in the ignition system can cause strong electrical shock which can result in serious injury. Avoid direct contact to the vehicle body during the following spark test. STEP INSPECTION 1 Remove high-tension lead from spark plug. Hold high-tension lead with pliers installed 510 mm {0.200.39 in} from GND. Crank the engine and verify that there is a strong blue spark. (Inspect each cylinder.) 2 Is high-tension lead resistance correct? RESULTS ACTION Yes Ignition system is okay. No Some cylinders do not spark: Go to next step. All cylinders do not spark: Go to Step 3. Inspect for cracks or damage of high-tension lead, distributor and Ignition coil. Replace the high-tension lead. Repair or replace connector. Go to next step. Go to next step. Replace igniter. Go to next step. Replace ignition coil. Go to next step. Replace distributor cap or rotor. Inspect for open or short in wiring harness and connector of CMP sensor. Repair or replace malfunctioning part.
Yes No
3 4 5 6 7
Does PCM or ignition coil connector have poor connection? Is igniter okay? Is ignition coil winding resistance okay? Are distributor cap and rotor okay? Are following parts okay? CMP sensor PCM terminal 2F voltage Specification Approx. 1.5 V
Yes No Yes No Yes No Yes No Yes
No
CONTINUED
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TROUBLESHOOTING
Purge Control Inspection 1. Start the engine. 2. Disconnect the vacuum hose between the purge solenoid valve and the charcoal canister. 3. Put a finger to the purge solenoid valve and verify that there is no vacuum applied when the engine is cold. 4. If there is a vacuum, inspect the following. Wiring harness and connectors (Purge solenoid valvePCM terminal 2X) Purge solenoid valve 5. Warm up the engine to the normal operating temperature. 6. Stop the engine. 7. Connect the SSTs (NGS tester) to DLC. A/C CUT-OFF CONTROL INSPECTION 1. Start the engine. 2. Turn the A/C switch and fan switch on. 3. Verify that the A/C compressor magnetic clutch actuates. 4. If it does not actuate, go to symptom troubleshooting No.22 "A/C does not work sufficiently". Note Specification of A/C cut-off control time is from 2 to 5 seconds. Fully open the throttle valve in a short period and verify that the A/C compressor magnetic clutch does not actuate. If it actuates, inspect the following. (1) Connect the SSTs (NGS tester) to DLC.
5.
6.
8. 9. 10. 11. 12. 13. 14. 15. 16.
Turn the ignition switch on. Select the PID/DATA MONITOR AND RECORD function on the NGS display. Select ECT PID. Verify that the engine coolant temperature is above 60C {140F}. If the SSTs (NGS tester) indicates below 60 C {140 F}, carry out the ECT sensor inspection. Select the SIMULATION TEST function on the NGS display. Select PRGV PID. Press START. Increase the duty value of the purge solenoid valve to 50% and inspect if the operating sound of the valve is heard. (1) If the operating sound is heard, inspect the loose or damaged vacuum hose. (Intake manifold purge solenoid valvecharcoal canister) (2) If the operating sound is not heard, carry out the purge solenoid valve inspection.
(2) (3) (4)
Turn the A/C switch off. Turn the ignition switch on. Select the SIMULATION TEST function on the NGS display. (5) Select IG ON TEST mode. (6) Select A/C RLY PID (7) Press START. (8) Turn the A/C relay from off to on and inspect if the operating sound of the relay is heard. (9) If the operating sound is heard, inspect TP V PID. (10) If the operating sound is not heard, inspect the following. /C relay Open or short to GND circuit in wiring harnesses and connectors (Main relayA/C relayPCM terminal 1J) A/C related parts
CONTINUED
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TO. MODEL .INDEX
FUEL AND EMISSION CONTROL SYSTEMS (WL, WL Turbo)

ENGINE TUNE-UP . . . . . . . . . . . . . . . . . . . . . . . . . F2 2 ENGINE TUNE-UP PREPARATION . . . . . . . . F2 2 IDLE SPEED ADJUSTMENT . . . . . . . . . . . . . . F2 2 IDLE-UP SPEED ADJUSTMENT . . . . . . . . . . . F2 2 INJECTION TIMING ADJUSTMENT . . . . . . . . F2 3 INTAKE-AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . F2 4 VACUUM HOSE ROUTING DIAGRAM . . . . . F2 4 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2 5/7 TURBOCHARGER INSPECTION . . . . . . . . . . F2 8/9 GLOW PLUG REMOVAL/INSTALLATION . . . F2 9 GLOW PLUG INSPECTION . . . . . . . . . . . . . . . F2 9 GLOW PLUG RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . F2 9 GLOW PLUG RELAY INSPECTION . . . . . . . . F210 GLOW PLUG CORD INSPECTION . . . . . . . . F210 ACCELERATOR PEDAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F210/11 ACCELERATOR CABLE INSPECTION/ADJUSTMENT . . . . . . . . . . . . F211 IDLING KNOB, IDLING CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F211 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . F212 BEFORE REPAIR PROCEDURE . . . . . . . . . . F212 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F212 FUEL TANK REMOVAL/INSTALLATION . . . . F213/15 FUEL FILTER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . F215/16 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . F216 FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F216 FUEL FILTER AIR BLEEDING . . . . . . . . . . . . . F216 SEDIMENTOR WATER DRAINING . . . . . . . . . F216 SEDIMENTOR SWITCH INSPECTION . . . . . F216/17 FUEL WARMER INSPECTION . . . . . . . . . . . . F217 FUEL INJECTION PUMP (FIP) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F217 FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F217/18 INJECTION NOZZLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . F218 INJECTION NOZZLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . F219 INJECTION NOZZLE INSPECTION . . . . . . . . F219/20 FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F220 FUEL CUT VALVE (FCV) INSPECTION . . . . . F220/21 FICD SOLENOID VALVE NO.1, NO.2 INSPECTION F221 TIMER CONTROL VALVE (TCV) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F222 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . F223 EXHAUST SYSTEM INSPECTION . . . . . . . . . F223 EXHAUST SYSTEM REMOVAL/INSTALLATION . . . . . . . . . . . . . . F223/25 EMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F225 ROLLOVER VALVE INSPECTION . . . . . . . . . F225 EVAPORATIVE CHAMBER INSPECTION . . . F225 EGR VALVE INSPECTION . . . . . . . . . . . . . . . . F226 EGR SOLENOID VALVE INSPECTION . . . . . F226 EGR PIPE, EGR VALVE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . F226 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . F227 COMPONENT PARTS . . . . . . . . . . . . . . . . . . . . F227 POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION . . . . . . . . . . . . . . F228 POWERTRAIN CONTROL MODULE (PCM) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F228/31 NE SENSOR INSPECTION . . . . . . . . . . . . . . . F232 ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION . . . . . . . . . . . . . . . . . F232/33 IDLE SWITCH INSPECTION . . . . . . . . . . . . . . F233 CONTROL LEVER POSITION SENSOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . F233/34 ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . . F235 DTC READING PROCEDURE . . . . . . . . . . . . . F235 AFTER REPAIR PROCEDURE . . . . . . . . . . . . F235 DTC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . F236/38 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . F239 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . F239 TROUBLESHOOTING ITEM TABLE . . . . . . . . F239 SYMPTOM TROUBLESHOOTING . . . . . . . . . F240/60 SYSTEM INSPECTION . . . . . . . . . . . . . . . . . . . F261/64
CONTINUED
F21
TO. MODEL .INDEX
ENGINE TUNE-UP
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION 1. Warm up the engine to normal operating temperature. 2. Turn the all electrical loads off. 3. Connect a tachometer. IDLE SPEED ADJUSTMENT WL 1. Perform Engine tune-up preparation. 2. Verify that the idle speed is within the specification. Specification 700740 (720$20) rpm 3. If not within the specification, adjust the idle speed by turning the IAS (idle adjustment screw).
LOCKNUT
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
4. After adjusting the idle speed, tighten the locknut securely. IDLE-UP SPEED ADJUSTMENT 1. Perform Engine tune-up preparation. 2. Turn all electrical loads off in neutral shift position. 3. Apply vacuum of 53.3 kPa {400 mmHg, 15.8 inHg} or over to actuator B, and measure the idle-up speed.
WL
ADJUSTING SCREW C ADJUSTING SCREW B
LOCKNUT B
ACTUATOR A ACTUATOR B
WL, WL Turbo
IAS ADJUSTING SCREW C ADJUSTING SCREW B
LOCKNUT B
4. After adjusting the idle speed, tighten the locknut securely. WL Turbo 1. Perform Engine tune-up preparation. 2. Verify that the idle speed is within the specification. Specification General (L.H.D.) : 760800 (780$20) rpm Europe and UK : 700740 (720$20) rpm Caution D Turning the idle switch (Europe and UK only) with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 3. If not as specified, loosen the idle switch locknut and adjust the idle speed by turning the idle switch.
LOCKNUT
11.814.7 Nm {120150 kgfcm, 104130 inlbf}
ACTUATOR A ACTUATOR B
Specification 12001500 (1,350$150) rpm 4. If not within the specification, do as follows; (1) Loosen the locknut B. (2) Adjust the idle-up speed by turning the adjusting screw B. (3) Tighten the locknut B. Tightening torque 5.98.8 Nm {6090 kgfcm, 5378 inlbf} 5. Release actuator B to atmosphere and apply vacuum of 53.3 kPa {400 mmHg, 15.8 inHg} or over to actuator A, and measure the idle-up speed. Specification WL vehicle: 805855 (830$25) rpm WL Turbo, WL (Europe only): 825875 (850$25) rpm 6. If not as specified, adjust the idle-up speed by turning adjusting screw C.
IDLE SWITCH
CONTINUED
F22
TO. MODEL .INDEX
ENGINE TUNE-UP
INJECTION TIMING ADJUSTMENT Warning D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always observe the Fuel Line Safety Procedures, Fuel Hose Installation. Caution D After tightening the FIP mounting nuts and bolt after loosening them, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.) 6. Turn the crankshaft counterclockwise to approx. 30 BTDC. (Align the SST installation hole on the crankshaft pulley.) 7. Turn the crankshaft lightly right and left, and verify that the dial gauge indicator does not move. Then set the indicator to 0 mm {0 in}. 8. Turn the crankshaft clockwise to position the indicator pin to 10 ATDC (white mark) and read the dial indicator.
INDICATOR PIN BTDC 0 (YELLOW MARK)
ATDC 10 (WHITE MARK)
1. Remove the injection pipes (Refer to FUEL SYSTEM, FUEL INJECTION PUMP (FIP) 9. If not as specified, adjust by loosening the FIP REMOVAL/INSTALLATION.) mounting nut and bolt and turn the FIP. 2. Remove the cooling fan 10. Tighten the FIP mounting nuts and then the bolt. (Refer to Section E, COOLING FAN, COOLING FAN REMOVAL/INSTALLATION.) Tightening torque 3. Turn the crankshaft pulley at slow rotation to align 1925 Nm {1.92.6 kgfm, 1418 ftlbf} the timing mark (BTDC 0 : yellow mark) with MOUNTING NUT indicator pin.
INDICATOR PIN BTDC 0 (YELLOW MARK)
Specification 0.951.05 mm {0.0380.041 in} (1.0$0.05 mm {0.039$0.019 in})
MOUNTING BOLT ATDC 10 (WHITE MARK)
4. Remove the hydraulic head plug from the injection pump. 5. Mount the SST into the plug hole on the hydraulic head so that the dial indicator probe touches the plunger end of the pump and the dial indicator indicates approx. 2.0 mm {0.079 in}.
49 9140 074
11. Remove the SST. 12. Install the hydraulic head plug and a new gasket. Tightening torque 1419 Nm {1.42.0 kgfm, 1114 ftlbf} 13. Connect the injection pipes. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 14. Bleed the air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 15. Inspect for fuel leakage. 16. Check the timing belt tension. (Refer to Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
CONTINUED
F23
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
WL
TO POWER BRAKE UNIT
FICD SOLENOID VALVE No.1 FICD SOLENOID VALVE No.2
FICD ACTUATOR
VACUUM PUMP
WL TURBO
TO POWER BRAKE UNIT FICD SOLENOID VALVE No.2
TO RFW ACTUATOR
4WD ONLY FICD SOLENOID VALVE No.1
EGR VALVE
EGR SOLENOID VALVE
FICD ACTUATOR
VACUUM PUMP
CONTINUED
F24
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION Warning D When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the intake-air system. WL 1. Disconnect the negative battery cable. 2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
7.910.7 Nm {80110 kgfcm, 7095 inlbf}
18.725.4 {1.92.6, 13.818.8} 2.02.9 Nm {2030 kgfcm, 1826 inlbf}
2.02.9 Nm {2030 kgfcm, 1826 inlbf} 7.911.7 Nm {80120 kgfcm, 70104 inlbf}
18.725.4 {1.92.6, 13.818.8}
8.912.7 Nm {90130 kgfcm, 79112 inlbf}
7.911.7 Nm {80120 kgfcm, 70104 inlbf} Nm {kgfm, ftlbf}
1 2 3 4 5
Fresh-air duct Air cleaner Air hose Resonance chamber Air intake pipe
6 7 8 9
FICD solenoid valve No.1 FICD solenoid valve No.2 FICD solenoid valve bracket Intake manifold
CONTINUED
F25
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
WL Turbo 1. Disconnect the negative battery cable. 2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Refill the engine coolant to radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1
4.9 Nm {50 kgfcm, 43 inlbf}
4.9 Nm {50 kgfcm, 43 inlbf}
8.912.7 Nm {90130 kgfcm, 79112 inlbf}
7.911.7 Nm {80120 kgfcm, 70104 inlbf}
2.02.9 Nm {2030 kgfcm, 1826 inlbf}
7.911.7 Nm {80120 kgfcm, 70104 inlbf} 4.9 Nm {50 kgfcm, 43 inlbf}
7.911.7 Nm {80120 kgfcm, 70104 inlbf}
1 2 3 4
Fresh-air duct Air cleaner Air intake hose Air hose
5 6 7 8
Air intake pipe Air hose Charge air cooler Air hose
CONTINUED
F26
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
STEP 2
1925 {1.92.6, 1418}
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
1925 {1.92.6, 1418}
1925 {1.92.6, 1418} 1925 {1.92.6, 1418}
R R
Nm {kgfm, ftlbf}
1 2 3
FICD solenoid valve No.1 FICD solenoid valve No.2 EGR solenoid valve
4 5 6
FICD solenoid valve bracket Air intake pipe Intake manifold
CONTINUED
F27
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTION Wastegate Actuator Inspection Caution D Compressed air used in the workshop is highly pressurized and can damage the actuator. Adjust the air pressure with a transformer, and inspect the actual pressure by using an air blower before actual use. Stop blowing air if the rod moved.
MIRROR TURBOCHARGER
4. Inspect all fins of compressor wheel while rotating the compressor wheel by hand. 5. If the compressor wheel is interfering with the housing, it is likely that more than two fins are damaged, cracked or bent. Replace the turbocharger. Note D If scratches are found inside the housing but the fins are okay, the turbocharger is okay. Scratches are made in the turbocharger made by factory.
1. Disconnect the air hose of the wastegate actuator on the compressor housing side. 2. Apply the compressed air using the air gun. 3. Note the air pressure when the wastegate actuator is moved. Specification 107115 kPa {1.091.18 kgf/cm2, 15.516.8 psi}
WASTEGATE ACTUATOR
ROD
4. If not within the specification, replace the turbocharger. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) Compressor Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the compressor wheel from view A. Note D To make work accurate, use a penlight to inspect.
Turbine Wheels Inspection 1. Remove the air hose. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 2. Remove the joint pipe. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 3. Set the small mirror as shown and inspect the turbine wheel from view B. Note D To make work accurate, use a penlight to inspect.
MIRROR TURBOCHARGER
4. Inspect all fins of turbine wheel while rotating the turbine wheel by hand.
CONTINUED
F28
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
5. If the turbine wheel is interfering with the housing, it is likely that one or more fins are damaged, cracked or bent. Replace the turbocharger. Note D Grinding marks on the shaft are normal. This mark is for adjusting the shaft balance at the factory. GLOW PLUG INSPECTION 1. Remove the glow plug cord. 2. Inspect the resistance between the glow plug terminal and the cylinder head. Specification Glow plug resistance Approx. 0.75 [20 C {68 F}]
GLOW PLUG
GRINDING MARK
GLOW PLUG REMOVAL/INSTALLATION 3. If not as specified, replace the glow plug. Caution D Do not damage the heated section of the glow plug. D Do not reuse a glow plug that has been dropped over a height of 10 cm {0.4 in}. D When removing the glow plug, first loosen it over one pitch by using a tool, then loosen by hand. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. GLOW PLUG RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove glow plug relay. 3. Install the glow plug relay.
8.912.7 Nm {90130 kgfcm, 79112 inlbf}
GLOW PLUG RELAY
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 0.815 Nm {815 kgfcm, 713 inlbf}
4. Connect the negative battery cable.
1 2
Glow plug cord Glow plug
CONTINUED
F29
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
GLOW PLUG RELAY INSPECTION System Inspection 1. Carry out the Glow system inspection. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Glow System Inspection.) 2. If not as specified, perform the further inspection for the glow plug relay. Continuity Inspection Note D Perform the following test only when directed. 1. Remove the glow plug relay. 2. Inspect for continuity between terminals C and D of the glow plug relay under the following conditions.
C D C A D R B
1925 {1.92.6, 1418}
GLOW PLUG CORD INSPECTION 1. Remove the glow plug cord. (Refer to GLOW PLUG REMOVAL/INSTALLATION.) 2. Verify that the glow plug cord is not broken or bent. 3. Verify there is continuity at both ends of the glow plug cord. 4. If there is no continuity, replace the glow plug cord. ACCELERATOR PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. (Refer to Section N, MANUAL STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. General (R.H.D.)
: Continuity
Step 1 2 A B+ B GND
1925 {1.92.6, 1418}
3. If there is no continuity, replace the glow plug relay. (Refer to GLOW PLUG RELAY REMOVAL/INSTALLATION.) If as specified but the System Inspection is failed, inspect following: Open circuit D Power circuit (Glow plug relay connector terminal A (1-pin: R/B) and battery) D Power circuit (Glow plug relay connector terminal A 123456567 (2-pin) and PCM connector terminal O) D GND circuit (Glow plug relay connector terminal A (1-pin: R) and glow plug cord) D GND circuit (Glow plug relay connector terminal B (2-pin) and engine GND) D Signal circuit (Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I) Short circuit D Glow plug relay connector terminal A (1-pin: R/B) and battery to GND. D Glow plug relay connector terminal A (2-pin) and PCM connector terminal O to GND. D Glow plug relay connector terminal A (1-pin: R) and PCM connector terminal I to GND. 4. Repair or replace faulty areas. 5. Install the glow plug relay.
R
5.0 Nm {50 kgfcm, 44 inlbf} Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Idling knob Idling cable Brake switch connector Accelerator cable + Installation Note Spring pin Clevis pin E clip Pin Bushing Push rod Clevis Nut Nut Pedal component + Installation Note
CONTINUED
F210
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
Except General (R.H.D.) ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Warm up the engine, then turn the engine switch off. 2. Measure the free play of the accelerator cable.
LOCKNUT
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
Free play 13 mm {0.040.11 in} 3. If not as specified, adjust by turning locknut.
IDLING KNOB, IDLING CABLE INSPECTION General (R.H.D.) 1 Accelerator cable 1. Verify that the accelerator pedal is in the idling + Installation Note position, when the idling knob is not turned. 2 Accelerator pedal 2. Verify that the accelerator pedal moves in the direction that engine speed increases, when the Pedal Component Installation Note idling knob is turned to the right. D Carry out the BRAKE PEDAL HEIGHT 3. Verify that the accelerator pedal returns to the INSPECTION procedure after installing the pedal idling position when the idling knob is turned to the component. left. (Refer to Section P, BRAKE PEDAL HEIGHT INSPECTION.) D Carry out the CLUTCH PEDAL INSPECTION procedure after installing the pedal component. (Refer to Section H, CLUTH PEDAL INSPECTION/ADJUSTMENT.) Accelerator Cable Installation Note D Carry out the ACCELERATOR CABLE INSPECTION/ADJUSTMENT procedure after installing the accelerator cable. (Refer to ACCELERATOR CABLE INSPECTION/ADJUSTMENT.)
IDLING KNOB
CONTINUED
F211
TO. MODEL .INDEX
FUEL SYSTEM
FUEL SYSTEM
BEFORE REPAIR PROCEDURE Warning D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
D Fuel in the fuel system is under high pressure
when the engine is not running. Warning D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following Fuel Line Safety Procedures. Fuel Line Safety Procedures D Avoid fuel line spills and leaks by completing the following procedures. (1) Remove the fuel-filler cap and release the pressure in the fuel tank. (2) When disconnecting a fuel hose, wrap a rag around it to protect against fuel leakage. (3) Plug the fuel hose after removal. AFTER REPAIR PROCEDURE Warning D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe Fuel Hose Installation described below. Fuel Hose Installation D Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
CONTINUED
F212
TO. MODEL .INDEX
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION Warning D Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. 1. Disconnect the negative battery cable. 2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the drain plug and drain the fuel from the fuel tank. 4. Remove the rear flap. 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
1.12.1 Nm {1122 kgfcm, 1019 inlbf}
1.12.1 Nm {1122 kgfcm, 1019 inlbf}
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
WITH BOX
1.12.1 Nm {1122 kgfcm, 1019 inlbf}
B SEAL RUBBER R
R
1622 {1.62.3, 1216} 1.12.1 Nm {1122 kgfcm, 1019 inlbf}
1622 {1.62.3, 1216}
WITHOUT BOX
3246 {3.24.7, 2433}
EUROPE
DRAIN PLUG
2632 {2.63.3, 1923} 3246 {3.24.7, 2433}
EXCEPT EUROPE
Nm {kgfm, ftlbf}
CONTINUED
F213
TO. MODEL .INDEX
FUEL SYSTEM
SEAL R RUBBER
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
R WITH BOX
1.12.1 Nm {1122 kgfcm, 1019 inlbf}
R
11.816.6 Nm {120170 kgfcm, 105147 inlbf} 11.816.6 Nm {120170 kgfcm, 105147 inlbf} 1622 {1.62.3, 1216}
1622 {1.62.3, 1216} 1.12.1 Nm {1122 kgfcm, 1019 inlbf} 3246 {3.24.7, 2433}
WITHOUT BOX
EUROPE DRAIN HOSE

2632 {2.63.3, 1923} 3246 {3.24.7, 2433}
EXCEPT EUROPE
Nm {kgfm, ftlbf}
1 2 3 4 5 6
Evaporative chamber (If equipped) Joint hose + Installation Note Breather hose + Installation Note Under guard Fuel hose + Installation Note Fuel tank
7 8 9 10 11 12 13 14
Evaporative hose + Installation Note Fuel gauge sender unit Rollover valve Fuel-filler pipe Dust cover Fuel inlet pipe Check valve (twoway) Evaporative chamber
CONTINUED
F214
TO. MODEL .INDEX
FUEL SYSTEM
Evaporative Hose Installation Note D Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
10 mm {0.39 in}
912 mm {0.360.47 in}
912 mm {0.360.47 in}
VIEW A
VIEW B
EVAPORATIVE HOSE
Fuel Hose Installation Note D Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Fuel hose: 25 mm {0.98 in}
FUEL FILTER DISASSEMBLY/ASSEMBLY 1. Disconnect the negative battery cable. 2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Disassemble in the order indicated in the table. 4. Assemble in the reverse order of removal. 5. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 6. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 7. Start the engine and verify that fuel does not leak from the fuel system. 8. If fuel leaks, reassemble the fuel filter.
WITH FUEL WARMER WITHOUT FUEL WARMER
1925 {1.92.6, 1418}
10 mm {0.39 in}
FUEL HOSE
Breather Hose Installation Note D Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Breather hose: 25 mm {0.98 in}
Nm {kgfm, ftlbf}
10 mm {0.39 in}
BREATHER HOSE
Joint Hose Installation Note D Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 35 {1.4 in}
CONTINUED
F215
TO. MODEL .INDEX
FUEL SYSTEM
SEDIMENTOR SWITCH INSPECTION Continuity Inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Drain fuel from the fuel filter. (Refer to FUEL SYSTEM, SEDIMENTOR WATER DRAINING.) 3. Remove the sedimentor switch. 4. Inspect continuity of the sedimentor switch by using an ohmmeter.
Float Up Down
UP DOWN
1 2 3 4 5 6 7
Connector Fuel hose Priming pump Fuel filter + Assembly Note Sedimentor switch + Assembly Note Drain plug Fuel warmer
Sedimentor Switch Assembly Note D Apply a small amount of fuel to a new O-ring. Tighten the sedimentor switch enough to the fuel filter by hand. Fuel Filter Assembly Note D Apply a small amount of fuel to the fuel filter O-ring. Tighten the fuel filter approx. 3/4 by hand after the O-ring contacts the priming pump. FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL FILTER AIR BLEEDING Caution D Continuously cranking the engine for over 30 seconds can damage the battery and the starter.
D Repeat cranking the engine for 30 seconds and
Continuity Yes No
FLOAT
5. If not as specified, replace the sedimentor switch. If as specified, inspect following: Open circuit D GND circuit (Sedimentor switch connector terminal B and body GND) D Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C)
SEDIMENTOR SWITCH A B
stop for 510 seconds until the engine starts. SEDIMENTOR WATER DRAINING 1. Disconnect the negative battery cable. 2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Loosen the drain plug located at the bottom of the fuel filter. 4. Pump the priming pump and drain the water. 5. After all the water has been drained, tighten the drain plug. 6. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 7. Reconnect the negative battery cable.
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
ENGINE SWITCH A B
A B
C D
CONTINUED
F216
TO. MODEL .INDEX
FUEL SYSTEM
Short circuit D GND circuit (Sedimentor switch connector terminal B and body GND to power circuit) D Power circuit (Sedimentor switch connector terminal A and engine switch connector terminal C to GND) FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION Caution D After removing/installing the FIP, be sure to inspect the timing belt tension. If the belt tension is not inspected, the timing belt and the camshaft may become damaged. (Refer to section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
6. Repair or replace faulty areas. 7. Install the sedimentor switch. 8. Reconnect the negative battery cable. 9. Bleed air from the fuel filter. (Refer to FUEL SYSTEM, FUEL FILTER AIR BLEEDING.) 1. Disconnect the negative battery cable. FUEL WARMER INSPECTION 2. Complete the BEFORE REPAIR PROCEDURE. With fuel warmer (Refer to FUEL SYSTEM, BEFORE REPAIR 1. Disconnect the negative battery cable. PROCEDURE.) 2. Complete the BEFORE REPAIR PROCEDURE. 3. Remove the FICD solenoid valve bracket. (Refer to FUEL SYSTEM, BEFORE REPAIR (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM PROCEDURE.) REMOVAL/INSTALLATION.) 3. Remove the fuel warmer. 4. Remove the air intake pipe. (Refer to FUEL SYSTEM, FUEL FILTER (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM DISASSEMBLY/ASSEMBLY.) REMOVAL/INSTALLATION.) 4. Verify that the resistance between terminal A and 5. Set the No.1 cylinder to TDC. the fuel warmer body is within the specification 6. Remove in the order indicated in the table. when vacuum of 26.640.0 kPa 7. Install in the reverse order of removal. {200300mmHg, 7.911.8 inHg} is applied 8. Complete the AFTER REPAIR PROCEDURE. to port A of the fuel warmer. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) 9. Inspect injection timing. (Refer to ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT.) 10. Check the timing belt tension. (Refer to Section B2,TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Installation Note.)
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
Specification
Water temperature C {F} 20 {68} Resistance () 0.51.5
2.43.4 Nm {2535 kgfcm, 2230 inlbf}
A
1925 {1.92.6, 1418}
5968 {6.07.0, 4450}
5. If not as specified, replace the fuel warmer. FUEL INJECTION PUMP (FIP) INSPECTION Caution D FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction.
D Consult your distributor for disassembly if any FIP
A R
internal parts are possibly malfunctioning.
2529 {2.53.0, 1921}
1925 {1.92.6, 1418}
Nm {kgfm, ftlbf}
CONTINUED
F217
TO. MODEL .INDEX
FUEL SYSTEM
1 2 3 4 5 6
Injection pipe Accelerator cable Fuel hose Connector Vacuum hose Timing belt cover + Section B2, TIMING BELT, TIMING BELT REMOVAL/INSTALLATION, Timing Belt Cover Installation Note. FIP mounting bolt FIP mounting nut FIP + Removal Note Key
5968 {6.07.0, 4450} 2732 {2.73.3, 2023}
R R
7 8 9 10
2.43.4 Nm {2535 kgfcm, 2230 inlbf}
FIP Removal Note 1. Remove the two FIP pulley mounting bolts. 2. Loosen the FIP pulley locknut. 3. Remove the pulley with the SST.
49 S120 215A 1 2 3 4 5 6
FIP PULLY LOCKNUT
2529 {2.53.0, 1921}
Nm {kgfm, ftlbf}
Injection pipe Fuel leak pipe Fuel leak washer Injection nozzle + Installation Note Nozzle washer Corrugated gasket + Installation Note
INJECTION NOZZLE REMOVAL/INSTALLATION Caution D Cover the outlet of the injection pipe and fuel hose with a rag. D Catch the fuel with a rag. 1. Disconnect the negative battery cable. 2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FICD solenoid valve bracket. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
Corrugated Gasket Installation Note D Install the bead side facing combustion chamber. Injection Nozzle Installation Note D Install each injection nozzle onto the FIP, matching their identification color rings as shown.
INJECTION NOZZLE FIP
COLOR RING
CONTINUED
F218
TO. MODEL .INDEX
FUEL SYSTEM
INJECTION NOZZLE DISASSEMBLY/ASSEMBLY Caution D The injection port is very small so it must be kept clean. Otherwise, foreign material may get stuck in the injection nozzle, causing damage. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. Injection Starting Pressure 1. Connect the injection nozzle to a nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Slowly lower the nozzle tester handle and note the pressure when injection starts. Injection starting pressure 11.412.1 MPa {116124 kgf/cm2, 16501760 psi} (New) More than 10.0 MPa {102 kgf/cm2, 1450 psi} (Inspection) 4. If the injection starting pressure is not within the specification, adjust it by installing the correct shim. Note D Adding/subtracting 0.02 mm {0.0008 in} thickness shim increases/decreases the starting pressure approx. 470 kPa {4.8 kgf/cm2, 68 psi}.
Nm {kgfm, ftlbf}
2949 {3.05.0, 2236}
1 2 3 4 5 6 7 8 9
Nozzle holder body + Disassembly Note Ring Shim Nozzle spring Spring seat Spacer Needle valve + Assembly Note Nozzle body Retaining nut
ADJUSTING SHIM
Nozzle Holder Body Disassembly Note D Secure the retaining nut in a vise and remove the nozzle holder body. Needle Valve Assembly Note D When the nozzle body or the needle valve is damaged, replace them as a set. INJECTION NOZZLE INSPECTION Caution D Fuel and fuel tank used for the nozzle tester must be kept clean. Otherwise, foreign material may get stuck between the nozzle and the nozzle tester, causing damage.
Atomization 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Lower the handle several times as quickly as possible so that a pulsating whistling sound is heard, and note the atomization pattern. (1) Uniform, proper atomization (2) Incorrect injection angle and direction
(1) (2)
NORMAL
FAULTY ANGLE
FAULTY DIRECTION
4. If necessary, disassemble and clean or replace the injection nozzle.
CONTINUED
F219
TO. MODEL .INDEX
FUEL SYSTEM
Nozzle Leakage 1. Connect the injection nozzle to the nozzle tester. 2. Bleed the air by pumping the nozzle tester handle several times. 3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to the injection nozzle, and inspect for fuel leakage from the nozzle spray port. 4. Remove the needle valve from the nozzle body. 5. Clean the needle valve and the nozzle body with clean light oil. 6. Verify that the needle valve moves smoothly in the nozzle body. 7. If not, replace the nozzle assembly.
CORRECT
WRONG
4. If fuel leaks, disassemble and clean or replace the injection nozzle. Operating Inspection 1. Verify that the needle valve and nozzle body are not damaged. 2. Verify that the nozzle body is not damaged. Hold the nozzle body upright and insert approximately two thirds of the needle valve; then see if the needle valve drops to the valve seat by its own weight when released.
NEEDLE VALVE
FUEL CUT VALVE (FCV) REMOVAL/INSTALLATION Without immobilizer system 1. Disconnect the negative battery cable. 2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 3. Remove the FCV. 4. Install in the reverse order of removal.
NUT
2.02.4 Nm {2025 kgfcm, 1821 inlbf}
FCV
1525 {1.52.6, 1118}
Nm {kgfm, ftlbf}
NOZZLE BODY
FUEL CUT VALVE (FCV) INSPECTION Without immobilizer system On-vehicle Inspection Note D Perform the following test only when directed. 1. With the engine idling, disconnect the FCV connector and verify that the engine stops. 2. If the engine does not stop, carry out the following inspection. Off-vehicle Inspection 1. Disconnect the negative battery cable. 2. Remove the FCV. 3. Connect the battery positive voltage to the FCV terminal and GND the FCV body, 4. Verify that the FCV stem is drawn into the FCV.
Injection Nozzle Cleaning 1. Inspect the outer and inner surfaces of the injection nozzle for carbon accumulation. 2. If carbon is observed on the outer surface, remove it by using a hard wood chip. 3. If carbon is observed inside of the nozzle, remove it by using a toothpick.
CONTINUED
F220
TO. MODEL .INDEX
FUEL SYSTEM
: Continuity
Step 1 2 B+ GND Terminal A B A Port B C
: Airflow
B GND
A B+ B
5. Replace the FCV if not as specified. If as specified, inspect following: Open circuit D GND circuit (FCV body and engine switch connector terminal IG1) D Power circuit (FCV connector terminal and engine switch connector terminal IG1)
ENGINE SWITCH A B
C
123456567
AIR FILTER
A B
C D
Short circuit D GND circuit (FCV body and engine switch connector terminal IG1 to GND) D Power circuit (FCV connector terminal and engine switch connector terminal IG1 to GND) 6. Repair or replace faulty areas. 7. Install the FCV. 8. Reconnect the negative battery cable. FICD SOLENOID VALVE NO.1, NO.2 INSPECTION System Inspection 1. Carry out the FICD System Inspection. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, FICD System Inspection.) 2. If not as specified, perform the further inspection for the FICD solenoid valve No.1, No.2. Airflow Inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the FICD solenoid valve No.1, No.2. (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 3. Inspect for airflow between ports of the solenoid valve.
4. If not as specified, replace the faulty FICD solenoid valve. If as specified but the System Inspection is failed, inspect following: Vacuum hose improper routing, kinks or leakage. Open circuit D GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal C) D GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) D Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1) D Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1)
ENGINE SWITCH A B
A B
C D
Short circuit D GND circuit (FICD solenoid valve No.1 connector terminal B and PCM connector terminal IG1) D GND circuit (FICD solenoid valve No.2 connector terminal B and PCM connector terminal P) D Power circuit (FICD solenoid valve No.1 connector terminal A and engine switch connector terminal IG1 to GND) D Power circuit (FICD solenoid valve No.2 connector terminal A and engine switch connector terminal IG1 to GND) 5. Repair or replace faulty areas. 6. Install the FICD solenoid valve No.1, No.2. 7. Reconnect the negative battery cable.
CONTINUED
F221
TO. MODEL .INDEX
FUEL SYSTEM
TIMER CONTROL VALVE (TCV) INSPECTION Europe and UK 1. Carry out the Timer Control Valve (TCV) Control Inspection. (Refer to TROUBLESHOOTING, SYSTEM INSPECTION, Timer Control Valve (TCV) Control Inspection.) 2. If not as specified, perform the further inspection for the TCV. Continuity Inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the FIP connector (8pin terminal). 3. Verify that there is continuity between the FIP connector terminal D and TCV body.
FIP
A B
C D
E F
G H
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
4. If not as specified, send TCV to a distributor for replacement. If the TCV is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Open circuit D Power circuit (FIP connector terminal D and PCM connector terminal H) Short circuit D FIP connector terminal D and PCM connector terminal H to GND 5. Repair or replace faulty areas. 6. Reconnect the FIP connector.
CONTINUED
F222
TO. MODEL .INDEX
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect each exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning D When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
WL
TURKEY and GENERAL (R.H.D., L.H.D.)
EUROPE and UK
Nm {kgfm, ftlbf}
1 2 3
Tail pipe Main silencer

D Middle pipe (Turkey and General (R.H.D.,
4 5 6
Front pipe Exhaust manifold insulator Exhaust manifold
L.H.D.) D OC (Europe and UK)
CONTINUED
F223
TO. MODEL .INDEX
EXHAUST SYSTEM
WL TURBO
EUROPE and UK
TURKEY and GENERAL (R.H.D., L.H.D.)
Nm {kgfm, ftlbf}
1 2 3 4 5
Tail pipe Main silencer

D Middle pipe (General (L.H.D.)) D OC (Europe and UK)
6 7 8 9
Joint pipe Turbocharger + Removal Note Oil pipe + Installation Note Exhaust manifold
Front pipe Exhaust manifold insulator
CONTINUED
F224
TO. MODEL .INDEX
EXHAUST SYSTEM, EMISSION SYSTEM

Oil Pipe Installation Note D Be sure to confirm that the turbocharger is installed correctly, then install the oil pipe. Water pipe D Install the water pipe and tighten to the specified torque. Tightening torque 2435 Nm {2.43.6 kgfm, 1826 ftlbf}
OIL PIPE A
EMISSION SYSTEM
ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow.
WATER PIPE
3. Turn the valve over and blow from port A. Verify that there is no airflow.
Turbocharger Removal Note D Do not drop the turbocharger. D Do not bend the wastegate actuator mounting or rod. D Cover the intake, exhaust and oil passages to prevent dirt or other objects from entering.
A
4. If not as specified, replace the rollover valve. EVAPORATIVE CHAMBER INSPECTION If equipped 1. Remove the evaporative chamber. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Blow from port A and verify that there is airflow from port B.
3. If not as specified, replace the evaporative chamber.
CONTINUED
F225
TO. MODEL .INDEX
EMISSION SYSTEM
EGR VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note D Perform the following test only when directed. 1. Remove the EGR valve. 2. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure. 4. If not as specified, replace the EGR solenoid valve. If the EGR solenoid valve is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. D Vacuum hose improper routing, kinks or leakage. Open circuit D Power circuit (EGR solenoid valve connector terminal A and PCM connector terminal 1R) D GND circuit (EGR solenoid valve connector terminal B and body GND through common connector)
EGR SOLENOID VALVE
Vacuum (kPa {mmHg, inHg}) Below 21.325.3 {160 190, 6.3 7.4} Except above
Airflow Yes No
Short circuit D EGR solenoid valve connector terminal A and PCM connector terminal 1R. 5. Repair or replace faulty areas. 6. Install the EGR solenoid valve connector. EGR PIPE, EGR VALVE REMOVAL/INSTALLATION WL Turbo for Europe and UK 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 1925 {1.92.6, 1418}
3. If not as specified, replace the EGR valve. EGR SOLENOID VALVE INSPECTION WL Turbo for Europe and UK Airflow Inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Remove the EGR solenoid valve (Refer to INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION, WL Turbo.) 3. Inspect for airflow between ports of the solenoid valve. : Continuity
Step 1 2 B+ GND Terminal A B A Port B C
1925 {1.92.6, 1418} 3540 {3.54.0, 2529} Nm {kgfm, ftlbf}
: Airflow
1 2
EGR pipe EGR valve
B GND
A B+ B
C
123456567
AIR FILTER
CONTINUED
F226
TO. MODEL .INDEX
CONTROL SYSTEM
CONTROL SYSTEM
COMPONENT PARTS
WL TURBO
WL TURBO
1 2 3 4 5 6 7 8 9
*1: *2:
Glow indicator light Temperature control dial Engine switch PCM FICD solenoid valve No.2 FICD solenoid valve No.1 EGR solenoid ECT sensor DLC valve*1
10 11 12 13 14 15 16 17
A/C relay TCV*2 Control lever position sensor*2 Glow plug NE sensor Idle switch*2 Starter Glow plug relay
WL Turbo for Europe and UK Europe and UK
CONTINUED
F227
TO. MODEL .INDEX
CONTROL SYSTEM
POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION 1. Disconnect the battery negative cable. 2. Remove the drivers side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
8.912.7 Nm {90130 kgfcm, 78112 inlbf}
1 2 3
PCM connector PCM installation nut PCM
POWERTRAIN CONTROL MODULE (PCM) INSPECTION Caution D The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. 1. Remove the drivers side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 2. Remove the PCM with the connector connected. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) Note D With the PCM connector connected, body ground the voltmeter negative () lead and measure the voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage of each PCM terminals by using a voltmeter. 4. If the output voltage is not normal while each input voltage is normal, inspect the related device systems. When they are normal, replace the PCM. 5. Install the PCM. (Refer to POWERTRAIN CONTROL MODULE (PCM) REMOVAL/INSTALLATION.) 6. Install the drivers side front side trim. (Refer to Section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
CONTINUED
F228
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal Voltage (Reference)
Europe and UK S T Terminal Q R O P M N K L I J G H E C F D A B Turkey and General (R.H.D. ,L.H.D.) O M K I G E C A P N L J H F D B
Signal Constant voltage
A A*1
Connected to D Control lever position osition sensor D EGR valve position sensor Ground FICD solenoid valve No.1
Test condition Engine switch ON OFF Idle Constant Idle ECT is below 20C {68F}.
Voltage (V) Approx. 5.0 Below 1.0 Approx. 5.0 Below 1.0 Below 1.0 B+ Below 1.0 Approx. 10 Approx. 3.1 Approx. 0.8 Approx. 0 Approx. 0.05 B+
Action
D Inspect related harness.
D Inspect PCM. D Inspect related harness.
B C
System ground FICD control
D Inspect related harness. D Inspect FICD solenoid
ECT is above 20C {68F}. D Start Engine switch (Starter) ECT sensor Engine switch is on. While cranking Engine switch is on. ECT is 20C {68F}. After warm-up F Engine speed (Input) A/C (With A/C) NE sensor Engine switch is on. Idle Temperature control dial Engine switch is on. Temperature control dial is off and fan switch is off.
valve No.1. + FUEL SYSTEM, FICD SOLENOID VALVE No No.1, 1 No.2 INSPECTION D Inspect related harness D Inspect related harness
ECT
D Inspect engine coolant
temperature sensor. + ECT SENSOR INSPECTION D Inspect related harness

D Inspect NE sensor. + NE SENSOR INSPECTION D Inspect related harness D Inspect microswitch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION D Inspect fan switch. + Section U, CONTROL SYSTEM, HEATER CONTROL UNIT INSPECTION D Inspect related harness D Inspect idle switch. + IDLE SWITCH INSPECTION D Inspect related harness.
Temperature control dial is at position other than off and fan switch is on.
Below 1.0
H H*1
Idle (Control lever open or close)
Idle switch
Engine switch is on.
Accelerator pedal is depressed. Accelerator pedal is released.
B+ Below 1.0
*1:
Europe and UK
CONTINUED
F229
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal
Signal Glow plug voltage
Connected to Glow plug
Test condition ECT is below 60C {140F}. For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on. For less than 10 minutes after starting engine. Over 10 minutes after starting engine. While cranking For less than approx. 2 seconds after turning engine switch on. Over approx. 2 seconds after turning engine switch on. While cranking
Voltage (V) B+
Action
D Inspect related harness
Below 1.0 B+ Below 1.0 B+ B+
ECT is above 60C {140F}.
Below 1.0 B+ Below 1.0 B+ Approx. 4.2 Approx. 0.81.5 B+ 6.97.1

D Inspect engine switch. + Section T, POWER SYSTEM, , IGNITION SWITCH INSPECTION D Inspect related harness. D Inspect control lever posi-
Power supply
Engine switch
Engine switch
OFF
ON J*1 Control lever position (Detection) ( ) Control lever position sensor Engine switch is on. Accelerator pedal is fully open. Accelerator pedal is fully closed. K Engine speed (Out(Out put) Power supply Instrument cluster Engine switch Engine switch is on. Idle Engine switch OFF
tion sensor. + CONTROL LEVER POSITION SENSOR INSPECTION D Inspect related harness.
L*1
Below 1.0 B+ B+ B+ Below 1.0 Below 1.0
ON L*2 A/C control (With A/C) A/C relay Engine switch is on. Idle A/C is not operating A/C is operating M Glow indicator light g control Glow indicator light g Engine switch is off. Engine switch is on and within approx. 4.5 sec. (25 C {77 F}). Over 4.5 seconds (25 C {77 F}) after turning engine switch on. N*1 A/C control (With A/C) A/C relay Engine switch is on. Idle A/C is not operating A/C is operating N*2
*1:
D Inspect engine switch. + Section T, POWER SYSTEM, , IGNITION SWITCH INSPECTION D Inspect related harness. D Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION D Inspect related harness. D Inspect glow indicator
B+
g light + Section T, WARNING AND INDICATOR SYSTEM, WARNING AND INDICATOR LIGHT BULB REPLACEMENT D Inspect related harness.
D Inspect A/C relay. + S Section ti U, U CONTROL SYSTEM, A/C RELAY INSPECTION D Inspect related harness.
B+ B+ Below 1.0
Europe and UK *2: Turkey and General (R.H.D., L.H.D.)
CONTINUED
F230
TO. MODEL .INDEX
CONTROL SYSTEM
Terminal
Signal Glow system
Connected to Glow plug relay Engine coolant temperature is below 60C {140F}.
Test condition For less than approx. 15 seconds after turning engine switch on. Over approx. 15 seconds after turning engine switch on. For less than 10 minutes after starting engine. Over 10 minutes after starting engine. While cranking Engine coolant temperature is above 60C {140F}. For less than approx. 2 seconds after turning engine switch on. Over approx. 2 seconds after turning engine switch on. While cranking
D Temperature control dial
Voltage (V) B+
Action
D Inspect glow plug relay. + INTAKE-AIR SYSTEM, GLOW PLUG RELAY INSPECTION D Inspect related harness.
Below 1.0 B+ Below 1.0 B+ B+
Below 1.0 B+ Below 1.0

D Inspect FICD solenoid
FICD control
FICD solenoid valve No.2
Idle
is not at OFF D Engine coolant temperature is below 60C {140F}.

D Temperature control dial
B+
valve No.2. + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION D Inspect related harness.
is not at OFF D Engine coolant temperature is above 60C {140F}. Q Q*1 Timer control TCV Engine switch is on. Idle B+ Below 1.0 Engine switch is on. Idle B+ Below 1.0 Engine switch is on on. Open terminal TEN Short terminal TEN No DTC output DTC output B+ Below 1.0 Below 1.0 0B+
D Inspect TCV. + CONTROL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION D Inspect related harness.
R R*3
EGR valve control
EGR solenoid valve
D Inspect EGR solenoid
valve. + EMISSION SYSTEM, SYSTEM EGR SOLENOID VALVE INSPECTION D Inspect related harness.
S S*1
Diagnostic test mode
Data link connector (DLC) (Terminal TEN) Data link connector (DLC) (Ter (Terminal FEN)
T T*1
DTC output
*1: *2:
Europe and UK Turkey and General (R.H.D., L.H.D.) *3: WL Turbo for Europe and UK
CONTINUED
F231
TO. MODEL .INDEX
CONTROL SYSTEM
NE SENSOR INSPECTION Note D Perform the following test only when directed. 1. Disconnect the NE sensor connector. 2. Measure the resistance between the NE sensor connector terminals A and B by using an ohmmeter. ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Note D Perform the following test only when directed. 1. Drain the engine coolant from the radiator. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Disconnect the ECT sensor connector. 3. Remove the ECT sensor. 4. Place the sensor in water with a thermometer, and heat the water gradually.
Specification 800920 3. If not as specified, replace the NE sensor. Tightening torque 7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 4. If NE sensor is okay, but PCM terminal F voltage is out of specification, inspect the following: Open circuit D Engine speed (input) circuit (NE sensor connector terminal A and PCM connector terminal F) D GND circuit (NE sensor connector terminal B and PCM connector terminal B) Short circuit D NE sensor connector terminal A and PCM connector terminal F to GND 5. Repair or replace faulty areas. 6. Reconnect the NE sensor connector.
5. Measure the resistance between engine coolant temperature sensor terminals A and B by using an ohmmeter. Specification
Water temperature (C {F}) 20 {68} 80 {176} Resistance (k) 2.272.73 0.290.34
6. If not as specified, replace the ECT sensor. 7. Refill the radiator with the specified engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 8. Install the ECT sensor. Tightening torque 1623 Nm {1.62.4 kgfm, 1217 inlbf} 9. If ECT sensor is okay, but PCM terminal E voltage is out of specification, inspect as follows:
CONTINUED
F232
TO. MODEL .INDEX
CONTROL SYSTEM
Open circuit D Reference voltage circuit (ECT sensor connector terminal A and PCM connector terminal E through common connector) D GND circuit (ECT sensor connector terminal B and PCM connector terminal B through common connector) Short circuit D ECT sensor connector terminal A and PCM connector terminal E through common connector to GND 10. Repair or replace faulty areas. 11. Reconnect the ECT sensor connector. IDLE SWITCH INSPECTION Europe and UK Continuity Inspection Note D Perform the following test only when directed. 1. Disconnect the negative battery cable. 2. Disconnect the 8-pin connector of FIP. 3. Inspect for continuity between the idle switch terminal E and ground using an ohmmeter. Open circuit D Power supply circuit (Idle switch connector terminal E and PCM connector terminal 2H through common connector) D GND circuit (Idle switch connector terminal and body GND)
G H
E F
C D
A B
Short circuit D Power supply circuit (Idle switch connector terminal E and PCM connector terminal H through common connector to GND) 6. Repair or replace faulty areas. 7. Reconnect the 8-pin connector of FIP. CONTROL LEVER POSITION SENSOR INSPECTION Europe and UK Output Voltage Inspection Note D Perform the following test only when directed. 1. Verify that the FIP control lever is fully closed. 2. Turn the engine switch on and measure the PCM terminal J voltage. Specification
A B
C D
E F
G H
COMPONENT SIDE CONNECTOR (VIEW FROM TERMINAL SIDE)
Specification : Continuity
Measuring g condition Not accelerated Other Terminal E GND
Measuring condition Accelerator pedal is fully open. Accelerator pedal is fully closed.
Voltage (V) Approx. 4.2 Approx. 0.81.5
Caution D Turning the idle switch with its connector connected can break the harness. Be sure to disconnect the connector when turning the idle switch more than one rotation. 4. If not as specified, loosen the idle switch locknut and adjust the continuity by turning the idle switch. 5. If not as specified, replace the idle switch. If the idle switch is okay, but PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary.
3. If not as specified, replace the control lever position sensor. When the reading is out of specification, send the FIP with the control lever position sensor to a distributor to repair. If the PCM terminal voltage is out of specification, inspect as follows and repair or replace as necessary. Open circuit D Constant voltage circuit (Control lever position sensor connector terminal B and PCM connector terminal A through common connector) D Control lever position signal circuit (Control lever position sensor connector terminal A and PCM connector terminal J through common connector) D GND circuit (Control lever position sensor connector terminal C and PCM connector terminal B through common connector)
CONTINUED
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CONTROL SYSTEM
G H
E F
C D
A B
Short circuit D Control lever position sensor connector terminal B and PCM connector terminal A through common connector to GND D Control lever position sensor connector terminal A and PCM connector terminal J through common connector to GND 4. Repair or replace faulty areas. 5. Reconnect the 8-pin connector of FIP.
CONTINUED
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Europe and UK only DTC READING PROCEDURE Using the SST (Self-Diagnosis Checker) 1. Connect the SSTs to the DLC located in the engine compartment and GND the black (negative) lead to the body.
49 B019 9A0 DLC
Using the Voltmeter 1. Turn the engine switch off. 2. Connect the DLC located in the engine compartment terminal TEN and GND using a jumper wire. Caution D Connecting the wrong DLC terminals may possibly cause a malfunction. Carefully connect the specified terminals only. 3. Connect the negative battery lead of voltmeter (20V range) to the DLC terminal FEN, and the positive lead to the DLC terminal +B.
49 H018 9A1A
FEN
2. Set the select switch on the SST (self-diagnosis checker) to A. 3. Turn the dial switch on the SST (system selector) to 1, and the test switch to SELF TEST. 4. Turn the engine switch on. 5. Verify that the buzzer sounds for approximately 3 seconds and code 88 flashes for 5 seconds. If DTC is not detected, 00 will then be indicated. Note D If the 88 does not flash, inspect +B terminal of the data link connector, and the related harnesses and connectors. D If the 88 flashes and the buzzer sounds more than 20 seconds, inspect the harness between the PCM terminal and the DLC. If the harness is normal, replace the PCM and inspect. 6. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. Note D A DTC consists of four numbers. They are flashed one by one in the right window on the display. (1 is always shown on the left window.) D When there are multiple malfunctions, the codes are displayed in numerical order. 7. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 8. Remove the SSTs.
DLC TEN +B GND
4. turn the engine switch on. 5. The voltmeter indicates the battery positive voltage for approximately 3 seconds, then indicates 0V. 6. Read the DTCs indicated by the movement of the voltmeters needle. If DTC is not detected, the needle does not move. 7. If any DTCs are indicated, inspect the appropriate areas and repair as necessary. 8. After completion of repairs, erase all DTCs from the memory. (Refer to AFTER REPAIR PROCEDURE.) 9. Remove the voltmeter and the jumper wire. AFTER REPAIR PROCEDURE 1. After repairs, disconnect the negative battery cable for at least 20 seconds, and depress the brake pedal. Reconnect the negative battery cable. 2. Warm up the engine to normal operating temperature. Note D If the engine will not start, keep the starter operated for 5-6 seconds. 3. Perform the DTC READING PROCEDURE again. 4. Verify that the DTC is not detected.
CONTINUED
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DTC INSPECTION DTC Table
DTC No. 09 Indicator Pattern Condition Engine coolant temperature (ECT) sensor malfunction Control lever position sensor malfunction
12
36
Glow plug relay malfunction
DTC 09 DETECTION CONDITION POSSIBLE CAUSE STEP 1 2
ENGINE COOLANT TEMPERATURE (ECT) SENSOR MALFUNCTION Input value to PCM is excessively high or low for more than 2.0 sec.
D ECT sensor malfunction D Open or short circuit in wiring from ECT sensor terminal A to PCM terminal E D Open or short circuit in wiring from ECT sensor terminal B to PCM terminal B
INSPECTION Does ECT sensor or PCM connector have poor connection? Disconnect ECT sensor connector. Turn engine switch on. Is there 5 V at connector terminal A? Is there continuity between connector terminal A and PCM terminal E? Is ECT sensor okay? + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION Clear DTC from memory. Is same code No. present after performing After Repair Procedure? Clear DTC from memory. Is there any DTC present after performing After Repair Procedure?
PCM (20 PIN) ECT SENSOR E J B A B
ACTION Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connector, then go to Step 6. Go to next step. Go to next step. Inspect for open or short circuit in wiring harness. (PCM terminal BECT sensor terminal B) Go to next step. Repair or replace wiring harness, then go to Step 6. Go to next step. Replace ECT sensor, then go to Step 6. Go to Step 1. Intermittent poor connection in harnesses or connector. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
3 4
HARNESS SIDE CONNECTOR (VIEW FROM HARNESS SIDE)
CONTINUED
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DTC 12 DETECTION CONDITION
CONTROL LEVER POSITION SENSOR MALFUNCTION

D Input voltage from control lever positIon sensor is below 0.1 V or above 4.75 V when continued for 1.0
sec.
D When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V. D Control lever position sensor malfunction D Idle switch malfunction D Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
POSSIBLE CAUSE
nal B
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
PCM terminal J
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A
D Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
STEP 1 2
INSPECTION Does control lever position sensor connector or PCM connector have poor connection? Disconnect control lever position sensor connector. Turn engine switch on. Is there 5 V at connector terminal B? Is there continuity between connector terminal A and PCM terminal J? Is there continuity between connector terminal C and PCM terminal B? Is there continuity between connector terminal E and PCM terminal H? Is idle switch okay? + CONTROL SYSTEM SYSTEM, IDLE SWITCH INSPECTION Clear DTC from memory. Is same code No. present after performing After Repair Procedure? Clear DTC from memory. Is there any DTC present after performing After Repair Procedure?
PCM (20 PIN) A J B G H E F C D
ACTION Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connectors, then go to Step 7. Go to next step. Go to next step. Inspect for open or short circuit in wiring harness. (PCM terminal Acontrol lever position sensor terminal B) Go to next step. Repair or replace wiring harness, then go to Step 7. Replace control lever position sensor, then go to Step 7. Repair or replace wiring harness, then go to Step 7. Go to next step. Repair or replace wiring harness, then go to Step 7. Go to next step. Replace idle switch. Go to Step 1. Intermittent poor connection in harness or connector. Repair connector and/or harness, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
CONTROL LEVER POSITION SENSOR
3 4 5 6
A B
CONTINUED
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DTC 36 DETECTION CONDITION
GLOW PLUG RELAY MALFUNCTION

D When the glow plug relay is on, current voltage signal of the relay below 1.0 V is inputted to the PCM
continuously for more than 1.0 sec.

D When the glow plug relay is off, signal of the relay current voltage above 4.0 V is inputted to the PCM
continuously for more than 1.0 sec. POSSIBLE CAUSE STEP 1 2

D D D D
Glow plug relay malfunction Open or short circuit in wiring from PCM terminal O to glow plug relay terminal A (BR) Open or short circuit in wiring from PCM terminal I to glow plug relay terminal A (B) Open or short circuit in wiring from glow plug relay terminal A (R) to glow fuse INSPECTION ACTION Yes No Yes No Yes No Yes No Yes No Yes No Yes No Repair or replace connectors, then go to Step 5. Go to next step. Go to next step. Repair or replace wiring harness. Go to next step. Repair or replace wiring harness. Go to next step. Repair or replace wiring harness. Go to next step. Replace glow plug relay. Go to Step 1. Intermittent poor connection in harnesses or connectors. Repair connectors and/or harnesses, then go to next step. Go to applicable DTC inspection. Troubleshooting completed.
GLOW PLUG RELAY A A O I (WIRE COLOR: R) (WIRE COLOR: B) A B
Does glow plug relay connector or PCM connector have poor connection? Remove glow plug relay. Is there continuity between connector terminal A and PCM terminal O? Is there continuity between connector terminal A (B) and PCM terminal I? Is there continuity between connector terminal B and body GND? Is there continuity between connector terminal A (R) and glow fuse? Is glow plug relay okay? + INTAKE-AIR INTAKE AIR SYSTEM, SYSTEM GLOW PLUG RELAY INSPECTION Clear DTC from memory. Is same code No. present after performing After Repair Procedure? Clear DTC from memory. Is there any DTC present after performing After Repair Procedure?
PCM (20 PIN)
3 4 5
CONTINUED
F238
TO. MODEL .INDEX
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD Before processing with the following troubleshooting, refer to section GI to understand the basic troubleshooting procedure.
No. 1 2 3 4 5 TROUBLESHOOTING ITEMS Melts main or other fuse Will not crank Hard start/long crank/erratic start/erratic crank Engine stalls After start At idle Cranks normally but will not start
TROUBLESHOOTING ITEM TABLE D Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart. D If a diagnostic trouble code is displayed, proceed with inspection steps for the code.
DESCRIPTION Starter does not work. Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition. Engine stops unexpectedly at idle and/or after start. Starter cranks engine at normal speed but engine will not run. Refer to ENGINE STALLS if this symptom appears after engine stall. Fuel is in tank Battery is in normal condition. Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up. Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively. Engine runs after engine switch is turned off. Engine stops unexpectedly at beginning of acceleration during acceleration or while cruising. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. Performance is poor under load (i.e. power down when climbing hills). Fuel economy is unsatisfactory. Oil consumption is excessive.
6 7
Slow return to idle/fast idle Engine runs rough/rolling idle
8 9
Runs on Engine stalls/quits Engine runs rough Misses Buck/jerk Hesitation/stumble Surges Acceleration/cruise Acceleration/cruise Acceleration/cruise Acceleration/cruise/ deceleration Acceleration Acceleration/cruise Acceleration/cruise
10 11 12 13 14 15 16 17 18 19 20
Lack/loss of power Poor fuel economy High oil consumption/leaks Cooling system concerns Cooling system concerns Excessive black smoke Engine noise Vibration concerns (engine) A/C does not work.
Overheating Runs cold
Engine runs at higher than normal temperature/overheats. Engine does not reach normal operating temperature. Excessive black smoke is observed in exhaust gas. Engine noise from under hood. Vibration from under hood or driveline. A/C compressor magnetic clutch does not engage when A/C is turned on. A/C compressor magnetic clutch does not disengage. Symptom occurs randomly and is difficult to diagnose.
A/C always on/A/C compressor runs continuously. Intermittent concerns
CONTINUED
F239
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Symptom 1-Melts main or other fuse Symptom 2-Will not crank Symptom 3-Hard start/long crank/erratic start/erratic crank Symptom 4-Engine stalls-after start/at idle Symptom 5-Cranks normally but will not start Symptom 6-Slow return to idle/fast idle Symptom 7-Engine runs rough/rolling idle Symptom 8-Runs on Symptom 9-Engie stalls/quits-acceleration/cruise Engine runs rough acceleration/cruise Misses-acceleration/cruise Buck/jerk acceleration/cruise/deceleration Hesitation/stumble acceleration Surges acceleration/cruise F2-49-50 F2-51-52 F2-53 F2-54 F2-55 F2-55 F2-56 F2-56-58 F2-58 F2-58-59 F2-59-60 F2-60 F2-40 F2-41 F2-42-43 F2-43-44 F2-45-46 F2-46 F2-47-48 F2-49
Symptom 10-Lack/loss of power-acceleration/cruise Symptom 11-Poor fuel economy Symptom 12-High oil consumption/leaks Symptom 13-Cooling system concerns-overheating Symptom 14-Cooling system concerns-runs cold Symptom 15-Excessive black smoke Symptom 16-Engine noise Symptom 17-Vibration concerns (engine) Symptom 18-A/C does not work Symptom 19-A/C is always on/a/c compressor runs continuously Symptom 20-Intermittent concerns
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM TROUBLESHOOTING
SYMPTOM 1 MELTS MAIN OR OTHER FUSE TROUBLESHOOTING HINTS Inspect the condition of the fuse.
Shorted harness fuse
Deterioration
Repair shorted harness and replace fuse
Replace fuse
Damaged Fuse MAIN (100 A)
Related Wiring Harness Main fuse D Engine switch D Generator D PCM Blower relay D Blower fan motor A/C relay D Refrigerant pressure switch HEAD fuse D Generator Glow plug relay D Glow plugs Engine fuse D PCM D FICD solenoid valve No.1 D FICD solenoid valve No.2 D FCV
HEAD (30 A) GLOW (60 A) ENGINE (15 A)
CONTINUED
F240
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TROUBLESHOOTING
SYMPTOM 2 DESCRIPTION POSSIBLE CAUSE STEP 1
WILL NOT CRANK Starter does not work.

D Open starter circuit between battery and starter through engine switch D Starter malfunction D Seized/hydrolocked engine, flywheel
INSPECTION Verify the following: D Battery condition D Battery connection D Fuses Are all items okay? Turn engine switch to START. Is clicking sound heard from starter? Do any other electrical accessories work?
RESULTS Yes No Yes No Yes No Go to next step.
ACTION
Service as necessary and repeat Step 1. Go to next step. Go to Step 6. Go to next step. Inspect the charging system. + Section G, CHARGING SYSTEM Go to next step.
2 3
Disconnect battery negative cable. Disconnect engine switch and starter connectors. Inspect for electrical connections, loose wire, bent or corroded terminals. Inspect Ins ect for continuity on following circuits: D Engine switch connector terminal STA and starter terminal S D Battery positive cable and starter magnet switch terminal B. Are all circuits okay? Inspect engine switch. + Section T, POWER SYSTEM, IGNITION SWITCH INSPECTION. Is engine switch okay? Inspect starting system. Is starting system okay?
Yes
No
Repair or replace open circuit.
Yes No Yes No
Go to next step. Replace engine switch. Inspect for seized/hydrolocked engine, flywheel. + Section H, CLUTCH, FLYWHEEL INSPECTION Service as required. + Section G, STARTING SYSTEM, STARTER INSPECTION
CONTINUED
F241
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TROUBLESHOOTING
HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK Starter cranks engine at normal speed but engine requires excessive cranking. Battery is in normal condition.
D D D D D D
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating Glow system malfunction RESULTS Yes
D D D D D D
Fuel leakage Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Fuel line clogging ACTION
STEP 1
INSPECTION Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system y D Cracks on intake-air system parts D Air cleaner element restriction Are all items okay? Is engine overheating?
Go to next step.
No
Service as necessary and repeat Step 1.
Yes No
Go to flowchart No.13 for COOLING SYSTEM CONCERNS OVERHEATING. Go to next step. Inspect glow system operation. + SYSTEM INSPECTION, Glow System Inspection Replace any defective parts as necessary. If quick start system is okay, go to next step. Go to next step. Go to next step. Adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT Repair or replace as necessary. Go to next step. Repair or replace as necessary. Go to next step. Go to Step 9. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket. D Damaged valve seat. D Worn valve stem or valve guide. Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace the timing belt. Go to next step. Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Does engine start normally after warm-up?
Yes
No 4 Is idle speed correct? Yes No 5 6 7 8 Is there any restriction in exhaust system? Inspect for fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe? Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay? Yes No Yes No Yes No Yes
No
Inspect injection timing. Is injection timing okay?
Yes No
CONTINUED
F242
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TROUBLESHOOTING
STEP 10
INSPECTION Remove and inspect injection nozzle as follows: D Clogged nozzle D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay?
RESULTS Yes
ACTION Remove FIP. Inspect FIP. If FIP okay, inspect fuel line for clogging. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
No
ENGINE STALLS AFTER START/AT IDLE Engine stops unexpectedly at idle and/or after start.
D D D D D D D
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction RESULTS Yes
D D D D D D D
Fuel leakage Fuel filter clogging Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION
STEP 1
INSPECTION Note: D The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system Does immobilizer indicator light flash and indicate?
Go to ON-BOARD DIAGNOSTIC FUNCTION of immobilizer system.
No
Go to next step.
Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system y D Cracks on intake-air system parts D Air cleaner element restriction Are all items okay? Is engine overheating?
Yes
Go to next step.
No
Yes No
Go to flowchart No.13 for COOLING SYSTEM CONCERNS-OVERHEATING. Go to next step. Go to next step. Go to Step 6 Go to next step. Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection Go to next step.
4 5
Does engine run normally after warm-up? Inspect glow system operation, + SYSTEM INSPECTION, Glow System Inspection. Is quick start system operation normal? Note: D If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C lines. Turn the fan switch on. Is pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes No Yes No
Yes
No
If A/C is always on, go to symptom troubleshooting No.19 A/C always ON/A/C compressor runs continuously. For other symptoms, inspect following: D Refrigerant charging amount. D Cooling fan operation.
CONTINUED
F243
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TROUBLESHOOTING
STEP 7
INSPECTION Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
RESULTS Yes No Go to next step.
ACTION
Inspect the following: D Engine coolant temperature sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE SENSOR INSPECTION D Vacuum pump D Vacuum leakage around vacuum pump or fittings D FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION D FICD actuator D PCM terminal voltage, J D Open circuit between FICD solenoid No.1 connector terminal B and PCM connector terminal C D Open circuit between FICD solenoid No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step. Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT If symptom still appears, go to next step. Go to next step. Repair or replace as necessary. Go to next step. Go to Step 12. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket. D Damaged valve seat D Worn valve seat or valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt. Go to next step. Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Replace fuel filter cartridge. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Remove FIP. Inspect FIP. Adjust valve clearance.
Depress accelerator pedal slightly. Crank the engine. Does engine start now?
Yes
No Yes No Yes No Yes
9 10 11
Inspect fuel leakage from fuel pipe. Is any fuel leakage found in fuel pipe? Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay?
No
12
Yes No
13 14
Inspect fuel filter for clogging. Is fuel filter okay? Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Is valve clearance correct?
Yes No Yes No
15
Yes No
CONTINUED
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TROUBLESHOOTING
SYMPTOM 5 DESCRIPTION
CRANKS NORMALLY BUT WILL NOT START

D D D D D D D D D
POSSIBLE CAUSE
Starter cranks engine at normal speed but engine will not run. Refer to ENGINE STALLS if this symptom appears after engine stall. Fuel is in tank. Battery is in normal condition. Poor fuel quality D Fuel filter clogged Air cleaner restriction D Incorrect injection timing FCV malfunction D FIP malfunction Low engine compression D Injection nozzle malfunction Fuel leakage RESULTS Yes ACTION Go to ON-BOARD DIAGNOSTIC FUNCTION of immobilizer system.
STEP 1
INSPECTION Note: D The following test should be performed on vehicles with immobilizer system. Go to next step for vehicles without immobilizer system. system Does immobilizer indicator light flash and indicate?
No
Go to next step.
Verify the following: D Fuel quality including water contamination D Loose bands on intake-air system D Cracks on intake-air system parts D Air cleaner element restriction D Fuses Are all items okay? Turn engine switch to ON. Is FCV operation sound heard?
Yes
Go to next step.
No
Yes No
4 5
Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay?
Yes No Yes
No
Yes No
Go to next step. Inspect for the following: D Stuck FCV D Open circuit in FCV D Open wiring harness between engine switch and FCV. D Poor ground of FCV. Go to step 6. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring or cylinder D Damaged cylinder head gasket. D Damaged valve seat D Worn valve stem or valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt. Go to next step. Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Replace fuel filter cartridge. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
7 8
Inspect fuel filter for clogging. Is fuel filter okay? Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay?
Yes No Yes No
CONTINUED
F245
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TROUBLESHOOTING
STEP 9
INSPECTION Is valve clearance correct?
RESULTS Yes No
ACTION Remove FIP. Inspect FIP. Adjust valve clearance.
SLOW RETURN TO IDLE/FAST IDLE Engine takes more time than normal to return to idle speed. Engine speed continues at fast idle after warm-up.
D Malfunction of ECT sensor D Thermostat stuck open D FICD malfunction D Injection timing is incorrect. D Accelerator cable free play incorrect adjustment D Idle speed incorrect adjustment
INSPECTION Inspect FICD system operation. + SYSTEM INSPECTION, FICD System Inspection. Is FICD operation normal?
ACTION
Inspect the following: D ECT sensor + CONTROL SYSTEM, ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION D FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION D FICD actuators. D PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION D Short to ground circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. D Short to ground circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P Repair or replace any defective part as necessary. If FICD system is okay, go to next step. Go to next step. Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Inspect for free play of accelerator cable. Adjust free play as necessary. If free play is okay, inspect and adjust idle and/or idleup speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT Replace thermostat.
Inspect injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT. Is injection timing okay? Remove thermostat and inspect operation. + section E, THERMOSTAT, THERMOSTAT INSPECTION. Is thermostat okay?
Yes No
Yes
No
CONTINUED
F246
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TROUBLESHOOTING
SYMPTOM 7 DESCRIPTION
ENGINE RUNS ROUGH/ROLLING IDLE Engine speed fluctuates between specified idle speed and lower speed and excessive engine shake. Idle speed is too slow and engine shakes excessively.
D D D D D D D
POSSIBLE CAUSE
Poor fuel quality Starting system malfunction Air cleaner restriction Incorrect idle speed Engine overheating A/C system improper operation Glow system malfunction RESULTS Yes No Yes No
D D D D D D D
Fuel leakage Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression FICD malfunction ACTION
STEP 1
INSPECTION Verify the following: D Fuel quality including water contamination D Air cleaner element restriction Is engine overheating?
Go to next step. Service as necessary and repeat Step 1. Go to flowchart No.13 for COOLING SYSTEM CONCERNS-OVERHEATING. Go to next step. Go to next step. Go to Step 5. Go to Step 6. Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection Go to next step.
3 4
Does engine run normally after warm-up? Inspect glow system operation. + SYSTEM INSPECTION INSPECTION, Glow System Inspection. Is glow system operation normal?
Yes No Yes No
Note: D If the following test cannot be performed due to engine stalls, go to step. next ste Connect the pressure gauge to A/C (if equipped) lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK.
Yes
No
If A/C is always on, go to symptom troubleshooting No.19 A/C always ON/ A/C compressor runs continuously. For other symptoms, inspect following: D Refrigerant charging amount. D Cooling fan operation.
Inspect for FICD system operation. + SYSTEM INSPECTION, FICD System Inspection Is FICD operation normal?
Yes No
Go to next step. Inspect the following: D Engine coolant temperature sensor + CONTROL SYSTEM, ECT SENSOR INSPECTION D Vacuum pump D Vacuum leaks around vacuum pump or fittings D FICD solenoid valves + FUEL SYSTEM, FICD SOLENOID VALVE No.1, No.2 INSPECTION Inspection D FICD actuators D PCM terminal voltage (J) + CONTROL SYSTEM, PCM INSPECTION D Open circuit between FICD solenoid valve No.1 connector terminal B and PCM connector terminal C. D Open circuit between FICD solenoid valve No.2 connector terminal B and PCM connector terminal P. Repair or replace any defective part as necessary. If FICD system is okay, go to next step.
CONTINUED
F247
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TROUBLESHOOTING
STEP 7
INSPECTION Depress accelerator pedal slightly. Crank the engine. Does engine start now?
RESULTS Yes
ACTION Inspect and adjust idle speed. + ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT. If symptom still appears, go to next step. Go to next step. Repair or replace as necessary. Go to next step. Go to next step.
No Yes No Yes
8 9
Inspect fuel leakage from fuel pipe. Is any fuel leakage found on fuel pipe? Note: D The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
No
Repair or replace as necessary.
10 11
Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay?
Yes No Yes
Go to Step12. Go to next step. Inspect follows: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem or valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt. Go to next step. Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Replace fuel filter cartridge. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the fuel injection nozzle. Incorrect valve opening pressure: Adjust fuel injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Remove fuel injection pump. Inspect fuel injection pump. Adjust valve clearance.
No
12
Yes No
13 14
Inspect fuel filter for clogging. Is fuel filter okay? Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Is valve clearance correct?
Yes No Yes No
15
Yes No
CONTINUED
F248
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TROUBLESHOOTING
RUNS ON Engine runs after engine switch is turned off.

D FCV malfunction
INSPECTION Run the engine at idle speed. Disconnect the FCV connector. Verify that the engine stops. Does the engine stop?
RESULTS Yes
ACTION Inspect for the following: D Short to power line between engine switch and FCV. Repair or replace wire harness. Inspect for FCV stuck to open.
No
SYMPTOM 9
ENGINE STALLS/QUITS-ACCELERATION/CRUISE ENGINE RUNS ROUGH-ACCELERATION/CRUISE MISSES-ACCELERATION/ CRUISE BUCK/JERK-ACCELERATION/CRUISE/DECELERATION HESITATION/STUMBLE-ACCELERATION SURGES-ACCELERATION/CRUISE
D Engine stops unexpectedly at beginning of acceleration, during acceleration or while cruisD D D D D
DESCRIPTION
ing. Engine speed fluctuates during acceleration or cruising. Engine misses during acceleration or cruising. Vehicle bucks/jerks during acceleration, cruising, or deceleration. Momentary pause at beginning of acceleration or during acceleration. Momentary minor irregularity in engine output. Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Fuel leakage RESULTS Yes No Go to next step. Go to flowchart No.7 ENGINE RUNS ROUGH/ROLLING IDLE. Go to flowchart No.13 COOLING SYSTEM CONCERNS OVERHEATING. Go to next step. Go to next step. Go to Step 5. Go to next step. Repair or replace any defective part according to glow system operation results. + SYSTEM INSPECTION, Glow System Inspection Go to next step. If A/C is always on, go to symptom troubleshooting No.19 A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY. For other symptoms, inspect following: D Refrigerant charging amount. D Cooling fan operation. Go to next step. Clean or replace air cleaner element.
D D D D D D D
POSSIBLE CAUSE
D D D D D D D
Glow system malfunction Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression Clutch slippage ACTION
STEP 1
INSPECTION Is idle speed stable?
Is engine overheating?
Yes No
3 4
Does symptom disappear after warm-up? Inspect for glow system operation. + SYSTEM INSPECTION, Glow System Inspection. Is glow system operation normal? Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specifications? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK. Inspect air cleaner for clogging. Is air cleaner okay?
Yes No Yes No
Yes No
Yes No
CONTINUED
F249
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TROUBLESHOOTING
STEP 7
INSPECTION Note: D The following test should be performed on turbocharger equipped model. For other models, go to Step 9. Inspect the hose band between the following parts: T b h i and d air i D Turbocharger compressor h housing cleaner D Turbocharger compressor housing and charge air cooler. Is the hose band loose?
RESULTS Yes
ACTION Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
No
Go to next step.
Inspect for improper operation, kinks, clogs, or disconnection on the wastegate actuator. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay? Remove injection nozzle. Inspect injection nozzle for the following D Clogged nozzle. D Seized needle valve D Incorrect valve opening pressure. D Faulty nozzle gasket. Is injection nozzle okay? Is there any restriction in exhaust system? Inspect for fuel leakage from pipe. Is any fuel leakage found in fuel pipe? Inspect fuel filter for clogs. Is fuel filter okay? Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay?
Yes No
Turbocharger is okay. Go to next step. Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Repair or replace as necessary. Go to next step. Repair or replace as necessary. Go to next step. Go to next step. Replace fuel filter cartridge. Go to Step 15. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt. If timing belt is broken, damaged or cracked, replace timing belt. Inspect follows: D Clutch slippage D FIP Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
Yes No
10 11 12 13 14
No
15
Yes
No
CONTINUED
F250
TO. MODEL .INDEX
TROUBLESHOOTING
LACK/LOSS OF POWER-ACCELERATION/CRUISE Performance is poor under load (i.e. power down when climbing hills).
D D D D D D D D
Poor fuel quality Starting system malfunction Air leaks from intake-air system Air cleaner restriction Engine overheating A/C system improper operation Clutch slippage Fuel leakage RESULTS Yes No
D D D D D D D D
Fuel filter clogged Incorrect injection timing FIP malfunction Injection nozzle malfunction Low engine compression pressure Turbocharger malfunction Brake system drags EGR system malfunction (WL Turbo) ACTION
STEP 1
INSPECTION Is idle speed stable?
Go to next step. Go to flowchart No.7 ENGINE RUNS ROUGH/ROLLING IDLE. Go to flowchart No. 13 COOLING CONCERNS OVERHEATING. Go to next step. Go to next step. If A/C is always on, go to symptom troubleshooting No.19 A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY. For other symptoms, inspect the following: D Refrigerant charging amount. D Cooling fan operation. Go to next step. Clean or replace air cleaner element. Retighten the hose band. If the concern is resolved, complete the inspection. If the concern still exists, go to next step.
Is engine overheating?
Yes No
Connect the pressure gauge to A/C lines. Turn the fan switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK. Inspect air cleaner for clogging. Is air cleaner okay? Note: D The following test should be performed on turbocharger equipped model. For other models, go to Step 13. Inspect the hose band between the following parts: D Turbocharger T b h compressor h housing i and d air i cleaner D Turbocharger compressor housing and charge air cooler. Is the hose band loose?
Yes No
4 5
Yes No Yes
No
Go to next step.
Inspect the wastegate actuator for improper operation, kinks, clogs, or disconnection. + INTAKE-AIR SYSTEM, WASTEGATE ACTUATOR INSPECTION. Is actuator okay? Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent, , damaged, g , or interfering g with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION. Is there any problem? Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem? Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly?
Yes No
Go to next step. Repair or replace as necessary. If the concern is resolved, complete the inspection. If the concern still exists, the turbocharger is okay. Go to next step. Replace the turbocharger.
Yes
No
Go to next step.
Yes No Yes No
Replace the turbocharger. Go to next step. Go to next step. Replace the turbocharger.
CONTINUED
F251
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TROUBLESHOOTING
STEP 10
INSPECTION Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles. Note: D Inspect all fins on each turbine wheel. Is there any problem?
RESULTS Yes
ACTION Replace the turbocharger.
No
Go to next step.
11
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step. Go to next step. Wipe the oil off the vehicle and install all removed parts in Step 7. Then, go to next step. The turbocharger is okay. Install all removed parts in Step 7. Then, go to next step. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Repair or replace as necessary. Go to next step. Repair or replace as necessary. Go to next step. Go to next step. Replace fuel filter cartridge. Go to next step.
No 12 Is any engine oil found inside the turbocharger compressor housing? Yes No 13 Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle. D Seized needle valve D Incorrect valve opening pressure. D Faulty nozzle gasket. Is injection nozzle okay? Is there any restriction in exhaust system? Inspect fuel leakage from pipe. Is any fuel leakage found on fuel pipe? Inspect fuel filter for clogging. Is fuel filter okay? Note: D The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay? 18 19 Measure engine compression. Is compression okay? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay? Yes No
14 15 16 17
No
Yes No Yes
Go to Step 20. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing. If timing belt is broken, damaged or cracked, replace timing belt. Inspect follows: D Brake system dragging D Clutch slippage D FIP Inspect TCV (if equipped). + TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
No
20
Yes
No
F252
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TO. MODEL .INDEX
TROUBLESHOOTING
POOR FUEL ECONOMY Fuel economy is unsatisfactory. D Idle speed or idle-up speed incorrect adjustment D Accelerator cable free play incorrect adjustment D Air cleaner restriction D Engine cooling system malfunction D Improper transmission fluid level D Poor fuel quality D Improper coolant level D Improper engine compression INSPECTION RESULTS Yes
D D D D D D D D D D
Exhaust system clogged Injection timing incorrect Injection nozzle malfunction FIP malfunction High idle speed High idle-up speed FICD malfunction Fuel leakage Brake dragging EGR system malfunction (WL Turbo) ACTION
STEP 1
Inspect the following: D Fuel quality including water contamination D Air cleaner element for restriction D Transmission fluid level D Coolant level Are all items okay? Inspect for idle speed and idle-up speed. + ENGINE TUNE-UP, TUNE-UP IDLE-UP SPEED ADJUSTMENT. Is idle-up speed within specifications? Inspect fuel leakage from pipe. Is any f fuel leakage f found in f fuel pipe? ? Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle. D Seized needle valve D Incorrect valve opening pressure. D Faulty nozzle gasket. Is injection nozzle okay? Is there restriction in exhaust system? Is brake system functioning properly? Note: D The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay? Measure engine compression. Is compression okay? ? Inspect timing belt for the following: D Chipping of gear teeth D Low tension D Breakage, damage, or cracks Is timing belt okay?
Go to next step.
No
Go to next step. Go to flowchart No.6 SLOW RETURN TO IDLE/FAST IDLE. Repair or replace as necessary. Go to next step. Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Inspect exhaust system. Go to next step. Go to next step. Inspect for cause. Go to next step.
3 4
5 6 7
Yes No Yes No Yes
No
8 9
Yes No Yes
No
Go to Step 10. Go to next step. Inspect for the following: D Burnt valve D Worn piston, piston ring, or cylinder D Damaged cylinder head gasket D Damaged valve seat D Worn valve stem and valve guide Repair or replace as necessary. If tension or timing of timing belt is incorrect, adjust timing belt . If timing belt is broken, damaged or cracked, replace timing belt. Inspect for the following: D FIP Adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT
10
Yes No
F253
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TROUBLESHOOTING
HIGH OIL CONSUMPTION/LEAKS Oil consumption is excessive.

D Improper engine oil level D Improper dipstick D Improper engine oil viscosity D Engine internal part malfunction D Oil leak D Turbocharger malfunction
INSPECTION Inspect the following: D Proper dipstick D Pro Proper er engine viscosity D Engine oil level Are all items okay? Note: D The following test should be performed on turbocharger equipped model. For other models, go to Step 10. Remove the parts necessary to inspect the turbocharger. Do not remove the turbocharger. Inspect if the turbocharger primary compressor wheel is bent, damaged, or interfering with the housing on the vehicle. + INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION Is there any problem?
RESULTS Yes No Yes Go to next step.
ACTION
Service as necessary and repeat Step 1. Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside turbocharger. Is there any problem? Turn the turbocharger compressor wheel by hand hand. Does the wheel turn easily and smoothly? Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicles. Note: D Inspect all fins on each turbine wheel. Is there any problem?
Yes No Yes No Yes
Replace the turbocharger. Go to next step. Go to next step. Replace the turbocharger. Replace the turbocharger.
No
Go to next step.
Is any engine oil found inside the turbocharger turbine housing?
Yes
If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step. Go to next step. Wipe the oil off the vehicle. Then, go to next step. Go to next step. If the oil leaked from the damaged pipe, replace the oil pipe. Then, go to next step. Go to next step. Wipe the engine oil off. The turbocharger is okay. Install all parts removed in step 2. Then, go to next step. Inspect oil leakage from outside of engine. Inspect for the following: D Damaged valve seat. D Worn valve stem and valve guide. D Worn or stuck piston ring. D Worn piston, piston ring, or cylinder. Service as necessary.
No 7 8 Is any engine oil found inside the turbocharger compressor housing? Is any engine oil found around oil pipes attached on the turbocharger center housing? Is any engine oil found inside the air intake pipes or Hoses? Measure engine compression. Is compression okay? Yes No Yes No 9 Yes No Yes No
10
F254
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TROUBLESHOOTING
COOLING SYSTEM CONCERNSOVERHEATING Engine runs at higher than normal temperature/overheats.

D D D D D D D
Cooling fan malfunction Low drive belt tension Drive belt damage Improper coolant level Thermostat malfunction Radiator clogging A/C system malfunction RESULTS Yes
D Water temperature gauge or sender unit malfunc-
tion
D Improper or damaged radiator cap D Radiator hose damage D Coolant leakage (engine internal, turbocharger, ex-
ternal) ACTION Go to next step.
STEP 1
INSPECTION Inspect the following: D Engine coolant level D Coolant leakage D Radiator condition D Collapsed or restricted radiator hoses D Radiator pressure cap D Drive belt tension D Drive belt Are all items okay? Connect the pressure gauge to A/C lines. Turn the blower switch on. Is the pressure within specification? + section U, REFRIGERANT SYSTEM SERVICE PROCEDURES, REFRIGERANT PRESSURE CHECK. Inspect water temperature sender unit. Is water temperature sender unit okay?
No
Yes No
Go to next step. If A/C is always on, go to symptom troubleshooting No.19 A/C ALWAYS ON/ A/C COMPRESSOR RUNS CONTINUOUSLY. For other symptoms, inspect the following: D Refrigerant charging amount D Cooling fan operation Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION Replace water temperature sender unit.
Yes
No SYMPTOM 14 DESCRIPTION POSSIBLE CAUSE STEP 1
COOLING SYSTEM CONCERNSRUNS COLD Engine does not reach normal operating temperature.
D Thermostat malfunction
INSPECTION Remove the thermostat from vehicle. Inspect thermostat. + section E, THERMOSTAT, THERMOSTAT INSPECTION INSPECTION. Is thermostat okay?
RESULTS Yes
ACTION Inspect water temperature sender unit operation. + section T, INSTRUMENT CLUSTER, WATER TEMPERATURE SENDER UNIT INSPECTION Replace thermostat.
No
CONTINUED
F255
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 15 DESCRIPTION POSSIBLE CAUSE STEP 1 2 3
EXCESSIVE BLACK SMOKE Excessive black smoke is observed in exhaust gas.

D Air cleaner element restriction D Incorrect fuel injection timing D Injection nozzle malfunction D FIP malfunction D Low engine compression D EGR system malfunction (WL Turbo)
INSPECTION Does any other symptom exist? Inspect air cleaner element for clogging. Is air cleaner element okay? Inspect injection timing. Is injection timing okay?
RESULTS Yes No Yes No Yes No
ACTION Go to appropriate flow chart. Go to next step. Go to next step. Repair or replace air cleaner element. Go to next step. Inspect TCV (if equipped). + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step. Clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket. Go to next step.
Remove injection nozzle. Inspect injection nozzle for the following: D Clogged nozzle. D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket Is injection nozzle okay? Note: D The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay?
Yes No
Yes
No
Measure engine compression. Is compression okay?
Yes No
Inspect fuel injection pump. Inspect for the following: D Damaged valve seat. D Worn valve stem and valve guide. D Worn or stuck piston ring. D Worn piston, piston ring, or cylinder. Service as necessary.
ENGINE NOISE Engine noise from under hood.

D D D D
Engine internal damage Timing belt displacement Injection nozzle malfunction Loose attaching bolts or worn parts
D D D D
Improper drive belt tension Air leaks from intake-air system Turbocharger operating noise EGR system malfunction (WL Turbo)
CONTINUED
F256
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 1
INSPECTION Note: D The following test should be performed on turbocharger equipped model. For other models, go to Step 9. Remove the necessary parts arts to inspect ins ect the turbocharger. Inspect if the turbocharger compressor wheel is bent, damaged, or interfering with the housing on the vehicle. Is there any problem?
RESULTS Yes
ACTION Replace the turbocharger.
No
Go to next step.
Inspect if the turbocharger compressor wheel locknut is loose or has fallen down inside the turbocharger. Is there any problem? Turn the turbocharger compressor wheel by hand hand. Does wheel turn easily and smoothly? Inspect if the turbocharger turbine wheel is damaged, cracked, or interfering with the housing on the vehicle. Is there any problem? Is any engine oil found inside the turbocharger turbine housing?
Replace the turbocharger. Go to next step. Go to next step. Replace the turbocharger. Replace the turbocharger. Go to next step. If an excessive amount of oil is found on the vehicle, replace the turbocharger. If a small amount of oil is found, wipe the oil off the vehicle. Then, go to next step. Go to next step. Wipe the oil off of the vehicle. Then, go to next step. Go to next step. Remove turbocharger. Inspect for cracks on center housing inlet surface. If cracks are found, replace turbocharger. If no cracks are found, DO NOT replace turbocharger. Replace gaskets, bolts, and nuts only. Then, go to next step. Go to next step. Retighten the loose bolts. If any bolt is missing, attach the appropriate new bolt. Turbocharger is okay. Install all removed parts in Step1. Go to next step. Inspect engine oil level or drive belt. Go to next step. Inspect drive belt. Go to next step. Inspect location of rattle for loose parts. Go to next step. Inspect for the following: D Vacuum leaks D Intake-air system leaks Go to next step. Inspect exhaust system for loose parts. Go to next step.
6 7
Is any engine oil found inside the turbocharger compressor housing? Is any exhaust gas leakage found around the location where the turbocharger is attached to the exhaust manifold?
No Yes No Yes
Are any of the attaching bolts of center housing and turbine housing loose?
No Yes No
9 10 11 12
Is squeal, click, or chirp sound present? Is rumble or grind sound present? Is rattle sound present? Is hiss sound present?
13
Is rap or roar sound present?
No Yes No
CONTINUED
F257
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TROUBLESHOOTING
STEP 14
INSPECTION Inspect the injection timing. Is injection timing okay?
RESULTS Yes No
ACTION Go to next step. Inspect TCV (if equipped) + FUEL SYSTEM, TIMER CONTROL VALVE (TCV) INSPECTION If TCV is okay, adjust injection timing. + ENGINE TUNE-UP, INJECTION TIMING ADJUSTMENT Go to next step.
15
Note: D The following test should be performed on vehicles with EGR system. Go to next step for vehicles without EGR system. Carry out EGR system inspection. + SYSTEM INSPECTION, EGR System Inspection Is EGR system okay? Remove the fuel injection nozzle. Inspect for the following: D Clogged nozzle. D Seized needle valve D Incorrect valve opening pressure D Faulty nozzle gasket D Fuel dripping (fuel leakage) Is injection nozzle okay?
Yes
No
16
Yes
No
Inspect for the following: D Metal flow D Bent connecting rod D Damaged valve seat After-leakege, clogged nozzle or seized needle valve: Disassemble and clean or replace the injection nozzle. Incorrect valve opening pressure: Adjust injection nozzle opening pressure. Faulty nozzle gasket: Replace nozzle gasket.
VIBRATION COCNERNS (ENGINE) Vibration from under hood or driveline.

D Loose attaching bolts or worn parts D Components malfunctions such as worn parts
INSPECTION Inspect the following components for loose attaching bolts or worn parts: D Cooling fan D Drive belt and pulley D Engine mounts D Exhaust system Are all items okay?
RESULTS Yes
ACTION Inspect the following: D Wheels D Transmission and mounts D Driveline D Suspension Service as necessary. Readjust or retighten engine mount installation position. Service as necessary for other parts.
No
A/C DOES NOT WORK. A/C compressor magnetic clutch does not engage when A/C is turned on.
D Improper refrigerant charging D D D D D D D D D D D D
amount Microswitch is stuck open. Open A/C magnetic clutch Open circuit in related wire harnesses Poor ground of A/C magnetic clutch A/C low/high pressure switch is stuck open.
A/C relay is stuck open. Seized A/C compressor Frost switch is stuck open. Open circuit in blower resistor Poor blower switch ground ECT sensor malfunction Improper magnet clutch clearance
CONTINUED
F258
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 1
INSPECTION Turn engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Verify the blower motor is operating. Is blower motor okay?
ACTION
Inspect for the following: D Poor ground of fan switch D Open circuit in blower resistor D Poor contact of fan switch D Blower relay is stuck open. D Open circuit in blower relay coil D Seized blower motor D Open circuit in blower motor coil. D Open circuit between blower motor and resistor D Open circuit between fan switch and resistor Repair or replace as necessary. Go to next step. Inspect for the following: D Frost switch is stuck open. D Poor contact of microswitch in heater control unit D Open circuit between PCM connector terminal G and frost switch connector terminal. D Open circuit between frost switch connector terminal and fan switch connector terminal. Repair or replace as necessary. Go to next step. Inspect for the following: D Open circuit in A/C relay coil D Poor contact in A/C relay D A/C relay stuck open D Open circuit between PCM connector terminal L and A/C relay connector terminal. D Open circuit in battery supply line D Open circuit between engine switch and A/C relay connector terminal D Engine coolant temperature sensor malfunction Repair or replace as necessary. Inspect for the following: D Poor ground of A/C magnetic is clutch D Open circuit in magnet is clutch coil D Refrigerant charging amount Repair or replace as necessary. Inspect for the following: D Open circuit between pressure switch connector terminal and A/C magnetic clutch connector terminal D Refrigerant charging amount D A/C pressure switch is stuck open. D Magnetic clutch clearance D A/C compressor is seized. Repair or replace as necessary.
Turn the engine switch on. Set the fan switch to 1st, 2nd, 3rd, or 4th position. Measure the voltage at PCM connector terminal G. + CONTROL SYSTEM, PCM INSPECTION Specification: Less than 2.7 V Is voltage correct? Start the engine and run it at idle speed. Set the fan switch to 1st position. Measure the voltage at terminal of A/C relay connector terminal C. Specification: More than 10.5 V Is voltage correct?
Yes No
Yes No
Disconnect the A/C magnetic clutch connector, Measure the A/C magnetic clutch connector terminal voltage. Specification: More than 10.5 V Is voltage okay?
Yes
No
A/C ALWAYS ON / A/C COMPRESSOR RUNS CONTINUOUSLY. A/C compressor magnetic clutch does not disengage.
D Improper magnetic clutch clearD Short to power line between A/C relay and pressure
ance D Short to ground circuit between PCM and frost switch D Short to ground circuit between PCM and A/C relay
switch
D A/C low/high pressure switch is stuck to close. D A/C relay is stuck to close. D Frost switch is stuck to close.
CONTINUED
F259
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 1
INSPECTION Turn the engine switch on. Turn the blower switch off. Measure the voltage at PCM connector terminal G. Specification: More than 2.7 V Is voltage correct? Start the engine and run it at idle speed. Turn the blower switch off. Measure the voltage at terminal of A/C relay connector terminal C. Specification: 0V Is voltage correct?
ACTION
Inspect for the following: D Short to ground circuit between PCM connector terminal G and frost switch D Short to ground circuit between frost switch and blower switch connector terminal Repair or replace as necessary. Inspect for magnetic is clutch clearance. Adjust it as necessary. Inspect for the following: D Short to ground circuit between PCM connector terminal L and A/C relay terminal C D A/C relay is stuck to close. D Short to power line between A/C relay connector terminal C and A/C pressure switch D Short to power line between pressure switch and A/C compressor magnetic is clutch connector Repair or replace as necessary.
Yes No
SYMPTOM 20 DESCRIPTION STEP 1
INTERMITTENT CONCERNS Symptom occurs randomly and is difficult to diagnose. INSPECTION RESULTS Yes No Yes Go to next step. Go to symptom index. Inspect each wire for corrosion, bent or loose terminal clamps. ACTION
Talk to customer. Retrieve vehicle service history. Does vehicle have a number of previous revious repairs and components replaced for a certain symptom? Key off. If input is switch-type component, turn on manually. Turn engine switch off. Connect the voltmeter to the PCM terminals. Lightly ta tap on sus suspect ect com component onent, wiggle and pull each wire/connector at suspect component or PCM. Is any voltage out of range, or do they suddenly change and go back into range? Start the engine and run it at idle speed. Lightly tap on suspect component, wiggle and pull each wire/connector at suspect component or PCM PCM. Are any voltages out of range, or do they suddenly change and go back into range? Accurately spray water on suspect component wire, component, or vacuum line related to possible fault area. Is any voltage out of range, or suddenly change and go back into range, or was there a noticeable engine stumble?
No
Go to next step.
Yes
Inspect each wire for corrosion, bent or loose terminal clamps. Go to next step. Fault area is identified. If fault occurred while spraying on component: Replace part and verify repair. If fault occurred while spraying water: Inspect each wire for corrosion, bent, loose terminals, or poor wire terminal clamps. If fault occurred while spraying vacuum line: Repair vacuum hoses. Inspect wire and connector at suspect component for corrosion, bent, loose terminals, or poor wire terminal crimps and high tension wire. Repair as necessary.
No Yes
No
CONTINUED
F260
TO. MODEL .INDEX
TROUBLESHOOTING
SYSTEM INSPECTION FICD System Inspection Fast-Idle Function 1. Verify that the FICD actuator rod is not pulled. 2. Verify that the engine is cold (ECT is below 20 C {68 F}). 3. Turn fan switch off. 4. Start the engine. 5. Verify that the FICD actuator rod is pulled.
11. If not, disconnect vacuum hose A from the FICD actuator and inspect if there is vacuum.
VACUUM HOSE A
6. If not, disconnect the vacuum hoses from the FICD actuator and inspect if there is vacuum as shown.
FICD ACTUATOR
Caution D FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 12. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 13. If there is vacuum, inspect the following. D FICD solenoid valve No.1 D PCM terminal C, E voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) D Wire harness between FICD solenoid valve No.1 and PCM terminal C 14. Warm up the engine (ECT is above 60 C {140 F}). 15. Verify that the FICD actuator rod returns completely.
Caution D FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 7. If there is vacuum, consult your distributor for replacement of the FICD actuator. 8. If there is no vacuum, inspect the following. D FICD solenoid valve No.1 and No.2 D Loose or damaged vacuum hoses between FICD actuator, FICD solenoid valve No.1 and No.2, and vacuum pump. D PCM terminal C, E and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) D Wiring harness between FICD solenoid valve No.1 and PCM terminal C. D Wiring harness between FICD solenoid valve No.2 and PCM terminal P. 9. Warm up the engine. (ECT above 20 C {68 F}). 10. Verify that the FICD actuator rod returns for one notch.
16. If not, disconnect vacuum hose B from the FICD actuator and inspect if there is vacuum.
CONTINUED
F261
TO. MODEL .INDEX
TROUBLESHOOTING
7. If there is no vacuum, inspect the following:
VACUUM HOSE B
D FICD solenoid valve No.2 D PCM terminal G and P voltages
(Refer to CONTROL SYSTEM,POWERTRAIN CONTROL MODULE (PCM) INSPECTION) D Wiring harness between FICD solenoid valve No.2 connector terminal B and PCM terminal P Turbocharger Boost Pressure 1. Disconnect the air hose between the intake pipe and the boost compensator. 2. Connect a pressure gauge (range of measurement is 93.3 kPa {700 mmHg, 27.6 inHg}).
Caution D FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 17. If there is no vacuum, consult your distributor for replacement of the FICD actuator. 18. If there is vacuum, inspect the following. D FICD solenoid valve No.2 D PCM terminal E, G and P voltages (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) D Wiring harness between FICD solenoid valve No.2 and PCM terminal P. A/C Idle-up Function 1. Start the engine. 2. Warm up the engine to normal operating temperature and run it at idle speed. 3. Set the fan switch at 1st position. 4. Verify that the FICD rod is pulled for one notch. 5. If not, disconnect the vacuum hose B from the FICD actuator and inspect if there is vacuum as shown.
BOOST COMPENSATOR PRESSURE GAUGE
TO INTAKE PIPE
3. Warm up the engine. 4. With the accelerator at the wide open throttle, increase the engine speed to 48005000 rpm and verify that the boost pressure is within the specification. Specification 60.073.3 kPa {0.620.74 kgf/cm2, 8.8210.52 psi} 5. If not as specified, inspect the exhaust system. (Refer to EXHAUST SYSTEM, EXHAUST SYSTEM INSPECTION.) 6. If the exhaust system is normal, inspect the wastegate actuator. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION, Wastegate Actuator Inspection.) 7. If the wastegate actuator is normal, inspect the turbocharger. (Refer to INTAKE-AIR SYSTEM, TURBOCHARGER INSPECTION.) TCV Control Inspection (Europe and UK) 1. Crank the engine and verify that the TCV operation sound is heard. WL
VACUUM HOSE B
Caution D FIP is sealed to maintain proper function. Special tools and testers are required when disassembling the FIP. Disassembling the FIP without special tools and testers will cause a malfunction. 6. If there is vacuum, consult your distributor for replacement of the FICD actuator.
TCV
CONTINUED
F262
TO. MODEL .INDEX
TROUBLESHOOTING
WL Turbo
TCV
2. If no operation sound is heard, inspect the TCV (in the FIP). 3. If the TCV is normal, inspect the following: D PCM terminal Q voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION) D Wire harness between TCV and PCM terminal Q EGR System Inspection (if equipped) 1. Make sure that all hoses are securely connected in the proper position. 2. Disconnect the vacuum hose from the EGR valve. 3. Start the engine at cold condition. 4. Verify that there is no vacuum at vacuum hose. 5. If there is vacuum, inspect the following: D EGR solenoid valve D PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) D Wire harness between EGR solenoid valve and PCM terminal R 6. Warm up the engine to the normal operating temperature and run it at idle speed. 7. Verify that there is vacuum at vacuum hose. 8. If there is no vacuum, inspect the following: D EGR solenoid valve D PCM terminal R voltage (Refer to CONTROL SYSTEM, POWERTRAIN CONTROL MODULE (PCM) INSPECTION.) D Wire harness between EGR solenoid valve and PCM terminal R 9. Connect the vacuum pump to the EGR valve. 10. Apply the vacuum to the EGR valve and inspect if the engine speed becomes unstable or the engine stalls. 11. If the engine speed does not change, stop the engine and inspect the EGR valve.
CONTINUED
F263
TO. MODEL .INDEX
TROUBLESHOOTING
Glow System Inspection
STEP 1 INSPECTION Connect NGS tester to DTC. Turn engine switch on and retrieve DTC. Are any of the following DTCs displayed? D 09 (ECT sensor) D 12 (Control lever position sensor) D 36 (Glow plug relay) Turn engine switch on while engine is cold. Does glow indicator light illuminate for approx. 19 seconds.? RESULTS Yes ACTION Go the appropriate DTC test. After repair is completed, go to next step. Go to next step. Go to next step. Inspect the following according to indication condition of glow indicator light: 1. Will not go out D Short circuit between glow indicator light and PCM connector terminal M D Short circuit in instrument cluster print plate 2. Illuminates for approx. 1 second (same condition after engine is warmed up and cold) D Extremely low resistance of engine coolant temperature sensor D Short circuit between engine coolant temperature sensor and PCM connector terminal E 3. Will not illuminate D Glow indicator light D Open circuit between glow indicator light and PCM connector terminal M D Open circuit in instrument cluster print plate 4. Illuminates for approx. 9 seconds (same condition after engine is warmed up and cold) D Extremely high resistance of engine coolant temperature sensor D Open circuit between engine coolant temperature sensor and PCM connector terminal E Go to next step. Inspect for open or short circuit in harnesses and connectors between battery, glow plug relay, and glow plug. Inspect if glow plug relay is stuck open or closed. Inspect glow plug relay ground circuit. Inspect for open circuit between glow relay and PCM terminal O. Go to next step. Inspect for open or short to ground circuit in harness and connectors between engine switch (starter) and PCM connector terminal D. Go to next step. Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F. Glow system is okay.
No Yes No
Leave engine switch on while engine is cold. Does glow plug voltage indicate B+ for approx. 15 seconds.?
Yes No
Does glow plug voltage indicate B+ while cranking engine?
Yes No
Is power supplied to the glow plug for maximum 10 minutes after engine started when engine is cold? Remove the glow plug wire from glow plugs. Measure resistance between glow plug and body ground. yg Is glow plug resistance approx. 1 or less? + INTAKE-AIR SYSTEM, GLOW PLUG INSPECTION
Yes No
Yes
No
Replace glow plug.
CONTINUED
F264
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
FUEL AND EMISSION CONTROL SYSTEMS (F2 CARB)

ENGINE TUNE-UP .........................................................F4-2 ENGINE TUNE-UP PREPARATION ........................F4-2 IGNITION TIMING ADJUSTMENT ...........................F4-2 IDLE SPEED ADJUSTMENT ...................................F4-2 IDLE MIXTURE ADJUSTMENT ...............................F4-2/3 DASHPOT (D/P) ADJUSTMENT ..............................F4-3 THROTTLE POSITIONER (T/P) ADJUSTMENT ........................................................F4-3/4 A/C IDLE-UP ADJUSTMENT ...................................F4-4/5 INTAKE-AIR SYSTEM .................................................F4-6 VACUUM HOSE ROUTING DIAGRAM ...................F4-6 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION ..................................F4-7 AIR CLEANER ELEMENT INSPECTION ..........................................................F4-8 IDLE COMPENSATOR INSPECTION ....................F4-8 AIR THERMO VALVE INSPECTION ..........................................................F4-8 VACUUM CONTROL DIAPHRAGM INSPECTION ..........................................................F4-8 ACCELERATOR PEDAL REMOVAL/INSTALLATION ..................................F4-9 ACCELERATOR CABLE INSPECTION/ADJUSTMENT .............................. F4-9 FUEL SYSTEM ..............................................................F4-10 BEFORE REPAIR PROCEDURE.............................F4-10 AFTER REPAIR PROCEDURE ...............................F4-10 FUEL TANK REMOVAL/INSTALLATION ...............F4-11/13 NONRETURN VALVE INSPECTION ......................F4-13 FUEL PUMP UNIT REMOVAL/INSTALLATION...................................F4-13 FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY ................................F4-13/14 FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION ..................................F4-14 FUEL GAUGE SENDER UNIT INSPECTION ..........................................................F4-14 FUEL PUMP INSPECTION ......................................F4-14/15 FUEL LINE PRESSURE INSPECTION ..................F4-15 FUEL LINE FLOW AMOUNT INSPECTION ..........................................................F4-15/16 FAST IDLE SPEED ADJUSTMENT ........................F4-16 DASHPOT (D/P) INSPECTION ................................F4-16 FUEL PUMP RELAY INSPECTION ........................F4-16/17 SERVO DIAPHRAGM REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR REMOVAL/INSTALLATION ..................................F4-17 CARBURETOR DISASSEMBLY/ASSEMBLY ............................... F4-18/21 CARBURETOR INSPECTION/ADJUSTMENT .............................. F4-21/24 HIGH-ALTITUDE COMPENSATOR INSPECTION ......................................................... F4-24 PTC HEATER INSPECTION ................................... F4-24 SLOW FUEL CUT SOLENOID VALVE INSPECTION ......................................................... F4-24 EXHAUST SYSTEM .................................................... F4-25 EXHAUST SYSTEM INSPECTION ........................ F4-25 EXHAUST SYSTEM REMOVAL/INSTALLATION ................................. F4-25 EMISSION SYSTEM .................................................... F4-26 N0.1 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 N0.2 PURGE CONTROL VALVE INSPECTION ......................................................... F4-26 WATER THERMO VALVE INSPECTION .............. F4-26 AIR VENT SOLENOID INSPECTION ...................... F4-26 CHECK VALVE (TWO-WAY) INSPECTION ......................................................... F4-26 CHARCOAL CANISTER INSPECTION ................. F4-26 ROLLOVER VALVE INSPECTION ......................... F4-26/27 WATER THERMO VALVE REMOVAL/INSTALLATION ................................. F4-27 PCV VALVE INSPECTION ...................................... F4-27 CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT ...................................... F4-27 FLANGE THERMOSWITCH INSPECTION ......................................................... F4-27 CONTROL SYSTEM .................................................... F4-28 COMPONENT LOCATION ...................................... F4-28 PCM REMOVAL/INSTALLATION ........................... F4-29 PCM INSPECTION .................................................... F4-29 PTC HEATER RELAY INSPECTION ..................... F4-30 THROTTLE POSITIONER T/P) SOLENOID VALVE INSPECTION ........................................... F4-30 WATER THERMOSWITCH (INTAKE MANIFOLD SIDE) INSPECTION ......................... F4-30/31 WATER THERMOSWITCH REMOVAL/INSTALLATION ................................. F4-31 TROUBLESHOOTING ................................................ F4-32 FOREWORD ............................................................. F4-32 TROUBLESHOOTING ITEM TABLE ...................... F4-32 QUICK DIAGNOSTIC CHART ................................. F4-33 SYMPTOM TROUBLESHOOTING ......................... F4-34/47
CONTINUED
F4-1
TO. MODEL .INDEX
ENGINE TUNE-UP ENGINE TUNE-UP

ENGINE TUNE-UP PREPARATION 1. Check the condition of the engine (plugs, leaks in hoses, etc.) 2. Make sure all accessories are OFF. 3. Connect a tacho dwell tacho tester to the engine. 4. Warm up the engine and run it for three minutes at 2,5003,000 rpm in neutral. IGNITION TIMING ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. IDLE MIXTURE ADJUSTMENT 1. Attach an exhaust gas analyzer and measure the CO concentration.
3.
While checking the ignition timing by using a timing light, adjust the crankshaft pulley alignment mark position (yellow paint) by turning the distributor as specified. Specification BTDC: 57(61)
2. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 3. Verify that CO concentration in exhaust gas at the tail pipe during idling is as specified in the table below. For GULF General
4.
CO concentration (%) 2.02.5 (2.0 ) 2.03.0 (2.5 0.5)
5.
If not within the specification, adjust the CO concentration by turning the MAS (mixture adjust screw). Remove the blind cap. (GULF)
Reconnect the proper vacuum hose to the port. IDLE SPEED ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION. 2. Verify that the idle speed is within the specification.
4. 6. 3.
Remove the spring pin.
If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw)
CONTINUED F4-2
TO. MODEL .INDEX
ENGINE TUNE-UP
DASHPOT (D/P) ADJUSTMENT 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT" 2. Increase the engine speed to 2,500 rpm. 3. Pull the throttle lever until the rod and arm of the dashpot separate. 4. Slowly return the throttle lever from the position above, then verify that the engine speed is as specified when the arm contacts the rod. Specification 1,9002,100 (2,000 100) rpm 5. If not as specified, loosen the dashpot locknut and turn the dashpot body to adjust.
Reconfirm that the engine speed is within the specification. 8. If not within the specification, adjust the idle speed by turning the TAS (throttle adjust screw). Note GULF only Run the engine at idle for 35 seconds, then fit a blind cap to the MAS (mixture adjust screw) of the vehicles for the following markets.
7.
6. After adjustment, tighten the locknut. Tightening torque 9.817.6 N.m {100180 kgf.cm, 87156 in.lbf} 7. Race the engine and again verify that the engine speed returns smoothly to idle speed. 8. If not, repeat the above procedure to adjust the idle speed or D/P inspect (Refer to FUEL SYSTEM, DASHPOT (D/P) INSPECTION) THROTTLE POSITIONER (T/P) ADJUSTMENT GULF only 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 3. Disconnect the vacuum hose from the servo diaphragm.
Run the engine at idle for 35 seconds, then tap in the spring pin as shown.
4. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as specified. Specification 1,0501,250 (1,150 100) rpm
CONTINUED F4-3
TO. MODEL .INDEX
ENGINE TUNE-UP
5. If not within the specification, adjust the engine speed by the adjust screw. 6. Disconnect the vacuum hose for vacuum spark advance between the distributor and the carburetor at the distributor side and plug it. 7. Disconnect the vacuum hose from port B.
6. After adjusting the engine speed, reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the engine speed is raced at 2,000 rpm or more. 7. If the servo diaphragm does not operate, inspect the T/P solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm. A/C IDLE-UP ADJUSTMENT GULF only with, A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from port A.
8. Connect the intake manifold vacuum directly to port B, and verify that the engine speed is as specified. Specification 1,0501,250 (1,150 100) rpm 9. If not within the specification, adjust the engine speed by the adjust locknut on the dual servo diaphragm head.
3. Connect the intake manifold vacuum directly to port A, and verify that the engine speed is as specified. Specification 1,4001,600 (1,500 100) rpm 4. If not within the specification, adjust the engine speed by the adjust screw.
10. Reconnect the proper vacuum hose to port B. 11. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 12. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve or T/P solenoid valve. 13. If the solenoid valve is okay, replace the dual servo diaphragm. Except GULF, with A/C 1. Perform the "ENGINE TUNE-UP PREPARATION" and "IDLE SPEED ADJUSTMENT." 2. Disconnect the vacuum hose from the servo diaphragm. 3. Connect the intake manifold vacuum directly to the servo diaphragm, and verify that the engine speed is as spec tied.
5. Reconnect the proper vacuum hose to port A.
CONTINUED F4-4
TO. MODEL .INDEX
ENGINE TUNE-UP
Specification 1,4001,600 (1,500 100) rpm 4. If not within the specification, adjust the engine speed by adjust screw.
5. Reconnect the proper vacuum hose to port. 6. After adjusting the engine speed reconnect the vacuum hose to the proper port. Verify that the servo diaphragm operates when the A/C is operated. 7. If the servo diaphragm does not operate, inspect the A/C idle-up solenoid valve. 8. If the solenoid valve is okay, replace the servo diaphragm.
CONTINUED
F4-5
TO. MODEL .INDEX
INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM

1 2 3 4 5 6 7 8 9 10 11
Air cleaner Carburetor Vacuum control diaphragm Idle compensator Air thermos sensor FICB solenoid valve High-altitude compensator FICB diaphragm Charcoal canister No.1 purge control valve Water thermo valve
12 Distributor 13 14 15 16 17 18 19 20 21 22 T/P solenoid valve Servo diaphragm A/C idle-up solenoid valve Dual servo diaphragm To intake manifold Fuel main line (to fuel tank) Fuel return line (to fuel tank) To charcoal canister or ventilation To carburetor To check valve (two-way)
CONTINUED
F4-6
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
INTAKE - AIR SYSTEM REMOVAL/INSTALLATION Warning When the engine and intake-air system are hot, they can badly bum. Turn off the engine and wait until they are cool before removing the intake-air system. Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 1. Disconnect the negative battery cable. 2. Drain the engine coolant from the radiator. (Refer to Section E.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2 3 4 5 6 7
Air cleaner (in idle compensator, vacuum control diaphragm, shutter valve, air thermo sensor) Air cleaner element Carburetor Fuel hose Accelerator cable PTC heater gasket PTC heater
8 9
Intake manifold Water thermoswitch CONTROL SYSTEM, WATER THERMOSWITCH REMOVAL/INSTALLATION Intake manifold gasket Water thermo valve FUEL SYSTEM, WATER THERMO VALVE REMOVAL/INSTALLATION Servo diaphragm
10 11
12
CONTINUED F4-7
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
AIR CLEANER ELEMENT INSPECTION Visually check the air cleaner element for excessive dirt, damage or oil, replace if necessary. IDLE COMPENSATOR INSPECTION 1. Confirm that the valve is in the closed position when the bimetal temperature is lower than the specified temperature. Opening temperature 6371 C {145.4159.8 F} AIR THERMO VALVE INSPECTION Note Perform the following test only when directed. 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Verify that vacuum is felt at the vacuum hose when the engine is cold (below 30 C {86 F}) and idling. 3. Warm up (above 30 C {86 F}) the engine and verify that vacuum is not felt.
2. To check, suck air from the tube A. If excessive air leakage is found, replace the idle compensator.
4. If vacuum condition is not as specified in Steps 2 and 3, replace the air thermo valve. VACUUM CONTROL DIAPHRAGM INSPECTION 1. Disconnect the vacuum hose from the vacuum control diaphragm. 2. Connect a vacuum pump to the vacuum control diaphragm. 3. Apply more than 24 KPa {180 mmHg, 7.087 inHg} vacuum and verify that the shutter valve is opened to the hot position.
3. When the bimetal temperature is more than approx. 71 C {159.8 F}, confirm that the valve is in the open position. If the valve is not open, replace the idle compensator as an assembly.
4. Replace the vacuum control diaphragm if not as specified.
CONTINUED
F4-8
TO. MODEL .INDEX
INTAKE-AIR SYSTEM
ACCELERATOR PEDAL REMOVAL/INSTALLATION
1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Accelerator cable ACCELERATOR CABLE INSPECTION/ADJUSTMENT Accelerator pedal
ACCELERATOR CABLE INSPECTION/ADJUSTMENT 1. Verify that the throttle valve is entirely closed. 2. Measure the free play of the accelerator cable. Free play 13 mm {0.040.11 in} 3. If not as specified, adjust by turning locknut A.
CONTINUED
F4-9
TO. MODEL .INDEX
FUEL SYSTEM
FUEL SYSTEM BEFORE REPAIR PROCEDURE Warning Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the following "Fuel Line Safety Procedures". Fuel Line Safety Procedures Note Fuel in the fuel system is under high pressure also when the engine is not running. 1. Remove the fuel-filler cap and release the pressure in the fuel tank. 2. Disconnect the fuel pump relay connector located under the passenger's side front side trim.
3. Install a hose clamp over the fuel hose within the clamp installation range as shown, avoiding the original clamp position.
3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn off the ignition switch. 6. Reconnect the fuel pump relay connector. AFTER REPAIR PROCEDURE Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. When installing the fuel hose, observe "Fuel Hose Installation" and described below. Fuel Hose Installation 1. Replace damaged or deformed fuel hoses, fuel pipes, and hose clamps. 2. When installing the fuel hose onto the fuel pipe, fit the hose onto the pipe over 25 mm {0.98 in}. When the pipe has a stopper, fit the hose until it contacts the stopper.
CONTINUED
F4-10
BACK.TO.CHAPTER.INDEX FUEL SYSTEM
TO. MODEL .INDEX
FUEL TANK REMOVAL/INSTALLATION Warning Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire may cause death or serious injury. Always properly steam clean a fuel tank before repairing it. Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. 2. 3. 4. 5. 6. 7. Level the vehicle. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) Disconnect the negative battery cable. Drain the fuel from the drain plug. Remove in the order indicated in the table. Install in the reverse order of removal. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
DOUBLE CAB
CONTINUED
F4-11
TO. MODEL .INDEX
FUEL SYSTEM
REGULAR CAB
1 2 3 4 5 6
Joint hose Installation Note Breather hose w Installation Note Under guard Fuel hose Fuel tank Evaporative hose - Installation Note
7 8 9
Rollover valve Fuel pump unit Fuel-filler pipe
10 Dust cover 11 Fuel inlet pipe 12 Non return valve Evaporative gas check valve (two-way) 13 Installation Note
CONTINUED
F4-12

Evaporative Gas Check Valve (Two-way) Installation Note Install the arrow mark of the evaporative gas check valve (two-way) facing the charcoal canister. Evaporative Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamps as shown. Length Evaporative hose: 25 mm {0.98 in}
TO. MODEL .INDEX
Breather Hose Installation Note Fit each hose onto the respective fittings within the specification, and install clamp as shown. Length Breather hose: 2530 mm {0.991.18 in}
NONRETURN VALVE INSPECTION 1. Remove the nonreturn valve with the fuel inlet pipe. 2. Verify that the nonreturn valve opening angle is 5056 when pushed out from the fuel inlet pipe side, and the clearance between the nonreturn valve and the fuel inlet pipe end is within 1.5 mm {0.06 in} when the nonreturn valve is returned to the closed position.
Joint Hose Installation Note Fit the joint hose onto the respective fittings within the specification, and install clamps as shown. Length Joint hose: 3540 mm {1.41.5 in}
3. If not as specified, replace the nonreturn valve. FUEL PUMP UNIT REMOVAUINSTALLATION 1. Remove the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Install the fuel pump unit. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY Warning Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, do not damage the sealing surface of the fuel pump unit when removing or installing. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
F4-13
CONTINUED

DOUBLE CAB
TO. MODEL .INDEX
Fuel Pump Assembly Note After installing the fuel pump body to the bracket; pull the pump down so that it is tight against the bracket.
Fuel Hose Assembly Note 1. Do not apply excessive side force when pushing the fuel hose onto the fuel pump nipple. 2. Install the clamps as shown. REGULAR CAB
FUEL GAUGE SENDER UNIT REMOVAL/INSTALLATION (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) FUEL GAUGE SENDER UNIT INSPECTION (Refer to Section T, WARNING AND INDICATOR SYSTEM, FUEL GAUGE SENDER UNIT INSPECTION.) FUEL PUMP INSPECTION Continuity Inspection Note Perform the following test only when directed, 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Remove the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 4. Inspect for continuity between fuel pump unit connector terminals C and D.
1 2 3 4 5 6 7
Fuel pump unit connector Rubber mount Fuel filter (low-pressure) Clamp Fuel hose Assembly Note Fuel pump body Assembly Note Fuel gauge sender unit
F4-14
CONTINUED
TO. MODEL .INDEX
4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
5. If there is no continuity, replace the fuel pump body. If there is continuity in the fuel pump but the fuel pump does not operate, inspect as follows and repair or replace as necessary. Open circuit GND circuit (fuel pump unit connector terminal C and body GND) Power circuit (fuel pump relay connector terminal C and fuel pump unit connector terminal D through common connector)
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) 5. Connect the negative battery cable. 6. Turn the ignition switch ON, and verify that fuel pressure is as specified. Specification 2 2025kPa {0.200.25 kgf/cm , 2.83.6 psi} 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FUEL LINE FLOW AMOUNT INSPECTION Note Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and insert the end into a measuring beaker. 4. Connect the C and D terminals of the fuel pump relay with a jumper wire.
HARNESS SIDE CONNECTOR (VIEW FROM TERMINAL SIDE) Short circuit Fuel pump relay connector terminal C and fuel pump unit connector terminal D through common connector to GND 6. Repair or replace faulty areas. If the harnesses are okay, inspect the fuel pump relay. (Refer to FUEL SYSTEM, FUEL PUMP RELAY INSPECTION.) 7. Install the fuel tank. (Refer to FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 8. Reconnect the negative battery cable. 9. Complete the "AFTER REPAIR PROCEDURE". (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.) FUEL LINE PRESSURE INSPECTION Note Perform the following test only when directed. 1. Complete the "BEFORE REPAIR PROCEDURE". (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.) 2. Disconnect the negative battery cable. 3. Disconnect the main fuel hose (A), and connect a fuel pressure gauge to it.
CONTINUED F4-15
TO. MODEL .INDEX
FUEL SYSTEM
5. Connect the negative battery cable. 6. Turn the ignition switch on. Drive the fuel pump for a minute and verify that the fuel flow amount is within the specification. Specification More than 1.150 cc {70.2 cu in} min. 7. If not as specified, perform the fuel pump inspection. (Refer to FUEL PUMP INSPECTION.) FAST IDLE SPEED ADJUSTMENT 1. Warm up the engine to normal operation temperature. 2. Stop the engine. 3. Plug the hoses of the idle compensator. 4. While holding the throttle valve slightly open, push the choke fully closed; then release the choke valve after releasing the throttle valve. 5. Start the engine, but do not touch the accelerator pedal. 6. Verify that the engine speed is 3,0004,000 rpm. If the engine speed is not as specified, turn the adjust screw to adjust.
FUEL PUMP RELAY INSPECTION On-Vehicle Inspection Note Perform the following test only when directed. 1. Remove the front left side trim. 2. Crank the engine while touching the fuel pump relay by hand. 3. Verify that clicking sound is heard or vibration is felt from the fuel pump relay white cranking the engine. 4. If there is no clicking sound or vibration, inspect the harness for the following, Open circuit Power circuit (fuel pump relay connector terminal A, D and ignition switch IG1) GND circuit (fuel pump relay connector terminal B and PCM terminal H)
DASHPOT (D/P) INSPECTION 1. Open the throttle valve fully then push the dash pot rod with a finger and make sure the rod goes into the dash pot slowly. 2. Release the finger and make sure the rod comes out quickly.
Short circuit Fuel pump relay connector terminal A, D and ignition switch IG1 to GND. 5. If the harnesses are okay, perform the following off-vehicle inspection. Off-Vehicle Inspection 1. Remove the fuel pump relay. 2. Inspect for continuity between the fuel pump relay terminals by using an ohmmeter.
CONTINUED
F4-16
TO. MODEL .INDEX
Tightening torque 9.824 N.m {100250 kgf.cm-cm, 87216 in.lbf} CARBURETOR REMOVAL/INSTALLATION (Refer to INTAKE-AIR SYSTEM INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
3. If not as specified, replace the fuel pump relay. SERVO DIAPHRAGM REMOVAL/INSTALLATION 1. Loosen the servo diaphragm installation nut.
2. Remove the servo diaphragm and the servo diaphragm bracket from the intake manifold.
3. Separate the servo diaphragm from the bracket. 4. Install the servo diaphragm onto the bracket, then hand-tighten the installation nut. 5. Install the servo diaphragm bracket to the intake manifold. Tightening torque 1925N.m {1.92.6 kgf.m, 1418ft.lbf} 6. Tighten the installation nut to the specification.
CONTINUED F4-17
TO. MODEL .INDEX
FUEL SYSTEM
CARBURETOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. (Refer to Carburetor After Assembly Note.) Caution Replace the O-rings, gaskets, and washers when assembling the carburetor. If not, it will possibly cause a malfunction.
CONTINUED
F4-18
TO. MODEL .INDEX
FUEL SYSTEM
1 2 3 4 5 6 7 8 9 Accelerator pump connecting rod Connect spring Air vent solenoid valve Choke rod Air horn Float Needle valve assembly Accelerator pump plunger Closed throttle position (CTP) switch (GENERAL (LH.D.), high-altitude models) 4 5 Air vent solenoid valve lead (separate from the connector) Disconnect choke rod
10 Slow fuel cut solenoid valve 11 Accelerator pump outlet check ball and spring 12 Accelerator pump inlet check ball 13 Primary slow jet 14 Secondary slow jet 15 Primary main jet 16 Secondary main jet 17 Primary venturi and nozzle 18 Secondary venturi and nozzle 19 Primary main air bleed 20 Secondary main air bleed 21 Main body 22 Vacuum diaphragm 23 Throttle body 24 Mixture adjust screw 25 Bimetal 26 Choke breaker diaphragm 27 Power jet 7
Air horn and automatic choke assembly (separate from main body) Air vent solenoid valve, spring, and gasket, if necessary
Needle Valve and Float Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Air Horn and Automatic Choke Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2
Float and pin Needle valve assembly
1 2 3
Vacuum hose Accelerator pump connecting rod, spring, and lever Connect spring
CONTINUED
F4-19
TO. MODEL .INDEX
FUEL SYSTEM
Air Bleeds and Jets Disassembly/Assembly 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 1 2 3 4 5 6 7 8 9 Secondary slow jet Secondary slow air bleed (No.1) Secondary main air bleed Secondary main jet Primary main air bleed Slow jet and plug Primary slow air bleed (No.1) Primary main jet Primary slow air bleed (No.2) 3
CTP switch and spring Slow fuel cut solenoid valve, needle valve, spring, and gasket.
10 Power jet Accelerator pump plunger assembly and spring Retaining clip Strainer and accelerator pump inlet check ball Check valve plug Accelerator pump outlet check ball and spring
Caution Note the size of all jets and air bleeds so that they will be reassembled in the correct position
4 5 6 7
Note One bolt is inside the throttle body
11 Coasting richer air bleed (No.2) 12 Secondary slow air bleed (No.2) 13 Coasting richer air bleed (No.1) 14 Coasting richer jet 8 9 Disconnect vacuum diaphragm connecting rod Throttle body (separate from main body)
Main Body Disassembly/Assembly Caution After installing the idle switch, be sure to adjust it. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
10 Vacuum diaphragm assembly and gasket
CONTINUED
F4-20
TO. MODEL .INDEX
11 Diaphragm cover screws and cover 12 Spring and diaphragm 13 Accelerator cable hanger Throttle Body Disassembly/Assembly Caution Do not remove the throttle valve and shaft, the Venturis, or the choke valve and shaft. 1. Disassemble in the following order. 2. Assemble in the reverse order of disassembly. (1) When removing the mixture adjust screw, tap out the spring pin as shown in the figure.
(4) Adjust the CTP switch. (5) After the idle adjustment has been completed, check the fast idle speed as follows. CARBURETOR INSPECTION/ADJUSTMENT Body, Valve, Jet 1. Check for cracks on the air horn, distortion on the installing surface attached to the main body, and wear on the contact surface of the choke valve shaft. If necessary, replace it. 2. Check for cracks and distortion on the throttle body, and wear on the contact surface of the throttle valve shaft. If necessary, replace it. 3. Check for deformity, bends, and wear on the levers, arms, and connecting rods. If necessary, replace it. Caution Do not use a piece of wire to clean the jets. The wire may scratch, crack, or deform the port of the jets and become the cause of malfunctions. 4. Check for clogging in jets and air bleeds. If necessary, clean with clean gasoline or kerosene and dry with compressed air. 5. Check the taper part of the MAS, solenoid valves, and needle valve (float) for cracks and dents, and wear. If necessary, replace it. 6. Check the rubber part of the accelerator pump for cracks and damage. If necessary, replace it.
Carburetor After Assembly Note Install the carburetor in the reverse order of removal. After installation, note the following. (1) Start the engine and check for leaks. (2) Make the idle adjustment. (3) After the idle adjustment is completed, press in the spring pin.
CONTINUED F4-21
TO. MODEL .INDEX
FUEL SYSTEM
Diaphragms 1. Push the rod fully and plug the port by hand. 2. Verify that the rod does not return when the port is plugged.
Clearance L 4445 mm {1.7321.772 in} 4. If not as specified, bend the float stopper B until the proper clearance is obtained. 3. If the rod returns to the original position, replace the diaphragm. Float Level Adjusting 1. Measure the clearance H between the float and air horn. Choke Valve 1. Use a vacuum pump to apply approximately 53 kPa {400 mmHg, 15.7 inHg} vacuum to the choke diaphragm. 2. Push the choke valve lightly to close it, and check the clearance R,
Clearance H 89 mm {0.3150.354 in} 2. If not as specified, bend the float seat lip A until the proper clearance is obtained.
Clearance R 1.722.22 mm {0.0680.087 In} 3. Measure the clearance L between the bottom of the float and air horn. 3. If the clearance is not as specified, adjust by bending the choke lever D.
CONTINUED
F4-22
TO. MODEL .INDEX
FUEL SYSTEM
Fast-idle cam 1. Set the fast-idle cam to the second highest position. 2. Adjust the throttle valve clearance G by turning the adjust screw. (The clearance becomes larger as the screw is turned clockwise.)
Clearance G 0.640.84 mm {0.0250.033 in} 3. Set the fast idle cam at the second highest position. 4. Check the choke valve clearance R. Clearance R 2.823.70 mm {0.1110.146 in} 3. If the clearance is not as specified, adjust by bending tab A. Secondary throttle valve 1. The secondary throttle valve should start to open when the primary throttle valve opens 48 52 and should be completely open at the same time the primary throttle valve is fully open. 2. Check the clearance between the primary throttle valve and the throttle bore when the secondary throttle valve starts to open. 3. If the clearance is not as specified, bend tab B to adjust.
Clearance R 0.601.20 mm {0.0240.047 in} 5. If necessary, adjust the choke valve clearance R by bending the starting arm B. If large adjustments are required, the choke rod should be bent. Unloader system 1. Open the primary throttle valve fully. 2. Measure the choke valve clearance R.
CONTINUED
F4-23
TO. MODEL .INDEX
FUEL SYSTEM
Clearance R 7.358.25 mm {0.2890.325 in} HIGH-ALTITUDE COMPENSATOR INSPECTION 1. Disconnect each air hose from the carburetor. 2. Check the high-altitude compensator by blowing through each hose.
500m {1,640 ft} or higher (High altitude): Air passes. Less than 500 m {1,640 ft } (Low altitude): Air does not pass. 3. If not as specified, replace the high-altitude compensator. PTC HEATER INSPECTION 1. Disconnect the PTC heater connector. 2. Connect an ohmmeter between the connector and the intake manifold, and verify continuity. 3. If it is not correct, replace the PTC heater. SLOW FUEL CUT SOLENOID VALVE INSPECTION Operation Inspection Note Perform the following test only when directed. Run the engine at idle speed. Disconnect the carburetor connector (6-pin). Disconnect the carburetor connector and verify that the engine stops. If the engine does not stop, replace the slow fuel cut solenoid valve.
1. 2. 3. 4.
CONTINUED
F4-24
TO. MODEL .INDEX
EXHAUST SYSTEM EXHAUST SYSTEM

EXHAUST SYSTEM INSPECTION 1. Start the engine and inspect the exhaust system component for exhaust gas leakage. 2. If leakage is found, repair or replace as necessary. EXHAUST SYSTEM REMOVAL/INSTALLATION Warning When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait until they are cool before removing the exhaust system. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1 2 3
After pipe Main silencer Pre-silencer
4 5
Front pipe Exhaust manifold
CONTINUED
F1-25
TO. MODEL .INDEX
EMISSION SYSTEM EMISSION SYSTEM

N0.1 PURGE CONTROL VALVE INSPECTION 1. Blow through port A and verify that air does not flow. 2. Connect a vacuum pump and apply vacuum of -14.7 KPa {-110 mmHg, -4.33 inHg} or above and blow through port A again. 3. Verify that air flows from port A. 3. Turn the ignition switch to "ON" and "OFF". If there is a "clicking" noise, the air vent solenoid valve is working properly.
CHECK VALVE (TWO-WAY) INSPECTION 1. Remove the check valve (two-way). 2. Inspect airflow of the valve under the following conditions. N0.2 PURGE CONTROL VALVE INSPECTION 1. Disconnect vacuum hose B from the pipe. 2. Blow into the hose and make sure air flows freely.
Condition Apply pressure below +2.9 kPa {+22 mmHg, +0.87 inHg} to port A Apply pressure over +5.9 kPa {+44 mmHg, +1.7 inHg} to port A Apply pressure over -0.98 KPa {-7.36 mmHg, -0.29 inHg} to port A Airflow No Yes Yes
3. If not as specified, replace the charcoal canister. WATER THERMO VALVE INSPECTION 1. Remove the water thermo valve. 2. Put the threaded part in a water-filled container and slowly increase the water temperature. 3. Check the airflow of the valve under the following conditions.
Port A-B C-D
Condition Below 50C {122F} Above50C {122F} No Airflow Airflow Airflow No Airflow
3. If not as specified, replace the check valve (twoway). CHARCOAL CANISTER INSPECTION 1. Remove the charcoal canister. 2. Visually check the charcoal canister for damage and leakage. 3. Shake the charcoal canister upside down and verify that no pieces of charcoal falls from either nipple. 4. Replace the charcoal canister if necessary. ROLLOVER VALVE INSPECTION 1. Remove the rollover valve. (Refer to FUEL SYSTEM,FUEL TANK REMOVAL/INSTALLATION.) 2. Hold the valve as shown. Blow air into port A and verify that there is airflow.
4. If not as specified, replace the water thermo valve. AIR VENT SOLENOID INSPECTION 1. Remove the air cleaner. 2. Touch the finger onto the air vent solenoid valve.
CONTINUED F4-26
TO. MODEL .INDEX
EMISSION SYSTEM
3. Turn the valve upside-down as shown. Blow air into port A and verify that there is no airflow. CLOSED THROTTLE POSITION (CTP) SWITCH ADJUSTMENT 1. Warm up the engine and run it at idle. 2. Connect a dwell tacho tester to the engine. 3. Connect a voltmeter to the CTP switch terminal. 4. Increase the engine speed to more than 2,000 rpm; decelerate gradually and verify that the volt meter indicates as follows. Engine speed At idle 1,0001,200 (1,100 100) rpm Voltage Approx. 12 V Less than 1.5 V
4. If not as specified, replace the rollover valve. WATER THERMO VALVE REMOVAL/NSTALLATION 1. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermo valve from the intake manifold. 3. Wrap sealing tape two or three times around the threaded part of the valve before installing.
5. If not as specified, turn the adjust screw to adjust.
4. Use a new washer and install in the reverse order of removal. Tightening torque 2539 N.m {2.54.0 kgf.m-m, 1928 ft.lbf} PCV VALVE INSPECTION 1. Remove the PCV valve. 2. Check the airflow of the valve under the following conditions.
FLANGE THERMOSWITCH INSPECTION Note Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the flange thermoswitch from the carburetor. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Condition Blow from port A
Airflow Yes 4. Inspect the thermoswitch terminals by using an ohmmeter. Specification Water temperature (C {F}) Below 67 {153} Above 67 {153} Continuity Yes No
Blow from port B No 3. If not as specified, replace the PCV valve.
5. If not as specified, replace the flange thermoswitch.
CONTINUED F4-27
TO. MODEL .INDEX
CONTROL SYSTEM CONTROL SYSTEM

COMPONENT LOCATION
1 2 3
Ignition coil Water thermoswitch PCM
4 5 6
T/P solenoid valve (GULF only) PTC heater relay Fuel pump relay
CONTINUED
F4-28
TO. MODEL .INDEX
CONTROL SYSTEM
PCM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front left side trim. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. PCM INSPECTION Caution The PCM terminal voltages vary with change in measuring conditions and vehicle conditions. Always carry out a total inspection of the input systems, output systems, and PCM to determine the cause of trouble. Otherwise, a wrong diagnosis will be made. PCM Terminal Voltage (Reference) 1. Remove the PCM. 2. Reconnect PCM connector and battery negative terminal. Note With the PCM connector connected, body ground the voltmeter negative (-) lead and measure voltage at each PCM terminal by inserting the voltmeter positive (+) lead. 3. Measure the voltage at PCM terminal using a voltmeter. 4. If any incorrect voltage is detected, inspect related systems, wiring harnesses and connectors referring to the Action column in the terminal voltage list.
Terminal *A
Signal Throttle positioner control
Connected to T/P solenoid valve GND
Test condition Below 1500 rpm Engine speed Above 1500 rpm Constant Coolant temperature Ignition SW Other Idle Below 40C {104F} ON
Voltage (V) B+ Below 1.0 Below 1.0 B+ Below 1.0 Approx 11V Below 1.0
Action
T/P solenoid valve Related wiring harnesses Related wiring harnesses FICB solenoid valve Related wiring harnesses Igniter Related wiring harnesses Ignition SW Related wiring harnesses Fuel pump relay PTC heater relay Related wiring Water thermoswitch Related wiring harnesses Fuel pump relay PTC heater relay Related wiring harnesses
FICB control
FICB solenoid valve
D E F G
Ignition IG1
Igniter Ignition SW ON Ignition SW Ignition SW OFF ON Ignition SW OFF Below 40C {104F} Above 40C {104F} ON Ignition SW OFF Below 1.0 Below 1.0 B+ 0V B+ Below 1.0 B+ ON B+
Fuel pump control PTC heater control
Fuel pump relay PTC heater relay
Coolant temperature
Water thermoswitch
Coolant temperature
Fuel pump control PTC heater control
Fuel pump relay PTC heater relay
*: GULF only
F4-29
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
PTC HEATER RELAY INSPECTION 1. Remove the PTC heater relay. 2. Inspect for continuity between the PTC heater relay terminals by using an ohmmeter.
3. If not as specified, replace the PTC heater relay. THROTTLE POSITIONER (T/P) SOLENOID VALVE INSPECTION Voltage Inspection Note Perform the following test only when directed. 1. Run the engine at idle. 2. Connect a voltmeter to terminals of the T/P solenoid valve as shown. 3. Measure the voltage as shown.
4. If not as specified, replace the T/P solenoid valve. If as specified, inspect the following: Vacuum hose improper routing, kinks or leakage. Open circuit Power circuit (T/P solenoid valve connector terminal A and ignition switch IG1 through common connector.) GND circuit (T/P solenoid valve connector terminal B and PCM connector terminal A.) Short circuit T/P solenoid valve connector terminal A and ignition switch IG1 through common connector to GND 5. Repair or replace faulty areas. 6. Install the T/P solenoid valve. 7. Connect the negative battery cable. WATER THERMOSWITCH INSPECTION Note Perform the following test only when directed. Continuity Inspection 1. Drain the coolant into a container. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.) 2. Remove the water thermoswitch from the under side of the intake manifold. 3. Place the thermoswitch in water with a thermometer, and heat the water gradually.
Engine speed (rpm) Below 1,500 Above 1,500
Voltage (V) B+ Below 1.0
8. If output voltage is as shown in the table above but there is no airflow in the T/P solenoid valve, perform the following airflow inspection. Airflow Inspection 1. Disconnect the negative battery cable. 2. Remove the T/P solenoid valve. 3. Inspect for airflow between each port under the following condition.
4. Inspect the thermoswitch terminals by using an ohmmeter.
F4-30
CONTINUED
TO. MODEL .INDEX
CONTROL SYSTEM
Specification Water temperature (C {F}) Below 40 {104} Above 40 {104}
Continuity Yes No
5. If not as specified, replace the water thermoswitch. WATER THERMOSWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to Section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) 3. Remove the water thermoswitch from the radiator. 4. The wrap sealing tape two or three times around the threaded part of the switch before installing.
5. Use a new washer and install in the reverse order of removal. Tightening torque 5.98.8 N.m {6090 kgf.cm-cm, 5378 in.lbf}
CONTINUED
F4-31
TO. MODEL .INDEX
TROUBLESHOOTING TROUBLESHOOTING
FOREWORD Before proceeding with the following troubleshooting; (1) Refer to section Gl to understand the basic troubleshooting procedure. (2) Perform the diagnostic trouble code inspection. (3) If a diagnostic trouble code is displayed, proceed with inspection steps for the code. (4) When the engine can be started, perform "ENGINE TUNE-UP". TROUBLESHOOTING ITEM TABLE Confirm trouble symptom by using the following diagnostic index, then go to appropriate troubleshooting chart.
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 TROUBLESHOOTING ITEM Cranks normally but won't start or hard start DESCRIPTION No combustion
Cranks normally but won't start or hard start (always) Requires excessive cranking time (more than 5 seconds) Cranks normally but won't start or hard start (engine Requires excessive cranking of longer than 5 seconds for cold) more than 3 times for engine to start. Cranks normally but won't start or hard start (engine Requires excessive cranking time (more than 5 seconds) warm) Rough idle/engine stalls at idle (always) Rough idle/engine stalls at idle (engine cold) Rough idle/engine stalls at idle (engine warm) Idling is stable when engine is warm. Idling is stable when engine is cold.
Rough idle/engine stalls at idle when A/C or P/S ON Engine runs normally at idle with no load, but stalls or vibrates (if equipped) excessively when load (A/C or P/S) is ON. Engine suddenly stalls often High idle speed after warm-up Engine stalls at drive away Engine stalls on deceleration Hesitation Poor acceleration No power, fastest speed is low Knocking Afterburn occurs during deceleration Poor fuel economy
CONTINUED
F4-32
TO. MODEL .INDEX
TROUBLESHOOTING
QUICK DIAGNOSTIC CHART Intake-air system Emission system O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O Malfunctioning slow cut solenoid valve Malfunctioning air vent solenoid valve Control system Engine Fuel system
Carburetor
No
Item
Engine electrical system
1 2 3 4 5 6 7 8
Cranks normally but won't start or hard start Cranks normally but won't start or hard start (always) Cranks normally but won't start or hard start (engine cold) Cranks normally but won't start or hard start (engine warm) Rough idle/engine stalls at idle (always) Rough idle/engine stalls at idle (engine cold) Rough idle/engine stalls at idle (engine warm) Rough idle/engine stalls at idle when A/C or P/S ON (If equipped) Engine suddenly stalls often
O O O
O O O O O O O
O O O O O O O O
O O O O O O O O O O
O O O O O O O O O
O O O O O O O O O O O O O O O O O O
O O O
O O O
O O
O O O
O O O O O O O O O O O O
10 High idle speed after warm-up 11 Engine stalls at drive away 12 Engine stalls on deceleration 13 Hesitation 14 Poor acceleration 15 No power, fastest speed is low 16 Knocking 17 Afterburn occurs during deceleration 18 Poor fuel economy
O O O O O O
Misadjusted CO, HC concentration
Manufacturing accelerator pump
Misadjusted accelerator cable
Malfunctioning choke system
Malfunctioning water switch
Malfunctioning ignition coil
Malfunctioning spark plug
Malfunctioning fuel pump
Malfunctioning distributor
Clogged secondary main
Clogged secondary slow
Engine internal damage
Malfunctioning fuel line
Clogged primary main
Clogged primary slow
Malfunctioning starter
Malfunctioning hoses
Clogged air cleaner
Float lever
Measure compression pressure Spark inspection
Lower than specification No spark
O O O O
F4-33
CONTINUED
Battery
TO. MODEL .INDEX
Symptom 1-Cranks normally but will not start or hard start Symptom 2-Cranks normally but will not start or hard start (always) Symptom 3-Cranks normally but will not start or hard start (engine cold) Symptom 4-Cranks normally but will not start or hard start (engine warm) Symptom 5-Rough idle/engine stalls at idle (always) Symptom 6-Rough idle/engine stalls at idle (engine cold) Symptom 7-Rough idle/engine stalls at idle (engine warm) Symptom 8-Rough idle/engine stalls at idle-when a/c or p/s on (if equipped) Symptom 9-Engine suddenly stalls often Symptom 10-High idle speed after warm-up Symptom 11-Engine stalls at drive away Symptom 12-Engine stalls on deceleration Symptom 13-Hesitation Symptom 14-Poor acceleration Symptom 15-No power, fastest speed is low Symptom 16-Knocking Symptom 17-Afterburn occurs during deceleration Symptom 18-Poor fuel economy F4-34 F4-35 F4-36-37 F4-37 F4-38 F4-39 F4-39 F4-40 F4-40 F4-41 F4-41-42 F4-42 F4-42-43 F4-43-44 F4-44-45 F4-46 F4-46 F4-47
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 1 CRANKS NORMALLY BUT WON'T START OR HARD START 1. Air/Fuel mixture too lean Air leak 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily Ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and teaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No 2 Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check float level. Is it okay? Yes No Yes No Go to next step. Go to next step. Refer to section G. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to step 10. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to step 12. Go to next step. Check pistons and cylinders for wear, Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace each jet and air bleed.
POSSIBLE CAUSE
STEP INSPECTION 1 Check if there is any air leakage. Is there any?
4 5 6 7 8 9
Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?
Yes No Yes No Yes No Yes No Yes No Yes No
10 11
Yes No Yes No
12
Check primary main, slow system. Is it okay?
Yes
No
F4-34
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 2 CRANKS NORMALLY BUT WON'T START OR HARD START (ALWAYS) 1. Air/Fuel mixture too lean Air leak Fuel level incorrect Restricted primary main, slow system 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich Float level incorrect Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. " FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Check if there is any air leakage. Is there any? Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check float level. Is it okay? RESULTS Yes No Yes No Yes No Yes No Yes No ACTION Repair or replace appropriate parts. Go to next step. Go to next step. Refer to Section G. Go to Step 8. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 10. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 12. Go to next step. Check pistons and cylinders for wear. Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace each jet and air bleed.
POSSIBLE CAUSE
STEP 1 2
3 4 5
6 7 8 9
Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?
Yes No Yes No Yes No Yes No Yes No Yes No
10 11
12
Yes
No
F4-35
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 3 CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE COLD) Air/Fuel mixture too lean Air leak 2. Poor ignition or misfire 3. Slow fuel cut solenoid valve malfunction 4. Low engine compression 5. Air/Fuel mixture too rich Choke system malfunction Loose primary main jet Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No Yes No Yes No Go to next step. Go to next step. Refer to Section G. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Check each jet and air bleed for clogging. Go to next step. Go to next step. Repair or replace spark plug. Go to Step 9. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step. Repair or replace choke system. Go to Step 11. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to Step 13. Go to next step. Check pistons and cylinders for wear. Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket 1.
POSSIBLE CAUSE
STEP INSPECTION 1 Check if there is any air leakage. Is there any? 2 Disconnect high-tension lead at idle, then check engine speed, Does it decrease equally at each cylinder? Check float level. Is it okay?
4 5 6 7 8 9 10
Open and close throttle valve 2-3 times. Does engine start? Check each spark plug. Are they okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check choke system. Is it okay? Check slow fuel cut solenoid. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?
Yes No Yes No Yes No Yes No Yes No Yes No Yes No
11 12
Yes No Yes No
F4-36
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 13 INSPECTION Check primary main, slow system. Is it okay? RESULTS Yes Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace each jet and air bleed. ACTION
No SYMPTOM 4
POSSIBLE CAUSE
CRANKS NORMALLY BUT WON'T START OR HARD START (ENGINE WARM) 1. Percolation Air vent solenoid valve malfunction 2. Air/Fuel mixture too rich High float level Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Repair or replace No Yes No Yes No Yes Go to next step. Go to next step. Repair or replace choke system. Go to next step. Replace air vent solenoid valve. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Inspect both float and needle valve. ACTION
STEP INSPECTION 1 Inspect spark plugs. Are spark plugs wet or covered with carbon? 2 3 4 Check choke system. Is it okay? Check air vent solenoid valve. Is it okay? Check float level? Is it okay? (float level is high.)
No
CONTINUED
F4-37
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 5 ROUGH IDLE/ENGINE STALLS AT IDLE (ALWAYS) Air/Fuel mixture too rich High float level Loose primary main jet Restricted primary slow air bleed 2. Poor ignition or misfire 3. Air/Fuel mixture too lean Air leakage Restricted primary main jet 4. Low engine compression Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described In this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace appropriate parts. No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Go to next step. Go to next step. Refer to Section G. Go to next step. Repair or adjust system. Go to Step 6. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to Step 8. Go to next step. Adjust idling speed. Adjust or inspect idling mixture. Go to next step. Repair or replace pcv valve. Go to Step 11. Go to next step. Check pistons and cylinders for wear. Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace each jet and air bleed. 1.
POSSIBLE CAUSE
STEP INSPECTION 1 Check if there is any air leakage. Is there any? 2 Disconnect high-tension lead at idle, then check engine speed. Does it decrease equally at each cylinder? Check idle-up system. Is it okay? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check idling speed. Is it okay? Perform idling speed adjustment. Can idling speed be adjusted? Check pcv valve. Is it okay? Check compression pressure? Is it okay? Drive vehicle. Does engine stop at takeoff?
3 4 5 6 7 8 9 10
11
Yes
No
CONTINUED F4-38
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 6 ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE COLD) Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Check choke system (quick release). Is it okay? RESULTS Yes Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Repair or replace choke system. ACTION
POSSIBLE CAUSE
STEP 1
No SYMPTOM 7
ROUGH IDLE/ENGINE STALLS AT IDLE (ENGINE WARM) 1. Choke system malfunction 2. Float level incorrect 3. Air vent solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes No Yes No Yes No Yes ACTION
POSSIBLE CAUSE
STEP INSPECTION 1 Start and warm engine. Check choke valve. Is it fully open? 2 3 4 5 Inspect spark plugs. re spark plugs wet or covered with carbon? Check air vent solenoid valve. Is it okay? Check fuel check valve. Is it okay? Check float level. Is it okay? (float level is high.)
Repair or replace choke system. Repair or replace spark plugs. Go to next step. Go to next step. Replace valve. Go to next step. Repair or replace valve. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Inspect both float and needle valve.
No
F4-39
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 8 ROUGH IDLE/ENGINE STALLS AT IDLE - WHEN A/C OR P/S ON (IF EQUIPPED Idle-up system malfunction Solenoid valve malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious Injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Inspect idle-up system. Is it okay? RESULTS Yes No SYMPTOM 9 ENGINE SUDDERLY STALLS OFTEN 1. Disconnected starter connector 2. Poor connection of starter connector Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor Is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes ACTION ACTION Follow steps for troubleshooting item "Rough idle/engine stalls at idle (Always)". Adjust or repair system, 1.
POSSIBLE CAUSE
STEP 1
POSSIBLE CAUSE
STEP INSPECTION 1 Check starter connector. Is it disconnected or is it not properly connected? 2 Check slow fuel cut valve. Is it okay?
Properly connect connector, or repair or replace if necessary. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve.
No 3 Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Yes No
CONTINUED
F4-40
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 10 HIGH IDLE SPEED AFTER WARM-UP Idle-up system malfunction Choke system malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes Go to next step. No Yes No Yes No Yes Go to next step. Adjust or repair. Go to next step. Repair or inspect secondary diaphragm link. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Inspect both float and needle valve. ACTION
POSSIBLE CAUSE
STEP INSPECTION 1 Check throttle wiring. Is there sufficient slack in wiring? 2 3 4 Check idle-up system. Is it okay? Check secondary throttle valve. Is it closed? Check float level. Is it okay? (float level is high.)
Adjust or repair accelerator cable.
No SYMPTOM 11
POSSIBLE CAUSE
ENGINE STALLS AT DRIVE AWAY Restricted primary main system Accelerator pump malfunction Poor ignition or misfire Malfunctioning unloader system Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace parts as necessary. No Yes No Yes No Yes No Yes No Go to next step. Go to next step. Adjust or repair accelerator cable. Go to next step. Repair or replace accelerator pump. Go to next step. Replace distributor vacuum control unit. Go to next step. Repair or replace unloader system.
STEP INSPECTION 1 Check system for air leakage. Is there any? 2 3 Check throttle wiring. Is there sufficient slack in wiring? Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? Check distributor's vacuum advance. Is it correct? Check unloader system. Is it okay?
4 5
F4-41
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 6 INSPECTION Check primary main, slow system. Is it okay? RESULTS Yes ACTION Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace each Jet and air bleed.
No SYMPTOM 12 ENGINE STALLS ON DECELERATION
POSSIBLE CAUSE
Slow fuel cut solenoid valve malfunction Throttle positioner (T/P) malfunction (GULF only) Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS Yes No Yes No Yes No Yes ACTION Go to next step. Repair or replace any parts as necessary. Go to Step 4. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Adjust dashpot.
STEP INSPECTION 1 Check idle-up system. Is it okay? 2 3 Check slow fuel cut valve. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check dashpot's touch speed. Is it correct?
No SYMPTOM 13 HESITATION
POSSIBLE CAUSE
Spark advance control malfunction Restricted jets Air leakage Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE RESULTS ACTION Yes Repair or replace any parts as necessary. No Go to next step. Yes No Go to next step. Adjust or repair accelerator cable.
STEP 1 2
INSPECTION Check system for air leakage. Is there any? Check throttle wiring. Is there sufficient slack in wiring?
CONTINUED F4-42
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 3 INSPECTION Check centrifugal spark advance control. Is it okay? RESULTS Yes No Go to next step. Check for the following: Over advance (Inspect for governor spring damage.) Under advance (Inspect governor weight, cam op eration.) Go to next step. Repair or replace pump. Go to next step. Replace secondary diaphragm. Go to next step. Clean or replace spark plugs. Go to next step. Repair or replace any parts as necessary. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace jets. Note Dirt and grime can be removed from jets by covering the air horn with your hand. ACTION
Check accelerator pump. Is fuel pumped out when accelerator pump is depressed? Check secondary diaphragm. Is it okay? Inspect spark plugs? Are they okay? Is linkage of primary and secondary valve smooth? Inspect every jet. Are they okay?
5 6 7 8
No
SYMPTOM 14
POOR ACCELERATION 1. 2. 3. Spark advance control malfunction Restricted intake/exhaust system Air/Fuel mixture too lean Low float level Restricted jets, air bleeds Accelerator pump malfunction 4. Secondary diaphragm malfunction RPM limiter malfunction 5. Low engine compression 6. Poor ignition Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Yes No Yes No Go to next step. Adjust or repair accelerator cable. Go to next step. Repair or replace intake system. Go to next step. Repair or replace choke system. Go to next step. Repair or replace distributor. ACTION
POSSIBLE CAUSE
STEP 1 2 3 4
Check throttle wiring. Is there sufficient slack in wiring? Inspect intake system. Is it restricted? (especially air cleaner) Check choke valve. Is it fully open after warm-up? Check distributor, (centrifugal spark advance, vacuum spark advance) It is okay?
F4-43
CONTINUED
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 5 6 7 INSPECTION Inspect exhaust system. Is it okay? Inspect accelerator pump. It is okay? Check float level. Is it okay? RESULTS Yes No Yes No Yes No Go to next step. Repair or replace exhaust system. Go to next step. Repair or replace accelerator pump. Go to next step. If float level is high, check float and needle valve. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Go to next step. Clean or replace spark plugs. Go to next step. Replace secondary diaphragm. Go to Step 12. Go to next step. Check pistons, rings, and cylinders for wear. Check the following: Cylinder heads, gaskets Valve clearance Clean or replace each jet and air bleed. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) ACTION
8 9 10 11
Inspect spark plugs. Are they okay? Check secondary diaphragm. Is it okay? Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?
12
Inspect all jets and air bleeds (including high speed richer) of both primary and secondary main passage. Is there blockage?
Yes No
SYMPTOM 15
POSSIBLE CAUSE
NO POWER, FASTEST SPEED IS LOW Restricted primary main, slow system Centrifugal spark advance malfunction Restricted exhaust system Restricted air cleaner Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can Ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION RESULTS Yes No Yes No Go to next step. Repair or replace any part as necessary. Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil. Go to next step. Go to next step. Adjust or repair accelerator cable. Go to next step. Repair or replace choke valve. Go to next step. Repair or replace intake system. ACTION
STEP 1 2
Check system for air leakage. Is there any Check engine. Does it seem to be overheating? Check throttle wiring. Is there sufficient slack in wiring? Check choke valve. Is it fully open after warm-up? Check intake system. Is it restricted? (especially air cleaner)
3 4 5
CONTINUED F4-44
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 6 7 INSPECTION Check exhaust system. Is it restricted? Check float level. Is it okay? (float level is low.) RESULTS Yes No Yes No Go to next step. Repair or replace exhaust system. Go to next step. If level is low, check for clogging between float to needle valve and to fuel pump, and between fuel pump to fuel tank. Go to next step. Clean or replace spark plugs. Go to next step. Replace secondary diaphragm. Go to next step. Check for the following: Over advance (Inspect for governor spring damage.) Under advance (Inspect governor weight, cam op eration.) Go to Step 13. Go to next step. Check pistons and cylinders for wear. Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket Go to next step. Check the following: Main jet Air bleed Note Dirt and grime can be removed from jets by covering the air horn with your hand. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Check the following: Main jet Air bleed Note Dirt and grime can be removed from jets by covering the air horn with your hand. ACTION
8 9 10
Inspect spark plugs. Are they okay? Check secondary diaphragm. Is it okay? Check centrifugal spark advance control. Is it okay?
11 12
Check compression pressure. Is it okay? Add oil through plug hole. Does engine start?
Yes No Yes No
13
Check main (primary) system. Is it okay?
Yes No
14
Check main (secondary) system. Is it okay?
Yes
No
CONTINUED
F4-45
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 16 KNOCKING 1. Air/Fuel mixture too lean Restricted primary main, slow system Poor ignition or misfire Insufficient engine coolant Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep CAUSE sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious Injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP 1 INSPECTION Check engine Does it seem to be overheating? Inspect spark plugs. Are spark plugs electrode free of carbon accumulation? RESULTS Yes No 2 Yes No ACTION Stop vehicle and let it idle to cool engine. Inspect coolant and engine oil, Go to next step. Replace fuel, Clean or replace spark plugs.
SYMPTOM 17 AFTERBURN OCCURS DURING DECELERATION Poor ignition or misfire Slow fuel cut solenoid valve malfunction Throttle position (T/P) malfunction (GULF only) Dashpot malfunction Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: POSSIBLE Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. CAUSE Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE STEP INSPECTION 1 Check ignition timing at idle. Is it okay? 2 3 Perform ignition timing adjustment. Can timing be adjusted? Inspect distributor, (centrifugal spark advance, vacuum spark advance) It is okay? Check thermostat. Is it okay? Inspect every jet. Are they okay? RESULTS Yes No Yes No Yes No Yes No Yes ACTION Go to Step 3. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to next step. Repair or replace distributor. Go to next step. Repair or replace thermostat. Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust)
4 5
No
Clean or replace jets.
CONTINUED
F4-46
TO. MODEL .INDEX
TROUBLESHOOTING
SYMPTOM 18 POOR FUEL ECONOMY Incorrect adjustment of main adjust screw Incorrect adjustment of idle speed High float level Poor ignition or misfire Warning Following troubleshooting flowchart contains fuel system diagnosis and repair procedures. Read following warnings before performing fuel system service: Fuel vapor is hazardous. It can easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel. Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete "BEFORE REPAIR PROCEDURE" and "AFTER REPAIR PROCEDURE" described in this manual. FUEL SYSTEM, BEFORE REPAIR PROCEDURE FUEL SYSTEM, AFTER REPAIR PROCEDURE INSPECTION Check system for air leakage. Is there any? Check ignition timing at idle. Is it okay? Perform ignition timing adjustment. Can timing be adjusted? Check idling speed. Is it correct? Perform idling speed adjustment. Can it be adjusted? Check slow fuel cut solenoid valve. Is it okay? Shake carburetor's connector (6-pin) with ignition switch at ON. Is a "click" sound heard? Check both CO and HC concentration. Are they okay? Check choke valve. Is it fully open after warm-up? Check float level. Is it okay? (float level is high.) RESULTS Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Go to next step. Repair or replace any part as necessary. Go to Step 4. Go to next step. Adjust ignition timing. Check both distributor and timing belt. Go to Step 6. Go to next step. Adjust idling speed. Adjust or repair any part as necessary. Go to Step 8. Go to next step. Repair or replace wiring harness between slow fuel cut solenoid valve and carburetor. Repair or replace slow fuel cut solenoid valve. Go to next step. Adjust CO and HC concentrations. Go to next step. Repair or replace choke system. Go to next step. Check the following: Float Needle valve Go to next step. Repair or replace distributor. Go to Step 14. Go to next step. Check pistons and cylinders for wear. Check for the following: Burnt valve Worn piston, piston ring, or cylinder Damaged cylinder gasket Check for the following: Fuel filter (clogging) Float room (dust) Fuel hose (clogging) Fuel tank (dust) Clean or replace jets. ACTION
POSSIBLE CAUSE
STEP 1 2 3 4 5 6 7
8 9 10
11
Check distributor, (centrifugal spark advance, vacuum spark advance) Is it okay? Check compression pressure. Is it normal? Add oil through plug hole. Does engine start?
12 13
14
Is main jet loose?
Yes
No
F4-47
CONTINUED
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
ENGINE ELECTRICAL SYSTEM

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . BATTERY REMOVAL/INSTALLATION . . . . . . BATTERY INSPECTION . . . . . . . . . . . . . . . . . . BATTERY RECHARGING . . . . . . . . . . . . . . . . . GENERATOR REMOVAL/INSTALLATION . . . GENERATOR INSPECTION . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . IGNITER INSPECTION . . . . . . . . . . . . . . . . . . . IGNITION COIL REMOVAL/INSTALLATION . G 1 G 1 G 1/2 G 2 G 2/3 G 3/4 G 5 G 5 G 5 IGNITION COIL INSPECTION . . . . . . . . . . . . . DISTRIBUTOR REMOVAL/INSTALLATION . . DISTRIBUTOR DISASSEMBLY/ASSEMBLY . DISTRIBUTOR INSPECTION (F2 CARB) . . . HIGH-TENSION LEAD REMOVAL/INSTALLATION . . . . . . . . . . . . . . STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . STARTER REMOVAL/INSTALLATION . . . . . . STARTER INSPECTION . . . . . . . . . . . . . . . . . . Battery Clamp Installation Note (RH) D Install the battery clamp as shown. G5/6 G6/7 G8 G9 G9 G10 G10 G10/11
CHARGING SYSTEM
BATTERY REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3.54.9 {3550, 3143}
FRONT
75D26R
FRONT
Nm {kgfcm, inlbf}
1 2 3 4 5
Negative battery cable Positive battery cable Battery clamp + Installation Note (RH) Battery Battery tray
BATTERY INSPECTION Battery ST D Inspect the battery in the following procedure.

Step Inspection Measure open circuit voltage of battery. Above 12.4 V Below 12.4 V Above 12.4 V Below 12.4 V Yes Action Go to Step 3. Go to next step. Go to next step. Replace battery. Battery is okay. Replace battery.
Quick charge for 30 minutes and recheck voltage. Apply test load (see test load chart) to battery using a battery y load tester and record battery voltage after 15 seconds. Is voltage more than specification?
No
CONTINUED
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CHARGING SYSTEM
Test load chart
Battery 34B19R 55D23R 75D26L 75D26R 80D26R 95D31R Load (A) 110 180 195 195 195 250
BATTERY
1. Place a battery in a pan of water to prevent it from overheating. The water level should come up about halfway on the battery. Keep water off the top of the battery.
Battery positive voltage with load

Approximate battery temp. 21 C {70 F} 15 C {60 F} 10 C {50 F} 4 C {40 F} 1 C {30 F} 7 C {20 F} 12 C {10 F} 18 C { 0 F} Minimum voltage(V) 9.6 9.5 9.4 9.3 9.1 8.9 8.7 8.5
2. Connect a battery charger to the battery. 3. Adjust the charging current as follows.
Battery type (5hour rate) 34B19R (27) 55D23R (48) 75D26L (52) 75D26R (52) 80D26R (55) 95D31R (64) Slow charge (A) 3.04.0 4.55.5 5.56.5 5.56.5 5.56.5 6.58.0 Quick charge (A)/(30 min.) 20 30 35 35 35 40
Back-up Current 1. Verify that the ignition switch (engine switch) is at the OFF position and that the key has been removed. 2. Disconnect the negative battery cable. Caution D Operating electrical loads while measuring the back-up current can damage the circuit tester. 3. Measure the back-up current between the negative battery terminal and the negative battery cable. Back-up current 20 mA max. 4. If the current exceeds the maximum, remove the fuse in the main fuse block and the fuse block one by one while measuring the back-up current. 5. Inspect and repair harnesses and connectors of the fuse at which the current reduces. BATTERY RECHARGING Caution D When disconnecting the battery, remove the negative cable first and install it last to prevent damage to electrical components or the battery. D To avoid deformation or damage to the battery, remove the battery plugs while charging the battery. D Do not quick charge for over 30 minutes. It will damage the battery.
4. After the battery has been recharged, measure the battery positive voltage and verify that the battery keeps specified voltage for more than 1 hour. Specification Above 12.4 V 5. If not as specified, replace the battery. GENERATOR REMOVAL/INSTALLATION Warning D When the battery cables are connected, touching the vehicle body with generator terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation. 1. Disconnect the negative battery cable. 2. Remove the fresh-air duct, air intake pipe and air hose. (WL, WL Turbo) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal. 5. Inspect the drive belt deflection/tension. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.)
CONTINUED
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CHARGING SYSTEM
G6
5.06.8 Nm {5070 kgfcm, 4460 inlbf}
WL, WL Turbo
2030 {2.03.1, 1522}
A B C
1925 {1.92.6, 1418} 3851 {3.85.3, 2838}
A
5.06.8 Nm {5070 kgfcm, 4460 inlbf}
B C
3851 {3.85.3, 2838}
3851 {3.85.3, 2838} Nm {kgfm, ftlbf} Nm {kgfm, ftlbf}
F2 CARB, F2 CIS
5.06.8 Nm {5070 kgfcm, 4460 inlbf} 1622 {1.62.3, 1216}
1 2 3 4 5
Terminal B wire Connector Drive belt (generator) Generator strap (G6) Generator
GENERATOR INSPECTION Generator Warning Light 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn the ignition switch (engine switch) on and verify that the generator warning light illuminates. 4. If not, inspect the generator warning light and wiring harnesses between the battery and generator warning light and between the battery and generator terminal L (G6, F2 CARB, F2 CIS), I (WL, WL Turbo).
3851 {3.85.3, 2838}
ST
G6, F2 CARB, F2 CIS
Nm {kgfm, ftlbf}
CONTINUED
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TO. MODEL .INDEX
CHARGING SYSTEM
Standard voltage
Terminal B
A S I
WL, WL Turbo
Engine switch ON (V) WL, WL Turbo B+ B+ 0 2.04.0
Idle (V) [20C {68F}] WL, WL Turbo 14.0514.85 14.0514.85 7.0257.425 13.0014.85
A S I
6. If not as specified, disassemble and inspect the generator. 5. Verify that the generator warning light goes out after engine starts. 6. If not, inspect the wiring harness between the S terminals of the generator (WL, WL Turbo) and the generator. Generator Voltage 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is within the specification. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Turn off all electrical loads. 4. Turn the ignition switch (engine switch) to START position and verify that the generator turns smoothly without any noise while the engine is running. 5. Measure the voltage at the terminals shown in the table.
G6, F2 CARB, F2 CIS
Current 1. Verify that the battery is fully charged. 2. Verify that the drive belt deflection/tension is correct. (Refer to Section B2, DRIVE BELT, DRIVE BELT INSPECTION.) 3. Disconnect the negative battery cable. 4. Connect an ammeter, capable of reading 120 A or over, between generator terminal B and the wiring harness. 5. Connect the negative battery cable. 6. Turn all electrical loads off. 7. Start the engine and increase the engine speed to 2,0002,500 rpm. 8. Turn the following electrical loads on and verify that the current reading increases. D Headlights D Blower motor D Rear window defroster Note D Current required for generating power varies with electrical loads applied. Standard current (Reference)
Measuring conditions Room temperature: 20 C {68 F} Voltage: 13.5 V Engine hot

Engine speed (rpm) 1,000 2,000
*:
Terminal B current (A)* G6, F2 CARB, F2 CIS Approx. 043 Approx. 062 WL, WL Turbo Approx. 058 Approx. 074
Standard voltage
Terminal B L S
WL, WL Turbo
Ignition switch ON (V) G6, F2 CARB, F2 CIS B+ Approx. 1 B+
Idle [20C {68F}] (V) G6, F2 CARB, F2 CIS 14.114.7 13.014.0 14.114.7
Must not be 0 A.
9. If generator terminal B current will not increase, disassemble and inspect the generator.
CONTINUED
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IGNITION SYSTEM
IGNITION SYSTEM
IGNITER INSPECTION G6, F2 CIS 1. Disconnect the igniter connector. 2. Turn the ignition switch on and measure the voltage at connector terminal A using the voltmeter.
G6, F2 CIS
G6, F2 CIS
8.912.7 {90130, 79112}
1.51.9 {1520, 1417}
Specification Battery positive voltage 3. Turn the ignition switch off and verify that there is continuity between terminal B and the body ground. 4. While cranking the engine, measure the voltage at terminal C using the voltmeter. Specification Approx. 0.5 V 5. If voltage and continuity are okay, replace the igniter. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) IGNITION COIL REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
6.879.80 {70100, 60.886.8]
6.879.80 {70100, 60.886.8] Nm {kgfcm, inlbf}
F2 CARB
8.912.7 {90130, 79112}
2.02.9 {2030, 1826}
ST
Nm {kgfcm, inlbf}
1 2 3 4 5 6
Center lead Connector Ignition coil bracket Condenser Ignition coil Igniter
IGNITION COIL INSPECTION G6, F2 CARB, F2 CIS Primary Coil Winding 1. Disconnect the ignition coil connector.
CONTINUED
G5
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IGNITION SYSTEM
2. Measure the resistance at the primary coil using an ohmmeter. Specification [20 C {68 F}] G6, F2 CIS: 0.810.99 F2 CARB: 1.0351.265
G6, F2 CIS F2 CARB
(+)
4. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) DISTRIBUTOR REMOVAL/INSTALLATION G6, F2 CARB, F2 CIS 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Adjust the ignition timing. (Refer to Section F2, ENGINE TUNE-UP, IGNITION TIMING ADJUSTMENT.)
G6
F2 CARB
3. If not as specified, replace the ignition coil. (Refer to IGNITION SYSTEM, IGNITION COIL REMOVAL/INSTALLATION.) Secondary Coil Winding 1. Disconnect the ignition coil connector. 2. Disconnect the center lead. 3. Measure the resistance at the secondary coil using an ohmmeter. Specification 1016 k [20 C {68 F}]
1925 {1.92.6, 1418} G6, F2 CIS
Nm {kgfm, ftlbf}
CONTINUED
G6
TO. MODEL .INDEX
IGNITION SYSTEM
Distributor Installation Note D Verify that the No.1 cylinder is at top dead center, and align the distributor matching marks.
F2 CARB
MATCHING MARKS
1925 {1.92.6, 1418}
Nm {kgfm, ftlbf}
F2 CIS
1925 {1.92.6, 1418}

Nm {kgfm, ftlbf}
ST
1 2
Vacuum hose High-tension lead + HIGH-TENSION LEAD REMOVAL/INSTALLATION Connector Distributor + Installation Note
3 4
CONTINUED
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IGNITION SYSTEM
DISTRIBUTOR DISASSEMBLY/ASSEMBLY G6, F2 CARB, F2 CIS 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
G6 F2 CIS
F2 CARB
1 2 3 4 5 6 7
Cap Rotor Cover Signal rotor Pick-up coil with igniter Vacuum control unit Breaker
8 9 10 11 12 13
Coupling set Governor set Oil seal Bearing Distributor body O-ring
CONTINUED
G8
TO. MODEL .INDEX
IGNITION SYSTEM
DISTRIBUTOR INSPECTION (F2 CARB) Centrifugal Spark Advance Control 1. Warm up the engine to the normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to Section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose.
TIMING LIGHT DIAPHRAGM A
( ! ) 1115
VACUUM HOSE
02 0 20 53.3 {150, 5.9} {400, 15.7}
5. While gradually increasing the engine speed, use the timing light to check the advance angle on crankshaft pulley.
1923 (!) 913
ADVANCE (DEGREE) VACUUM ( kPa { mmHg , inHg })
6. If necessary, disassemble and inspect the distributor. Pick-up Coil With Igniter Inspection 1. Connect an ohmmeter to the pick-up coil.
02 ADVANCE (DEGREE) 0
1,200 2,200 6,000 ENGINE SPEED ( rpm )
(1) Excess advance . . . weak governor spring (if the governor spring is broken, the advance will rise very high) (2) Insufficient advance . governor weight or cam malfunction 6. If necessary, disassemble and inspect the distributor. Vacuum Spark Advance Control 1. Warm up the engine to normal operating temperature. 2. Check to be sure that the idle speed and ignition timing are correct. (Refer to section F2, ENGINE TUNE-UP.) 3. Turn off all electrical loads. 4. Disconnect the vacuum hose to the vacuum control unit, and plug the end of the hose. 5. Attach a vacuum pump to the diaphragm A and check using the timing light while applying vacuum.
2. Measure the resistance.
ST Resistance 9001,200 "

3. If it is not within specification, replace it. HIGH-TENSION LEAD REMOVAL/INSTALLATION Caution D The high-tension leads must be reinstalled to their original positions. Incorrect installation can damage the leads and cause power loss, and negatively affect the electronic components.
CONTINUED
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STARTING SYSTEM
STARTING SYSTEM
WL, WL Turbo
STARTER REMOVAL/INSTALLATION Warning D When the battery cables are connected, touching the vehicle body with starter terminal B will generate sparks. This can cause personal injury, fire, and damage to the electrical components. Always disconnect the battery before performing the following operation. 1. Disconnect the negative battery cable. 2. Remove the battery. (WL, WL Turbo) (Refer to CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.) 3. Remove the intake manifold bracket. (G6) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
G6, F2 CARB, F2 CIS
3851 {3.85.3, 2838} 9.911.7 Nm {100120 kgfcm, 87104 inlbf} 9.911.7 Nm {100120 kgfcm, 87104 inlbf}
3851 {3.85.3, 2838}
Nm {kgfm, ftlbf}
1 2 3
Terminal B wire Terminal S wire Starter
STARTER INSPECTION On-vehicle Inspection 1. Verify that the battery is fully charged. 2. Crank the engine and verify that the starter turns smoothly without any noise. 3. If not as specified, measure the voltage at terminals S and B when the ignition switch (engine switch) is at START position. Specification Above 8 V 4. If the voltage is within the specification, remove the starter and inspect the magnetic switch and the starter. 5. If the voltage is not as specified, inspect the wiring harness, ignition switch (engine switch). No Load Test 1. Verify that the battery is fully charged. 2. Connect the starter, battery, voltmeter, and ammeter as shown.
A B IGNITION SWITCH (ENGINE SWITCH) M V STARTER BATTERY TERMINAL S
Nm {kgfm, ftlbf}
CONTINUED
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STARTING SYSTEM
3. Operate the starter and verify that it turns smoothly. 4. Measure the voltage and current while the starter is operating. Specification
Engine type Item Voltage (V) Current (A) G6 11.5 Below 100 F2 CARB, F2 CIS 11.5 Below 60 WL, WL Turbo 11 Below 130
5. If not as specified, repair or replace the inner parts as necessary.
CONTINUED
G11
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CLUTCH
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH FLUID INSPECTION . . . . . . . . . . . . . CLUTCH FLUID REPLACEMENT/AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL INSPECTION/ ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH PEDAL DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H 1 H 1 H 1 H 1/2 H 2 H 2/3 H 3 H 4 H 5 H 5 H 5/6 CLUTCH RELEASE CYLINDER . . . . . . . . . . . . . . H 7 CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . H 7 CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . H 7 CLUTCH UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H 8 CLUTCH UNIT REMOVAL/INSTALLATION . . . H 8/10 CLUTCH COVER INSPECTION . . . . . . . . . . . . H10 CLUTCH DISC INSPECTION . . . . . . . . . . . . . . . H11 CLUTCH RELEASE COLLAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . H11 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H11 PILOT BEARING INSPECTION . . . . . . . . . . . . . H11 FLYWHEEL INSPECTION . . . . . . . . . . . . . . . . . H11
GENERAL PROCEDURES
Clutch Pipe Removal/Installation 1. If any clutch pipe has been disconnected any time during the procedure, add brake fluid, bleed the air, and inspect for leakage after the procedure has been completed. 2. If removing the clutch pipe, remove it using the SST (49 0259 770B). If installing the clutch pipe, modify the clutch pipe tightening torque to allow for the use of a torque wrenchSST (49 0259 770B) combination, and then tighten the clutch pipe using the SST (49 0259 770B).
CLUTCH FLUID
CLUTCH FLUID INSPECTION Note D The fluid in the reservoir must be maintained between the MIN/MAX level during replacement. CLUTCH FLUID REPLACEMENT/AIR BLEEDING Caution D Clutch fluid will damage painted surfaces, be careful not to spill clutch fluid on a painted surface. If this should happen, wash it off immediately. D Do not mix different brands of clutch fluid. D Do not reuse the clutch fluid that was drained out. 1. Draw the fluid from the reserve tank with a suction pump. 2. Remove the bleeder cap from the clutch release cylinder and attach a vinyl hose to the bleeder plug. 3. Place the other end of the vinyl hose into a container. 4. Slowly pump the clutch pedal several times. 5. With the clutch pedal depressed, loosen the bleeder screw using the SST to let fluid escape. Close the bleeder screw using the SST.
BLEEDER SCREW
49 0259 770B
CONTINUED
H1
TO. MODEL .INDEX
CLUTCH FLUID, CLUTCH PEDAL

1.Repeat steps 4 and 5 until only clean fluid is seen. 2.Tighten the bleeder screw. Tightening torque 5.98.8 Nm {6090 kgfcm, 5278 inlbf} 3.Add fluid to the MAX mark. 4.Check for correct clutch operation.
CLUTCH PEDAL
CLUTCH PEDAL INSPECTION/ADJUSTMENT Clutch Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet. Pedal height 241.6246.6 mm {9.529.70 in}
A 1417
{1.41.8, 1113}
PEDAL HEIGHT
CARPET
Nm {kgfm, ftlbf}
2.If necessary, adjust the pedal height by turning stopper bolt A and clutch switch (or adjust bolt) B.
CONTINUED
H2
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CLUTCH PEDAL
Clutch Pedal Free Play 1. Depress the clutch pedal by hand until clutch resistance is felt, and measure the pedal free play. Pedal free play 3.08.0 mm {0.120.31 in} CLUTCH PEDAL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2.Remove in the order indicated in the table. 3.Install in the reverse order of removal. 4.After installation, adjust the clutch pedal. (Refer to CLUTCH PEDAL INSPECTION/ADJUSTMENT) L.H.D.
D
1925 {1.92.6, 1418}
C
1216 {1.21.7, 8.712.3}
PEDAL FREE PLAY

Nm {kgfm, ftlbf}
1925 {1.92.6, 1418}
2.If necessary, adjust the pedal free play by turning locknut C and adjusting push rod D. Clutch Release Point Inspection 1. Without depressing the clutch pedal, slowly shift the shift lever into reverse position until the gears contact. 2.Gradually depress the clutch pedal and measure the stroke distance from the point the gear noise stops (release point) up to the full stroke end position. Standard distance A: 14.637.5 mm {0.581.47 in} (reference value)
A
6.99.80 Nm {70100 kgfcm, 6186.8 inlbf}
Nm {kgfm, ftlbf}
1 2 3 4 5
Clutch switch connector (G6, F2 CIS) Spring pin Clevis pin Nut Clutch pedal component
R.H.D. G6, F2 CIS, F2 Carb D Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION. WL, WL Turbo D Refer to section F2, INTAKE-AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION.
RELEASE POINT FULL STROKE END POSITION
PEDAL STROKE
3.If the clutch pedal disengagement stroke is outside of the specification, adjust the pedal height and pedal free play, and verify the pedal stroke. Pedal stroke 146.5151.5 mm {5.85.9 in} (reference value)
CONTINUED
H3
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CLUTCH PEDAL
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. Note D Apply lithium-based grease to the spring and bush when assembling. 2. Assemble in the reverse order of disassembly.
1216 {1.21.7, 8.712.3}
1417 {1.41.8, 1113}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10 11 12 13
Clutch switch (G6, F2 CIS) Adjustment bolt (WL, WL Turbo, F2 Carb) Nut Stopper rubber Retaining ring Washer Bush Pin Fork Push rod Nut Pedal pad Clutch pedal component
CONTINUED
H4
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CLUTCH MASTER CYLINDER

CLUTCH MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
6.99.8 {70100, 60.886.7}
SST *
12.821.5 {130220, 113190}
* 49 0259 770B
Nm {kgfcm, inlbf}
1 2
Clutch pipe Nut
3 4
Clutch master cylinder Gasket
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
84112 Nm {8.511.5 kgfm, 61.583.1 ftlbf}
CONTINUED
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Snap ring + Disassembly Note + Assembly Note Piston Protector Primary cap Return spring Tank cap Reservoir Bushing Joint bolt Gasket One-way valve piston Return spring One way valve pin Clutch master cylinder body
2 3 4 5 6 7 8 9 10 11 12 13 14
Snap Ring Disassembly Note D Hold the piston down using a cloth-wrapped pin punch.
Snap Ring Assembly Note D Hold the piston down using a cloth-wrapped pin punch.
CONTINUED
H6
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CLUTCH RELEASE CYLINDER
CLUTCH RELEASE CYLINDER

CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
2226 {2.22.7, 1619}
1622 {1.62.3, 1216}
(LITHIUM BASED GREASE)
Nm {kgfm, ftlbf}
1 2
E-clip Clutch hose
3 4
Bolt Clutch release cylinder
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
G6
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
EXCEPT G6
1 2 3 4
Boot Push rod Piston and cap Return spring
5 6 7 8
Bleeder cap Bleeder screw Steel ball Clutch release cylinder body
CONTINUED
H7
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CLUTCH UNIT
CLUTCH UNIT
CLUTCH UNIT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
G6 :9298 {9.310.0, 67.372.3} EXCEPT G6 :97102 {9.810.5, 70.975.9} ENGINE SIDE SST TRANSMISSION SIDE
1826 {1.82.7, 1419}
SST SST SST
(MOLYBDENUM SULFIDE)
Nm {kgfm, ftlbf}
2 3 4
Transmission + Section J1, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION + Section J2, MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION Clutch release collar Clutch release fork Clutch cover + Removal Note + Installation Note
5 6
Clutch disc + Installation Note Pilot bearing + Removal Note + Installation Note Flywheel + Removal Note + Installation Note
CONTINUED
H8
TO. MODEL .INDEX
CLUTCH UNIT
Clutch Cover Removal Note 1. Install the SSTs. 2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
49 E011 1A0
Flywheel Installation Note 1. Install the flywheel to the crankshaft. 2. Hand-tighten the flywheel lock bolts. 3. Install the SST to the flywheel. 4. Apply sealant to the bolt threads before installing the bolt to prevent oil leakage from the bolt. 5. Gradually tighten the flywheel lock bolts in a crisscross pattern. G6
1
49 SE01 310A
3
7 4 6
49 E011 1A0
Pilot Bearing Removal Note Note D The pilot bearing does not need to be removed unless you are replacing it.
D Use the SSTs to remove the pilot bearing.
3 1 6
EXCEPT G6
49 E011 1A0
5 4 2
49 1285 071
Flywheel Removal Note 1. Hold the flywheel using the SST. 2. Remove the bolts evenly and gradually in a crisscross pattern. G6
Pilot Bearing Installation Note G6, F2 CIS, F2 Carb D Install a new pilot bearing using a pipe until depth is as follows: Depth 4.0 mm {0.16 in}
PILOT BEARING
49 E011 1A0
CRANK SHAFT
EXCEPT G6
1 6
49 E011 1A0
5 2
CONTINUED
H9
TO. MODEL .INDEX
CLUTCH UNIT
WL, WL Turbo D Install a new pilot bearing using a pipe until protrusion height is as follows: Protrusion height 00.2 mm {00.008 in}
PILOT BEARING FLY WHEEL
CLUTCH COVER INSPECTION 1. Measure the wear of the diaphragm spring figures. Depth 0.6 mm {0.024 in} min.
DEPTH
Clutch Disc Installation Note D Hold the clutch disc in position using the SST.
2. Measure the flatness of the pressure plate using a straight edge and a feeler gauge. Clearance 0.5 mm {0.020 in} max.
49 SE01 310A
Clutch Cover Installation Note 1. Install the SSTs. 2. Tighten the bolts evenly and gradually in a crisscross pattern.
3. When checking the diaphragm spring fingers, mount a dial indicator on the cylinder block. 4. Rotate the flywheel and check for misaligned diaphragm spring fingers. Misalignment 0.6 mm {0.030 in} max.
49 E011 1A0
49 SE01 310A
5. Replace the clutch cover if not as specified.
CONTINUED
H10
TO. MODEL .INDEX
CLUTCH UNIT
CLUTCH DISC INSPECTION 1. Using vernier calipers, measure the thickness of the lining at a rivet head on both sides. 2. If clutch disc thickness is less than the minimum, replace the clutch disc. Thickness 0.3 mm {0.012 in} min.
0.3 mm {0.012 in}
FLYWHEEL
PILOT BEARING INSPECTION 1. Without removing the pilot bearing from the flywheel, turn the bearing while applying force in the axial direction.
2. If the bearing sticks or has excessive resistance, replace it. 3. Measure the clutch disc runout using a dial indicator. Runout 0.7 mm {0.027 in} max. FLYWHEEL INSPECTION 1. Install a dial indicator on the cylinder block. 2. Measure the flywheel runout using a dial indicator. Runout 0.2 mm {0.079 in} max.
4. If runout is excessive, replace the clutch disc. CLUTCH RELEASE COLLAR INSPECTION Caution D Cleaning the clutch release collar with cleaning fluids or a steam cleaner can wash the grease out of the sealed bearing. Otherwise, clutch release collar may not operate properly. 1. Turn the collar while applying force in the axial direction. 3. If runout is excessive, replace the flywheel.
2. If the collar sticks or has excessive resistance, replace the clutch release collar.
CONTINUED
H11
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
MANUAL TRANSMISSION (M15M-D, M15MX-D)

MANUAL TRANSMISSION .............................. J1-1 TRANSMISSION OIL INSPECTION ................ J1-1 TRANSMISSION OIL REPLACEMENT ........... J1-1/2 OIL SEAL (M15M-D) REPLACEMENT ............. J1-2 VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION ........................ J1-2 MANUAL TRANSMISSION TRANSMISSION OIL INSPECTION 1. Remove the check plug A. VEHICLE SPEEDOMETER SENSOR INSPECTION .....................................................J1-2 MANUAL TRANSMISSION REMOVAL/INSTALLATION ................................J1-3/7
2.
Verify that the oil is at the brim of the check plug hole as shown. If it is low, add the specified oil from the check plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 C {50 F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D) 3. Install a new check plug A. Tightening torque A: 2539 N.m {2.5-4.0 kgf.m, 1928 ft.lbf}
2. 3. 4.
Drain the oil into a container. Clean the drain plug B. Install the drain plug B with new washer. Tightening torque B: 4058 N.m {4.06.0 kgf.m, 2943 ft.lbf} Add the specified oil from check plug A port until the level reaches the brim of check plug hole.
5.
TRANSMISSION OIL REPLACEMENT 1. Remove the drain plug B with washer and the check plug A.
Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 C {50 F}) Capacity: 2.0 L {2.1 US qt, 1.8 Imp qt} (M15M-D) 2.5 L {2.6 US qt, 2.2 Imp qt} (M15MX-D)
6. Install a new check plug A.

Tightening torque A: 2539 N.m {2.54.0 kgf.m, 1928 ft.lbf}
CONTINUED J1-1
TO. MODEL .INDEX
MANUAL TRANSMISSION
6. Install the vehicle speedometer sensor. Tightening torque 7.910.7 N.m {80110 kgf.cm, 69.595.4 in.Ibf} 7. 8. Connect the vehicle speedometer sensor connector. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) Connect the negative battery cable.
9.
OIL SEAL (M15M-D) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 3. Remove the oil seal using a screwdriver.
VEHICLE SPEEDOMETER SENSOR INSPECTION 1. Remove the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.) 2. Measure voltage between terminals of the vehicle speedometer sensor while the gear is turning. Meter needle Action Speedometer sensor is normal. Inspect wiring harness. (Instrument cluster-Vehicle speedometer sensor) Replace vehicle speedometer sensor.
Moves slightly under 5 V
Does not move
4. 5.
Apply the specified oil to new oil seal. Install the oil seal until it touches the case using a suitable piece of pipe.
3.
Install the vehicle speedometer sensor. (Refer to MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/ INSTALLATION.)
Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/ INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the transmission oil. 3. Disconnect the vehicle speedometer sensor connector. 4. Remove the vehicle speedometer sensor. 5. Apply transmission oil to new O-ring and install it on new vehicle speedometer sensor.
6.
J1-2
CONTINUED
TO. MODEL .INDEX
MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION 4x2(M15M-D)
1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1 2 3 4 5 6 7 8 9 10 11
Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever Change seat
12 13 14 15 16 17 18 19
Speedometer sensor connector Back-up light switch connector Neutral switch connector (F2 CIS) Front pipe bracket Clutch release cylinder Crossmember Removal Note Transmission lower mount Transmission Removal Note Installation Note
CONTINUED J1-3
TO. MODEL .INDEX
MANUAL TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19
Speedometer sensor connector Back-up light switch connector Front pipe bracket Clutch release cylinder Crossmember Removal Note Dynamic damper Transmission lower mount Transmission Removal Note & Installation Note
CONTINUED
J1-4
TO. MODEL .INDEX
MANUAL TRANSMISSION
Crossmember removal note Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note Maintain the stability of the transmission while removing it.
Transmission installation note Warning A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. 2. Place the transmission on a transmission jack. Maintain the stability of the transmission while installing it.
CONTINUED
J1-5
TO. MODEL .INDEX
MANUAL TRANSMISSION
4x4(M15MX-D) 1. Disconnect the negative battery cable.
2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft, (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
1 2 3 4 5 6 7 8 9 10 11
Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat
12 13 14 15 16 17 18
Transfer under cover Speedometer sensor connector Back-up light switch connector 4x4 indicator switch connector Front pipe bracket Clutch release cylinder Crossmember MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 4x2 (M15M-D), Crossmember removal Note
CONTINUED
J1-6
TO. MODEL .INDEX
MANUAL TRANSMISSION
19 20 Transmission lower mount Transmission and transfer Removal Note & Installation Note
Transmission and transfer removal note Maintain the stability of the transmission and transfer while removing them .
Transmission and transfer installation note Warning A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
CONTINUED
J1-7
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
MANUAL TRANSMISSION (R15MD, R15MXD)

MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . TRANSMISSION OIL INSPECTION . . . . . . . . . TRANSMISSION OIL REPLACEMENT . . . . . . OIL SEAL (R15MD) REPLACEMENT . . . . . . VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J21 J21 J21/2 J22 J22 TRANSMISSION OIL REPLACEMENT 1. Remove drain plugs A and B, and drain the oil into a container. 2. Clean the drain plug A. 3. Install the drain plug A with new washer and a new drain plug B. Tightening torque A: 4058 Nm {4.06.0 kgfm, 2943 ftlbf} B: 2131 Nm {2.13.2 kgfm, 1623 ftlbf}
FILLER PLUG
VEHICLE SPEEDOMETER SENSOR INSPECTION...J22 MANUAL TRANSMISSION REMOVAL/INSTALLATION . . . . . . . . . . . . . . . J23/9
MANUAL TRANSMISSION
TRANSMISSION OIL INSPECTION 1. Remove the filler plug.
FILLER PLUG
2. Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL4 or GL5 Viscosity: SAE 75W90 (All season) or SAE 80W90 (Above 10C {50F})
DRAIN PLUG A DRAIN PLUG B
FILLER PLUG HOLE
4. Remove the filler plug and add the specified oil through the filler plug port until the level rises to the bottom of the port. Specified oil Grade: API service GL4 or GL5 Viscosity: SAE 75W90 (All season) or SAE 80W90 (Above 10C {50F}) Capacity: 2.8 L {3.0 US qt, 2.5 lmp qt} (R15MD) 3.2 L {3.4 US qt, 2.8 lmp qt} (R15MXD)
3. Install a new filler plug. Tightening torque 2539 Nm {2.64.0 kgfm, 1928 ftlbf}
FILLER PLUG HOLE
CONTINUED
J21
TO. MODEL .INDEX
MANUAL TRANSMISSION
1. Install a new filler plug. Tightening torque 2539 Nm {2.64.0 kgfm, 1928 ftlbf} OIL SEAL (R15MD) REPLACEMENT 1. Drain the transmission oil. 2. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove the oil seal using a screwdriver.
4. Apply the specified oil to the new oil seal. 5. Install the oil seal until it touches the case using a suitable piece of pipe.
PIPE
6. Install the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 7. Add the transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR REMOVAL/INSTALLATION.) VEHICLE SPEEDOMETER SENSOR INSPECTION (Refer to section J1, MANUAL TRANSMISSION, VEHICLE SPEEDOMETER SENSOR INSPECTION.)
CONTINUED
J22
TO. MODEL .INDEX
MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION 4 2 (R15MD) 1. Disconnect the negative battery cable. 2. Drain the transmission oil into a container. 3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Add the specified amount and type of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) 8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
F2
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
6988 {7.09.0, 5165}
1925 {1.92.6, 1418}
6988 {7.09.0, 5165} 3851 {3.85.3, 2838} 1622 {1.62.3, 1216} 6988 {7.09.0, 5165} 6988 {7.09.0, 5165}
1622 {1.62.3, 1216}
ST
3851 {3.85.3, 2838} 3851 {3.85.3, 2838} 7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf} 3246 {3.24.7, 2433} 2228 {2.22.9, 1620} 3846 {3.84.7, 2833} Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19
Vehicle speedometer sensor connector Backup light switch connector Neutral switch connector (F2 CIS) Front pipe bracket Clutch release cylinder Crossmember + Removal Note Transmission lower mount Transmission + Removal note + Installation note
CONTINUED
J23
TO. MODEL .INDEX
MANUAL TRANSMISSION
G6
1 2 3 4 5 6 7 8 9 10 11
12 13 14 15 16 17 18 19
Vehicle speedometer sensor connector Back-up light switch connector Neutral switch connector Front pipe bracket Clutch release cylinder Crossmember Removal Note Transmission lower mount Transmission Removal note Installation note
CONTINUED
J2-4
TO. MODEL .INDEX
MANUAL TRANSMISSION
WL, WL TURBO
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
1925 {1.92.6, 1418}
3851 {3.85.3, 2838}
3851 {3.85.3, 2838}
A
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
3246 {3.24.7, 2433} 2228 {2.22.9, 1620} 3846 {3.84.7, 2833}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10
Shift lever knob Console Dust boot Change boot upper plate Boot Dust boot Gasket Wave washer Change bush Change lever
11 12 13 14 15 16 17 18
Change seat Vehicle speedometer sensor connector Back-up light switch connector Front pipe bracket Clutch release cylinder Crossmember + Removal Note Transmission lower mount Transmission + Removal note + Installation note
CONTINUED
J25
TO. MODEL .INDEX
MANUAL TRANSMISSION
Crossmember removal note D Securely support the transmission on a transmission jack, then remove the crossmember. Transmission removal note Warning D Do not allow the transmission to fall from the transmission jack.
D Maintain the stability of the transmission while
removing it.
Transmission installation note Warning D A transmission that is not securely supported on a transmission jack is dangerous. It can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission on a transmission jack. 2. Maintain the stability of the transmission while installing them.
ST
CONTINUED
J26
TO. MODEL .INDEX
MANUAL TRANSMISSION
4 4 (R15MXD) 1. Disconnect the negative battery cable. 2. Drain the transmission and transfer oil into a container. 3. Remove the front and rear propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) (Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 4. Remove the front pipe. (G6 engine) (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.) 5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.) 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal. 8. Add the specified type and amount of transmission and transfer oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.) (Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.) 9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
G6
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
R R
3851 {3.85.3, 2838}
1925 {1.92.6, 1418}
A
3851 {3.85.3, 2838}
3851 {3.85.3, 2838}
1622 {1.62.3, 1216}
3246 {3.24.7, 2433}
6988 {7.09.0, 5165}
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
3750 {3.75.1, 2736} 3851 {3.85.3, 2838}
4453 {4.45.3, 3239}
Nm {kgfm, ftlbf}
CONTINUED
J27
TO. MODEL .INDEX
MANUAL TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12 13 Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat Transfer under cover Vehicle speedometer sensor connector 21 22 14 15 16 17 18 19 20 Backup light switch connector Neutral switch connector 4x4 indicator switch connector Transfer neutral switch connector (RFW model) Front pipe bracket Clutch release cylinder Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 4 2 (R15MD), Crossmember removal note Transmission lower mount Transmission and transfer + Removal note + Installation note
WL, WL TURBO
7.910.7 Nm {80110 kgfcm, 69.595.4 inlbf}
R R
1925 {1.92.6, 1418}
3851 {3.85.3, 2838}
ST
A
3851 {3.85.3, 2838} 3246 {3.24.7, 2433}
1622 {1.62.3, 1216}
3750 {3.75.1, 2736}
4453 {4.45.3, 3239} 2228 {2.22.9, 1620}
Nm {kgfm, ftlbf}
CONTINUED
J28
TO. MODEL .INDEX
MANUAL TRANSMISSION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Shift lever knob Console Dust boot Change boot upper mount Boot Dust boot Gasket Wave washer Change bush Change lever Change seat Transfer under cover Vehicle speedometer sensor connector Backup light switch connector Transfer neutral switch connector (RFW model) 4x4 indicator switch connector Front pipe bracket Clutch release cylinder Crossmember + MANUAL TRANSMISSION, MANUAL TRANSMISSION REMOVAL/INSTALLATION, 4 2 (R15MD), Crossmember removal note Transmission lower mount Transmission and transfer + Removal note + Installation note
Transmission and transfer removal note Warning D Do not allow the transmission to fall from the transmission jack.
D Maintain the stability of the transmission and
transfer while removing them.
Transmission and transfer installation note Warning D A transmission and transfer that are not securely supported on a transmission jack are dangerous. They can slip or fall, causing serious injury. Never work without the transmission jack until crossmember installation is finished. 1. Place the transmission and transfer on a transmission jack. 2. Maintain the stability of the transmission and transfer while installing them.
20 21
CONTINUED
J29
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
TRANSFER
TRANSFER ..................................................................J3-1 TRANSFER OIL INSPECTION ...............................J3-1 TRANSFER
TRANSFER OIL INSPECTION 1. Remove the filler plug with washer.
TRANSFER OIL REPLACEMENT ................ J3-1
TRANSFER OIL REPLACEMENT 1. Remove the filler plug with washer and drain plug with washer.
2.
Verify that the oil is at the brim of the filler plug hole as shown. If it is low, add the specified oil from the filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 C {50 F}) Capacity: 2.0 L {2.1 USqt,1.8 lmp qt}
2. 3. 4.
Drain the oil into a container. Clean the filler and drain plugs. Install the drain plug with new washer. Tightening torque 4058 N.m {4.06.0 kgf.m, 2943 ft.lbf}
5.
Add the specified oil from filler plug port until the level reaches the brim of filler plug hole. Specified oil Grade: API service GL-4 or GL-5 Viscosity: SAE 75W-90 (All season) or SAE 80W-90 (Above 10 C {50 F}) Capacity: 2.0 L {2.1 USqt,1.8lmpqt}
3. 4.
Clean the filler plug. Install the filler plug with new washer. Tightening torque 4058 N-m {4.06.0 kgf.m, 2943 ft.lbf} 6. Install the filler plug with new washer. Tightening torque 4058 N-m {4.0-6.0 kgf.m, 2943 ft.lbf}
CONTINUED
J3-1
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
PROPELLER SHAFT
PROPELLER SHAFT (4 2) . . . . . . . . . . . . . . . . . . PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . PROPELLER SHAFT INSPECTION . . . . . . . . . . FRONT PROPELLER SHAFT (4 4) . . . . . . . . . . . FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . L1 L1 L2 L2 L2 FRONT PROPELLER SHAFT INSPECTION . . FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR PROPELLER SHAFT (4 4) . . . . . . . . . . . . REAR PROPELLER SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR PROPELLER SHAFT INSPECTION . . . . L3 L3/4 L5 L5 L5
PROPELLER SHAFT (4
2)
PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
5058 {5.06.0, 3743}
WL TURBO, G6: WL, F2 CIS, F2 CARB: SST
49 S120 440 49 0259 440
3752 {3.75.4, 2739} Nm {kgfm, ftlbf}
Propeller Shaft Installation Note D Align the marks made during removal, and install the propeller shaft. If installing a new propeller shaft, align the differential companion flange precast marking with the tag on the propeller shaft.
TAG MARK
1 2 3
Bolt, nut Nut + Installation Note Propeller shaft + Removal Note + Installation Note
Propeller Shaft Removal Note 1. Before removing the propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation.
TAG MARK
Nut Installation Note ST D Tighten the center bearing installation nuts with the vehicle *unloaded. *unloaded...Fuel tank is full; engine coolant and engine oil are at specified levels; spare tire, jack and tools are in designated position.
2. Remove the propeller shaft from the extension housing and immediately install the SST to prevent oil leakage.
CONTINUED
L1
TO. MODEL .INDEX
PROPELLER SHAFT (4 2), FRONT PROPELLER SHAFT (4

PROPELLER SHAFT INSPECTION 1. Measure the propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
4)
FRONT PROPELLER SHAFT (4 4)

FRONT PROPELLER SHAFT REMOVAL/ INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
2830 {2.83.1, 2122}
2. If the runout is excessive, replace the propeller shaft. 3. Move the universal joint in the direction shown, and inspect joint play. Note D Starting torque 0.31.1 Nm {3.012.0 kgfcm, 2.710.4 inlbf}
Nm {kgfm, ftlbf}
1 2
Bolt, nut Front propeller shaft + Removal Note + Installation Note
Front Propeller Shaft Removal Note D Before removing the front propeller shaft, put marks on the yoke and the companion flange on the propeller shaft tag side for proper reinstallation. 4. If there is excessive play or the starting torque is not within the specification, replace the propeller shaft.
TAG
MARK
Front Propeller Shaft Installation Note D Align the marks made during removal, and install the front propeller shaft. If installing a new propeller shaft, align the precast marking with the tag on the front propeller shaft.
CONTINUED
L2
TO. MODEL .INDEX

FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
TAG
MARK
FRONT PROPELLER SHAFT INSPECTION 1. Measure the front propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
1 2 3
Snap ring + Disassembly Note Universal joint yoke Universal joint + Disassembly Note + Assembly Note Sliding yoke Propeller shaft
4 5
Snap ring Disassembly Note 1. Mark the yoke and propeller shaft for proper reassembly. 2. If the runout is excessive, replace the front propeller shaft. 3. Move the universal joint in the direction shown, and inspect the joint play. Note D Starting torque 0.30.7 Nm {3.08.0 kgfcm, 2.76.9 inlbf}
MARK
ST
2. Clamp the propeller shaft in a vise. 3. Remove the snap ring.
Universal joint Disassembly Note 1. Push one bearing cup out of the propeller shaft by tapping the yoke with a plastic hammer.
4. If there is excessive play or the starting torque is not within the specification, repair the front propeller shaft. (Refer to FRONT PROPELLER SHAFT (4 4), FRONT PROPELLER SHAFT DISASSEMBLY/ASSEMBLY.)
YOKE
BEARING CUP
CONTINUED
L3
TO. MODEL .INDEX

1. Remove the opposite bearing cup in the same manner. 2. Separate the propeller shaft and yoke. 3. Clamp the yoke in a vise. 4. Remove the bearing cups and the spider from the yoke in the same manner as in Steps 1 and 2. Universal joint Assembly Note 1. Verify that the inside of the bearing cup is filled with 1.151.45g {0.040.05 oz} grease. Add the specified amount of disulphide molybdem grease as necessary. 2. Set the new spider into the yoke and tap in a new bearing cup until the snap ring groove is exposed.
6. If there is excessive play or the starting torque is not within the specification, replace the front propeller shaft.
SPIDER
3. Measure the snap ring clearance, then select and install two new snap rings of equal thickness. Snap ring thicknesses mm {in}
1.22 {0.0480} 1.24 {0.0488} 1.26 {0.0496} 1.28 {0.0504} 1.30 {0.0512}
BEARING CUP YOKE
1.32 {0.0520} 1.34 {0.0528} 1.36 {0.0536} 1.38 {0.0543}
SNAP RING CLEARANCE
SPIDER
4. Install the remaining bearing cups and snap rings as in Steps 13. 5. Move the universal joint in the direction shown, and inspect joint play. Note D Starting torque 0.30.7 Nm {3.08.0 kgfcm, 2.76.9 in lbf}
CONTINUED
L4
TO. MODEL .INDEX
REAR PROPELLER SHAFT (4 4)
REAR PROPELLER SHAFT (4 4)

REAR PROPELLER SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
TAG
MARK
5058 {5.06.0, 3743}
REAR PROPELLER SHAFT INSPECTION 1. Measure the rear propeller shaft runout using a dial indicator. Runout 0.4 mm {0.016 in} max.
3752 {3.75.4, 2739} 5058 {5.06.0, 3743} Nm {kgfm, ftlbf}
1 2
Bolt, nut Nut + PROPELLER SHAFT (4 2), PROPELLER SHAFT REMOVAL/INSTALLATION, Nut Installation Note Rear propeller shaft + Removal Note + Installation Note Dynamic damper (WL Turbo)
2. If the runout is excessive, replace the rear propeller shaft. 3. Move the universal joint in the direction shown. Inspect starting torque and joint play. Note D Starting torque 0.31.1 Nm {3.012.0 kgfcm, 2.710.4 inlbf}
Rear Propeller Shaft Removal Note 1. Before removing the rear propeller shaft, put marks on the yoke and the companion flange on the rear propeller shaft tag side for proper reinstallation.
TAG MARK
ST
4. If there is excessive play or the starting torque is not within the specification, replace the rear propeller shaft.
Rear Propeller Shaft Installation Note D Align the marks made during removal, and install the rear propeller shaft. If installing a new propeller shaft, align precast marking with the tag on the rear propeller shaft.
CONTINUED
L5
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
FRONT AND REAR AXLES

GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . FRONT AXLE (4 2) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . FRONT AXLE (4 4) . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR AXLE INSPECTION . . . . . . . . . . . . . . . . AXLE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SHAFT DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION . . . . . . . . . . . . . . OUTPUT SHAFT DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . REAR DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL OIL INSPECTION . . . . REAR DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . REAR DIFFERENTIAL REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . STANDARD DIFFERENTIAL ASSEMBLY . . . M 2 M 2 M 2 M 3/5 M 5 M 5 M 6/8 M 9 M 9 M 9/11 M12 M12 M13/15 M16 M17/18 M19 M19 M19 M20 M21/23 M24/27 REMOTE FREEWHEEL (RFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 4 INDICATOR SWITCH INSPECTION . . . TRANSFER NEUTRAL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW SWITCH INSPECTION . . . . . . . . . . . . . . RFW MAIN SWITCH REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . RFW MAIN SWITCH INSPECTION . . . . . . . . ONE-WAY CHECK VALVE INSPECTION . . . LOCK AND FREE SOLENOID VALVES INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . RFW ACTUATOR INSPECTION . . . . . . . . . . . RFW CONTROL MODULE INSPECTION . . . . RFW CONTROL MODULE REMOVAL/ INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . JOINT SHAFT INSPECTION . . . . . . . . . . . . . . JOINT SHAFT COMPONENT ASSEMBLY . . . CONTROL BOX REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . CONTROL BOX DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT FORK INSPECTION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . FRONT DIFFERENTIAL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT DIFFERENTIAL DISASSEMBLY . . . . FRONT DIFFERENTIAL ASSEMBLY . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . REMOTE FREEWHEEL (RFW) . . . . . . . . . . . . M32 M32 M32/33 M33 M33 M33 M34 M34 M34 M35 M35/36 M37 M38/39 M39 M40/42 M42 M43/44 M44 M45 M45 M45 M45 M46/47 M48/50 M51/55 M56 M56/62
MANUAL FREEEWHEEL (MFW) MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M32 ON-VEHICLE INSPECTION . . . . . . . . . . . . . . . M32
CONTINUED
M1
TO. MODEL .INDEX
GENERAL PROCEDURES, FRONT AXLE (4
2)
GENERAL PROCEDURES
Wheel and tire removal/installation D The removal and installation procedure for the wheels and tires are not mentioned in this section. When a wheel is removed, tighten it to the specified torque. (Refer to section TD, SUSPENSION, Wheels and Tires.) Suspension arm removal/installation D Tighten any part of the suspension that uses rubber bushings only after vehicle has been lowered and unloaded.* *Unloaded: Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Brake line disconnection/connection Caution D Brake fluid will damage painted surfaces. If brake fluid gets on a painted surface, wipe it off immediately.
D Tighten the brake pipe flare nut using the
FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection D After jacking up the vehicle and supporting it at the specified places with safety stands, inspect for noticeable bearing play by holding the top and bottom of the tire. Wheel bearing axial play 0 mm {0 in} Preload Adjustment 1. Verify that the tire rotates smoothly when rotated strongly, and that there is no rough feeling or is abnormal noise from the bearing. 2. Remove the brake caliper component and suspend it by a rope. 3. Remove the hub cap, pull out the cotter pin and remove the set cover. 4. Loosen the locknut to the extent that it can be turned by hand. 5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.910.7 N {0.61.1 kgf, 1.42.4 lbf} 7. Install the set cover, and secure with a new cotter pin. 8. Install the hub cap and brake caliper component.
SST (49 0259 770B). Be sure to modify the brake pipe fIare nut tightening torque to allow use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) D If any brake line has been disconnected any time during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed. Connectors disconnection/connection D Disconnect the negative battery cable before doing any work that requires the handling of connectors. Reconnect the negative battery cable only after the work is completed.
CONTINUED
M2
TO. MODEL .INDEX
FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
5468 {5.57.0, 4050}
108127 {1113, 8094}
SST R R SST R
SST
3050 {3.05.2, 2250} 80100 {8.110.2, 5973}
R SST R R
R SST SST
R
4558 {4.56.0, 3343}
R
1925 {1.92.6, 1418}
118156 {1216, 87115}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9
Hub cap Cotter pin Set cover Locknut Washer Brake caliper component + Removal Note Hub and disc plate component + Installation Note Dust cover Tie-rod end ball joint + section N, MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note Knuckle arm
11
Lower arm ball joint + section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note Upper arm ball joint + section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note Steering knuckle Disc plate + Removal Note Wheel hub + Removal Note Hub bolt + Removal Note + Installation Note
12
13 14 15 16
10
CONTINUED
M3
TO. MODEL .INDEX
FRONT AXLE (4 2)
17 18 19 20
Outer bearing inner race Oil seal + Installation Note Inner bearing inner race Inner bearing outer race + Removal Note + Installation Note Outer bearing outer race + Removal Note + Installation Note
21
Brake Caliper Component Removal Note D Remove the brake caliper component, and suspend it by a rope.
Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note D Install the bearing outer race using the SSTs and a press. For the other side, reverse the wheel hub and install the outer race.
OUTSIDE BEARING
49 H033 101
INSIDE BEARING
49 B025 001
Disc Plate, Wheel Hub, Hub Bolt Removal Note Note D The hub bolt does not need to be removed unless it is being replaced. 1. After putting markings on the disc plate and the wheel hub, remove the bolt and disassemble the plate and hub. Oil Seal Installation 1. After inserting the bearing in the hub, use the SST to tap in the oil seal until it is flush with the hub end surface. 2. Apply grease to the oil seal lip.
49 F019 001
MARK
2. Remove the hub bolt using a press as necessary. Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note Note D When the inner bearing outer race is removed, the inner race and oil seal are removed together.
D Remove the bearing outer race using a suitable
Hub Bolt Installation Note D Press new hub bolts into the wheel hub using a press.
round bar and a hammer. For the other side, reverse the wheel hub and remove the outer race.
CONTINUED
M4
TO. MODEL .INDEX
FRONT AXLE (4 2), FRONT AXLE (4 4)

Hub and Disc Plate Component Installation Note 1. Apply grease to the areas indicated in the figure.
FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE INSPECTION Wheel Bearing Play Inspection (Refer to FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE INSPECTION, Wheel Bearing Play Inspection.) Preload Adjustment Caution D When replacing the locknut, tighten it using the SST and turn the wheel hub a few times to seat the bearing. Then, perform the preload adjustment. 1. For RFW model, remove the hub cap and drive shaft end flange. For MFW model, remove the freewheel hub component. 2. Remove the spacer and set plate. 3. Remove the brake caliper component, and suspend it by a rope. 4. Loosen the locknut to the extent that it can be turned by hand using the SST.
49 S231 635
2. Install the hub and disc plate component, then adjust the preload. (Refer to FRONT AXLE (42), WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment.)
5. Attach a pull scale to a hub bolt and measure the frictional force. 6. Tighten the locknut until the reading reaches the specified amount. Preload Frictional force plus 5.910.7 N {0.61.1 kgf, 1.42.4 lbf} 7. Install the set plate, spacer, freewheel hub or drive shaft end flange, hub cap and brake caliper component.
CONTINUED
M5
TO. MODEL .INDEX
FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
5580 {5.68.2, 4159}
R SST R SST
SST
5567 {5.66.9, 4149}
5468 {5.57.0}
R
3051 {3.05.2, 2237}
SST
R R SST R SST R R
SST SST R SST R

1925 {1.92.6, 1418} 118156 {1216, 87115} 4044 {4.04.5, 2932} 4558 {4.56.0, 3343}
(RFW MODEL)
(MFW MODEL)
2529 {2.53.0, 1921}
Nm {kgfm, ftlbf}
1 2 3 4 5 6
Hub cap Drive shaft end flange Freewheel hub component Spacer Set plate Locknut + Removal Note + Installation Note Brake caliper component + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Brake Caliper Component Removal Note. Hub and disc plate component
9 10
Dust cover Tie-rod end ball joint + Section N, MANUAL STEERING, STEERIG GEAR AND LINKAGE REMOVAL/ INSTALLATION, Tie-rod End Ball Joint Removal Note Disc plate + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Disc Plate Removal Note Wheel hub + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Wheel Hub Removal Note
11
12
CONTINUED
M6
TO. MODEL .INDEX
FRONT AXLE (4 4)
Steering Knuckle Component Removal Note 1. Remove the lower arm ball joint from the knuckle using the SST. (Refer to section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Lower Arm Ball Joint/Knuckle Removal Note.) 2. Remove the lower arm installation bolt and remove the lower arm with the knuckle. Oil Seal Removal Note D Remove the oil seal using a screwdriver.
13
Hub bolt + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Removal Note + FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Hub Bolt Installation Note Outer bearing inner race Oil seal + Installation Note Inner bearing inner race Inner bearing outer race + FRONT AXLE (4 2) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note Outer bearing outer race + FRONT AXLE (4 2) WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION, Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note + Installation Note Nut + Section R, FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM (4 2) REMOVAL/INSTALLATION, Nut Installation Note Shock absorber bolt Upper arm ball joint + Section R, FRONT SUSPENSION, UPPER ARM REMOVAL/INSTALLATION, Upper Arm Ball Joint/Knuckle Removal Note Steering knuckle component + Removal Note Lower arm ball joint Oil seal + Removal Note + Installation Note Spacer Needle bearing + Removal Note + Installation Note Steering knuckle
14 15 16 17
18
19
Needle Bearing Removal Note D Remove the needle bearing using the SST.
49 S231 660
20 21
22 23 24
25 26
Needle Bearing Installation Note 1. Install the needle bearing using the SST and a press. 2. Apply grease to the needle bearing.
49 S033 108
27
Locknut Removal Note D Remove the locknut using the SST.

49 S231 635
CONTINUED
M7
TO. MODEL .INDEX
FRONT AXLE (4 4)
Oil Seal Installation Note 1. Install the new oil seal using the SST and a press. 2. Apply grease to the oil seal lip. Locknut Installation Note 1. Install the locknut using the SST.
49 S231 635 49 S033 107
Outer Bearing Outer Race Installation Note D Install the outer bearing outer race using the SST and press.
2. Adjust the preload. (Refer to FRONT AXLE (44) WHEEL HUB, STEERING KNUCKLE INSPECTION, Preload Adjustment)
49 F027 005
Inner Bearing Outer Race Installation Note D Install the inner bearing outer race using the SST and a press.
49 F027 007
Oil Seal Installation Note D Install the new oil seal using the SST and a press.
49 S033 106
CONTINUED
M8
TO. MODEL .INDEX
REAR AXLE
REAR AXLE
REAR AXLE INSPECTION Wheel Bearing Play Inspection 1. Jack up the rear end and support it with safety stands. 2. Verify that there is no abnormal noise and that the tire rotates smoothly when forcefully rotated by hand. 3. With a hand on top of the tire, inspect the bearing play. Wheel bearing axial play 0.050.25 mm {0.0020.010 in} AXLE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
4. If not as specified, adjust the bearing play. (Refer to REAR AXLE, AXLE SHAFT REMOVAL/INSTALLATION, Bearing Inner Race, Bearing Locknut Installation Note, Bearing play adjustment.)
SST
*
275313 {2832, 203231}
SST
R SST
R SST SST
1621 Nm {1.62.2 kgfcm, 1215 inlbf}
SST R
108127 {1113, 8094}
SST R
CONTINUED
*49
0259 770B
Nm {kgfm, ftlbf}
M9
TO. MODEL .INDEX
REAR AXLE
Bearing Housing Removal Note D Remove the bearing and bearing housing using the SSTs.
49 S026 204 49 S026 205
1 2 3 4 5 6 7
Brake drum Parking brake connecting pin Brake pipe Nut Axle shaft and back plate component Shim Bearing locknut + Removal Note + Installation Note Lock washer Bearing housing + Removal Note Bearing inner race + Installation Note Bearing spacer Oil seal (bearing housing side) + Installation Note Bearing outer race + Removal Note + Installation Note Back plate component Axle shaft Hub bolt Baffle Oil seal (axle casing side) + Removal Note + Installation Note
49 S026 208
8 9 10 11 12 13
Bearing Outer Race Removal Note D After removing the bearing inner race and oil seal from the rear wheel hub, tap lightly using a suitable round bar to force out the outer race.
14 15 16 17 18
Bearing Locknut Removal Note Note D Be careful when removing or installing the bearing locknuts for the left wheels because they are left threaded (tightened by turning counterclockwise).
D Set the SSTs as shown in the figure, and remove
Oil Seal (Axle Casing Side) Removal Note D Remove the oil seal from the axle casing using a screwdriver.
OIL SEAL
the bearing locknut from the rear axle shaft.

AXLE CASING
49 0603 635A 49 S120 645A
Oil Seal (Axle Casing Side) Installation Note 1. Use the SST to tap the oil seal in until it is flush with the end of the axle casing. 2. After installation, apply grease to the oil seal lip.
OIL SEAL
49 H025 001
AXLE CASING
CONTINUED
M10
TO. MODEL .INDEX
REAR AXLE
Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note D Press the bearing outer race and the oil seal using the SSTs.
OIL SEAL BEARING OUTER RACE
49 U027 003 49 F027 004
Bearing play adjustment D Adjust the bearing play in the axial direction (only when the bearing is replaced). (1) First insert one side of the rear axle shaft component and push the end of the shaft to the thrust block, then insert a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.650.95 mm {0.0260.037 in}. (2) Next insert the opposite shaft component and push the end of the shaft to the thrust block. (3) Use a shim(s) at point A so that the clearance between the end of the shaft and the thrust block becomes 0.050.25 mm {0.0020.010 in}. Bearing play in axial direction 0.050.25 mm {0.0020.010 in}
Bearing Inner Race, Bearing Locknut Installation Note Caution D The torque wrench must be attached perpendicular to the SST.
PINION SHAFT A SHIM THRUST BLOCK
1. Set the SST and then press the bearing inner race in until 3 to 5 threads of the bearing locknut mounting screw of the axle shaft are visible above the top of the bearing outer race.
49 S120 748
2. Remove the SST, and then install the bearing locknut to the axle shaft. 3. Tighten the bearing locknut using the SST to press in the bearing inner race. 4. Remove the SST and install the lock washer so that its tab fits into the groove of the axle shaft. 5. Tighten the bearing locknut to the specified torque. Bearing locknut tightening torque 275313 Nm {28.032.0 kgfm, 203231 ftlbf}
49 0603 635A 49 S120 645A
CONTINUED
M11
TO. MODEL .INDEX
DRIVE SHAFT
DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
Wheel hub, steering knuckle + FRONT AXLE (4 4), WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION Drive shaft + Removal Note + Installation Note
3 4
Snap ring Clip + Installation Note
Drive Shaft Removal Note Caution D Do not damage the dust cover or oil seal.
D Remove the drive shaft by prying with a bar
Clip Installation Note Left side D Install a new clip to the output shaft clip groove with the opening facing upward. Right side D Install a new clip to the clip groove of the drive shaft end with the opening facing upward.
CLIP
inserted between the differential casing and the drive shaft.
OPENING 28 mm {1.1 in}
Drive Shaft Installation Note D Be careful not to damage the oil seal with the shaft spline when installing the drive shaft.
CONTINUED
M12
TO. MODEL .INDEX
DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of removal.
R RIGHT SIDE
R R
R R
LEFT SIDE
Boot band + Disassembly Note + Assembly Note Clip Outer ring + Disassembly Note + Assembly Note Snap ring + Assembly Note Balls + Disassembly Note + Assembly Note
Inner ring + Disassembly Note + Assembly Note Cage + Disassembly Note + Assembly Note Boot + Disassembly Note + Assembly Note Bell joint component Drive shaft
2 3
4 5
9 10
CONTINUED
M13
TO. MODEL .INDEX
DRIVE SHAFT
Boot Band Disassembly Note Note D The wheel side boot band does not need to be removed unless replacing it. 1. Pry up the locking clip using a screwdriver and remove the band using pliers. 2. Slide the boot along the shaft to expose the joint. 3. Disassemble the balls, inner ring, cage from the drive shaft as component. 4. Turn the cage by approximately 30 degrees and pull the cage and balls away from the inner ring.
30_
Boot Disassembly Note Note D The wheel side boot does not need to be removed unless it is being replaced. Outer Ring Disassembly Note Caution D Mark with paint; do not use a punch. 1. Mark the cage and outer ring for proper assembly. 2. Remove the clip using a screwdriver. 3. Remove the outer ring from the inner ring and the balls. 4. Clean the grease away.
MARKS
1. Wrap the shaft splines with tape. 2. Remove the boot.
TAPE
Boot Assembly Note Note D The wheel side and differential side boots are different. Balls, Inner Ring, Cage Disassembly Note Caution D Mark with paint; do not use a punch. 1. Mark the drive shaft and inner ring for proper assembly.
100.5 mm {4.0 in} 99.2 mm {3.9 in}
WHEEL SIDE
DIFFERENTIAL SIDE
MARKS
2. Disassemble the snap ring from the drive shaft using a snap-ring pliers.
1. With the splines of the shaft still wrapped in tape from disassembly, assemble the boot. 2. Temporarily assemble the wheel side boot, new boot bands, and differential side boot to the drive shaft. 3. Remove the tape.
CONTINUED
M14
TO. MODEL .INDEX
DRIVE SHAFT
Cage, Inner Ring, Balls, Snap Ring Assembly Note 1. Align the marks, and install the balls and cage to the inner ring in the direction shown in the figure. Caution D Install the cage with the offset facing the snap ring groove. If incorrectly installed, the drive shaft may become disengaged. 2. Install a new snap ring.
BALLS CAGE
LEFT SIDE
RIGHT SIDE
Standard length Right side : 619.0629.0 mm {24.424.7 in} Left side : 551.0561.0 mm {21.722.0 in} 3. Release trapped air from inside the boot using a screwdriver covered with a rag.
SNAP RING GROOVE INNER RING
Outer Ring Assembly Note Note D Use the specified grease supplied in the boot kit. 1. Apply grease to the cage, inner ring, balls, and the outer ring. Wheel side : 110130 g {3.84.6 oz} Differential side : 95105 g {3.43.7 oz} 2. Align the marks, and install the outer ring onto the shaft. 3. Install a new clip.
MARKS
4. Set the new boot band to the boot groove. 5. Fold the band back and use pliers to pull it tight. 6. Lock the end of the band by bending the locking clips.
Boot Band Assembly Note Caution D Do not damage the boot. D For wheel side, apply grease only when assembling the boot. 1. Apply grease to the inside of the boot. 2. Set the drive shaft to the standard length.
CONTINUED
M15
TO. MODEL .INDEX
DRIVE SHAFT
OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3757 {3.75.5, 2739}
Nm {kgfm, ftlbf}
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION Bolt
3 4
Screw Output shaft component + Removal Note
Output Shaft Component Removal Note D Remove the output shaft by prying with a bar inserted between the bearing housing of the output shaft and the differential casing.
CONTINUED
M16
TO. MODEL .INDEX
DRIVE SHAFT
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R SST R R R
Clip + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Clip Assembly Note Output shaft component + Disassembly Note + Assembly Note Oil seal + Assembly Note
Bearing + Disassembly Note + Assembly Note Output shaft Bearing housing Oil seal + Assembly Note O-ring
5 6 7 8
Output Shaft Component Disassembly Note D Disassemble the output shaft component using a press.
CONTINUED
M17
TO. MODEL .INDEX
DRIVE SHAFT
Bearing Disassembly Note D Remove the bearing from the output shaft component using a press. Oil Seal Assembly Note D Assemble the new oil seal by lightly tapping it using a plastic hammer.
Oil Seal Assembly Note D Use the SST to assemble the new oil seal until it is flush with the bearing housing end using the SST.
49 M005 796
Output Shaft Component Assmebly Note D Press the output shaft and bearing to the bearing housing.
Bearing Assembly Note Caution D Press the bearing center and shaft center vertically.
D Press the new bearing to the output shaft.
CONTINUED
M18
TO. MODEL .INDEX
REAR DIFFERENTIAL
REAR DIFFERENTIAL
REAR DIFFERENTIAL OIL INSPECTION Caution D Position the vehicle level. 1. Remove the filler plug. 2. Verify that the oil is at the brim of the filler plug hole. If it is low, add the specified oil. Specified oil Type Standard differential: API service GL5, SAE 90 LSD: API service GL6, SAE 90 Capacity 4 2: 1.40 L {1.48 US qt, 1.23 lmp qt} 4 4: 1.85 L {1.96 US qt, 1.63 lmp qt}
Specified oil Type Standard differential: API service GL5, SAE 90 LSD: API service GL6, SAE 90 Capacity: 4 2: 1.40 L {1.48 US qt, 1.23 lmp qt} 4 4: 1.85 L {1.96 US qt, 1.63 lmp qt} 6. Install a new washer and the filler plug. Tightening torque 4053 Nm {4.05.5 kgfm, 2939 ftlbf}
FILLER PLUG
WASHER
3. Install a new washer and the filler plug. Tightening torque 4053 Nm {4.05.5 kgfm, 2939 ftlbf} REAR DIFFERENTIAL OIL REPLACEMENT 1. Remove the filler and drain plugs. 2. Drain the differential oil into a container.
3. Wipe the plugs clean. 4. Install a new washer and the drain plug. Tightening torque 4053 Nm {4.05.5 kgfm, 2939 ftlbf} 5. Add the specified oil from the filler plug hole until it reaches the brim of the hole.
CONTINUED
M19
TO. MODEL .INDEX
REAR DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION Caution D Clean away the old sealant before applying the new sealant. D Install the differential carrier within 10 minutes after applying sealant. D Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oil. 1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the rear propeller shaft. (Refer to section L, REAR PROPELLER SHAFT (44), REAR PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
2628 {2.62.9, 1920}
5058 {5.06.0, 3743}
Nm {kgfm, ftlbf}
Axle shaft and back plate component + REAR AXLE, AXLE SHAFT REMOVAL/ INSTALLATION
Differential + Removal Note
Differential Removal Note D To prevent the differential from dropping, leave the two bolts loosely tightened. Then hit the differential carrier using a wooden hammer.
CONTINUED
M20
TO. MODEL .INDEX
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL DISASSEMBLY D Disassemble in the order indicated in the table.
SST SST
SST SST
SST
1 2 3 4 5 6 7 8 9 10 11 12 13
Differential component + Disassembly Note Bearing cap + Disassembly Note Adjusting shim Side bearing cup Side bearing cone + Disassembly Note Pinion nut + Disassembly Note Companion flange + Disassembly Note Oil seal + Disassembly Note Thrust washer Drive pinion + Disassembly Note Front bearing cone Collapsible spacer Rear bearing cone + Disassembly Note
14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Adjusting shim Front bearing cup + Disassembly Note Oil buffle Rear bearing cup + Disassembly Note Carrier Hex screw Ring gear Roll pin + Disassembly Note Pinion shaft Thrust block Pinion gear Pinion gear thrust washer Side gear Side gear thrust washer Case
CONTINUED
M21
TO. MODEL .INDEX
REAR DIFFERENTIAL
Differential Component Disassembly Note D Mount a carrier component to the SST or equivalent.
T57L500B
Pinion Nut Removal Note D Hold the companion frange and remove the pinion nut.
Bearing Cap Disassembly Note D Place a mark on one of the bearing caps so that the left and right bearing caps wont get mixed up. Use the mark for matching at the time of assembly.
MARK
Companion Flange Disassembly Note D Remove the companion flange using universal puller.
Side Bearing Cone Disassembly Note Warning D When pulling the side bearing cone, do not allow differential component to fall. It can strike legs or feet and may cause serious injury. Caution D Mark the left bearing in order to install in the same position.
D Remove the side bearing cone using a press and
Oil Seal Disassembly Note D Pull out the oil seal using the SST.
308047 T77F1102A
the SST.
Drive Pinion Disassembly Note D Remove the drive pinion by tapping with a plastic hammer.
205D064 D84L1123A
CONTINUED
M22
TO. MODEL .INDEX
REAR DIFFERENTIAL
Rear Bearing Cone Disassembly Note Note D Mark or otherwise distinguish between the front and rear cones so that they are not mixed up at the time of reassembly.
D Remove the rear bearing cone using the SST.
205D064 D84L1123A
Front Bearing Cup, Rear Bearing Cup Disassembly Note Note D Mark or otherwise distinguish between the front and rear cups so that they are not mixed up at the time of reassembly.
D Remove the bearing races using the SSTs (308 047 T77F1102A and 100 001 T50T100A). 100001 T50T100A
Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note Note Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly. Remove the bearing outer races by using the two grooves on the carrier and tapping the outer races alternately.
3308047 T77F1102A
Knock Pin Disassembly Note Caution Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed. Secure the gear case in a vise and remove the knock pin by using a 4 mm {0.16 in} diameter bar.
Roll Pin Disassembly Note Caution D Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
D Secure the gear case in a vise and remove the roll
pin using a small drift.
CONTINUED
M23
TO. MODEL .INDEX
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL ASSEMBLY D Assemble in the order indicated in the table.
7595 {7.69.7, 5570}
SST R
SST
SST R R R SST
130150 {13.215.3, 96110}
SST R SST R
R R SST
298500 {30.350.9, 220368}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Case + Assembly Note Side gear thrust washer + Assembly Note Side gear Pinion gear thrust washer Pinion gear Thrust block Pinion shaft Roll pin Ring gear Hex screw Side bearing cone + Assembly Note Carrier Oil buffle Front bearing cup + Assembly Note Rear bearing cup + Assembly Note
16 17 18 19 20 21 22 23 24 25 26 27
Adjusting shim + Assembly Note Rear bearing cone + Assembly Note Drive pinion + Assembly Note Collapsible spacer Front bearing cone Thrust washer Oil seal + Assembly Note Companion flange Pinion nut Side bearing cup + Assembly Note Adjusting shim + Assembly Note Bearing cap + Assembly Note
CONTINUED
M24
TO. MODEL .INDEX
REAR DIFFERENTIAL
Adjusting Shim Assembly Note Pinion height Adjustment 1. Assemble the rear bearing cone over the SST and insert it into the rear bearing cup of the carrier. 2. Assemble the front bearing cone into the front bearing cup and assemble the SSTs.
205456
6. This measurement is the thickness needed for the selective shim if there was no marking on the drive pinion. If the drive pinion is marked with a plus (+) reading, the amount marked should be subtracted from the feeler gauge measurement. If the drive pinion is marked with a minus () reading, the amount marked should be added to the feeler gauge measurement. Rear Bearing Cone Assembly Note D Assemble the selected spacer on the drive pinion and press the rear bearing inner race until it is firmly seated on the shaft.
205110, T76P4020A10 205457
205105, T76P4020A3
205090 T75L1165B
205109, T76P4020A9
205111, T76P4020A11
Drive Pinion Assembly Note Drive pinion preload adjustment Caution D Never loosen pinion nut to decrease drive pinion preload torque, and never exceed specified preload torque. If preload torque is exceeded, a new collapsible spacer must be installed and the torque sequence repeated. 1. Install the drive pinion, collapsible spacer and companion flange to the carrier, and tighten the pinion nut until all end play is removed. 2. Continue to tighten in small increments until the specified preload can be obtained. Drive pinion preload 1.21.5 Nm {12.215.3 kgfcm, 10.613.2 inlbf} 3. If the specified preload cant be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again.
3. Roll the SST component back and forth a few times to seat the bearings while tightening the SST by hand. Tightening torque 27 Nm {2.8 kgfm, 20 ftlbf} 4. Center the SST (205456) into the side bearing bore. Install the bearing caps and tighten the bolt. Tightening torque 7595 Nm {7.69.7 kgfm, 5570 ftlbf} Note D There should be drag on the feeler gauge when it is inserted between the SSTs (205110, T76P4020A10 and 205456). 5. Insert the thickest feeler gauge possible between the SSTs (205110, T76P4020A10 and 205456).
205110 T76P4020A10
FEELER GAUGE
205456
CONTINUED
M25
TO. MODEL .INDEX
REAR DIFFERENTIAL
Case Assembly Note D Assemble the side gears, thrust washer, thrust block, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case. Front Bearing Cup, Rear Bearing Cup Assembly Note 1. Install the oil baffle in the outer bearing cup bore of the carrier. 2. Install the outer bearing cup and inner bearing cup using the SST.
205024 T76P4616A
Side Gear Thrust Washer Assembly Note D Adjust the backlash of the side gears and pinon gear as follows. (1) Set a dial gauge to the pinion gear as shown in the figure. (2) Secure one of the side gears. (3) Move the pinion gear and measure the backlash at the end of the pinion gear.
Oil Seal Assembly Note 1. Apply a light coat of oil to the lip of a new oil seal. 2. Assemble the new oil seal using the SST.
Standard backlash 00.1 mm {00.004 in} (4) If the backlash exceeds the standard, use the thrust washers to adjust. Side Bearing Cone Assembly Note Caution D Bearings should be assembled to the original positions.
D Press the side bearings into the gear case using
205007 T56T4676B
the SST.
205092 T75L1165DA
Side Bearing Cup, Adjusting Shim, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the gear case component on the carrier. 2. Push the gear case component to the left side of the carrier and measure the clearance between the side bearing and carrier. This measurement is the left and right total shim thickness. 3. Divide the amount of shim in step 2 appropriately between the right and left side, then install the bearing cap. 4. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90 intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90 angle with one of the ring gear teeth.
CONTINUED
M26
TO. MODEL .INDEX
REAR DIFFERENTIAL
DIAL INDICATOR WITH BRACKETRY RING GEAR
5. Inspect the backlash at the three other marked points and make sure that the minimum backlash is more than 0.12 mm {0.005 in} and difference of the maximum and minimum backlash value is less than 0.08 mm {0.003 in}.
6. If backlash is not as specified, correct the backlash by switching shims from one side of the differential case to the other. 7. Using a torque wrench, inspect the total rotating torque of the pinion and differential component by rotating the pinion three complete revolutions, and then reading the rotating torque. The readings should not exceed 2.4 Nm {24.0 kgfcm, 20.8 inlbf}. If the backlash is within specification but the rotating torque is to high, the preload may be adjusted by removing an equal amount of shims from both sides of the differential. 8. Inspect the drive pinion and ring gear tooth contact. (1) Coat both surfaces of 68 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash.
CONTINUED
M27
TO. MODEL .INDEX
MANUAL FREEWHEEL (MFW) MECHANISM REMOTE FREEWHEEL (RFW) MECHANISM
MANUAL FREEWHEEL (MFW) MECHANISM

ON-VEHICLE INSPECTION 1. Jack up the front of the vehicle and support it on safety stands. 2. Set the select lever in 2H position. 3. Set the freewheel hub control handle to the FREE position, then turn the handle clockwise and counterclockwise by hand, and inspect that it turns smoothly. 4. Set the freewheel hub control handle to LOCK position and inspect that the wheel turns with considerable force applied to make it turn. 5. If not as specified, replace the freewheel hub component as necessary.
REMOTE FREEWHEEL (RFW) MECHANISM

4 4 INDICATOR SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (4 4 indicator switch).
3. Inspect for continuity between the terminals as shown using an ohmmeter.

Continuity Yes No Switch Depressed (ON) Released (OFF)
4. If not correct, replace the switch. TRANSFER NEUTRAL SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Remove the transfer case switch (neutral switch).
CONTINUED
M32
TO. MODEL .INDEX

1. Inspect for continuity at the switch using an ohmmeter.
RFW MAIN SWITCH REMOVAL/INSTALLATION 1. Remove the meter hood. (Refer to Section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
OFF
ON
12 mm {0.472 in} 13 mm {0.512 in}
1 RFW main switch
2. If not correct, replace the switch. RFW SWITCH INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the RFW switch connector and remove the switch.
RFW MAIN SWITCH INSPECTION 1. Remove the RFW main switch. 2. Inspect for continuity between the terminals as shown using an ohmmeter. : Continuity
Switch OFF ON Terminal A B D F
3. Inspect for continuity at the switch using an ohmmeter.

123456567
3. If not correct, replace the switch.
4. If not correct, replace the switch.
CONTINUED
M33
TO. MODEL .INDEX

ONEWAY CHECK VALVE INSPECTION 1. Remove the oneway check valve. 2. Blow through A and inspect that air flows from B. 3. Blow through B and inspect that air does not flow from A.
B A
RFW ACTUATOR INSPECTION 1. Jack up the vehicle and support it on safety stands. 2. Disconnect the vacuum hoses from the actuator. 3. Connect a vacuum pump tester to the actuator (free side) as shown. 4. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and verify that the rod moves toward the left (drivers side).
4. If not correct, replace the oneway check valve. LOCK AND FREE SOLENOID VALVES INSPECTION 1. Disconnect the vacuum hoses and the connector from each solenoid valve. 2. Blow through each valve from port B. 3. Inspect that air flows from the air filter.
BLOW B
5. Disconnect the vacuum pump tester. 6. Connect the vacuum pump tester to the actuator (lock side) as shown. 7. Apply 26.66 kPa {200 mmHg, 7.87 inHg} vacuum, and inspect that the rod moves toward the right (passenger side).
AIR FILTER
4. Connect 12V and a ground to the terminals of each valve. 5. Blow through each valve from port B. 6. Inspect that air flows from port A.
B A
8. If not correct, replace the actuator.
7. If not correct, replace the solenoid valve(s).
CONTINUED
M34
TO. MODEL .INDEX

RFW CONTROL MODULE INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Turn the ignition switch on and inspect the RFW control module terminal voltages, referring to the Terminal Voltage Chart.
RFW CONTROL MODULE
4. If not correct, replace the component(s), wiring, and/or RFW control module. REW CONTROL MODULE REMOVAL/INSPECTION 1. Remove the scuff plate. (Refer to section S, TRIM, SCUFF PLATE REMOVAL/INSTALLATION.) 2. Remove the front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2 3 4
Connector Nut Bolt RFW control module
CONTINUED
M35
TO. MODEL .INDEX

Terminal Voltage Chart
RFW CONTROL MODULE TERMINAL
B+: Battery positive voltage

Terminal A B C D E Signal name Lock solenoid Ground Free solenoid 4 4 indicator light Lock indicator light Battery Connected to Lock solenoid Solenoid ON Body Free solenoid Solenoid ON 4 4 indicator light LOCK indicator light Battery 4 4 indicator light OFF 4 4 indicator light ON Lock indicator light OFF Lock indicator light ON Ignition swtich ON Ignition swtich OFF RFW main switch released (OFF) RFW main switch depreased (ON) RFW switch OFF RFW switch ON 4 4 indicator switch OFF 4 4 indicator switch ON Transfer neutral switch OFF Transfer neutral switch ON B+ Below 0.5 V B+ Below 0.5 V B+ Below 0.5 V B+ Below 0.5 V B+ Below 0.5 V B+ Below 0.5 V B+ Below 0.5 V Below 0.5 V
D Harness (4
Condition Solenoid OFF
Voltage B+ Below 0.5 V Below 0.5 V B+ CM)
Inspection point
D Harness (Lock solenoidRFW D Lock solenoid
Solenoid OFF
Harness to ground point

D Harness (Free solenoidRFW
CM)
D Free solenoid
4 indicator light RFW CM) lightRFW D 4 4 indicator light

D Harness (Lock indicator
light RFW CM) lightRFW

D Lock indicator light
Harness, , Fuse ( (Battery-Ignition y g switchRFW CM)

D Harness (RFW main
RFW main switch
RFW main switch
switchRFW switch RFW CM)

D RFW main switch D Harness ( (RFW switchRFW CM) ) D RFW switch D Harness (4
RFW switch
RFW switch
4 4 indicator switch
4 4 indicator switch
4 indicator switchRFW switch RFW CM) D 4 4 indicator switch

D Harness (Transfer neutral
Transfer neutral switch
Transfer neutral switch
switchRFW switch RFW CM)

D Transfer neutral switch
CONTINUED
M36
TO. MODEL .INDEX

JOINT SHAFT COMPONENT REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
2326 {2.32.7, 1719}
SST
3753 {3.75.5, 2739} 3753 {3.75.5, 2739}
Nm {kgfm, ftlbf}
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION Vacuum hose RFW switch connector
4 5 6 7
Snap pin Joint shaft component, control box component Gear sleeve Output shaft + Removal Note
2 3
Output Shaft Removal Note D Remove the output shaft using the SST.
49 0813 215A
CONTINUED
M37
TO. MODEL .INDEX

JOINT SHAFT COMPONENT DISASSEMBLY D Disassemble in the order indicated in the table.
SST
SST
SST
1 2 3 4 5 6 7 8
Control box Clip Remote freewheel hub + Disassembly Note Spacer Retaining ring Ball bearing + Disassembly Note Adjustment shim (s) Dust seal
9 10 11 12 13 14 15
Bearing + Disassembly Note Oil seal + Disassembly Note Joint shaft Needle bearing Clip Casing Output shaft and gear sleeve
CONTINUED
M38
TO. MODEL .INDEX

Remote Free Wheel Hub Disassembly Note D Remove the remote free wheel hub using the SST. Oil Seal Disassembly Note D Remove the oil seal using the SST.
49 0710 520
49 U027 004
Ball Bearing Disassembly Note 1. Remove the ball bearing and the joint shaft using a press.
JOINT SHAFT INSPECTION 1. Measure the joint shaft runout. Maximum runout 0.03 mm {0.0012 in}
2. Remove the ball bearing using a press. 2. If not correct, replace the joint shaft.
Bearing Disassembly Note D Remove the dust seal and bearing using the SST and a suitable bar.
49 W027 001
CONTINUED
M39
TO. MODEL .INDEX

JOINT SHAFT COMPONENT ASSEMBLY D Assemble in the order indicated in the table.
1622 {1.62.3, 1216}
SST SST SST R R R SELECTIVE SST SELECTIVE SST R R
SST
SST
Nm {kgfm , ftlbf}
1 2 3 4 5 6 7 8
Output shaft and gear sleeve Casing Oil seal + Assembly Note Adjustment shim(s) + Assembly Note Ball bearing + Assembly Note Joint shaft + Assembly Note Bearing + Assembly Note Retaining ring
9 10 11 12 13 14 15
Spacer + Assembly Note Remote freewheel hub + Assembly Note Clip Dust seal + Assembly Note Needle bearing Clip Control box
CONTINUED
M40
TO. MODEL .INDEX

Oil Seal Assembly Note 1. Apply differential oil to a new oil seal. 2. Install the new oil seal using the SST and a press. Joint Shaft Assembly Note D Install the joint shaft using the SST and a press.
49 U027 006 49 U027 006
Ajustment Shim(s), Ball Bearing Assembly Note 1. Install the removed shim(s) and the ball bearing using the SST and a press.
49 U027 006
Bearing Assembly Note D Install the bearing using the SSTs and a press.
49 U027 005
49 U027 006
2. Install a new retaining ring. 3. Measure the clearance between the ball bearing and the retaining ring.
Spacer, Remote FreeWheel Hub Assembly Note 1. Install the removed spacer and the remote freewheel hub using a suitable pipe and the SST and a press.
49 U027 005
4. If not as specified, adjust by adding or removing shims. Use no more than two shims on either side. Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} 5. Remove the retaining ring.
2. Install a new clip. 3. Measure the clearance between the remote freewheel hub and the clip.
CONTINUED
M41
TO. MODEL .INDEX

4. If not as specified, adjust by adding or removing spacers. Use no more than two spacers on either side. Maximum clearance 0.15 mm {0.0059 in} Available shim thickness 0.15 mm {0.0059 in}, 0.30 mm {0.0118 in}, 0.35 mm {0.0138 in}, 0.40 mm {0.0157 in}, 0.50 mm {0.0197 in} Dust Seal Assembly Note 1. Install the new dust seal using the SST and a press.
49 M005 796
CONTROL BOX REMOVAL/INSTALLATION 1. Drain the front differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
2326 {2.32.7, 1719}
1622 {1.62.3, 1216}
Nm {kgfm , ftlbf}
1 2 3
Vacuum hose RFW switch connector Control box
CONTINUED
M42
TO. MODEL .INDEX

CONTROL BOX DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
R
R SST
Nm {kgfm , ftlbf}
1 2 3 4 5 6 7 8
Snap pin Washer RFW actuator RFW switch and washer Spring cap Spring and ball Washer Roll pin + Disassembly Note + Assembly Note
9 10 11 12 13
Change rod Shift fork Boot + Assembly Note Oil seal + Assembly Note Control box
CONTINUED
M43
TO. MODEL .INDEX

Roll Pin Disassembly Note D Remove the roll pin as shown in the figure. SHIFT FORK INSPECTION 1. Measure the clearance between the gear sleeve and the shift fork. Standard clearance 0.10.40 mm {0.00400.0157 in} Maximum clearance 0.50 mm {0.0197 in}
Oil Seal Assembly Note D Install a new oil seal using the SST and a press.
49 U027 007
2. Inspect the output shaft and gear sleeve of the splines for damage and wear. 3. If not correct, replace the output shaft and gear sleeve as necessary.
Boot Assembly Note D Install the boot as shown in the figure.
Roll Pin Assembly Note D Install a new roll pin as shown in the figure.
CONTINUED
M44
TO. MODEL .INDEX
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL OIL INSPECTION (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL INSPECTION.) Specified oil Type Above 18 C {0 F}: API GL5, SAE 90 Below 18 C {0 F}: API GL5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL REPLACEMENT (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) Specified oil Type Above 18 C {0 F}: API GL5, SAE 90 Below 18 C {0 F}: API GL5, SAE 80 Capacity MFW: 1.2 L {1.3 US qt, 1.1 lmp qt} RFW: 1.5 L {1.6 US qt, 1.3 lmp qt} FRONT DIFFERENTIAL OIL SEAL REPLACEMENT 1. Remove the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive shaft removal Note.) 2. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.) 3. Remove the oil seal using a screwdriver. 4. Tap in the new oil seal to the differential using the SST.
49 G030 795
5. Install the drive shaft. (Refer to DRIVE SHAFT, DRIVE SHAFT REMOVAL/INSTALLATION, Drive Shaft Installation Note.) 6. Add the differential oil to the specified level. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
CONTINUED
M45
TO. MODEL .INDEX
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL REMOVAL/INSTALLATION 1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.) 2. Remove the propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (44), FRONT PROPELLER SHAFT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
MFW
APPLY SCREW LOCK AGENT

95115 {9.511.8, 6985}
3753 {3.75.5, 2739}
6393 {6.49.5, 4768}
5580 {5.68.2, 4159} Nm {kgfm, ftlbf}
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note
2 3
Front differential component + Removal Note Differential bracket
CONTINUED
M46
TO. MODEL .INDEX
FRONT DIFFERENTIAL
RFW
APPLY LOCKING COMPOUND

94.2115.7 {9.511.8, 68.885.3}
2830 {2.83.1, 2122}
2326 {2.32.7, 1719}
94.2115.7 {9.511.8, 68.885.3}
62.893.1 {6.49.5, 46.368.7} 3753 {3.75.5, 2739}
APPLY SCREW LOCK AGENT
Nm {kgfm, ftlbf}
Drive shaft + DRIVE SHAFT, DRIVE SHAFT REMOVAL/ INSTALLATION, Drive Shaft Removal Note Vacuum hose RFW switch component
4 5 6
Front differential, joint shaft component + Removal Note Joint shaft, crossmember Front differential
2 3
Front Differential, Joint Shaft Component Removal Note 1. Set the transmission jack on the differential. 2. Remove the bolts and nuts indicated by arrows.
3. Remove the front differential and joint shaft component from the vehicle using the transmission jack.
CONTINUED
M47
TO. MODEL .INDEX
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL DISASSEMBLY D Disassemble in the order indicated in the table.
SST
SST
SST
SST
SST
1 2 3 4 5 6 Bolt
SST
7 8 9 10 11
Adjusting screw Side bearing outer race Locknut + Disassembly Note Washer Companion flange + Disassembly Note
Differential casing Oil baffle Differential component + Disassembly Note Lock plate Bearing cap + Disassembly Note
CONTINUED
M48
TO. MODEL .INDEX
FRONT DIFFERENTIAL
Locknut Disassembly Note D Hold the companion flange using the SST and remove the locknut.
49 S120 710
12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Oil seal + Disassembly Note Drive pinion + Disassembly Note Front bearing inner race Collapsible spacer Rear bearing inner race + Disassembly Note Spacer Front bearing outer race + Disassembly Note Rear Bearing outer race + Disassembly Note Carrier Bolt Ring gear Knock pin + Disassembly Note Pinion shaft Pinion gear Thrust washer Side gear Thrust washer Side bearing inner race + Disassembly Note Gear case
Companion Frange Disassembly Note D Pull the companion flange out using the SST.
49 0839 425C
Oil Seal Disassembly Note D Remove the oil seal using a screw driver.
Differential Component Disassembly Note D Install the differential component on the SSTs.
49 M005 561
49 0107 680A
Bearing Cap Disassembly Note D Place a mark on one of the bearing caps so that the left and right bearing caps wont get mixed up. Use the mark for matching at the time of assembly.
MARK
Drive Pinion Disassembly Note D Remove the drive pinion by tapping with a plastic hammer.
CONTINUED
M49
TO. MODEL .INDEX
FRONT DIFFERENTIAL
Rear Bearing Inner Race Disassembly Note Note D Mark or otherwise distinguish between the front and rear inner races so that they are not mixed up at the time of reassembly.
D Remove the rear bearing inner race using the SST.
Side Bearing Inner Race Disassembly Note

49 H027 002
Caution D Mark the left bearing in order to install in the same position.
D Remove the side bearing inner race from the gear
case using the SST. Front Bearing Outer Race, Rear Bearing Outer Race Disassembly Note Note D Mark or otherwise distinguish between the front and rear outer races so that they are not mixed up at the time of reassembly.
D Remove the bearing outer races using the two 49 0839 425C
grooves on the carrier and tapping the outer races alternately.
Knock Pin Disassembly Note Caution D Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
D Secure the gear case in a vise and remove the
knock pin using a 4 mm {0.16 in} diameter bar.
CONTINUED
M50
TO. MODEL .INDEX
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL ASSEMBLY Caution D Clean away the old sealant before applying the new sealant. D Install the differential carrier within 10 minutes after applying sealant. D Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified oll.
D Assemble in the order indicated in the table.
184284 {1329, 95209} 2327 {2.32.7, 1719}
R SST
1451 {3.85.3, 2838}
R
1825 {1.82.6, 1418}
R SST R SST
6983 {7.08.5, 5161}
SST
SST SST
SST
R SST SST R
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8
Gear case + Assembly Note Thrust washer + Assembly Note Side gear Thrust washer Pinion gear Pinion shaft Knock pin Ring gear + Assembly Note
9 10 11 12 13 14 15
Side bearing inner race + Assembly Note Bolt Carrier Front Bearing outer Race + Assembly Note Rear bearing outer race + Assembly Note Spacer + Assembly Note Rear bearing inner race + Assembly Note
CONTINUED
M51
TO. MODEL .INDEX
FRONT DIFFERENTIAL
Standard backlash 00.1 mm {00.004 in} 4. If the backlash exceeds the standard, use the thrust washers to adjust. Ring Gear Assembly Note 1. Coat the ring gear and gear case facing surfaces with locking agent. 2. Install the ring gear and tighten the bolt to the specified torque. Side Bearing Inner Race Assembly Note Caution D Bearings should be assembled to the original positions.
D Press the side bearings into the gear case using
16 17 18 19 20 21 22 23 24 25 26 27 28 29
Drive pinion + Assembly Note Collapsible spacer Front bearing inner race Oil seal + Assembly Note Companion flange Washer Locknut + Assembly Note Side bearing outer race + Assembly Note Adjusting screw + Assembly Note Bearing cap + Assembly Note Lock plate Baffle plate Differential casing Bolt
the SST.
49 G030 338
Gear Case Assembly Note D Assemble the side gears, thrust washer, pinion gears, pinion shaft and knock pin. After assembling the knock pin, make a crimp so that the pin will not come out of the gear case. Front Bearing Outer Race Assembly Note D Press the front bearing outer race into the carrier using the SST and a press.
49 F027 005
Thrust Washer Assembly Note 1. Set a dial gauge to the pinion gear as shown in the figure. 2. Secure one of the side gears. 3. Move the pinion gear and measure the backlash at the end of the pinion gear.
Rear Bearing Outer Race Assembly Note D Press the rear bearing outer race into the carrier using the SST and a press.
49 F027 004
CONTINUED
M52
TO. MODEL .INDEX
FRONT DIFFERENTIAL
Spacer Assembly Note Pinion height adjustment Notes D Use the same spacer and nut. D Be careful to install collars A and B in the correct position and facing in the correct direction. 1. Assemble the spacer, rear bearing inner race and SST (49 8531 568) on to the SST (49 8531 565). Secure the collar with the O-ring. Then install this to the carrier. 2. Assemble the front bearing inner race, SST (49 8531 567), companion flange, washer and nut to the SST (49 8531 565). 3. Tighten the nut to the extent that the SST (49 8531 565) can be turned by hand.
49 0727 570
49 0350 555
7. Add the two (left and right) values obtained by the measurements taken in Step 6 and then divide the total by 2. From this result, subtract the result obtained by dividing the number inscribed on the end surface of the drive pinion by 100. (If there is no figure inscribed, use 0.) This is the pinion height adjustment value. Note D For example, the measured results obtained at Step 6 are 0.06 mm and 0.04 mm, and the figure inscribed on the end of the drive pinion is 2: pinion height 0.06+0.04 2 = 0.07 = adjustment value 2 100 Therefore, replace it with a spacer 0.07 mm {0.003 in} thicker than the currently used one.
49 0350 555 49 8531 565
SPACER REAR BEARING
49 8531 568
O RING
49 8531 567
FRONT BEARING
4. Place the SST on the surface plate and set the dial indicator to zero.
Rear Bearing Inner Race Assembly Note Caution D Press in until the force required suddenly increases. D Install the spacer selected for the pinion height adjustment, confirm that the installation direction is correct.
D Press the rear bearing inner race in using the
49 0727 570
SSTs.
SPACER
5. Place the SST (49 0350 555) on top of the SST (49 8531 565), and then set the SST (49 0727 570) on top of the SST (49 0350 555). 6. Place the measuring probe of the dial indicator so that it contacts the place where the side bearing is installed in the carrier. Then measure left and right side of the lower position.
49 F401 331 49 G030 338
CONTINUED
M53
TO. MODEL .INDEX
FRONT DIFFERENTIAL
Drive Pinion Assembly Note Drive pinion preload adjustment Caution D Do not install the oil seal. 1. Install the drive pinion, spacer, front bearing, collapsible spacer and companion flange to the carrier, and temporarily tighten the locknut. 2. Adjust the preload of the drive pinon bearing as follows. (1) Turn the companion flange by hand to seat the bearing. (2) Use a torque wrench to tighten the locknut temporarily tightened in Step 1, and confirm that the specified preload can be obtained within the specified tightening torque range. The torque applied at this time will be used after the oil seal is installed. Locknut tightening torque 128284 Nm {1329 kgfm, 95209 fflbf} Drive pinion preload 0.913.4 Nm {914 kgfcm, 7.912.1 inlbf}
49 S120 710
Locknut Assembly Note 1. Assemble the companion flange and washer. 2. Tighten the new locknut using the SST with the determined torque while performing drive pinion preload adjustment. 3. Verify that the preload is within the specification. Preload 0.91.3 Nm {914 kgfcm, 7.912.1 inlbf}
49 S120 710
Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note Ring gear backlash adjustment 1. Install the differential gear component to the carrier. After loosely tightening the bearing outer race and bearing cap mounting bolts, completely tighten the adjustment screw by hand. Then, while turning the ring gear, alternately tighten the left and right adjustment screws using the SST.
49 0259 720
(3) If the specified preload cant be obtained within the specified tightening torque range, replace the collapsible spacer and inspect again. (4) Remove the locknut, washer and companion flange. Oil Seal Assembly Note D Apply differential oil to the oil seal lip and press the oil seal in until it touches the end of the differential carrier using the SST. 2. Adjust the drive pinion, ring gear backlash and the side bearing preload as follows. (1) Mark the ring gear at four points at approx. 90 intervals and mount a dial indicator to the carrier so that the feeler comes in contact at a 90 angle with one of the ring gear teeth. (2) Turn both bearing adjusters equally until the backlash becomes 0.090.11 mm {0.00350.0043 in} using the SST.
49 0259 720 49 U027 003
CONTINUED
M54
TO. MODEL .INDEX
FRONT DIFFERENTIAL
(3) Inspect for the backlash at the three other marked points and make sure that the minimum backlash is more than 0.05 mm {0.002 in} and difference of the maximum and minimum backlash value is less than 0.07 mm {0.0028 in}. Toe and flank contact Replace the spacer with a thinner one, and move the drive pinion outward.
TOE CONTACT FLANK CONTACT
Heel and face contact Replace the spacer with a thicker one. Bring the drive pinion inward. (4) After adjusting the backlash, tighten the adjustment screws equally until the distance between both pilot sections on the bearing caps (L) become as specified. Bearing cap bolt tightening torque 3851 Nm {3.85.3 kgfm, 2838 ftlbf}
HEEL CONTACT FACE CONTACT
Standard distance 185.43185.50 mm {7.3007.303 in} 3. The inspection and adjustment procedure is as follows: (1) Coat both surfaces of 68 teeth of the ring gear uniformly with a thin red lead coating. (2) While moving the ring gear back and forth by hand, rotate the drive pinion several times and inspect the tooth contact. (3) If the tooth contact is good, wipe off the red lead coating. (4) If it is not good, adjust the pinion height, then adjust the backlash.
RED LEAD
CONTINUED
M55
TO. MODEL .INDEX
TROUBLESHOOTING
TROUBLESHOOTING
REMOTE FREEWHEEL (RFW) Foreword D Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read and understand the basic flow of troubleshooting in order to properly perform the basic procedures. Precaution D This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary for trouble caused by other sources. D Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.) Diagnostic Index
No 1 TROUBLESHOOTING ITEM No RFW operation from free to lock (RFW indicator light does not illuminate)
D D D D D D D D D D D D D D D D D D D D D D D D D D D D D
DESCRIPTION Free solenoid valve malfunction RFW indicator light bulb malfunction RFW actuator malfunction RFW switch malfunction Print plate in instrument cluster malfunction METER 15 A fuse malfunction ENGINE 15 A fuse malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction Lock solenoid valve malfunction RFW switch malfunction RFW actuator malfunction Print plate in instrument cluster malfunction Engine 15 A fuse malfunction RFW main switch malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction RFW control box malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harness malfunction
No RFW operation from lock to free (RFW indicator light does not go off)
Noise
D Joint shaft bearing abrasion or damage D RFW hub abrasion D Joint shaft abrasion D RFW control box is poorly installed.
Oil leakage
CONTINUED
M56
TO. MODEL .INDEX
TROUBLESHOOTING
Quick Diagnosis Chart
Possible factor
Troubleshooting item No RFW operation from free to lock No RFW operation from lock to free Noise Oil leakage R R R Pr M EN Tr 4 R R Lo Fr R O Jo R Jo Con Va R
Symptom Troubleshooting
1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE) RFW does not change from free to lock.
D D D D D D D
DESCRIPTION
D D D D D D D
[TROUBLESHOOTING HINTS] Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Lock solenoid valve malfunction Free solenoid valve malfunction RFW indicator light bulb malfunction RFW control box malfunction INSPECTION Disconnect RFW control module connector. Turn ignition (engine) g ( g ) switch on. Measure voltage between RFW control module connector terminal F and ground. Is the voltage greater than 10 V? Is the METER 15 A fuse okay? Yes No Go to Step 6. Turn ignition (engine) switch off. Then go to next step. Go to next step. Replace 15 A METER fuse. Then go to Step 31. Go to next step. Replace RFW indicator light bulb. Then go to Step 31. Go to next step. Repair wiring harness between METER 15 A fuse and instrument cluster. Then go to Step 31. Repair wiring harness between instrument cluster and RFW control module. Then go to Step 31. Replace print plate in instrument cluster. Then go to Step 31. Go to Step 8. Turn ignition (engine) switch off. Then go to next step. 1 METER 15 A fuse and/of ENGINE 15 A fuse malfunction Print plate in instrument cluster malfunction RFW switch malfunction RFW actuator malfunction Air leakage from vacuum hose One-way check valve malfunction Related fuses and/or harnesses malfunction ACTION
STEP
Yes No
Inspect RFW indicator light bulb. Is it okay? Measure voltage between instrument cluster connector terminal 1J and ground. Is the voltage greater than 10 V? Measure voltage between instrument cluster connector terminal 2H and ground. Is the voltage greater than 10 V?
Yes No Yes No
Yes
No 6 Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V? Yes No
CONTINUED
M57
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 7
INSPECTION Is the ENG 15 A fuse okay? Yes
ACTION Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31. Replace the ENG 15 A fuse. Then go to Step 31. Connect free solenoid valve. Then go to next step. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31. Go to next step. Inspect free solenoid valve. Then go to Step 31. Go to next step. Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 31. Connect lock solenoid valve. Then go to next step. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 31. Go to next step. Inspect lock solenoid valve. Then go to Step 31. Go to next step. Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 31. Go to next step. Repair wiring harness between RFW control module and ground. Then go to Step 31. Go to Step 19. Go to next step. Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 31. Go to next step. Go to next step. Replace transfer neutral switch. Then go to Step 31. Go to next step. Repair wiring harness between transfer neutral switch and ground. Then go to Step 31. Go to Step 23. Go to next step. Repair wiring harness between 4 switch and RFW control module. Then go to Step 31. Go to next step. 4 indicator
No 8 Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V? Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V? Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V? Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V? Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground? Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground? Is there continuity between transfer neutral switch connector terminal A and ground? Yes No
Yes No Yes No
10
11
Yes No
12
Yes No Yes No
13
14
Yes No
15
Yes No Yes
16
No 17 Inspect transfer neutral switch. Is it okay? Is there continuity between transfer neutral switch connector terminal B and ground? Yes No Yes No
18
19
Shift select lever to 4 4 indicator position. Is there continuity between RFW control module connector terminal K and ground? Is there continuity between 4 4 indicator switch connector terminal A and ground?
Yes No Yes
20
No
CONTINUED
M58
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 21
INSPECTION Inspect 4 4 indicator switch. Is it okay? Is there continuity between 4 4 indicator switch connector terminal B and ground? Yes No Yes No Go to next step.
ACTION Replace 4 4 indicator switch. Then go to Step 31. Go to next step. Repair wiring harness between 4 switch and ground. Then go to Step 31. Go to Step 27 Go to next step. Repair wiring harness between RFW control module and RFW switch. Then go to Step 31. Go to next step. Go to next step. Replace RFW switch. Then go to Step 31. Go to next step. Repair wiring harness between RFW switch and ground. Then go to Step 31. Go to next step. Replace one-way check valve. Then go to Step 31. Go to next step. Replace RFW control box. Then go to Step 31. Go to next step. Repair vacuum in vacuum hoses. Then go to Step 31. Go to next step. Repair or replace RFW control module. Then go to next step. Troubleshooting completed. Explain repairs to customer. Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again. 4 indicator
22
23
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground? Is there continuity between RFW switch connector terminal A and ground?
Yes No Yes
24
No 25 Inspect RFW switch. Is it okay? Is there continuity between RFW switch connector terminal B and ground? Yes No Yes No
26
27
Inspect one-way check valve. Is it okay? Inspect RFW control box. Is it okay? Inspect vacuum in vacuum hoses. Is it okay? Inspect RFW control module. Is it okay? Turn ignition (engine) switch on. Shift select lever from 2H to 4H position. Does RFW operate from free to lock?
Yes No Yes No Yes No Yes No Yes No
28
29
30
31
NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF) RFW does not change from lock to free.
D D D D D D D D
DESCRIPTION
D D D D D D D
[TROUBLESHOOTING HINTS] RFW main switch malfunction Transfer neutral switch malfunction 4 4 indicator switch malfunction RFW control module malfunction Free solenoid valve malfunction Lock solenoid valve malfunction RFW control box malfunction INSPECTION Disconnect RFW control module connector. Is there continuity between RFW control module connector terminal F and ground? Yes No Go to next step. Go to Step 3. ENGINE 15 A fuse malfunction RFW main switch malfunction RFW actuator malfunction RFW switch malfunction Air leakage from vacuum reservoir or actuator system One-way check valve Print plate in instrument cluster malfunction Related fuses and/or harnesses malfunction ACTION
STEP 1
CONTINUED
M59
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 2
INSPECTION Disconnect instrument cluster connector No.2. Is there continuity between instrument cluster terminal 2H and ground? Yes
ACTION Repair wiring harness between RFW control module and instrument cluster. Then go to Step 32. Inspect for no continuity between Instrument cluster terminal 2H and ground. Go to Step 5. Turn ignition (engine) switch off. Then go to next step. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32. Replace the ENG 15 A fuse. Then go to Step 32. Connect free solenoid valve. Then go to next step. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32. Go to next step. Inspect free solenoid valve. Then go to Step 32. Go to next step. Repair wiring harness between free solenoid valve and RFW control module. Then go to Step 32. Connect lock solenoid valve. Then go to next step. Repair wiring harness between ENG 15 A fuse and RFW control module. Then go to Step 32. Go next step. Inspect lock solenoid valve. Then go to Step 32. Go next step. Repair wiring harness between lock solenoid valve and RFW control module. Then go to Step 32. Go to next step. Repair wiring harness between RFW control module and ground. Then go to Step 32. Go to Step 16. Go to next step. Repair wiring harness between RFW control module and transfer neutral switch. Then go to Step 32. Go to next step. Go to next step. Replace transfer neutral switch. Then go to Step 32.
No 3 Turn ignition (engine) switch off. Disconnect RFW control module connector. Turn ignition (engine) switch on on. Measure voltage between RFW control module connector terminal H and ground. Is the voltage greater than 10 V? Is the ENG 15 A fuse okay? Yes No
Yes
No 5 Disconnect free solenoid valve connector. Measure voltage between free solenoid valve connector terminal A and ground. Is the voltage greater than 10 V? Measure voltage between free solenoid valve connector terminal B and ground. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal C and ground. Is the voltage greater than 10 V? Disconnect lock solenoid valve connector. Measure voltage between lock solenoid valve connector terminal A and ground. Is the voltage greater than 10 V? Measure voltage between lock solenoid valve connector terminal B and ground. Is the voltage greater than 10 V? Measure voltage between RFW control module connector terminal A and ground. Is the voltage greater than 10 V? Turn ignition (engine) switch off. Is there continuity between RFW control module connector terminal B and ground? Shift select lever to N position. Is there continuity between RFW control module connector terminal L and ground? Is there continuity between transfer neutral switch connector terminal A and ground? Yes No
Yes No Yes No
Yes No
Yes No Yes No
10
11
Yes No
12
Yes No Yes
13
No 14 Inspect transfer neutral switch. Is it okay? Yes No
CONTINUED
M60
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 15
INSPECTION Is there continuity between transfer neutral switch connector terminal B and ground? Yes No Go to next step.
ACTION Repair wiring harness between transfer neutral switch and ground. Then go to Step 32. Go to Step 20. Go to next step. Repair wiring harness between RFW control module and 4 4 indicator switch. Then go to Step 32. Go to next step. Go to next step. Replace 4 4 indicator switch. Then go to Step 32. Go to next step. Repair wiring harness between 4 and ground. Then go to Step 32. Go to Step 28. Go to next step. Repair wiring harness between RFW switch. Then go to Step 32. Go to next step. Go to next step. Replace RFW switch. Then go to Step 32. Go to next step. Repair wiring harness between RFW switch and ground. Then go to Step 32. Go to Step 28. Go to next step. Repair wiring harness between RFW main switch and RFW control module. Then go to Step 32. Go to next step. Go to next step. Replace RFW main switch. Go to next step. Repair wiring harness between RFW main switch and ground. Then go to Step 32. Go to next step. Replace one-way check valve. Then go to Step 32. Go to next step. Replace RFW actuator. Then go to Step 32. Go to next step. Repair vacuum in vacuum hoses. Then go to Step 32. 4 indicator switch
16
Shift select lever to 2H position. Is there continuity between RFW control module connector terminal K and ground? Is there continuity between 4 4 indicator switch connector terminal A and ground?
Yes No Yes
17
No 18 Inspect 4 4 indicator switch. Is it okay? Is there continuity between 4 4 indicator switch connector terminal B and ground? Yes No Yes No
19
20
Shift select lever to 4H position. Is there continuity between RFW control module connector terminal J and ground? Is there continuity between RFW switch connector terminal A and ground? Inspect RFW switch. Is it okay? Is there continuity between RFW switch connector terminal B and ground?
Yes No Yes No
21
22
Yes No Yes No
23
24
Push RFW main switch on. Is there continuity between RFW main switch connector terminal I and ground? Is there continuity between RFW main switch connector terminal F and ground?
Yes No Yes
25
No 26 27 Inspect RFW main switch. Is it okay? Is there continuity between RFW main switch connector terminal D and ground? Yes No Yes No
28
Inspect one-way check valve. Is it okay? Inspect RFW actuator. Is it okay? Inspect vacuum in vacuum hoses. Is it okay?
29
30
CONTINUED
M61
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 31
INSPECTION Inspect RFW control module. Is it okay? Turn ignition (engine) switch on. Move selector lever from 2H to 4H position. Does RFW operate from free to lock? Yes No Yes No Go to next step.
ACTION Repair or replace RFW control module. Then go to next step. Troubleshooting completed. Explain repairs to customer. Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
32
NOISE Noise is heard from front differential.

D Joint shaft abrasion D Conventional front differential parts malfunction
DESCRIPTION
[TROUBLESHOOTING HINTS]
D Joint shaft bearing abrasion or damage D RFW hub abrasion
STEP 1 2 3 4
INSPECTION Inspect joint shaft bearing. Is it okay? Inspect RFW hub. Is it okay? Inspect joint shaft. Is it okay? Malfunction is caused by other than RFW. Inspect conventional front differential parts. parts Are they okay? Has front differential noise stopped? Yes No Yes No Yes No Yes No Yes No Go to next step.
ACTION Replace joint shaft bearing. Go to next step. Replace RFW hub. Go to next step. Replace joint shaft. Go to next step. Replace defective part(s). Troubleshooting completed. Explain repairs to customer. Inspect malfunction symptoms again, then repeat from Step 1 if malfunction occurs again.
OIL LEAKAGE The oil leaks from front differential.

D Malfunction of conventional front differential parts
DESCRIPTION
[TROUBLESHOOTING HINTS]
D Poor installation of the RFW control box
STEP 1
INSPECTION Is RFW control box installed completely? Yes No Go to next step.
ACTION Install RFW control box securely. Then go to Step 3. Go to next step. Replace defective part(s). Inspect malfunction symptoms again, then repeat from Step 1 if malfunction still occurs. Troubleshooting completed. Explain repairs to customer.
Malfunction is caused by something other than RFW. Inspect conventional front differential parts. Are they okay? Is there any oil leakage from front differential?
Yes No Yes No
CONTINUED
M62
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
STEERING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N1 MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N1 STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N1/2 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N3/4 STEERING SHAFT INSPECTION . . . . . . . . . . . N4 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N5/6 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N7/9 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N9 POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . N10 AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N10 POWER STEERING FLUID INSPECTION . . . N10/12 STEERING WHEEL AND COLUMN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N12 STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N12 STEERING SHAFT INSPECTION . . . . . . . . . . . N12 STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N13 STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N14/15 STEERING GEAR AND LINKAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N15 POWER STEERING OIL PUMP REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N16/18 POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N19/20 POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N21
GENERAL PROCEDURES
MANUAL STEERING
Wheels and tires removal/installation STEERING WHEEL AND COLUMN INSPECTION D The removal and installation procedures for the Steering Wheel Play Inspection wheels and tires are not mentioned in this section. D If the play exceeds specification, either the steering When a wheel is removed, retighten it to the joints are worn or the backlash of the steering gear specified torque. is excessive. With the wheels in the straight-ahead (Refer to section TD,SUSPENSION, Wheels and Tires.) position, gently turn the steering wheel to the left and right and verify that the play is within Power steering components removal/installation specification. D If any power steering fluid line has been disconnected anytime during the procedure, add Steering wheel play ATF MIII or equivalent (e.g. Dexron II), bleed 030 mm {01.18 in} the fluid lines, and inspect for leakage after the procedure has been completed. Steering Wheel Looseness Inspection D Move the steering wheel as shown in the figure to Connectors disconnection/connection inspect for column bearing wear, steering shaft D Disconnect the negative battery cable before doing joint play, steering wheel looseness, and column any work that requires handling of connectors. looseness. Reconnect the negative battery cable only after the work is completed.
CONTINUED
N1
TO. MODEL .INDEX
MANUAL STEERING
Steering Wheel Effort Inspection 1. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 2. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 4.5 Nm {460 kgfcm, 399 inlbf} max. 4. If not as specified, inspect the following: rotation starting torque of pinion, rotation torque of each ball joint, and steering joints.
CONTINUED
N2
TO. MODEL .INDEX
MANUAL STEERING
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
4050 {4.05.0, 2936}
4050 {4.05.0, 2936}
AIR BAG MODEL
1622 {1.62.3, 1216} 1622 {1.62.3, 1216} 2026 {2.02.7, 1519} 1824 {1.82.5, 1418}
2026 {2.02.7, 1519}
Nm {kgfm, ftlbf}
1 2
Horn cap Air bag module (with air bag) + section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION Locknut Steering wheel + Removal Note + Installation Note Column cover
6 7 8 9 10 11
Combination switch Steering shaft + Installation Note Universal joint Boot Intermediate shaft Steering lock component + Removal Note + Installation Note
3 4
CONTINUED
N3
TO. MODEL .INDEX
MANUAL STEERING
Steering Wheel Removal Note Caution D Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will collapse.
D Set the wheels in the straight-ahead position,
remove the steering wheel using a suitable puller. Steering Lock Component Removal Note D Use a chisel to make a groove in the heads of the steering lock mounting bolts. Remove the bolts using a screwdriver. Remove the steering lock component.
Steering Lock Component Installation Note D Install the new steering lock mounting bolts. Tighten the bolts until the heads break off.
Steering Wheel Installation Note 1. For vehicles with air bags, adjust the clock spring. (Refer to section T, CLOCK SPRING, CLOCK SPRING ADJUSTMENT.) 2. Install the steering wheel with the vehicle in the straight-ahead position. STEERING SHAFT INSPECTION D Inspect the following, and replace the column component as necessary. 1. Needle and ball bearing damage. 2. Steering shaft length. Length 816.9819.9 mm {32.1732.27 in}
Steering Shaft Installation Note 1. Temporarily tighten the bolt A. 2. Tighten the nut B to the specified torque. 3. Tighten the bolt A to the specified torque. Tightening torque 1622 Nm {1.62.3 kgfm, 1216 ftlbf} 3. Dust boot damage.
CONTINUED
N4
TO. MODEL .INDEX
MANUAL STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. With the wheels in the straight-ahead position, remove in the order indicated in the table. 2. Install in the reverse order of removal.
3754 {3.75.5, 2739} 2026 {2.02.7, 1519}
4558 {4.56.0, 3343} 4558 {4.56.0, 3343} 79157 {8.016.0, 58115}
SST
6978 {7.08.0, 5157}
SST
R R SST
4558 {4.56.0, 3343} 3754 {3.75.5, 2739}
4558 {4.56.0, 3343}
SST
SST
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8
Cotter pin Nut Ball joint + Removal Note Locknut Tie rod Center link Idler arm + Removal Note Bushing
9 10 11 12 13 14 15
Washer Bolt, nut, washer Idler arm bracket Bolt, nut, washer Bolt Steering gear and pitman arm + Removal Note Dust boot + Removal Note + Installation Note
CONTINUED
N5
TO. MODEL .INDEX
MANUAL STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman Arm Removal Note D Remove the ball joint from the knuckle and center link, the idler arm from the center link, and steering gear and pitman arm from the center link using the SST.
49 T028 3A0
Dust Boot Removal Note 1. Place the chisel against the boot and hold it at the angle shown. 2. Remove the dust boot by tapping it with a hammer.
Dust Boot Installion Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot using the SST and a press.
49 1243 785A
CONTINUED
N6
TO. MODEL .INDEX
MANUAL STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
2534 {2.53.5, 2534} 1521 {1.52.2, 1115}
1524 {1.52.5, 1118}
128166 {13.017.0, 95122}
R SST R
R R
197235 {20.024.0, 145173}
SST
Nm {kgfm, ftlbf}
1 2 3 4 5 6
Nut Pitman arm + Disassembly Note Clip Dust boot + Assembly Note Locknut (side cover) + Disassembly Note Sector shaft + Disassembly Note + Assembly Note Side cover Adjusting shim
9 10 11 12 13 14 15 16 17
Adjusting screw Oil seal Retaining ring Locknut + Disassembly Note Oil seal Adjusting nut + Disassembly Note Bearing Worm ball nut + Assembly Note Bearing
7 8
CONTINUED
N7
TO. MODEL .INDEX
MANUAL STEERING
Pitman Arm Disassembly Note D Separate the pitman arm from the steering gear using the SST. Adjusting Nut Disassembly Note D Remove the adjusting nut using the SST.
49 UB39 585A
49 U032 3A0
Locknut (Side Cover), Sector Shaft Disassembly Note 1. Loosen the locknut. 2. Remove the side cover attaching bolts. 3. Set the sector shaft in the middle position. 4. Tap the sector shaft lower end using a plastic hammer to loosen the sector shaft. 5. Lift and remove the sector shaft with the locknut and the side cover from the gear housing.
Worm Ball Nut Assembly Note 1. Inspect the worm ball nut preload using the SST.
49 0180 510B
Worm ball nut preload 1.01.3 Nm {1014 kgfcm, 8.712.1 inlbf} [Without the sector shaft] 2. If not as specified, adjust the preload. (1) Loosen the locknut and turn the adjusting screw using the SST. Locknut Disassembly Note D Remove the locknut using the SST.
49 U032 201 49 U032 201
CONTINUED
N8
TO. MODEL .INDEX
MANUAL STEERING
(2) Tighten the locknut to the specified torque using the SST. Tightening torque 128166 Nm {1317 kgfm, 95122 ftlbf}
49 U032 201 49 U034 209
5. Wipe away excessive grease. STEERING GEAR AND LINKAGE INSPECTION Steering Gear Backlash Adjustment (3) Inspect the worm ball nut preload again. Sector Shaft Assembly Note 1. Set the adjusting screw and shim, in the T groove. 2. Measure the clearance in the axial direction. Caution D Adjust the backlash while keeping the steering gear in the center position. Otherwise, the backlash becomes excessively small and gears may be damaged.
D Turn the adjusting screw to adjust steering gear
backlash. Backlash 0 mm
ADJUSTING SHIM
3. Adjust the clearance to the specified value if the clearance is more than the specified value. Clearance 00.1 mm (00.004 in) Adjusting shim thickness 1.97 mm {0.077 in} 2.00 mm {0.079 in} 2.03 mm {0.079 in} 2.06 mm {0.081 in} 2.09 mm {0.082 in} Caution D Be careful not to damage the oil seal and bearing. 4. Assemble the sector shaft in such a way that the teeth of the sector shaft mesh with the center part of the teeth of the worm ball nut. Dust Boot Assembly Note 1. Wipe the grease off the ball joint. 2. Put a small amount of lithium-based grease into a new dust boot. 3. Install the dust boot onto the ball joint. 4. Set the SST over the boot and install a new clip.
CONTINUED
N9
TO. MODEL .INDEX
POWER STEERING
POWER STEERING
AIR BLEEDING 1. Inspect the fluid level. (Refer to POWER STEERING, POWER STEERING FLUID INSPECTION, Fluid Level Inspection.) 2. Jack up the front of the vehicle and support it on safety stands. 3. Turn the steering wheel fully to the left and right several times with the engine not running. 4. Reinspect the fluid level. If it has dropped, add fluid. 5. Repeat Steps 3 and 4 until the fluid level stabilizes. 6. Lower the vehicle. 7. Start the engine and let it idle. 8. Turn the steering wheel fully to the left and right several times. 9. Verify that the fluid is not foamy and that the fluid level has not dropped. 10. Add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION Fluid Level Inspection D Inspect the power steering fluid level. Add fluid to the specified level as necessary. Fluid specification ATF MIII or equivalent (e.g. Dexron II) Fluid Leakage Inspection Caution D To prevent damage to the steering system, do not keep the steering wheel in the fully turned position for more than 5 seconds. 1. Start the engine and let it idle. Turn the steering wheel fully to the left and right to apply fluid pressure. Note D The points where fluid leakage may occur are indicated in the figure. 2. Inspect for fluid leakage.
R.H.D.
L.H.D.
F2 CIS F2 CARB
F2 CIS F2 CARB
WL WL TURBO
WL WL TURBO
G6
G6
CONTINUED
N10
TO. MODEL .INDEX
POWER STEERING
Fluid Pressure Inspection 1. Assemble the SSTs as shown in the figure.
49 1232 670A
7. Close the gauge valve completely. Increase the engine speed to 1,0001,500 rpm and measure the fluid pressure generated by the oil pump. If the pressure is not within the specification, replace the oil pump component. Oil pump fluid pressure 8.99.3 MPa {9095 kgf/cm2, 12801350 psi}
49 H002 671
THERMOMETER 5060 C {122140 F} GAUGE CLOSE VALVE COMPLETELY
2. Mark both hose connections to ensure that the hose is reinstalled in its original position. 3. Disconnect the pressure hose from the oil pump. Attach the SST (49 G032 304). Tightening torque G6: 3247 Nm {3.24.8 kgfm, 2434 ftlbf} F2 CIS, F2 CARB, WL, WL Turbo: 3044 Nm {3.04.5 kgfm, 2232 ftlbf} 4. Connect the SSTs (49 1232 670A and 49 H002 671) to the SST (49 G032 304).
G6
Caution D If the steering wheel is kept in the fully turned position for more than 5 seconds, the fluid temperature will rise excessively and adversely affect the oil pump. 8. Open the gauge valve fully and increase the engine speed to 1,0001,500 rpm. 9. Turn the steering wheel fully to left and right and measure the fluid pressure generated at the gear housing. If the pressure is not within the specification, repair or replace the steering gear component. Gear housing fluid pressure 8.99.3 MPa {9095 kgf/cm2, 12801350 psi}
49 B032 304
F2 CIS, F2 CARB, WL, WL TURBO
49 G032 3A4
THERMOMETER 5060 C {122140 F} GAUGE OPEN VALVE COMPLETELY
49 H002 671
5. Bleed the air from the system. 6. Open the gauge valve fully. Start the engine and turn the steering wheel fully left and right to raise the fluid temperature to 5060 C {122140 F}. Caution D If the valve is left closed for more than 5 seconds, the fluid temperature will increase excessively and adversely affect the oil pump.
10. Remove the SSTs. Install and tighten the pressure pipe to the specified torque. Tightening torque 3044 Nm {3.04.5 kgfm, 2232 ftlbf} 11. Bleed the air from the system.
CONTINUED
N11
TO. MODEL .INDEX
POWER STEERING
Note D To determine whether the steering effort is satisfactory or not, perform the inspection on another vehicle of the same model and under the same conditions, and compare the results. D The steering wheel effort varies with conditions as shown below. 1. Road conditions, such as dry or wet, and asphalt or concrete. 2. Tire conditions, such as brand, wear, and tire pressure. 12. If not as specified, inspect the following points: D Air in system D Fluid leakage at hose or connectors D Function of oil pump and steering gear STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) STEERING SHAFT INSPECTION (Refer to MANUAL STEERING, STEERING SHAFT INSPECTION.) STEERING WHEEL AND COLUMN INSPECTION Steering Wheel Play Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Play Inspection.) Steering Wheel Looseness Inspection (Refer to MANUAL STEERING, STEERING WHEEL AND COLUMN INSPECTION, Steering Wheel Looseness Inspection.) Steering Wheel Effort Inspection 1. Inspect the following points: D Tire size and tire pressure D Fluid level 2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position. 3. Start the engine and warm the power steering fluid to 5060 C {122140 F}. 4. Remove the air bag module, if equipped. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 5. Measure the steering wheel effort using a torque wrench.
Steering wheel effort 7.8 Nm {80 kgfcm, 69 inlbf} max.
CONTINUED
N12
TO. MODEL .INDEX
POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3247 {3.24.8, 2434} 2435 {2.43.6, 1826} 3754 {3.75.5, 2739}
2026 {2.02.7, 1519}
SST
6978 {7.08.0, 5157}
SST
79157 {7.016.0, 58115}
R
3754 {3.75.5, 2739} 4558 {4.56.0, 3343}
R SST
R
4558 {4.56.0, 3343}
SST
SST
Nm {kgfm, ftlbf}
1 2 3
Cotter pin Locknut Ball joint + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Ball Joint Removal Note Locknut Tie rod Center link Idler arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Idler Arm Removal Note Bushing Washer Bolt, nut, washer
11 12 13 14 15 16
Idler arm bracket Pressure pipe Return pipe Bolt Bolt, nut, washer Steering gear and pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Steering Gear and Pitman Arm Removal Note Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Disassembly Note + MANUAL STEERING, STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION, Dust Boot Assembly Note
4 5 6 7
17
8 9 10
CONTINUED
N13
TO. MODEL .INDEX
POWER STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
5764 {5.76.5, 4247} 3044 {3.04.5, 2232}
R R
R R
R R R R
5663 {5.76.5, 4247}
SST R R
SST
197235 {20.024.0, 145173}
Nm {kgfm, ftlbf}
1 2
Nut Pitman arm + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Pitman Arm Disassembly Note Clip Dust boot + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Dust Boot Assembly Note Locknut + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover), Sector Shaft Disassembly Note Sector shaft + MANUAL STEERING, STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY, Locknut (Side Cover) Sector Shaft Disassembly Note Side cover
8 9 10 11 12 13 14 15 16 17 18 19 20 21
O-ring Y packing Back up ring Oil seal Back up ring Y packing Dust cover Snap ring Washer Oil seal Valve and piston component + Assembly Note O-ring Seal ring Gear housing
3 4
CONTINUED
N14
TO. MODEL .INDEX
POWER STEERING
Valve and Piston Component Assembly Note Caution D Do not scratch the seal ring and O-ring on the piston against the entrance to the housing. D Insert the piston by slightly turning to the left and right so as not to create flection at the O-ring and seal ring.
D Insert the valve and piston component to the gear
housing.
STEERING GEAR AND LINKAGE INSPECTION (Refer to MANUAL STEERING, STEERING GEAR AND LINKAGE INSPECTION, Steering Gear Backlash Adjustment.)
CONTINUED
N15
TO. MODEL .INDEX
POWER STEERING
POWER STEERING OIL PUMP REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. For F2 CIS, F2 Carb and G6 engine model, adjust the drive belt. (Refer to Section B2, DRIVE BELT,DRIVE BELT ADJUSTMENT.)
F2 CIS, F2 CARB
3044 {3.04.5, 2232}
3039 {3.04.0, 2228}
SST
5059 {5.06.0, 3743} Nm {kgfm, ftlbf}
CONTINUED
N16
TO. MODEL .INDEX
POWER STEERING
G6
1925 {1.92.6, 1418}
3247 {3.24.8, 2434}
3246 {3.24.7, 2433}
5059 {5.06.0, 3743}
SST
CLAMP POSITION
30 mm {1.2 in}
Nm {kgfm, ftlbf}
1 2 3 4
Drive belt Locknut + Removal Note Oil pump pulley Pressure pipe (F2 CIS, F2 Carb), pressure hose (G6)
5 6 7
Return hose Power steering fluid pressure switch connector (except F2 Carb) Power steering oil pump component
Locknut Removal Note D Secure the pulley using the SST and remove the locknut.
49 G032 354
CONTINUED
N17
TO. MODEL .INDEX
POWER STEERING
WL, WL TURBO
3044 {3.04.5, 2232}
1925 {1.92.6, 1418}
1925 {1.92.6, 1418}
Nm {kgfm, ftlbf}
1 2 3
Pressure pipe Return hose Bolt and nut
4 5
Power steering oil pump O-ring
CONTINUED
N18
TO. MODEL .INDEX
POWER STEERING
POWER STEERING OIL PUMP (F2 CIS, F2 CARB, G6) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly.
1519 {1.52.0, 1114}
9.913.7 Nm {100140 kgfcm, 87121 inlbf}
G6
7.911.7 Nm {80120 kgfcm, 70104 inlbf}
2225 {2.22.6, 1618}
R F2 CIS
5068 {5.07.0, 3750}
F2 CARB
1623 {1.62.4, 1217}
1821 {1.82.2, 1416}
2225 {2.22.6, 1618}
SST
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10 11 12
Power steering oil pump component + Disassembly Note Pressure switch component O-ring Nut (G6) Connector (G6) Connector bolt O-ring Control valve component Spring Suction pipe O-ring Shaft component
13 14 15 16 17 18 19 20 21 22
Rear body + Assembly Note O-ring Cam ring + Assembly Note Rotor Vane + Assembly Note Pin Side plate + Assembly Note O-ring Oil seal Front body
CONTINUED
N19
TO. MODEL .INDEX
POWER STEERING
Power Steering Oil Pump Disassembly Note Caution D To secure the oil pump in a vise, use the SST as shown to prevent damage to the pump. 3. Install the vanes in the rotor with the rounded edges outward.
49 F032 301
ROUND EDGE
Rear Body Assembly Note D After installing the rear body, manually turn the shaft to verify that it rotates smoothly. Side Plate Assembly Note 1. Install a new O-ring and the side plate to the front body. 2. Position the side plate using the rear body.
Vane, Cam Ring Assembly Note 1. Install the cam ring with the marks facing the front body.
2. Install the rotor with the mark facing the rear body.
MARK
CONTINUED
N20
TO. MODEL .INDEX
POWER STEERING
POWER STEERING OIL PUMP (WL, WL TURBO) DISASSEMBLY/ASSEMBLY 1. The following procedure is for replacement of the O-rings only. Replace the pump component if other repairs are necessary. 2. Disassemble in the order indicated in the table. 3. Assemble in the reverse order of disassembly.
R
7.911.7 Nm {80120 kgfcm, 69.5104.1 inlbf}
2225 {2.22.6, 1618}
R SST
R R
5068 {5.07.0, 3750} Nm {kgfm, ftlbf}
Power steering oil pump component + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Power Steering Oil Pump Component Disassembly Note Suction pipe O-ring Connector O-ring Control valve Spring Rear body + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Rear Body Assembly Note O-ring
10
Cam ring + POWER STEERING POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Cam Ring Assembly Note Rotor Vane + POWERSTEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Vane Assembly Note Side plate + POWER STEERING, POWER STEERING OIL PUMP (G6) REMOVAL/INSTALLATION, Side Plate Assembly Note O-ring Front body
2 3 4 5 6 7 8
11 12
13
14 15
CONTINUED
N21
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
BRAKING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . . AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM LINE INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL INSPECTION . . . . . . . . . . . . . . BRAKE PEDAL REMOVAL/INSTALLATION . . BRAKE SWITCH INSPECTION . . . . . . . . . . . . . MASTER CYLINDER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FLUID LEVEL SENSOR INSPECTION . . . . . . MASTER CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER BRAKE UNIT INSPECTION . . . . . . . . POWER BRAKE UNIT REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . VACUUM SWITCH INSPECTION . . . . . . . . . . . VACUUM SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . VACUUM PUMP INSPECTION . . . . . . . . . . . . . VACUUM PUMP REMOVAL/INSTALLATION . LOAD SENSING PROPORTIONING VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . LOAD SENSING PROPORTIONING VALVE ADJUSTMENT . . . . . . . . . . . . . . . . . . . P 1 P 2 P 2 P 2 P 2 P 3 P 4 P 4/6 P 6 P 7/8 P 8 P 9 P 9 P10 P10 P10 P11 P11 Brake pipe flare nut tightening D Tighten the brake pipe flare nut by using the SST (49 0259 770B). Be sure to modify the brake pipe flare nut tightening torque to allow for use of a torque wrench-SST combination. (Refer to section GI, FUNDAMENTAL PROCEDURES, TORQUE FORMULAS.) Connectors disconnection D Disconnect the negative battery cable before doing any work that requires handling of connectors. Reconnect the negative battery cable only after the work is completed. LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION . . . . . . . . . FRONT BRAKE (DISC) INSPECTION . . . . . . . FRONT BRAKE (DISC) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . DISC PAD (FRONT) REPLACEMENT . . . . . . . CALIPER (FRONT) DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE (DRUM) INSPECTION . . . . . . . REAR BRAKE (DRUM) REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DRUM INSPECTION . . . . . . . . . . . . . . . WHEEL CYLINDER DISASSEMBLY/ ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE (STICK TYPE) ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION . . . . . . . . . . . . . . . P11 P12 P13/14 P14 P14 P15 P15 P16 P16 P16 P16 P16 P17 P18/19
GENERAL PROCEDURES
Wheel and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. When a wheel is removed, retighten it to the specified tightening torque, referring to section TD. Brake lines disconnection/connection Caution D Brake fluid will damage painted surfaces. If brake fluid get on a painted surface, wipe it off immediately.
D If any brake line has been disconnected anytime
during the procedure, add brake fluid, bleed the brakes, and inspect leakage after the procedure has been completed. Fluid specification SAE J1703 or FMVSS116 DOT3 or DOT4
CONTINUED
P1
TO. MODEL .INDEX
CONVENTIONAL BRAKE SYSTEM

AIR BLEEDING Note D The reservoir should be kept 3/4 full during bleeding. D The brakes should be bled whenever a brake line is disconnected. If a hydraulic line is disconnected at the master cylinder, start at the slave cylinder farthest from the brake master cylinder, and move to the next farthest slave cylinder until all four cylinders have been bled. If the disconnection point is anywhere except the master cylinder, start at the point closest to the disconnection, and move to the next closest slave cylinder until all four cylinders have been bled. 1. Remove the bleeder cap and attach a vinyl tube to the bleeder screw. 2. Place the other end of the vinyl tube in a clear fluid-filled container. 3. One person should depress the brake pedal a few times, and then hold it in the depressed position. 4. A second person should loosen the bleeder screw, drain out the fluid and retighten the screw using the SST. Tightening torque Front: 914 Nm {92142 kgfcm, 80123 inlbf} Rear: 5.98.8 Nm {6090 kgfcm, 5378 inlbf}
49 0259 770B
VACUUM LINE INSPECTION 1. Remove the clamps and the vacuum hose. 2. Apply both suction and pressure to the engine-side hose (Gasoline) or vacuum pump side of the hose (Diesel), and verify that air blows only toward that side. If air flows in both directions or not at all, replace the vacuum hose.
CHECK VALVE
ENG
BRAKE PEDAL INSPECTION Brake Pedal Height Inspection D Verify that the distance from the center of the upper surface of the pedal pad to the floor pannel is as specified. Pedal height L.H.D.: 214219 mm {8.438.81 in} R.H.D.:219224 mm {8.638.81 in}
PEDAL HEIGHT
5. Repeat steps 3 and 4 until no air bubbles are seen. 6. After air bleeding, inspect the following: (1) brake operation (2) fluid leakage (3) fluid level
CONTINUED
P2
TO. MODEL .INDEX

Brake Pedal Height Adjustment 1. Disconnect the brake switch connector. 2. Loosen locknut B and turn switch A until it does not contact the pedal. 3. Loosen locknut D and turn rod C to adjust the height. 4. Tighten the bolt with locknut B so that clearance between the bolt for brake light switch A and pedal stopper is within the specification. Specification 0.11.0 mm {0.0040.039 in} Tightening torque 1417 Nm {140180 kgfcm, 122156 inlbf} 5. Connect the brake switch connector. 6. After adjustment, inspect the pedal play and the brake light operation.
5. After adjustment, inspect the pedal height and the brake light operation. Pedal-to-floor Clearance Inspection 1. Start the engine and verify that the distance from the floor panel to the pedal pad center is as specified when the pedal is depressed with a force of 589 N {60 kgf, 132 lbf}. Clearance 105 mm {4.2 in} min.
D A
Brake Pedal Play Inspection 1. Depress the pedal a few times to eliminate the vacuum in the system. 2. Remove the snap pin, verify that the holes in the fork and in the pedal are aligned, and reinstall the pin. 3. Gently depress the pedal by hand until resistance is felt (approx. 20N {2 kgf, 4.4 lbf}) and inspect the free play. Pedal play 38 mm {0.120.31 in}
PEDAL-TO-FLOOR CLEARANCE
2. If the distance is less than specified, inspect the following: (1) Air in brake system (2) Malfunction of the automatic adjuster (3) Excessive shoe clearance BRAKE PEDAL REMOVAL/INSTALLATION R.H.D. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal. Refer to section F2, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal removal/installation. L.H.D. The brake pedal is mounted on the bracket integrated with the clutch Pedal. Refer to section H, CLUTCH PEDAL REMOVAL/ INSTALLATION for the brake pedal removal/installation.
Brake Pedal Play Adjustment 1. Remove the snap pin and clevis pin. 2. Loosen locknut D and turn rod C to align the holes in the fork and in the pedal. 3. Install the clevis pin and the snap pin. 4. Tighten locknut D. Tightening torque 2434 Nm {2.43.5 kgfm, 1825 ftlbf}
CONTINUED
P3
TO. MODEL .INDEX

BRAKE SWITCH INSPECTION 1. Disconnect the brake switch connector. 2. Inspect for continuity between the terminals of the brake switch connector using the circuit tester. : Continuity
Condition When the brake pedal is depressed. When the brake pedal is not depressed. Terminal A B
R.H.D.
SST R
SST * A B * 49 0259 770B

Nm {kgfcm, inlbf} 12.921.5 {130220, 113190} 9.8115.6 {100160, 87138}
Brake fluid level sensor connector Brake pipe Bracket (R.H.D.) Master cylinder + Installation Note O-ring
3. If not as specified, replace the brake switch. MASTER CYLINDER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
L.H.D.
2 3 4 5
Master Cylinder Installation Note 1. Loosen the adjusting nut of the SST. 2. Place the SST on the power brake unit and tighten the nut and washer.
SST
Tightening torque 9.8115.6 Nm {100160 kgfcm, 87138 inlbf} 3. Apply 66.7 kPa {500 mmHg, 19.7 inHg} vacuum to the power brake unit using a vacuum pump.
9.8115.6 {100160, 87138}
SST *
12.921.5 {130220, 113190}
* 49 0259 770B
Nm {kgfcm, inlbf}
49 B043 001
CONTINUED
P4
TO. MODEL .INDEX

4. Turn the adjusting nut of the SST counterclockwise until the gauge rod just contacts the push rod end of the power brake unit. Push lightly on the end of the gauge rod to be sure it is seated. Verify that there is no gap between the adjusting nut and SST body. 5. Remove the SST from the power brake unit.
TOUCHING
Clearance at B 1. Measure and record the height D1 of the gauge rod.
(D1)
49 B043 001
49 B043 001
TOUCHING ADJUSTING NUT
2. Turn the adjusting nut until the SST body sets closely on the master cylinder. Turn only enough for the body to touch. 3. Measure and record height D2 of the gauge rod.
ADJUSTING NUT (D2)
6. Remove the SST from the power brake unit without disturbing the adjusting nut. Set the SST onto the master cylinder as shown in the figure. 7. Push lightly on the end of the SST gauge rod to be sure that it is contacting the bottom of the master cylinder piston, but do not push so hard that the piston moves. Note any clearance between the SST body and the adjusting nut: clearance B, or between the body and the master cylinder: clearance C. Adjust the push rod as necessary as outlined in Adjustment below. Adjustment
Measurement Clearance at B Clearance at C No clearance at B or C Push rod Too long Too short Okay
CLEARANCE (C)
CLEARANCE (B)
49 B043 001
4. Subtract D1 from D2. Using the SST, turn the nut to shorten the power brake unit push rod an amount equal to the difference.
49 B043 004
49 B043 001 49 E043 003A
CLEARANCE (B)
CONTINUED
P5
TO. MODEL .INDEX

Clearance at C 1. Push lightly on the end of the SST gauge rod, and measure the clearance between the adjusting nut and the SST body.
CLEARANCE (C)
49 B043 001
2. Using the SSTs, turn the nut to lengthen the power brake unit push rod an amount equal to the clearance measured at B.
49 B043 004
49 E043 003A
FLUID LEVEL SENSOR INSPECTION 1. Disconnect the sensor connector. 2. Connect an ohmmeter to the connector. 3. Starting with the fluid level above MIN, verify that there is no continuity. 4. Remove the brake fluid and verify that there is continuity when the level is below MIN. : Continuity
Fl id level Fluid Below MIN. Above MIN. Terminal A B
5. If not as specified, replace the sensor.
A B
CONTINUED
P6
TO. MODEL .INDEX

MASTER CYLINDER DISASSEMBLY/ASSEMBLY Caution D If the master cylinder body is damaged, replace the unit as a component. When securing the master cylinder in a vise, tighten only the flange of the master cylinder. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1.01.5 {1015, 8.713}
R
2.02.4 {2025, 1821}
Nm {kgfcm , inlbf}
1 2 3 4 5 6 7 8 9
Cap set Screw Reservoir Joint bushing Fluid level sensor Snap ring Spacer Piston guide O-ring
10 11 12 13 14 15 16
Cup Primary piston stopper Primary piston Stop screw + Assembly Note O-ring Secondary piston Master cylinder body
CONTINUED
P7
TO. MODEL .INDEX

Stop Screw and O-ring Assembly Note 1. Install a new O-ring onto the stop screw. 2. Push the primary piston component in full. 3. Install and tighten the stop screw. Tightening torque 2.02.4 Nm {2025 kgfcm, 1821 inlbf} (Inspection using the testers) 1. Connect the SSTs, vacuum gauge, and pedal depression force gauge as shown in the figure. Note D Use commercially available gauges and pedal depression force gauge. D Bleed the air from the SST at gauge A.
49 U043 004 49 U043 005
A A
PEDAL DEPRESSION FORCE GAUGE VACUUM GAUGE
49 U043 006
POWER BRAKE UNIT INSPECTION Power Brake Unit Function Inspection (Simple method) Note D Replace power brake unit component as necessary. Step 1 1. With the engine stopped, depress the pedal a few times. 2. With the pedal depressed, start the engine. 3. If the pedal moves down slightly, immediately after the engine starts, the unit is operating. Step 2 1. Start the engine. 2. Stop the engine after it has run for 1 or 2 minutes. 3. Depress the pedal with the usual force. 4. If the first pedal stroke is long and becomes shorter with subsequent strokes, the unit is operating. Note D If a problem is found, inspect for damage on the check valve or vacuum hose, and examine the installation. Repair as necessary, and inspect it again. Step 3 1. Start the engine. 2. Depress the pedal with the usual force. 3. Stop the engine with the pedal held depressed. 4. Hold the pedal down for about 30 seconds. 5. If the pedal height does not change, the unit is operating.
2. After bleeding the air from the SST, conduct the test as described in the following steps. a) Inspection for vacuum loss Unloaded condition 1. Start the engine. 2. Stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 3. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.366.7 kPa {475500 mmHg, 18.719.7 inHg}, the unit is operating. Loaded condition 1. Start the engine. 2. Depress the brake pedal with a force of 196 N {20 kgf, 44 lbf}. 3. With the brake pedal depressed, stop the engine when the vacuum gauge reading reaches 66.7 kPa {500 mmHg, 19.7 inHg}. 4. Observe the vacuum gauge for 15 seconds. If the gauge shows 63.366.7 kPa {475500 mmHg, 18.719.7 inHg}, the unit is operating. b) Inspection for hydraulic pressure 1. When the engine is stopped (vacuum 0 kPa {0 mmHg, 0 inHg}) and the fluid pressure is within the specification, the unit is operating.
Pedal force 196 N {20 kgf, 44 lbf} Fluid pressure 790 kPa {8 kgf/cm2, 114 psi} min
2. Start the engine. Depress the brake pedal when the vacuum reaches 66.7 kPa {500 mmHg, 19.7 inHg}. If the fluid pressure is within the specification, the unit is operating.
Pedal force 196 N {20 kgf, 44 lbf} Fluid pressure 8,240 kPa {84 kgf/cm2, 1,200 psi} min
CONTINUED
P8
TO. MODEL .INDEX

POWER BRAKE UNIT REMOVAL/INSTALLATION 1. Remove the master cylinder. (Refer to CONVENTIONAL BRAKE SYSTEM, MASTER CYLINDER REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
L.H.D.
1 2 3 4 5 6 7 8 9
Vacuum switch connector (Diesel) Vacuum hose Snap pin Clevis pin Nut Power brake unit Gasket Fork Nut
1925 {1.92.6, 1418}
VACUUM SWITCH INSPECTION (DIESEL) 1. Remove the vacuum hose from the power brake unit. 2. Set the vacuum pump hose (commercially available on the market) onto the power brake unit as shown.
2434 {2.43.5, 1825}
Nm {kgfm, ftlbf}
R.H.D.
3. Turn the engine switch on. 4. Release the parking brake. 5. Apply vacuum to the power brake unit using the vacuum pump (commercially available on the market) and verify the operating condition of the brake light warning light.
R
Vacuum kPa {mmHg, inHg} Below 10.7"1.3 {80"10, 3.2"0.4} Above 10.7"1.3 {80"10, 3.2"0.4}
1925 {1.92.6, 1418}
Brake warning light ON OFF
6. The vacuum switch is functioning normally if it corresponds to the above specifications. Replace the vacuum switch as necessary.
2434 {2.43.5, 1825}
Nm {kgfm, ftlbf}
CONTINUED
P9
TO. MODEL .INDEX

VACUUM SWITCH REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
L.H.D.
VACUUM PUMP INSPECTION (DIESEL) 1. Warm up the engine. 2. Disconnect the vacuum hose from the vacuum pump and connect a vacuum gauge as shown in the figure, then inspect the vacuum. Vacuum specification (In 20 seconds) Engine speed 1,500 rpm 73.3 kPa {550 mmHg, 21.7 inHg} Maximum vacuum Engine speed 3,000 rpm 93.3 kPa {700 mmHg, 27.6 inHg}
2024 {2.02.5, 1518}
Nm {kgfm, ftlbf}
R.H.D.
2024 {2.02.5, 1518} Nm {kgfm, ftlbf}
3. If the pressure is less than the specification, inspect for the following. (1) Malfunction of the vacuum pump (2) Shortage of the lubrication oil pressure VACUUM PUMP REMOVAL/INSTALLATION (DIESEL) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
1 2
Vacuum switch connector Vacuum switch + Installation Note
Vacuum Switch Installation Note 1. Remove the old sealant. Caution D Do not apply sealant to the tip of the vacuum switch as a malfunction may occur. 2. Apply sealant to the area shown before installation of the vacuum switch onto the power brake unit, and then tighten it to the specified torque. Tightening torque 2024 Nm {2.02.5 kgfm, 1518 ftlbf}
R DO NOT APPLY SEALANT ON THIS AREA
1925 {1.92.6, 1418} Nm {kgfm, ftlbf}
1 2 3 4
Vacuum hose Bolt Vacuum pump O-ring
CONTINUED
P10
TO. MODEL .INDEX

LOAD SENSING PROPORTIONING VALVE INSPECTION 1. Place the vehicle on level ground. 2. Inspect the tire inflations and set them to the recommended pressure as necessary. 3. Prepare the vehicle with a person in the drivers seat; include the standard vehicle tools, the spare wheel and tire, and a full tank of fuel. 4. Connect pressure gauges (commercially available) to the front and rear calipers. LOAD SENSING PROPORTIONING VALVE ADJUSTMENT 1. Place the unloaded vehicle on level ground. Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position. Note D A change of 5 mm {0.197 in} dimension L results in a change of 853 kPa {8.7 kgf/cm2, 124 psi} for 4 2 and 1020 kPa {10.4 kgf/cm2, 148 psi} for 4 4. 2. Adjust main spring dimension L between the LSPV and the adjustment link by loosening and repositioning the LSPV. (1) Decrease dimension L if the fluid pressure is low. (2) Increase dimension L if the fluid pressure is high. Note D When applying the specified pressure, the brake pedal must not be double pumped or released. D Approximately two seconds after setting the front wheel cylinder fluid pressure, read the rear pressure. 5. Bleed the air from the brake system. 6. Slowly depress the brake pedal until the front pressure gauge indicates the specified pressure shown in the table, then note the reading on the rear pressure gauge. kPa {kgf/cm2, psi}
Front pressure 4,900 {50, 711} 9,810 {100, 1,422} Rear pressure 2,550 {26, 370} 3,530 {36, 512}
ADJUSTMENT LINK
Reference value Dimension L 4 2: 147.5154.5 mm {5.8086.082 in} 4 4: 175.5182.5 mm {6.9107.185 in}
MAIN SPRING
LOADED A PERSON IN DRIVERS SEAT BOLT 4,900 {50, 711} 9,810 {100, 1,422} REAR PRESSURE FRONT PRESSURE
kPa {kgf/cm2, psi}
AXLE CASING
3. After adjustment, recheck the fluid pressure. If not as specified, replace the LSPV as a component. LOAD SENSING PROPORTIONING VALVE REMOVAL/INSTALLATION Caution D Do not disassemble the LSPV. D Do not move the nut A. 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
7. If not as specified, replace and adjust the LSPV.
CONTINUED
P11
TO. MODEL .INDEX

3. After installation, adjust the main spring dimension. (Refer to CONVENTIONAL BRAKE SYSTEM, LOAD SENSING PROPORTIONING VALVE ADJUSTMENT.)
12.821.5 Nm {130220 kgfcm, 113190 inlbf}
Disc Plate Thickness Inspection 1. Measure the thickness of the disc plate. Caution D When it is necessary to machine the disc plate, if the disc plate is removed from the vehicle then machined, excessive runout may result. Machine the disc plate with it installed on the vehicle. Standard 24 mm {0.94 in} Minimum 22 mm {0.87 in} Minimum thickness after machining by using a brake lathe on-vehicle 22.8 mm {0.90 in} 2. If the thickness is not within the specification, replace the disc plate.
SST * A
SST * 12.821.5 Nm
{130220 kgfcm, 113190 inlbf}
1925 {1.92.6, 1418}
1925 {1.92.6, 1418}
* 49 0259 770B
Nm {kgfm, ftlbf}
1 2 3 4
Brake pipe Nut Bolt Load sensing proportioning valve
FRONT BRAKE (DISC) INSPECTION Disc Pad Thickness Inspection 1. Jack up the front of the vehicle and support it on safety stands. 2. Remove the wheel and tires. 3. Look through the caliper inspection hole and inspect the remaining thickness of the pads. Thickness 2.0 mm {0.08 in} min. 4. Replace the pads as a set (right and left wheels) if either is at or less than the minimum thickness.
Disc Plate Runout Inspection 1. Verify that there is no wheel bearing looseness. 2. Measure the runout at the outer edge of the contact surface of the disc pad. Runout 0.05 mm {0.002 in} max. 3. If the runout is not within the specification, repair or replace the disc plate.
CONTINUED
P12
TO. MODEL .INDEX

FRONT BRAKE (DISC) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not drag.
2229 {2.23.0, 1629}
R
2934 {2.93.5, 2125}
108127 {10.414.0, 8094}
SST
Nm {kgfm, ftlbf}
1 2 3 4 5
Brake hose Bolt Guide pin Dust boot Caliper
6 7 8 9
Disc pad + Installation Note Plate Guide plate Mounting support
CONTINUED
P13
TO. MODEL .INDEX

Disc Pad Installation Note 1. Push the piston fully inward using the SST. 2. Install the disc pad. CALIPER (FRONT) DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
* SST
914 {92143, 80123}
49 0221 600C SST
DISC PAD (FRONT) REPLACEMENT 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
R
2934 {2.93.5, 2125}
*49 0259 770B R
Nm {kgfcm, inlbf}
1 2 3 4 5
Piston + Disassembly Note Dust seal Piston seal + Disassembly Note Bleeder cap, screw Caliper body
Piston Disassembly Note

SST
Nm {kgfm, ftlbf}
Caution D Blow the compressed air slowly to prevent the piston from suddenly popping out.
D Place a piece of wood in the caliper, then blow
1 2 3
Bolt Caliper Disc pad + CONVENTIONAL BRAKE SYSTEM, FRONT BRAKE (DISC) REMOVAL/INSTALLATION, Disc Pad Installation Note Plate Guide plate
compressed air through the hole to force the piston out of the caliper.
WOOD
4 5
Piston Seal Disassembly Note D Remove the piston seal from the brake caliper using the SST.
CONTINUED
P14
TO. MODEL .INDEX

REAR BRAKE (DRUM) INSPECTION Brake Lining Thickness Inspection 1. Remove the brake drum. 2. Inspect the remaining thickness of the lining. Thickness 1.0 mm {0.04 in} min. 3. Replace both left and right brake shoes if either is at or less than the minimum thickness.
REAR BRAKE (DRUM) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation. (1) Depress the brake pedal a few times, then verify that the brakes do not drag. (2) Inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION, Parking Brake Lever Stroke Inspection.)
9.812.7 {100130, 87112}
* SST
12.821.5 {130220, 113190}
APPLY
TO SHADED EREA
*49 0259 770B
Nm {kgfcm, inlbf}
1 2 3 4 5 6 7
Brake drum Hold spring, washer Hold pin Lower return spring Upper return spring Pawl lever spring Pawl lever
8 9 10 11 12 13 14
Adjust strut Brake shoe Parking brake cable Operating lever Brake pipe Wheel cylinder Gasket
CONTINUED
P15
TO. MODEL .INDEX
CONVENTIONAL BRAKE SYSTEM, PARKING BRAKE SYSTEM

BRAKE DRUM INSPECTION 1. Measure the inner diameter of the drum. Maximum diameter 4 2: 271.5 mm {10.68 in} 4 4: 296.5 mm {11.67 in} 2. Apply chalk to the inside of the brake drum. 3. Inspect for scratches and uneven or abnormal wear inside the drum as shown in the figure.
PARKING BRAKE SYSTEM

PARKING BRAKE (STICK TYPE) INSPECTION Parking Brake Lever Stroke Inspection 1. Pull the parking brake lever a few times. 2. Verify that the stroke is within the specification when the parking brake lever is pulled with a force of 98 N {10 kgf, 22 ibf}. Stroke 17 notches 3. If not as specified, adjust the parking brake lever stroke. PARKING BRAKE (STICK TYPE) ADJUSTMENT Parking Brake Lever Stroke Adjustment 1. Before adjustment, depress the brake pedal several times while the vehicle is moving in reverse. 2. Loosen the locknut A and turn the adjustment nut B so that the stroke is within the above range. 3. After adjustment, tighten the locknut A.
4. Repair or replace the drum as necessary. Repair if the problem is minor. 5. When repairing or replacing the drum, check the contact with the shoes. 6. Wipe the chalk off after inspection. WHEEL CYLINDER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
Tightening torque 6.99.8 Nm {70100 kgfcm, 4386 inlbf}
B A
R SST *
5.98.8 { 6090 , 5378 }
4. After adjustment, inspect the following points. (1) Turn the ignition (engine) switch on, pull the parking brake lever one notch, and verify that the brake warning light illuminates. (2) Verify that the rear brakes do not drag when the wheels are turned by hand.
* 49 0259 770B
Nm { kgfcm , inlbf }
1 2 3 4 5 6
Dust boot Piston Piston cap Spring Bleeder cap, screw Cylinder body
CONTINUED
P16
TO. MODEL .INDEX

PARKING BRAKE LEVER (STICK TYPE) REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
12.818.6 {130190, 113164}
6.99.8 {70100, 4386}
Nm {kgfcm, inlbf}
1 2 3 4 5 6 7 8
Clip Joint pin Cable connector Parking brake switch Clip Pin Clip and joint pin Lever
9 10 11 12 13 14 15 16
Pin and clip Spring Rachet pawl Stopper Fork joint Spring Guide Rod
CONTINUED
P17
TO. MODEL .INDEX

PARKING BRAKE CABLE (STICK TYPE) REMOVAL/INSTALLATION 1. Remove the under guard. (Refer to section F1F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. After installation, inspect the parking brake lever stroke. (Refer to PARKING BRAKE SYSTEM, PARKING BRAKE (STICK TYPE) INSPECTION.)
4x2
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
6.99.8 Nm {70100 kgfcm, 4386 inlbf}
4x4
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
6.99.8 Nm {70100 kgfcm, 4386 inlbf}
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
Nm {kgfm, ftlbf}
CONTINUED
P18
TO. MODEL .INDEX

LHD model with F2 and G6 engine
1 2 3 4 5 6
Nut Bolt Spring Front brake cable Bolt (4 4) 4) Bracket (4
7 8 9 10 11 12
Grommet Bolt Spring (4 Clip Rear cable (left) Rear cable (right) 4)
CONTINUED
P-19
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
SUSPENSION
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . WHEEL ALIGNMENT PREINSPECTION . . . . . FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . . FRONT SHOCK ABSORBER REMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT SHOCK ABSORBER INSPECTION . . TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) . . . . . . . . . R1 R1 R1 R 2/3 R3 R3 R5 R5 R 6/8 TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) . . . . . . . . . R 9/11 LOWER ARM INSPECTION . . . . . . . . . . . . . . . . R11 UPPER ARM REMOVAL/INSTALLATION . . . . R12 UPPER ARM INSPECTION . . . . . . . . . . . . . . . . R13 STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) . . . . . . . . . R13/14 STABILIZER REMOVAL/INSTALLATION (4 4) . R14 REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . R15 REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION . . . . . . . R15
GENERAL PROCEDURES
Wheels and tires removal/installation D The removal and installation procedures for the wheels and tires are not mentioned in this section. If a wheel is removed, retighten it to the specified tightening torque, referring to section TD. Suspension arms removal/installation D Tighten any part of the suspension that uses rubber bushings only after the vehicle has been lowered and unloaded*. * Unloaded condition: Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated position.
WHEEL ALIGNMENT
WHEEL ALIGNMENT PREINSPECTION 1. Inspect the inflation of each tire, and set to the recommended pressure, as necessary. 2. Inspect the front wheel bearing play. Adjust the bearing preload or replace bearing(s) as necessary. (Refer to section M, FRONT AXLE (4 2), WHEEL HUB, STEERING KNUCKLE INSPECTION or FRONT AXLE (4 4), WHEEL HUB, STEERING KNUCKLE INSPECTION.) 3. Inspect the wheel and tire runout at all wheels. (Refer to section TD, SUSPENSION, Wheels and Tires.) 4. Inspect the ball joints and steering linkage for excessive looseness. 5. Place the vehicle on level ground with no luggage and passenger load. 6. The difference in height between the left and right sides from the center of the wheel to the fender brim must not exceed 10 mm {0.39 in}. If not within the specification, adjust the vehicle height. (Refer to FRONT SUSPENSION, VEHICLE HEIGHT ADJUSTMENT.)
7. Shake the vehicle to settle the suspension.
CONTINUED
R1
TO. MODEL .INDEX
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT Specifications
Item Total toe toe-in in Maximum steering g angle Camber angle*2 Caster angle*3 Steering axis inclination (reference value)
*1 *2 *3
Specification 4 2 (mm {in}) (degree) Inner Outer 0! 16 "16 35! 00 33! 00

+2! 3! +2! 3!
4 4 3"3 {0.12"0.12} 0! 14 "14 33! 30 30! 00

+2! 3! +2! 3!
Front wheel heel alignment (*1Unloaded condition)
0! 56 "30 1! 37 "45 8! 04
1! 06 "30 2! 02 "45 10! 15
Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated position. Difference between left and right must not exceed 30. Difference between left and right must not exceed 45. Total Toe-in Adjustment 1. Loosen the tie-rod end locknuts. 2. Turn the tie rods by the same amount in the opposite direction. Note D One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}. D The left and right tie rods are both right threaded. To increase the toe-in, turn the right tie rod toward the front of the vehicle and the left tie rod equally toward the rear. 3. Tighten the tie-rod end locknuts. Tightening torque 6978 Nm {7.08.0 kgfm, 5157 ftlbf}
TIE ROD
Maximum Steering Angle Adjustment 1. Loosen the adjusting bolt locknut. 2. Turn the adjusting bolt to provide the correct turning angle. 3. After adjustment, tighten the locknut to the specified torque. Tightening torque 4058 Nm {4.06.0 kgfm, 2943 ftlbf}
4 2
ADJUSTING BOLT 4 4
ADJUSTING BOLT
CONTINUED
R2
TO. MODEL .INDEX
WHEEL ALIGNMENT, FRONT SUSPENSION

Caster and Camber Adjustment 1. Loosen the upper arm shaft bolt and insert or remove adjustment shims to provide the correct angle.
No.15 No.611
FRONT SUSPENSION
VEHICLE HEIGHT ADJUSTMENT 1. Place the vehicle on level ground. 2. Inspect the front and rear tire pressure and adjust it as necessary. 3. Measure the distance from the center of each front wheel to the fender brim.
FRONT
Left/right difference 10 mm {0.39 in} max. Standard vehicle height (reference value) 4 2
Cab type
mm {in}
Vehicle height 427 {16.8} 422 {16.6}
Adjustment shim
No. 1 2 3 4 5 6 Thickness (mm {in}) 1.0 {0.039} 1.6 {0.063} 2.0 {0.079} 3.2 {0.126} 4.0 {0.157} 0.6 {0.024} No. 7 8 9 10 11 Thickness (mm {in}) 1.0 {0.039} 1.6 {0.063} 2.0 {0.079} 3.2 {0.126} 4.0 {0.157}
Regular Cab, Stretch Cab Double Cab
4 4
Cab type Regular g Cab, , Stretch Cab Double Cab Tire size 205R16 235/75R15 205R16 235/75R15 Vehicle height 519 {20.4} 515 {20.3} 510 {20.1} 506 {19.9}
Note D Shims No.15 are used on either side. Do not use more than two. D Shims No.611 are used at the front and rear of either sides. Do not use more than one. D Camber: A change of shim thickness (at front and rear) of 1 mm {0.039 in} results in a change of about 15. D Caster: A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results in a change of about 30. 2. After adjustment, tighten the upper arm shaft bolt to the specified torque. Tightening torque 94116 Nm {9.511.9 kgfm, 6986 ftlbf}
CONTINUED
R3
TO. MODEL .INDEX
FRONT SUSPENSION
1. If the difference between left and right is not within the specification, adjust the vehicle height by turning the torsion bar spring anchor bolt.
4 2
4 4
ANCHOR BOLT
ANCHOR BOLT
CONTINUED
R4
TO. MODEL .INDEX
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
68 mm {0.240.31 in}
5580 {5.68.2, 4159}
Nm {kgfm, ftlbf}
1 2
Nut + Installation Note Retainer, bushing
3 4 5
Bolt Washer and nut Shock absorber
Nut Installation Note D Tighten the nut so that the exposed thread of the shock absorber piston is 68 mm {0.240.31 in}.
FRONT SHOCK ABSORBER INSPECTION 1. Remove the front shock absorber from the vehicle. 2. Inspect for damage and oil leakage. 3. Inspect the rubber bushing for deterioration and wear. 4. Compress and extend the shock absorber piston at least three (3) times. Verify that the operational force does not change and that there is no unusual noise. 5. Compress the shock absorber piston and release it. Verify that the piston extends fully at a normal speed.
CONTINUED
R5
TO. MODEL .INDEX
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the vehicle height and adjust it as necessary.
APPLY THREAD LOCKING COMPOUND
118156 {12.016.0, 87115} 118156 {12.016.0, 87115}
SST R
Nm {kgfm, ftlbf}
1 2 3 4 5
Cotter pin Nut Lower arm ball joint/Knuckle arm + Removal Note Bolt, washer, and nut (shock absorber) Anchor bolt + Removal Note + Installation Note Anchor swivel Bolt and washer Torsion bar component Anchor arm Torsion bar spring + Removal Note + Installation Note
11 12 13
Torque plate Lower arm spindle, washer, and nut Rubber bushing + Removal Note + Installation Note Tension rod bolt Stabilizer bolt, bushing, retainer, spacer, and nut + Installation Note Lower arm Bound bumper, washer, and nut Bolts and washer (ball joint) Lower arm ball joint Clip + Installation Note Lower arm ball joint boot
14 15 16 17 18 19 20 21
6 7 8 9 10
CONTINUED
R6
TO. MODEL .INDEX
FRONT SUSPENSION
Lower Arm Ball Joint/Knuckle Arm Removal Note D Separate the ball joint from the knuckle arm using the SST. Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
KNUCKLE
49 T028 3A0
49 U034 208
Anchor Bolt Removal Note D Mark the anchor bolt and swivel for reference during installation.
Stabilizer Bolt, Bushing, Retainer, Spacer And Nut Installation Note D Tighten the nuts so that 1821 mm {0.710.82 in} of thread is exposed at the end of the bolt.
MATCHING MARK
1821 mm {0.710.82 in}
Torsion Bar Spring Removal Note D Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
Rubber Bushing Installation Note D Install a new bushing using the SST.
MATCHING MARK
MATCHING MARK
49 UB39 615
Rubber Bushing Removal Note D Remove the rubber bushing from the body using the SST.
49 UB39 615
CONTINUED
R7
TO. MODEL .INDEX
FRONT SUSPENSION
Torsion Bar Spring Installation Note 1. Before installation, check the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
MATCHING MARK
MATCHING MARK
Anchor Bolt Installation Note D Install the anchor bolt, and tighten it until the marks made during removal are aligned.
MATCHING MARK
Note D If the anchor bolt was not marked during removal, install it as follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 34 "4.5. (3) Install the anchor bolt and tighten it 27.3 turns.
CONTINUED
R8
TO. MODEL .INDEX
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4) 1. Remove the driveshaft snap ring. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. 4. Inspect the vehicle height and adjust it as necessary.
118156 {12.016.0, 87115}
118156 {12.016.0, 87115}
SST R
1 2 3
Cotter pin Nut Lower arm ball joint/Knuckle arm + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2), Lower Arm Ball Joint/Knuckle Arm Removal Note Bolt, washer and nut (shock absorber) Anchor bolt and washer + Installation Note Anchor swivel Bolt and washer Torsion bar spring component Anchor arm + Removal Note + Installation Note Torsion bar spring + Removal Note + Installation Note Torque plate Lower arm spindle (rear), washer and nut
13 14
Lower arm spindle (front), washer and nut Stabilizer bolt, bushing, retainer, spacer and nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note Lower arm Bound bumper, washer, and nut Bolt, washer and nut Lower arm ball joint Clip + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2), Clip Installation Note Lower arm ball joint boot Lower arm bushing + Removal Note + Installation Note
4 5 6 7 8 9
15 16 17 18 19
10
20 21
11 12
CONTINUED
R9
TO. MODEL .INDEX
FRONT SUSPENSION
Anchor Arm Removal Note D Mark the anchor arm and body for reference during installation. Lower Arm Bushing Installation Note 1. Apply soapy water to the new bushing. 2. Install the bushing using the SST.
49 U034 2A0
Torsion Bar Spring Removal Note D Mark the torsion bar spring and anchor arm and the torsion bar spring and torque plate for reference during installation.
Torsion Bar Spring Installation Note 1. Before installation, inspect the identification mark on the end of the torsion bar spring. L: Left bar, R: Right bar 2. Align the marks made during removal, and connect the torsion bar spring to the torque plate.
Anchor Arm Installation Note D Align the marks made during removal, and install the anchor arm onto the torsion bar spring.
Lower Arm Bushing Removal Note D Remove the lower arm bushing using the SST.
49 U034 2A0
CONTINUED
R10
TO. MODEL .INDEX
FRONT SUSPENSION
Anchor Bolt Installation Note D Install the anchor bolt, and tighten it until the marks made during removal are aligned.
Note D If the anchor bolt was not marked during removal, install it at follows: (1) Lower the front suspension until the upper arm contacts the rebound stopper. (2) Install the anchor arm so that the angle A is 60"4.5. (3) Install the anchor bolt and tighten it 26.9 turns.
LOWER ARM INSPECTION 1. Remove the lower arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification. Pull scale reading 2034 N {2.03.5 kgf, 4.47.7 lbf}
49 0180 510B
CONTINUED
R11
TO. MODEL .INDEX
FRONT SUSPENSION
UPPER ARM REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Inspect the wheel alignment and adjust it as necessary.
R SST
1 2 3 4 5
Clip Cotter pin and nut Upper arm ball joint/Knuckle arm + Removal Note Bolt and washer Adjustment shim + Removal Note
6 7 8 9 10
Upper arm component Bolt and washer Upper arm ball joint Clip + Installation Note Upper arm ball joint boot
Upper Arm Ball Joint/Knuckle Arm Removal Note D Separate the upper arm ball joint from the knuckle arm using the SST.
49 T028 3A0
Clip Installation Note 1. Install the SST to the ball joint stud with the stud stands straight up. 2. Install the clip in the dust boot groove.
KNUCKLE
49 U034 209
Adjustment Shim Removal Note D Note the number, amount and position of the shims so that they are reinstalled in the correct positions.
CONTINUED
R12
TO. MODEL .INDEX
FRONT SUSPENSION
UPPER ARM INSPECTION 1. Remove the upper arm from the vehicle. 2. Inspect for damage, cracks, and bending. 3. Check the ball joint rotation torque. (1) Rotate the ball joint five times. (2) Connect the SST to the ball stud, and measure the rotation torque using a pull scale. (3) Replace it if not within the specification. Pull scale reading 5.024 N {0.52.5 kgf, 1.25.5 lbf} STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
49 0180 510B
2226 {2.22.7, 1619}
94116 {9.511.9, 6986}
94127 {9.513.0, 6994} Nm {kgfm, ftlbf}
Nut + FRONT SUSPENSION, TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2), Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note Retainer Bolt Bushing, retainer and spacer Bolt
6 7 8 9 10 11 12
Stabilizer bracket Bushing Stabilizer bar Tension rod nut + Installation Note Bushing and retainer Bolt Tension rod
2 3 4 5
CONTINUED
R13
TO. MODEL .INDEX
FRONT SUSPENSION
Tension Rod Nut Installation Note D Tighten the tension rod nuts so that length L is 98.5 mm {3.88 in}.
STABILIZER REMOVAL/INSTALLATION (4 4) 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
2226 {2.22.7, 1619}
Nm {kgfm, ftlbf}
Nut + FRONT SUSPENSION, STABILIZER AND TENSION ROD REMOVAL/INSTALLATION (4 2), Nut Installation Note Retainer and bushing Bolt Retainer and bushing
5 6 7 8 9
Retainer, bushing, and spacer Bolt Stabilizer bracket Bushing Stabilizer bar
2 3 4
CONTINUED
R14
TO. MODEL .INDEX
REAR SUSPENSION
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION 1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary. 2. Install in the reverse order of removal.
4 2
6478 {6.58.0, 4857}
5978 {6.08.0, 4457}
APPLY THREAD LOCKING COMPOUND R

2026 {2.02.7, 1519.5} 5473 {5.57.5, 4054}
7898 {8.010.0, 5872}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9
Nut, washer, retainer, and bushing Nut, washer, retainer, and bushing Shock absorber Nut and washer Nut and washer U-bolt Spring clamp Stopper rubber Bolt and washer
10 11 12 13 14 15
Spring pin Nut and washer Shackle pin Shackle plate Leaf spring component Leaf spring bushing + Removal Note + Installation Note
CONTINUED
R15
TO. MODEL .INDEX
REAR SUSPENSION
4 4
99.1112 {10.111.5, 73.183.1}
6478 {6.58.0, 4857}
5978 {6.08.0, 4457}
R
7898 {8.010.0, 5872}
2026 {2.02.7, 1519.5}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10
Bolt and nut Washer, retainer, and bushing Nut, washer, retainer, and bushing Shock absorber Nut and washer Nut and washer U-bolt Set plate Spring clamp Stopper rubber
11 12 13 14 15 16 17
Bolt and washer Spring pin Nut and washer Shackle pin Shackle plate Leaf spring component Leaf spring bushing + Removal Note + Installation Note
CONTINUED
R16
TO. MODEL .INDEX
REAR SUSPENSION
Leaf Spring Bushing Removal Note D Secure the leaf spring in a vise and remove the bushing using a chisel.
Leaf Spring Bushing Installation Note D Press in the bushing using a suitable pipe.
CONTINUED
R17
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
PAGE 1 OF 2
BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BONNET REMOVAL/INSTALLATION . . . . . . . . BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . FRONT FENDER PANEL REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT DOOR REMOVAL/INSTALLATION . . . FRONT DOOR DISASSEMBLY/ASSEMBLY . . FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . REAR DOOR REMOVAL/INSTALLATION . . . . REAR DOOR DISASSEMBLY/ASSEMBLY . . . REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . DOOR LOCK STRIKER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REGULATOR HANDLE REMOVAL . . . . . . . . . . REGULATOR HANDLE INSTALLATION . . . . . POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW MAIN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER WINDOW SUBSWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . POWER WINDOW MOTOR INSPECTION . . . POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR KEY CYLINDER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK-LINK SWITCH INSPECTION . . . DOOR LOCK ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK ACTUATOR INSPECTION . . . . . DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . DOOR LOCK TIMER UNIT INSPECTION . . . . FUEL-FILLER LID AND OPENER . . . . . . . . . . . . FUEL-FILLER LID REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FUEL-FILLER LID ADJUSTMENT . . . . . . . . . . BUMPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT BUMPER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . . REAR BUMPER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BUMPER DISASSEMBLY/ASSEMBLY . .
BODY
S 2 S 2/3 S 3 S 4 S 4 S 5 S 5 S 6 S 7 S 7 S 8/9 S 9 S 9 S 9 S 9 S10 S10 S10/12 S12 S12/13 S13 S13 S13/14 S14 S14 S15 S15 S15 S15 S15 S15 S16 S16 S17 S19 S19 S19 S19 S19 S19 S20 S20/21 EXTERIOR ATTACHMENT . . . . . . . . . . . . . . . . . . . RADIATOR GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COWL GRILLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD GARNISH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . SIDE PROTECTOR REMOVAL . . . . . . . . . . . . . SIDE PROTECTOR INSTALLATION . . . . . . . . OVER FENDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TAILGATE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . TAILGATE ADJUSTMENT . . . . . . . . . . . . . . . . . ROPE HOOK REMOVAL/INSTALLATION . . . . MOLDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD UPPER MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD SIDE MOLDING REMOVAL . . . WINDSHIELD SIDE MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR BELTLINE MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ROOF MOLDING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR INSPECTION . . POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . POWER OUTSIDE MIRROR SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . . REARVIEW MIRROR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . FILAMENT INSPECTION . . . . . . . . . . . . . . . . . . FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW DEFROSTER RELAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . . WINDSHIELD INSTALLATION . . . . . . . . . . . . . . QUARTER WINDOW GLASS REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR WINDOW GLASS REMOVAL . . . . . . . . REAR WINDOW GLASS INSTALLATION . . . . DASHBOARD AND CONSOLE . . . . . . . . . . . . . . . S21 S21 S21 S21/22 S22 S22/23 S23 S23 S23 S24 S24 S24 S24 S24 S24 S24 S25 S25 S25 S25 S25 S25/26 S26 S26 S27 S27 S27 S27 S27 S27/28 S28 S28 S28 S29 S29/30 S30/31 S32 S33 S33 S34
S1
CONTINUED
TO. MODEL .INDEX
BONNET
PAGE 2 OF 2
DASHBOARD REMOVAL/INSTALLATION . . . DASHBOARD DISASSEMBLY/ASSEMBLY . . DASHBOARD MEMBER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COLUMN COVER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . REAR CONSOLE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR CONSOLE DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . GLOVE COMPARTMENT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . METER HOOD REMOVAL/INSTALLATION . . . . . . . . . . . . . . . TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . B-PILLAR UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR SCUFF PLATE REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BODY
S34 S35 S36 S36 S36 S36 S36 S37 S37 S37 S38 S38 S38 S38 S38 S39 S39 S39 C-PILLAR TRIM REMOVAL/INSTALLATION . . S39 QUARTER UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S39/40 QUARTER LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S40 BACK UPPER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S40 BACK LOWER TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S40 FRONT DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S41 REAR DOOR TRIM REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S41 HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S42 HEADLINER REMOVAL/INSTALLATION . . . . . S42 FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . . S42 FLOOR COVERING REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S42/43 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S44 SEAT BELT REMOVAL/INSTALLATION . . . . . . S44/45 SEAT BELT INSPECTION . . . . . . . . . . . . . . . . . S45/46 BUCKLE REMOVAL/INSTALLATION . . . . . . . . . S46 BUCKLE SWITCH INSPECTION . . . . . . . . . . . . S47 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S48 FRONT SEAT REMOVAL/INSTALLATION . . . . S48 FRONT SEAT DISASSEMBLY/ASSEMBLY . . . S49/50 CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . S51 REAR SEAT REMOVAL/INSTALLATION . . . . . S51/52 REAR SEAT DISASSEMBLY/ASSEMBLY . . . . S52/53 SEAT WARMER SWITCH REMOVAL . . . . . . . S54 SEAT WARMER SWITCH INSTALLATION . . . S54 SEAT WARMER SWITCH INSPECTION . . . . . S54 SEAT WARMER UNIT INSPECTION . . . . . . . . S54
BONNET
Warning D Removing the bonnet without supporting it can be dangerous. The bonnet may fall and injure you. Always perform these procedures together with at least another person. BONNET REMOVAL/INSTALLATION 1. Pull out the windshield washer pipe. 2. To remove the bonnet hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 3. To remove the bonnet lock, remove the radiator grille. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the bonnet. (Refer to BONNET ADJUSTMENT.)
3.03.9 {3040, 2734}
TO. MODEL .INDEX
A A
7.910.7 {80110, 69.595.4}
Nm {kgfcm, inlbf}
1 2 3 4
Shroud seal weatherstrip Bonnet Bonnet hinge Bonnet stay
S2
CONTINUED
TO. MODEL .INDEX
BONNET
Height Adjustment 1. Loosen the bonnet lock installation bolts and move the bonnet lock to reposition the bonnet.
BOLT
5 6 7
Bonnet lock Bonnet release lever Bonnet release cable
BONNET ADJUSTMENT 1. Measure the gap and height between the bonnet and the body. Clearance a: 2.75.3 mm {0.110.20 in} b: 1.80.8 mm {0.070.03 in} (sec. AA) c: 2.30.8 mm {0.090.03 in} (sec. BB) d: 2.30.3 mm {0.090.01 in} (sec. CC) e: 6.010.0 mm {0.240.39 in} f: 7.013.0 mm {0.280.51 in}
2. Tighten the bonnet lock installation bolts.
50 {2.0} 30 {1.2} D D E E B B C C
A A
a e b , c, d f SEC. DD
SEC. AA SEC. BB SEC. CC
SEC. EE mm {in}
2. If not as specified, adjust the gap and height. (Refer to Gap Adjustment.) (Refer to Height Adjustment.) Gap Adjustment 1. Loosen the bonnet installation bolts and reposition the bonnet.
BOLT
2. Tighten the bonnet installation bolts.
CONTINUED
S3
TO. MODEL .INDEX
FRONT FENDER PANEL
FRONT FENDER PANEL

FRONT FENDER PANEL REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front side turn light. 3. Remove the front bumper. 4. Remove the front turn light. 5. Remove the front flap. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
B B
6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf}
1 2
Mud guard Front fender panel
CONTINUED
S4
BACK.TO.CHAPTER.INDEX DOOR DOOR

FRONT DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the front door hinge, remove the front fender panel. (Refer to FRONT FENDER PANEL, FRONT FENDER PANEL REMOVAL/INSTALLATION.) 4. To remove the checker, remove the speaker. (Refer to section T, AUDIO, SPEAKER REMOVAL/INSTALLATION.) 5. Remove in the order indicated in the table. 6. Install in the reverse order of removal. 7. Adjust the front door. (Refer to FRONT DOOR ADJUSTMENT.)
TO. MODEL .INDEX
Front Door Harness Removal Note 1. Disconnect the connectors indicated in the table, if equipped. Symbol A B C D E Connector name Passenger's side Driver's side Door lock-link switch Door lock actuator Power window main Power window switch subswitch Power outside mirror Front power window regulator Speaker
2. Disengage the clips.
3. Remove the rubber boot and pull out the door harness. 1 2 3 4 5 Front door harness Removal Note Checker pin Front door hinge Front door Checker
CONTINUED
S-5
TO. MODEL .INDEX
DOOR
FRONT DOOR DISASSEMBLY/ASSEMBLY 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. To remove the inner handle, peel off the door screen partially. 5. Disassemble in the order indicated in the table. 6. Assemble in the reverse order of disassembly.
WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
B B A D
6.879.80 {70100, 60.886.7}
H C
4.36.1 {4363, 3854}
C
6.879.80 {70100, 60.886.7}
D WITH POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM F

8.912.7 {90130, 79112}
E A
J G I
4.36.1 {4363, 3854} 2.02.9 {2030, 1826}
6.879.80 {70100, 60.886.7}
J I
Nm {kgfcm, inlbf}
1 2 3 4 5 6 7
Inner handle Door screen Front door glass Glass run channel Front glass guide Rear glass guide Front manual window regulator
8 9 10 11 12 13 14
Front power window regulator Outer handle Retainer Door key cylinder Front door lock (manual) Front door lock (power) Door lock knob
CONTINUED
S6
TO. MODEL .INDEX
DOOR
FRONT DOOR ADJUSTMENT 1. Measure the clearance between the door and the body. Clearance a: 4.06.0 mm {0.160.23 in} b: 1.51.0 mm {0.0590.039 in} c: 2.00.5 mm {0.0780.019 in} d: 4.58.5 mm {0.180.33 in} e: 1.2 mm {0.047 in} f: 3.56.5 mm {0.140.25 in} g: 2.7 mm {0.11 in} h: 5.5 mm {0.22 in}
2230 {2.23.1, 1622}
E E
C A A B B
F F a (+) b () SEC. AA f g () SEC. DD SEC. EE h SEC. BB (+) b () f a (+) c
d e
1 2 3
Connector Checker pin Rear door hinge Rear door Checker
SEC. CC
4 5
SEC. FF
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation screws, and move them to reposition the door. (Refer to FRONT DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.) 3. Tighten the bolts or the screws. REAR DOOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. To remove the checker, remove the ashtray bracket. (Refer to REAR DOOR DISASSEMBY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the rear door. (Refer to REAR DOOR ADJUSTMENT.)
CONTINUED
S7
TO. MODEL .INDEX
DOOR
REAR DOOR DISASSEMBLY/ASSEMBLY 1. Close the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.) 4. Disassemble in the order indicated in the table. 5. Assemble in the reverse order of disassembly.
WITH POWER WINDOW SYSTEM
6.879.80 {70100, 60.886.7}
E WITHOUT POWER WINDOW SYSTEM
6.879.80 {70100, 60.886.7}
2.53.5 {2536, 2231}
B B D A D C
4.36.1 {4363, 3854}
6.879.80 {70100, 60.886.7}
Nm {kgfcm, inlbf}
1 2 3 4 5 6
Inner handle Door screen Ashtray bracket Glass hole lid Rear manual window regulator Rear power window regulator
7 8 9 10 11 12
Rear door glass + Removal Note Glass run channel Glass guide Door lock knob Rear door lock Outer handle
CONTINUED
S8
TO. MODEL .INDEX
DOOR
Rear Door Glass Removal Note D Draw out the rear door glass through the glass hole. DOOR LOCK STRIKER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the door lock striker.
DOOR LOCK STRIKER
SCREW REAR DOOR
1826 {1.82.7, 1419}
REAR DOOR GLASS

Nm {kgfm, ftlbf}
REAR DOOR ADJUSTMENT 1. Measure the clearance between the door and the body. Clearance a: 3.56.5 mm {0.140.25 in} b: 1.51.0 mm {0.0590.039 in} c: 5.5 mm {0.22 in}
DD A A E E B B
3. Install in the reverse order of removal. REGULATOR HANDLE REMOVAL 1. Remove the regulator handle clip using a rag as shown.
RAG C C (+) b () SEC. AA (+) b () a b () SEC. BB (+) a a (+) b () c SEC. CC
CLIP
2. Remove the regulator handle. REGULATOR HANDLE INSTALLATION 1. Install the clip in the regulator handle. 2. Set the door glass at the fully raised position and push the regulator handle on as shown.
SEC. DD
SEC. EE
2. If not as specified, loosen the door hinge installation bolts or the door lock striker installation CLIP screws, and move them to reposition the door. (Refer to REAR DOOR REMOVAL/INSTALLATION.) (Refer to DOOR LOCK STRIKER REMOVAL/INSTALLATION.) 3. Tighten the bolts or screws.
FRONT
CONTINUED
S9
TO. MODEL .INDEX
POWER WINDOW SYSTEM
POWER WINDOW SYSTEM

POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the switch panel forward, and disengage the hook.
POWER WINDOW MAIN SWITCH INSPECTION Regular Cab, Stretch Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the drivers side, connect the battery positive voltage to terminal F and connect the ground to terminal D. 4. When inspecting the passengers side, turn the power-cut switch to ON. Power window switch Drivers side : Continuity
SWITCH PANEL BODY CLIP
BODY
Switch position Manual close Off Auto open Manual open
Terminal F D A (H) B (I)
HOOK
( ): R.H.D. Passengers side : Continuity

Switch position Terminal F D H (A) I (B)
4. Disconnect the power window main switch connector. 5. Remove the screws to remove the power window main switch from the switch panel.
SWITCH PANEL
Close Off Open
( ): R.H.D. Power-cut switch : Continuity

Switch position ON OFF Terminal D A (H) B (I) H (A) I (B)
POWER WINDOW MAIN SWITCH
( ): R.H.D.
SCREW
6. Install in the reverse order of removal.
CONTINUED
S10
TO. MODEL .INDEX
POWER WINDOW SYSTEM

Rear left
F D
: Continuity
POWER-CUT SWITCH MANUAL OPEN CLOSE AUTO CIRCUIT AUTO OPEN OPEN
Switch position Close Off O en Open
Terminal A H K I
MANUAL CLOSE
I (B) H (A) PASSENGERS SIDE CLOSE A (H) B (I) DRIVERS SIDE H I ( ) : R.H.D. F D A B OPEN
( ): R.H.D. Rear right : Continuity

Switch position Close Off O en Open Terminal A H E C
5. If not as specified, replace the power window main switch. Double Cab 1. Remove the switch panel. (Refer to POWER WINDOW MAIN SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window main switch terminals using an ohmmeter. 3. When inspecting the drivers side, connect the battery positive voltage to terminal A (L.H.D.) or F (R.H.D.) and connect the ground to terminal H. 4. When inspecting the passengers side and rear, turn the power-cut switch to ON. Power window switch Drivers side : Continuity
Switch position Manual close Off Auto open Manual open Terminal A (F) H L (D) J (B)
( ): R.H.D. Power-cut switch : Continuity

Terminal Switch position ON OFF H L (D ) J (B ) D (L ) B (J) E C K I
( ): R.H.D. L.H.D.
A H
( ): R.H.D. Passengers side : Continuity

Switch position Close Off Open O en Terminal A (F) H D (L) B (J)
J D B PASSENGERS K I E C RIGH T
( ): R.H.D.
CONTINUED
S11
TO. MODEL .INDEX
POWER WINDOW SYSTEM

R.H.D. Rear 1. Disconnect the negative battery cable. 2. Remove the hook by inserting a tape-wrapped, flathead screwdriver between the switch and the rear door trim.
A
F H
HOOK
J PASSENGERS D B K L I J
E H F
C D
A B
POWER WINDOW SUBSWITCH
3. Disconnect the connector, and remove the power window subswitch. 4. Install in the reverse order of removal. POWER WINDOW SUBSWITCH INSPECTION 1. Remove the power window subswitch. (Refer to POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power window subswitch terminals using an ohmmeter. Passengers side : Continuity
Switch position Off Close Open O en Terminal A B D E F
5. If not as specified, replace the power window main switch. POWER WINDOW SUBSWITCH REMOVAL/INSTALLATION Passengers side 1. Disconnect the negative battery cable. 2. Disengage the clip using a tape-wrapped flathead screwdriver. 3. Pull the power window subswitch forward, and disengage the hook.
BODY CLIP POWER WINDOW SUBSWITCH CLOSE OPEN HOOK
BODY
E F D
A B
Rear : Continuity
Switch position Close Terminal A B D E F
4. Disconnect the power window subswitch connector. 5. Install in the reverse order of removal.
Off Open
CONTINUED
S12
TO. MODEL .INDEX
POWER WINDOW SYSTEM
F D
F CLOSE OPEN E A
3. If not as specified, replace the power window subswitch. FRONT POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position. 2. Disconnect the negative battery cable. 3. Remove the front glass guide and the rear glass guide. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 1 Bolt 5. Install in the reverse order of removal.
2 Power window motor + Disassembly Note + Assembly Note Frame
3.04.9 Nm {3050 kgfcm, 2743 inlbf}
B A
8.912.7 {90130, 79112}
3
D C
Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor.
BASE MARK
A B
D C
6.879.80 {70100, 60.886.7}
GEAR
Nm {kgfcm, inlbf}
Power Window Motor Assembly Note D Align the marks of the gear and the frame to install the power window motor. REAR POWER WINDOW REGULATOR REMOVAL/INSTALLATION 1. Raise the rear door glass completely. 2. Disconnect the negative battery cable. 3. Remove the door screen. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
1 2 3 4
Front power window regulator connector Bolt Nut Front power window regulator
FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
CONTINUED
S13
TO. MODEL .INDEX
POWER WINDOW SYSTEM

Power Window Motor Disassembly Note D Make marks on the gear and base of the frame before disassembling the power window motor.
MARK A
BASE D C
6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf}
GEAR
Power Window Motor Assembly Note D Align the marks of the gear and base of the frame to install the power window motor. POWER WINDOW MOTOR INSPECTION 1. Remove the power window motor. (Refer to FRONT POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) (Refer to REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY.) 2. Apply battery positive voltage to the power window motor terminals and inspect the operation of the power window motor. B+: Battery positive voltage
Connection B+ A B
UP
1 2 3
Rear power window regulator connector Bolt Rear power window regulator
REAR POWER WINDOW REGULATOR DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
3.14.8 Nm {3149 kgfcm, 2742 inlbf}
GND B A
DOWN
Motor operation Up Down
A B
3. If not as specified, replace the power window motor.
1 2
Bolt Power window motor + Disassembly Note + Assembly Note Frame
CONTINUED
S14
TO. MODEL .INDEX
POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM

DOOR LOCK-LINK SWITCH REMOVAL/INSTALLATION Note The door lock-link switch is mounted to the driver-side door lock. 1. Disconnect the negative battery cable. 2. Remove the driver-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the door lock-link switch from the front door lock.
5. If not as specified, replace the door lock-link switch. DOOR LOCK ACTUATOR REMOVAL/INSTALLATION Front Note The front door lock actuator is mounted to the passenger-side door lock. 1. Disconnect the negative battery cable. 2. Remove the passenger-side door lock. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Remove the front door lock actuator from the front door lock.
5. Install in the reverse order of removal. DOOR LOCK-LINK SWITCH INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock-link switch connector. 4. Inspect for continuity between the door lock-link switch terminals using an ohmmeter. 5. Install in the reverse order of removal.
CONTINUED S-15
TO. MODEL .INDEX
POWER DOOR LOCK SYSTEM

Rear Note The rear door lock actuator is mounted to the rear door lock. 1. Disconnect the negative battery cable. 2. Remove the rear door lock. (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Remove the screws. 4. Disconnect the rod. 5. Remove the rear door lock actuator from the rear door lock.
5. If not as specified, replace the door lock actuator. DOOR LOCK TIMER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
6. Install in the reverse order of removal. DOOR LOCK ACTUATOR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the door screen. (Refer to DOOR, FRONT DOOR DISASSEMBLY/ASSEMBLY.) (Refer to DOOR, REAR DOOR DISASSEMBLY/ASSEMBLY.) 3. Disconnect the door lock actuator connector. 4. Apply battery positive voltage to the door lock actuator terminals and inspect the operation of the door lock actuator. B+: Battery positive voltage Terminal A GND B+ B B+ GND Actuator operation Lock Unlock
1 2 3 4
Door lock timer unit connector Nut Bracket Door lock timer unit
CONTINUED S-16
TO. MODEL .INDEX
POWER DOOR LOCK SYSTEM

DOOR LOCK TIMER UNIT INSPECTION 1. Remove the flasher unit. (Refer to section T, EXTERIOR LIGHTING SYSTEM, FLASHER UNIT REMOVAL/INSTALLATION.) 2. Measure the voltage at the door lock timer unit terminals as indicated below. 3. Disconnect the door lock timer unit connector before inspecting for continuity at terminals A, C, D, and H. 4. If not as specified, inspect the parts listed under "Inspection area" and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the door lock timer unit. Terminal Voltage List (Reference)
Terminal A B C GND
Signal
Connection Body ground D/L 30 A fuse Door lock-link switch
Test condition Constant: inspect for continuity to ground Constant Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock-link switch is at lock: inspect for continuity to terminal H Door lock-link switch is at unlock: inspect for continuity to terminal H Door lock actuators are locked Other Door lock actuators are unlocked Other Constant: inspect for continuity to terminal A
Voltage (V) /Continuity Yes B+ No Yes Yes No 0 B+ 0 0 0 B+ 0 0 Yes
Inspection area D/L 30 A fuse Door lock-link switch
Power supply Unlock input
Lock input
Door lock-link switch Door lock actuator Door lock actuator Not used Terminal A of door lock timer unit
Door lock-link switch Door lock actuator Door lock actuator -
E F G H
Lock output Unlock output GND
CONTINUED
S-17
TO. MODEL .INDEX
FUEL-FILLER LID AND OPENER, BUMPER
FUEL-FILLER LID AND OPENER

FUEL-FILLER LID REMOVAL/INSTALLATION 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
BUMPER
FRONT BUMPER REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
6393 {6.49.5, 4768} 6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf}
Fuel-filler lid
FUEL-FILLER LID ADJUSTMENT 1. Measure the gap and height between the fuel-filler lid and the body. Clearance a: 3.55.5 mm {0.140.21 in} b: 0.52.0 mm {0.010.07 in}
A a
6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf}
6393 {6.49.5, 4768} Nm {kgfm, ftlbf}
1 2
Front bumper Front bumper stay
b A
FRONT BUMPER DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
0.20.8 {29, 27}
SEC.AA
2. If not as specified, loosen the fuel-filler lid installation bolts and reposition the fuel-filler lid. 3. Tighten the fuel-filler lid installation bolts.
6.879.80 {70100, 60.886.7}
0.20.3 {24, 23}
12345678
Nm {kgfcm, inlbf}
1 2 3
Front bumper side fascia Front bumper upper fascia Front bumper lower fascia
CONTINUED
S19
TO. MODEL .INDEX
BUMPER
REAR BUMPER REMOVAL/INSTALLATION With Step 1. Remove the bolts, then remove the rear bumper. REAR BUMPER DISASSEMBLY/ASSEMBLY With Step 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf} 3246 {3.24.7, 2433}

A B A A B
BOLT
79116 {8.011.9, 58.086.0}
REAR BUMPER
6.879.80 Nm {70100 kgfcm, 60.886.7 inlbf}
A B
Nm {kgfm, ftlbf}
0.300.78 Nm {3.08.0 kgfcm, 2.76.9 inlbf}
Nm {kgfm, ftlbf}
2. Install in the reverse order of removal. Without Step 1. Disconnect the negative battery cable. 2. Disconnect the rear fog light connector. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2 3 4 5 6 Side bumper step + Removal Note Center bumper step + Removal Note Rear bumper fascia Rear bumper stay Rear bracket Set plate
Side Bumper Step Removal Note 1. Disengage clips A using pliers. 2. Pull the side bumper step upward, then remove it.
A SIDE BUMPER STEP
79116 {8.011.9, 58.086.0}
1622 {1.62.3, 1216} Nm {kgfm, ftlbf}
CLIP A
1 3
Rear bumper stay Rear bumper fascia
Center Bumper Step Removal Note 1. Remove the screws. 2. Disengage clips A using pliers. 3. Disengage clips B, then remove the center bumper step. 12345678
CONTINUED
S20
TO. MODEL .INDEX
BUMPER, EXTERIOR ATTACHMENT

B SCREW A B A B SCREW A B
EXTERIOR ATTACHMENT
RADIATOR GRILLE REMOVAL/INSTALLATION 1. Pull the radiator grille toward you, then disengage clips A to remove the radiator grille.
A SCREW
A SCREW
CENTER BUMPER STEP
CLIP B
CLIP A
A RADIATOR GRILLE
A CLIP
2. Install in the reverse order of removal. COWL GRILLE REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to section T, WIPER AND WASHER, WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the weatherstrip. 3. Remove the screws, then remove the cowl grille.
SCREW
COWL GRILLE
WEATHERSTRIP
4. Install in the reverse order of removal. WINDSHIELD GARNISH REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the windshield garnish upward, then disengage hook A from the cowl grille.
CONTINUED
S21
TO. MODEL .INDEX
EXTERIOR ATTACHMENT
CENTER SIDE PROTECTOR (REGULAR CAB) d c SCREW a a e a c c WINDSHIELD GARNISH COWL GRILLE DOUBLE-SIDED ADHESIVE TAPE CENTER SIDE REAR SIDE PROTECTOR PROTECTOR (STRETCH CAB) d d d b c c a a A A HOOK c e c a c c e e a c a c a d ca d
FRONT SIDE PROTECTOR b
1. Install in the reverse order of removal. SIDE PROTECTOR REMOVAL Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife. 1. Pry the side protector end 2030 mm {0.81.1 in} using a flathead screwdriver or a razor knife. 2. Pull the side protector, then remove it. Note D The side protector is installed with double-sided adhesive tape. If the side protector is difficult to remove, soften the double-sided adhesive tape using a hot air blower. SIDE PROTECTOR INSTALLATION 1. Remove the adhesive remaining on the side protector (if it will be reused) and the body using a razor knife. 2. Remove any grease or dirt from the adhesion surface of the side protector (if it will be reused) and the body. 3. Attach double-sided adhesive tape to the side protector as shown (if it will be reused). Clearance a : 03.0 mm {00.11 in} b : 37.5 mm {1.48 in} c : 10.0 mm {0.39 in} d : 2.05.0 mm {0.080.19 in} e : 25.0 mm {0.98 in}
4. Peel off the backing paper from the double-sided adhesive tape and attach the side protector onto the body as shown. Clearance a : 4.85.8 mm {0.190.22 in} b : 5.06.0 mm {0.200.23 in} c : 13.014.0 mm {0.510.55 in} d : 16.517.0 mm {0.650.66 in} e : 12.313.3 mm {0.490.52 in} f : 6.08.0 mm {0.240.31 in} Regular Cab
CENTER SIDE PROTECTOR FRONT SIDE PROTECTOR A A b a c REAR SIDE PROTECTOR f
SEC. AA
Stretch Cab
CENTER SIDE PROTECTOR FRONT SIDE PROTECTOR A A b a d REAR SIDE PROTECTOR f
SEC. AA
CONTINUED
S22
TO. MODEL .INDEX
EXTERIOR ATTACHMENT
Double Cab
NUT REAR SIDE PROTECTOR f e b TAILGATE LOCK
FRONT SIDE PROTECTOR A A
SEC. AA
ROD
5. After installing the side protector to the body, apply pressure of 50 Nm {5.0 kgfm, 37 ftlbf} or more with a roller, etc. OVER FENDER REMOVAL/INSTALLATION 1. Remove the screws. 2. Remove the fasteners. 3. Disengage clips A of the over fender using a fastener remover, then remove the over fender.
FRONT CLIP A A A A A A
5. Remove the bolts, then remove the latch guide, latch and rod.
BOLT LATCH GUIDE ROD
LATCH
6. Remove the handle. 7. Assemble in the reverse order of disassembly. TAILGATE ADJUSTMENT 1. Loosen the bolts. 2. Move the striker forward and rearward until the tailgate will lock properly. 3. After the correct adjustment is made, tighten the bolts securely.
OVER FENDER FASTENER REAR A A A A A A A OVER FENDER SCREW CLIP
BOLT STRIKER
SCREW FASTENER
4. Install in the reverse order of removal. TAILGATE DISASSEMBLY/ASSEMBLY 1. Remove the cover. 2. Remove the nuts attaching the tailgate lock. 3. Disconnect the rods from the tailgate lock. 4. Remove the tailgate lock.
CONTINUED
S23
TO. MODEL .INDEX
EXTERIOR ATTACHMENT, MOLDING

ROPE HOOK REMOVAL/INSTALLATION 1. Remove the screws and bolts, then remove the rope hook.
MOLDING
WINDSHIELD UPPER MOLDING REMOVAL D Remove the windshield upper molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.) WINDSHIELD UPPER MOLDING INSTALLATION D Install the windshield upper molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.) WINDSHIELD SIDE MOLDING REMOVAL D Remove the windshield side molding from the windshield. (Refer to WINDOW GLASS, WINDSHIELD REMOVAL.)
ROPE HOOK SCREW
ROPE HOOK
WINDSHIELD SIDE MOLDING INSTALLATION D Install the windshield side molding to the windshield. (Refer to WINDOW GLASS, WINDSHIELD INSTALLATION.) FRONT BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the front door glass fully. 2. Remove the manual outside mirror or the power outside mirror. (Refer to OUTSIDE MIRROR, MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION.) (Refer to OUTSIDE MIRROR, POWER OUTSIDE MIRROR REMOVAL/INSTALLATION.) 3. Pull the rear end of the front beltline molding to disengage the hook.
FRONT BELTLINE MOLDING
BOLT
HOOK
4. Pull the front beltline molding upward, then remove clips A.

A
CLIP A A
BELTLINE MOLDING A
CONTINUED
S24
TO. MODEL .INDEX
MOLDING, OUTSIDE MIRROR

REAR BELTLINE MOLDING REMOVAL/INSTALLATION 1. Lower the rear door glass fully. 2. Pull the rear end of the rear beltline molding to disengage the hook.
REAR BELTLINE MOLDING
OUTSIDE MIRROR
MANUAL OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Remove the inner garnish. 2. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 3. Remove the screws. 4. Remove the manual outside mirror.
MANUAL OUTSIDE MIRROR SCREW
HOOK
3. Pull the rear beltline molding upward, then remove clips A. 5. Install in the reverse order of removal.
BELTLINE MOLDING CLIP A A A
4. Install in the reverse order of removal. ROOF MOLDING REMOVAL/INSTALLATION 1. Pull the rear edge of roof molding upward, then disengage clips A.
A ROOF MOLDING ROOF MOLDING CLIP BODY A A A
POWER OUTSIDE MIRROR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Remove the screws. 7. Remove the power outside mirror.
POWER OUTSIDE MIRROR SCREW
POWER OUTSIDE MIRROR CONNECTOR
8. Install in the reverse order of removal. POWER OUTSIDE MIRROR INSPECTION 1. Disconnect the negative battery cable. 2. Remove the inner garnish. 3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) 4. Partially peel off the door screen. 5. Disconnect the power outside mirror connector. 6. Apply battery positive voltage to the power outside mirror and inspect the operation of the power outside mirror.
CONTINUED
S25
TO. MODEL .INDEX
OUTSIDE MIRROR
Connection B+ A C C D GND C A D C Mirror operation Up Down Left Right LH Left
C A D
: Continuity
Switch position Up Down Terminal I L A D C B K
Right Up
DOWN UP
Down
*
123456567
M
LEFT
RH Left Right
RIGHT
1. If not as specified, replace the power outside mirror. POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the fuse block cover. 3. Remove the fuse block installation screws, and push the fuse block into the dashboard. 4. Insert your hand into the hole for the fuse block, and press the hooks of the power outside mirror switch. 5. Push the power outside mirror switch out, then remove it. 6. Disconnect the power outside mirror switch connector.
POWER OUTSIDE MIRROR SWITCH POWER OUTSIDE MIRROR SWITCH CONNECTOR
3. If not as specified, replace the power outside mirror switch.
7. Install in the reverse order of removal. POWER OUTSIDE MIRROR SWITCH INSPECTION 1. Remove the power outside mirror switch. (Refer to POWER OUTSIDE MIRROR SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the power outside mirror switch terminals using an ohmmeter.
CONTINUED
S26
TO. MODEL .INDEX
REARVIEW MIRROR, REAR WINDOW DEFROSTER
REARVIEW MIRROR
REARVIEW MIRROR REMOVAL/INSTALLATION Regular Cab
REAR WINDOW DEFROSTER

REAR WINDOW DEFROSTER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. 3. Press the hooks of the rear window defroster switch and push the switch out.
Note D The rearview mirror is attached to the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION, Regular Cab.) Stretch Cab, Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
HOOK
2.03.9 {2040, 1834}
REAR WINDOW DEFROSTER SWITCH
METER HOOD
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER SWITCH INSPECTION 1. Remove the rear window defroster switch. 2. Inspect for continuity between the rear window defroster switch terminals using an ohmmeter. : Continuity : Bulb
Switch position ON OFF Terminal A B C D
Nm {kgfcm, inlbf}
1 2 3
Cover Screw Rearview mirror
: :
C D
A B
3. If not as specified, replace the rear window defroster switch. FILAMENT INSPECTION 1. Turn the ignition switch to ON position. 2. Turn the rear window defroster switch on. Caution D Directly touching the rear window defroster filament with the lead of the circuit tester will damage it. Wrap aluminum foil around the end of the lead and test the filament by touching it with the foil.
CONTINUED
S27
TO. MODEL .INDEX
REAR WINDOW DEFROSTER

Caution D Do not use the rear window defroster until the paint is completely dry. It may cause other malfunctions if it is used before the paint is dry. 5. Use a hot air blower heated to 150C {302F} for 30 minutes or let the paint set for 24 hours at 25C {77F} to allow it to dry completely.
ALUMINUM FOIL
LEAD OF THE CIRCUIT TESTER PUSH
FILAMENT
1. Connect the positive ()) lead of the voltmeter to the positive side of each filament and the negative (*) lead to ground. 2. Gradually, slide the positive ()) lead from the positive side to the negative side and measure the voltage. Verify that the voltage decreases accordingly.
Measurement place (1) (2) Voltage (Reference value) Approx. 12 V Approx. 0 V
REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the rear window defroster relay connector. 3. Slide the rear window defroster relay upward, then remove it.
REAR WINDOW DEFROSTER RELAY
(2) NEGATIVE SIDE
(1) POSITIVE SIDE
REAR WINDOW DEFROSTER RELAY CONNECTOR
4. Install in the reverse order of removal. REAR WINDOW DEFROSTER RELAY INSPECTION 1. Remove the rear window defroster relay. (Refer to REAR WINDOW DEFROSTER RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear window defroster relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
Step 1 2 B) GND Terminal A B C D
3. If the voltage is not as specified or it changes rapidly, the filament is faulty. Repair the filament. FILAMENT REPAIR 1. Use white gasoline to clean around the damaged section of the filament. 2. Attach tape above and below the damaged section of the filament.
BROKEN FILAMENT TAPE
C D SECTION TO BE REPAIRED
A B
3. Using a small brush or marking pen, repair the filament with silver paint or equivalent. 4. After approximately 23 minutes, carefully remove the tape without disturbing the repaired area.
3. If not as specified, replace the rear window defroster relay.
CONTINUED
S28
TO. MODEL .INDEX
WINDOW GLASS
WINDOW GLASS
WINDSHIELD REMOVAL 1. Remove the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.) 2. Apply protective tape to the headliner, the body and the dashboard. Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife. Note D The windshield upper molding and windshield side molding are replacement parts. 3. Cut the lip of the windshield upper molding using a razor knife.
R WINDSHIELD UPPER MOLDING
Reusing Windshield 1. Make a hole through the sealant from the inside of the vehicle using an awl. 2. Pass the SST (piano wire) through the hole.
PROTECTIVE TAPE
49 0305 870A
WINDSHIELD UPPER MOLDING R
SEALANT
WINDSHIELD DAM
HEADLINER PROTECTIVE TAPE
3. Wind each end of the wire around a bar. Note D Use the entire length of piano wire to prevent it from breaking when cutting through the sealant. 4. Working with another person, saw through the sealant around the edge of the glass, being careful not to damage the body.
PROTECTIVE TAPE
LIP
Not Reusing Windshield Warning D Using a piano wire with bare hands can cause injury. Always wear gloves when using a piano wire. Note D For the areas of the sealant that are difficult to cut, use a piano wire and follow the procedures under Reusing Windshield. 1. Use a tool like that shown in the figure, and insert the blade into the sealant. 2. Pull through the sealant around the edge of the glass.
49 0305 870A
5. Remove the windshield. 6. Remove the spacers from the body. 7. Remove the spacer and the dam from the glass.
CENTER
DAM
SPACER
8. Remove the windshield upper molding and the windshield side molding from the windshield.
3. Remove the windshield. 4. Remove the spacers from the body.
CONTINUED
S29
TO. MODEL .INDEX
WINDOW GLASS
WINDSHIELD UPPER MOLDING WINDSHIELD
GLASS MARK
WINDSHIELD SIDE MOLDING
WINDSHIELD
WINDSHIELD SIDE MOLDING
WINDSHIELD INSTALLATION Warning D Using a razor knife with bare hands can cause injury. Always wear gloves when using a razor knife. Caution D To prevent the sealant from cracking or the glass from being pushed out by air pressure if a door is closed, open all of the windows and leave them open until the sealant has hardened. 1. Cut away the old sealant using a razor knife so that 12 mm {0.040.07 in} thickness of sealant remains around the circumference of the frame. If all the sealant has come off in any one place, apply some primer after degreasing, and allow it 30 minutes to dry. Then put on new sealant to create a 2 mm {0.08 in} layer. 2. Clean and degrease an approximately 50 mm {1.97 in} wide strip around the circumference of the glass and the bonding area on the body. 3. Align the center mark on the windshield upper molding with the glass mark. 4. Install the windshield upper molding from the center toward both sides.
WINDSHIELD UPPER MOLDING MARK
7. Securely bond a dam along the circumference of the glass 8.5 mm {0.33 in} from the upper edge and 14.5 mm {0.57 in} from the lower and side edge. 8. Install the spacer to the glass.
CENTER
8.5 {0.33} 14.5 {0.57} 6.0 {0.24}
DAM CERAMIC PARTING LINE

mm {in}
SPACER
14.5 {0.57}
14.5 {0.57}
9. Install spacers into the hole of the body. 10. Temporarily install the glass onto the body and adjust the glass to body clearance. 11. Make a mark on the glass directly above the V-notch of spacers. 12. Verify that the gap along the upper edge is 7.5 mm {0.30 in}.
7.5 {0.30}
CENTER
BODY
MARKING
GLASS MARK
SPACER
mm {in}
13. Remove the windshield.

WINDSHIELD
5. Align the upper edge of the windshield side molding with the glass mark. 6. Install the windshield side molding from the upper part towards the lower part.
Caution D Keep the area free of dirt and grease, and do not touch the surface or the primer may not properly bond to the surface of the glass and body, which may cause leaks to occur. 14. Use a brush to apply primer to the bonding area of the glass and body within the region shown. Use only glass primer on the glass and body primer on the body and molding. Allow it to dry for approximately 30 minutes.
CONTINUED
S30
TO. MODEL .INDEX
WINDOW GLASS
8.5 {0.33}
GLASS PRIMER
UPPER
14.5 {0.57}
WINDSHIELD
BODY
GLASS PRIMER BODY PRIMER

13.0 {0.51} 19.0 {0.75}
BODY PRIMER UPPER

14.5 {0.57}
DAM SEALANT SIDE ADJUST SEALANT IN THIS AREA
SIDE
GLASS PRIMER BODY PRIMER
BODY PRIMER
19.0 {0.75}
WINDSHIELD
LOWER
16.0 {0.63}
BODY DAM
WINDSHIELD SIDE MOLDING WINDSHIELD UPPER MOLDING BODY PRIMER ADJUST SEALANT IN THIS AREA
mm {in}
15. Once the primer is dry, apply a 11.0 mm {0.43 in} high, 5.0 mm {0.20 in} wide bead of sealant along the dam around the entire circumference to fill the gap between the dam and the edge of the windshield.
5.0 {0.20}
Hardening time of sealant

Temperature 5 C {41 F} 20 C {68 F} 35 C {95 F} Surface hardening time Approx. 1.5 h Approx. 1 h Approx. 10 min Time required until car can be put into service Approx. 12 h Approx. 4 h Approx. 2 h
11.0 {0.43}
DAM
20. Use white gasoline to remove any sealant that oozes out. 21. Install the cowl grille. (Refer to EXTERIOR ATTACHMENT, COWL GRILLE REMOVAL/INSTALLATION.)
mm {in}
16. Align the glass marks with the V-notches in spacers and install the glass onto the body. 17. Press firmly inward on the glass to compress the sealant. 18. Verify that the gap along the upper and side edge is 7.5 mm {0.30 in}. 19. Adjust the sealant as indicated in the figure.
CONTINUED
S31
TO. MODEL .INDEX
WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION Stretch Cab 1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 3
Hinge cover Quarter window hinge Quarter window lock
4 5
Quarter window glass Quarter window glass weatherstrip
CONTINUED
S32
TO. MODEL .INDEX
WINDOW GLASS
REAR WINDOW GLASS REMOVAL 1. Remove the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.) 2. Remove the rear window defroster connector if equipped. 3. While another person presses the rear window glass, use the SST to push the lip of the rear window weatherstrip from the inside.
REAR WINDOW WEATHERSTRIP SOAPY WATER
REAR WINDOW WEATHERSTRIP BODY
LIP
5. Align the rear window glass with the rear window weatherstrip and body. 6. While another person lightly taps the outside of the rear window glass near the rear window weatherstrip all around its circumference, pull one end of the SST and install the rear window glass.
49 0259 866A
4. After the top of the rear window weatherstrip is removed, push the rear window glass outside and remove it with the rear window weatherstrip attached. 5. Remove the rear window weatherstrip from the rear window glass.
49 0259 866A
REAR WINDOW GLASS INSTALLATION 1. Clean and degrease the body and the rear window glass. 2. Install the rear window weatherstrip to the rear window glass.
REAR WINDOW WEATHERSTRIP
7. Install the rear window defroster connector if equipped. 8. Install the headliner. (Refer to HEADLINER, HEADLINER REMOVAL/INSTALLATION.)
3. Fit the SST into the rear window weatherstrip and cross the ends as shown, leave 200 mm {7.87 in}.
REAR WINDOW WEATHERSTRIP
49 0259 866A
200 {7.87}
mm {in}
4. Apply soapy water as shown.
CONTINUED
S33
TO. MODEL .INDEX
DASHBOARD AND CONSOLE

DASHBOARD REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side air bag module. (Refer to section T, AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the passenger-side air bag module. (Refer to section T, AIR BAG SYSTEM, PASSENGER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 4. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 5. Remove the installation bolts then lower the assembled steering shaft from the dashboard. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 6. Remove the meter hood. 7. Remove the instrument cluster. 8. Remove the front console. (Refer to FRONT CONSOLE REMOVAL/INSTALLATION.) 9. Remove the glove compartment. 10. Remove the bonnet release cable installation nut. 11. Remove the A-pillar trims. (Refer to TRIM, A-PILLAR TRIM REMOVAL/INSTALLATION.) 12. Disconnect the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT REMOVAL.) (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT INSTALLATION.) 13. Remove the fuse block. 14. Remove in the order indicated in the table. 15. Install in the reverse order of removal. 16. Adjust the wires for both the blower unit and the heater unit. (Refer to section U, CONTROL SYSTEM, CLIMATE CONTROL UNIT ADJUSTMENT.)
7.911.7 {80120, 70104}
7.911.7 {80120, 70104}
7.911.7 {80120, 70104}
Nm {kgfcm, inlbf}
Bolt
Dashboard
CONTINUED
S34
TO. MODEL .INDEX

DASHBOARD DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3
Defroster nozzle Side demister nozzle Center duct
4 5
Duct Dashboard crash pad
CONTINUED
S35
TO. MODEL .INDEX

DASHBOARD MEMBER REMOVAL/INSTALLATION 1. Remove the dashboard. (Refer to DASHBOARD REMOVAL/INSTALLATION.) 2. Remove the bolts, then remove the dashboard member.
DASHBOARD MEMBER
1622 {1.62.3, 1216} 1622 {1.62.3, 1216}
FRONT CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
BOLT
1622 {1.62.3, 1216} 1622 {1.62.3, 1216}
Nm {kgfm, ftlbf}
3. Install in the reverse order of removal. COLUMN COVER REMOVAL/INSTALLATION 1. Remove the screws, then remove the column cover.
COLUMN COVER
1 2 3 4
SCREW
Screw Front console Boot Set plate
2. Install in the reverse order of removal. FRONT CONSOLE REMOVAL/INSTALLATION 1. Remove the rear console. 2. For manual transaxle vehicle, remove the shift lever knob. 3. Remove the screws, then remove the front console. Caution D In order to prevent noise caused by interference with the dashboard, install the screws to the rear of the front console before installing the front of the front console.
FRONT CONSOLE
REAR CONSOLE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the rear console upward, then remove it.
REAR CONSOLE
SCREW
SCREW
3. Install in the reverse order of removal. 4. Install in the reverse order of removal.
CONTINUED
S36
TO. MODEL .INDEX

REAR CONSOLE DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. METER HOOD REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the meter hood toward you, then disengage clips A and pins B.
A B SCREW A B A A
B A
A CLIP
B PIN A
3. Disconnect the connectors, then remove the meter hood. 4. Install in the reverse order of removal.
1 2 3 4 5 6 7
Screw Console lid outer Console lid inner Rear console Console lid lock Console lid hinge Console lid bracket
GLOVE COMPARTMENT REMOVAL/INSTALLATION 1. Open the glove compartment and bend the sides inward to disengage the pins. 2. Pull the glove compartment downward, then disengage clips A.
PIN PIN
A CLIP A GLOVE COMPARTMENT
CONTINUED
S37
TO. MODEL .INDEX
TRIM
TRIM
A-PILLAR TRIM REMOVAL/INSTALLATION 1. Remove the quarter upper trim. (Regular cab, stretch cab) (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the B-pillar upper trim. (Double cab) (Refer to B-PILLAR UPPER TRIM REMOVAL/INSTALLATION.) 3. Pull the A-pillar trim toward you, then disengage clips A and pin B. 4. Pull the A-pillar trim upward, then disengage the hook.
A A B A CLIP A-PILLAR TRIM
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the front scuff plate. 2. Remove the rear scuff plate. 3. Turn over the seaming welt. 4. Pull the B-pillar lower trim indicated by the arrow, then disengage clips A and pin B. 5. Remove the seat belt from B-pillar trim. 6. Pull the B-pillar lower trim upward, then disengage hooks C from the body.
CLIP A A B PIN A
PIN
A B A A B-PILLAR LOWER TRIM HOOK C C
HOOK A B
5. Install in the reverse order of removal. B-PILLAR TRIM REMOVAL/INSTALLATION Regular Cab 1. Turn over the seaming welt. 2. Remove the seat belt upper anchor installation bolt. 3. Remove the back upper trim. 4. Pull the B-pillar trim toward you, then disengage clips A and pins B. 5. Remove clip C. 6. Remove the seat belt from the B-pillar trim.
C
7. Install in the reverse order of removal. B-PILLAR UPPER TRIM REMOVAL/INSTALLATION Double Cab 1. Remove the B-pillar lower trim.(Refer to B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the front seat belt upper anchor installation bolt. 3. Remove the C-pillar trim. (Refer to C-PILLAR TRIM REMOVAL/INSTALLATION.) 4. Remove the fastener. 5. Pull the B-pillar upper trim toward you, then disengage clips A and pins B from the body.
A A A B A
B A A CLIP A A
A PIN CLIP C A CLIP A HOOK B A B A B
B-PILLAR TRIM
A A
B-PILLAR UPPER TRIM FASTENER
CONTINUED
S38
TO. MODEL .INDEX
TRIM
FRONT SIDE TRIM REMOVAL/INSTALLATION 1. Remove the scuff plate. 2. Loosen the nut. 3. Pull the front side trim in the direction indicated by the arrow, then remove it.
SCREW REAR SCUFF PLATE A A B
NUT CLIP FRONT SIDE TRIM
B PIN
3. Install in the reverse order of removal. C-PILLAR TRIM REMOVAL/INSTALLATION Double Cab 1. Turn over the seaming welt. 2. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Double Cab, Rear.) 3. Remove the rear seat belt upper anchor installation bolt. 4. Remove the fasteners. 5. Pull the C-pillar trim toward you, then disengage clips A and pin B. 6. Remove the seat belt from C-pillar trim.
A A A B CLIP A A PIN B
4. Install in the reverse order of removal. FRONT SCUFF PLATE REMOVAL/INSTALLATION 1. Remove the screws. 2. Pull the front scuff plate upward, then disengage pin A.
SCREW A
PIN C-PILLAR TRIM A A FRONT SCUFF PLATE
3. Install in the reverse order of removal. REAR SCUFF PLATE REMOVAL/INSTALLATION Double Cab 1. Remove the screw. 2. Pull the rear scuff plate upward, then disengage clips A and pin B.
FASTENER
7. Pull the C-pillar trim upward, then remove it from the body. 8. Install in the reverse order of removal. QUARTER UPPER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the back upper trim. 2. Remove the upper anchor of the seat belt. 3. Remove the quarter window lock. (Refer to WINDOW GLASS, QUARTER WINDOW GLASS REMOVAL/INSTALLATION.) 4. Remove the hook. 5. Remove the fasteners. 6. Pull the quarter upper trim toward you, then disengage clips A and pins B.
CONTINUED
S39
TO. MODEL .INDEX
TRIM
BACK UPPER TRIM REMOVAL/INSTALLATION 1. Pull the back upper trim toward you, then disengage clips A and pins B.
A B A
A A CLIP HOOK A A B A A PIN A A A A PIN CLIP A A A A A A B A B BACK UPPER TRIM
A A
B FASTENER
QUARTER UPPER TRIM
7. Install in the reverse order of removal. QUARTER LOWER TRIM REMOVAL/INSTALLATION Stretch Cab 1. Remove the quarter upper trim. (Refer to QUARTER UPPER TRIM REMOVAL/INSTALLATION.) 2. Remove the back lower trim. 3. Remove the fasteners. 4. Pull the quarter lower trim toward you, then disengage clips A and pins B.
QUARTER LOWER TRIM FASTENER
A B
2. Install in the reverse order of removal. BACK LOWER TRIM REMOVAL/INSTALLATION 1. Remove the fasteners, then remove the back lower trim.
B B A
A A A
CLIP PIN A FASTENER
BACK LOWER TRIM A B
CONTINUED
S40
TO. MODEL .INDEX
TRIM
FRONT DOOR TRIM REMOVAL/INSTALLATION 1. Disconnect the negative battery cable if equipped with a power window system. 2. Remove the regulator handle if equipped. 3. Remove the inner garnish. 4. Remove the power window switch if equipped. 5. Remove the screws and the fastener. 6. Pull the front door trim toward you, then disengage clips A. 7. Pull the front door trim upward, then disengage hook B.
FASTENER A A A A A SCREW FASTENER A A SCREW A A A A A A HOOK B A CLIP A A A FRONT DOOR TRIM A A B HOOK CLIP A B FRONT DOOR TRIM
7. Extract the inner handle from the rear door trim. 8. Pull the rear door trim upward, then disengage hooks B. 9. Install in the reverse order of removal.
8. Install in the reverse order of removal. REAR DOOR TRIM REMOVAL/INSTALLATION Double cab 1. Disconnect the negative battery cable if equipped with power window. 2. Remove the regulator handle if equipped. 3. Remove the power window switch if equipped. 4. Remove the screws. 5. Remove the ashtray. 6. Pull the door trim toward you, then disengage clips A.
SCREW A A A ASHTRAY A A A A A A B HOOK INNER HANDLE B A CLIP A
REAR DOOR TRIM
CONTINUED
S41
TO. MODEL .INDEX
HEADLINER, FLOOR COVERING
HEADLINER
HEADLINER REMOVAL/INSTALLATION 1. Remove the A-pillar trims. 2. Remove the B-pillar upper trims. (Refer to TRIM, B-PILLAR UPPER TRIM REMOVAL/INSTALLATION, Double Cab.) 3. Remove the quarter upper trims. (Refer to TRIM, QUARTER UPPER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 4. Remove the C-pillar trims. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION, Double Cab.) 5. Remove the assist handle. 6. Remove the rearview mirror. 7. Remove the sunvisors and adapters. 8. Remove the interior light. (Refer to section T, INTERIOR LIGHTING SYSTEM, INTERIOR LIGHT REMOVAL/INSTALLATION.) 9. Remove the fasteners, then remove the headliner.
FLOOR COVERING
FLOOR COVERING REMOVAL/INSTALLATION Regular Cab, Stretch Cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the quarter lower trims. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION, Stretch Cab.) 3. Remove the back lower trim. 4. Remove the front seats. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Regular Cab.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) 5. Remove the rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 6. Remove the rear console bracket. 7. Remove the lower anchor installation bolts of front seat belts. 8. Remove the front side trims. 9. Remove the air outlet ducts. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 10. Remove the footrest. 11. Remove the fasteners, then remove the floor covering.
HEADLINER
FASTENER
ASSIST HANDLE FASTENER
ADAPTER SUNVISOR
10. Remove the headliner from the vehicle through the passenger-side door.
FLOOR COVERING
12. Install in the reverse order of removal. Double cab 1. Remove the dashboard member. (Refer to DASHBOARD AND CONSOLE, DASHBOARD MEMBER REMOVAL/INSTALLATION.) 2. Remove the B-pillar lower trims. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION.) 3. Remove the C-pillar trims. (Refer to TRIM,C-PILLAR TRIM REMOVAL/INSTALLATION)
HEADLINER
CONTINUED
S42
TO. MODEL .INDEX
FLOOR COVERING
4. Remove the front seats and rear seat. (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Front.) (Refer to SEAT, SEAT REMOVAL/INSTALLATION, Stretch Cab, Double cab, Rear.) 5. Remove the rear console bracket. 6. Remove the lower anchor installation bolts of front seat belts and rear seat belts. 7. Remove the front side trim. 8. Remove the air outlet duct. (Refer to section U, BASIC SYSTEM, AIR OUTLET DUCT REMOVAL/INSTALLATION.) 9. Remove the footrest. 10. Remove the fasteners, then remove the floor covering.
Type 1 FASTENER
FLOOR COVERING Type 2 FLOOR COVERING FASTENER
CONTINUED
S43
TO. MODEL .INDEX
SEAT BELT
SEAT BELT
SEAT BELT REMOVAL/INSTALLATION Caution D The ELR has a spring that will unwind if the retractors cover is removed. The spring cannot be rewound by hand. If this occurs, the ELR will not work properly. Therefore, do not disassemble the retractor. Regular Cab Drivers side and passengers side 1. Remove the B-pillar trim if equipped with a B-pillar trim. (Refer to TRIM, B-PILLAR TRIM REMOVAL/INSTALLATION, Regular Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Stretch Cab Front 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
3978 {3.98.0, 2957}
3978 {3.98.0, 2957}
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
1 2
3978 {3.98.0, 2957}
Anchor cover Seat belt
Nm {kgfm, ftlbf}
Rear 1. Remove the quarter lower trim. (Refer to TRIM, QUARTER LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 3
Anchor cover Retractor cover (if equipped) Seat belt
Except drivers side and passengers side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
Seat belt
CONTINUED
S44
TO. MODEL .INDEX
SEAT BELT
Rear 1. Remove the C-pillar trim. (Refer to TRIM, C-PILLAR TRIM REMOVAL/INSTALLATION.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
3978 {3.98.0, 2957}
3978 {3.98.0, 2957}
3978 {3.98.0, 2957}
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
1 2

Nm {kgfm, ftlbf}
Double Cab Front 1. Remove the B-pillar lower trim. (Refer to TRIM, B-PILLAR LOWER TRIM REMOVAL/INSTALLATION, Double Cab.) 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
3978 {3.98.0, 2957}
1 2
SEAT BELT INSPECTION Belt 1. Inspect the webbing for scars, tears, and wear. 2. Inspect the fitting for deformation or damage. 3. If a problem is found, replace the seat belt. ELR 1. Verify that the belt can be pulled out smoothly, and that it moves smoothly when worn. 2. Verify that the retractor locks when the belt is quickly pulled.
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
1 2
3. Remove the retractor. 4. Make sure that the seat belt does not lock when the retractor is tilted slowly up to 15 from the mounted position. Make sure that the seat belt locks when the retractor is tilted 40 or more.
CONTINUED
S45
TO. MODEL .INDEX
SEAT BELT
RETRACTOR
3978 {3.98.0, 2957} Nm {kgfm, ftlbf}
5. If any of the above-mentioned steps are not as specified, replace the seat belt. BUCKLE REMOVAL/INSTALLATION Bench Seat Drivers side and passengers side 1. Disconnect the negative battery cable. 2. Remove as indicated in the table. 3. Install in the reverse order of removal.
3978 {3.98.0, 2957}
Front buckle
Stretch Cab Rear 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Rear buckle
Buckle
Except drivers side and passengers side Except Europe and UK 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
3978 {3.98.0, 2957}
Double Cab Rear 1. Remove the seat cushion. (Refer to SEAT, REAR SEAT REMOVAL/INSTALLATION, Double Cab.) 2. Remove as indicated in the table. 3. Install in the reverse order of removal.
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Buckle
Rear buckle
Bucket Seat Front 1. Disconnect the negative battery cable. 2. Remove the side cover. (Refer to SEAT, FRONT SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
CONTINUED
S46
BACK.TO.CHAPTER.INDEX SEAT BELT

BUCKLE SWITCH INSPECTION
TO. MODEL .INDEX
1. Disconnect the negative battery cable. 2. Disconnect the buckle switch connector. 3. Inspect for continuity between the buckle switch terminals using an ohmmeter.
4. If not as specified, replace the buckle.
CONTINUED
S-47
TO. MODEL .INDEX
SEAT
SEAT
FRONT SEAT REMOVAL/INSTALLATION Bench Seat 1. Remove as indicated in the table. 2. Install in the reverse order of removal.
Bucket Seat 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
3563 {3.56.5, 2647} 3563 {3.56.5, 2647}
3563 {3.56.5, 2647} 3563 {3.56.5, 2647} Nm {kgfm, ftlbf} Nm {kgfm, ftlbf}
1 2 3
Connector Cover Front seat + Installation note
Front seat + Installation note
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure.
FRONT
Front seat installation note 1. To install the seat, tighten the bolts in the order indicated in the figure.
FRONT
LEFT SIDE
RIGHT SIDE
DOOR SIDE
TUNNEL SIDE
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
2. Verify that the seat slider is securely locked in position before fully tightening the bolts. 3. After installing the seat, slide it forward and backward and verify that the seat slider securely locks in position.
CONTINUED
S48
TO. MODEL .INDEX
SEAT
FRONT SEAT DISASSEMBLY/ASSEMBLY Bench Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
A
3246 {3.24.7, 2433}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7
Headrest Pole guide Recliner lever Side cover Lower cover Seat back trim Seat back pad
8 9 10 11 12 13 14
Seat back frame Seat cushion trim Seat cushion pad Seat cushion frame Cable Slide adjuster Connecting rod
CONTINUED
S49
TO. MODEL .INDEX
SEAT
Bucket Seat 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. When removing the cable (passengers seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
3978 {3.98.0, 2957}
PASSENGERS SEAT
3753 {3.75.5, 2739}
B A
C B
3978 {3.98.0, 2957}
Nm {kgfm, ftlbf}
1 2 3 4 5 6 7 8 9 10
Headrest Recliner lever Side cover Front buckle Spring (stretch cab) Cable (stretch cab) Wire Connecting rod Slide adjuster No.1 Slide adjuster No.2
11 12 13 14 15 16 17 18 19
Slide adjuster No.3 Pole guide Seat back trim Seat back warmer unit (Europe only) Seat back pad Seat cushion trim Seat cushion warmer unit (Europe only) Seat cushion pad Seat cushion frame
CONTINUED
S50
TO. MODEL .INDEX
SEAT
CABLE ADJUSTMENT D Verify the slide adjuster slides and locks smoothly when the slide adjuster lever is operated.
SEAT BACK
LEVER
BOLT SLIDE LOCK LEVER

1622 {1.62.3, 1216}
SCREW
REAR SEAT REMOVAL/INSTALLATION Stretch Cab Seat back 1. Remove the back upper trim. 2. Remove the bolts. 3. Lift the seat back up in the direction of the arrow, then unhook it from the body.
Hinge 1. Remove the back lower trim. (Refer to TRIM, BACK LOWER TRIM REMOVAL/INSTALLATION.) 2. Remove the fasteners, and then turn over the floor covering. 3. Remove the bolts, and then remove the hinge.
BOLT
1622 {1.62.3, 1216}
HOOK
SEAT BACK
HOOK
HOOK HINGE
BOLT
6.879.80 {70100, 60.886.7} Nm {kgfm, ftlbf}
Nm {kgfcm, inlbf}
Seat cushion 1. Lift up the rear seat cushion. 2. Remove the screws. 3. Remove the bolts, and then remove the seat cushion.
CONTINUED
S51
TO. MODEL .INDEX
SEAT
Double Cab 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal.
3563 {3.56.5, 2647}
1 2
Seat cushion trim Seat cushion pad
PULL
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
1622 {1.62.3, 1216}
3563 {3.56.5, 2647} Nm {kgfm, ftlbf}
1 2 3 4
Seat cushion Seat back + Installation note Hinge Striker
Seat back installation note D After installing the seat back, verify that it securely locks to the striker. REAR SEAT DISASSEMBLY/ASSEMBLY Stretch Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
CONTINUED
S52
TO. MODEL .INDEX
SEAT
Double Cab 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3 4 5
Headrest Pole guide Seat back trim Seat back pad Rear back catch
6 7 8 9 10
Side cover Stopper Seat back frame Seat cushion trim Seat cushion pad
CONTINUED
S53
TO. MODEL .INDEX
SEAT
SEAT WARMER SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the seat warmer switch and pull it forward to remove it. 3. Disconnect the seat warmer switch connector, and then remove the seat warmer switch. SEAT WARMER UNIT INSPECTION 1. Remove the front seat. (Refer to FRONT SEAT REMOVAL/INSTALLATION, Bucket Seat.) 2. Inspect seat warmer unit at roor temperature of 20 C {68 F}. 3. Apply battery positive voltage to the seat warmer unit terminal A, connect the ground to terminal B, and measure the temperature of the thermometal switch with a thermometer.
A HOOK
A B SEAT WARMER SWITCH B
CONNECTOR
SEAT WARMER SWITCH INSTALLATION 1. Connect the seat warmer switch connector. 2. Insert the seat warmer switch in the hole to install it. 3. Connect the negative battery cable. SEAT WARMER SWITCH INSPECTION 1. Remove the seat warmer switch. (Refer to SEAT WARMER SWITCH REMOVAL.) 2. Inspect for continuity between the seat warmer switch terminals using an ohmmeter. : Continuity
Switch position On Off Terminal D C F
THERMOMETER
: Bulb
THERMOMETAL SWITCH
D : F : :
3. If not as specified, replace the seat warmer switch.
4. When the temperature of the thermometal switch is approximately 40 C {104 F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 4.8 to approximately 13.0 . 5. Remove battery positive voltage from seat warmer unit terminals. 6. When the temperature of the thermometal switch is approximately 30 C {86 F}, inspect the resistance between the seat warmer unit terminals using an ohmmeter. Verify that the resistance changes from approximately 13.0 to approximately 4.8 . 7. If any of the above-mentioned steps are not as specified, replace the seat back pad (with seat warmer unit) and seat cushion pad (with seat warmer unit).
CONTINUED
S54
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
BODY ELECTRICAL SYSTEM

PAGE 1 OF 2
POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE SERVICE CAUTION . . . . . . . . . . . . . . . . . MAIN FUSE REMOVAL/INSTALLATION . . . . . IGNITION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . IGNITION SWITCH INSPECTION . . . . . . . . . . . KEY REMINDER SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . KEY REMINDER SWITCH INSPECTION . . . . CIGARETTE LIGHTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . CIGARETTE LIGHTER INSPECTION . . . . . . . EXTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . FRONT COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT AIMING . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PARKING LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT TURN LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LICENSE PLATE LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . COMBINATION SWITCH DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . HAZARD WARNING SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HAZARD WARNING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH REMOVAL . . . . . REAR FOG LIGHT SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT LEVELING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . BACK-UP LIGHT SWITCH INSPECTION . . . . T 3 T 3 T 3 T 3 T 3 T 3 T 4 T 4 T 4 T 5 T 5 T 5 T 5/6 T 6 T 6 T 6 T 6 T 7 T 7 T 7 T 7 T 8 T 8 T 8 T 8 T 8/9 T 9 T 9 T10 T10 T10 T10 T10 T10 T11 T11 FLASHER UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . FLASHER UNIT INSPECTION . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . HEADLIGHT LEVELING ACTUATOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . REAR FOG LIGHT RELAY INSPECTION . . . . RUNNING LIGHT RELAY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . RUNNING LIGHT RELAY INSPECTION . . . . . INTERIOR LIGHTING SYSTEM . . . . . . . . . . . . . . . INTERIOR LIGHT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INTERIOR LIGHT INSPECTION . . . . . . . . . . . . DOOR SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . DOOR SWITCH INSPECTION . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION . . . . . . . . . . . . . . . PANEL LIGHT CONTROL SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WIPER AND WASHER . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WIPER LINK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER TANK REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WASHER MOTOR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER NOZZLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION . . . . . . . WINDSHIELD WIPER AND WASHER SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . WARNING AND INDICATOR SYSTEM . . . . . . . . INSTRUMENT CLUSTER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . INSTRUMENT CLUSTER INSPECTION . . . . . INSTRUMENT CLUSTER REPAIR . . . . . . . . . . T11 T12 T12 T13 T14 T14 T14 T14/15 T16 T16 T16 T17 T17 T17 T18 T19 T19 T19 T19 T19 T20 T20 T20 T20 T20 T20 T21 T21 T21 T21 T22 T22 T22 T22/24 T24
CONTINUED
T1
TO. MODEL .INDEX
POWER SYSTEM

PAGE 2 OF 2
WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION . . . . . . . . . . FUEL GAUGE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . WATER TEMPERATURE SENDER UNIT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PRESSURE SWITCH INSPECTION . . . . . HORN REMOVAL/INSTALLATION . . . . . . . . . . HORN RELAY REMOVAL/INSTALLATION . . . HORN RELAY INSPECTION . . . . . . . . . . . . . . . CLOCK REMOVAL/INSTALLATION . . . . . . . . . AUDIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AUDIO UNIT REMOVAL . . . . . . . . . . . . . . . . . . . AUDIO UNIT INSTALLATION . . . . . . . . . . . . . . . SPEAKER REMOVAL/INSTALLATION . . . . . . . SPEAKER INSPECTION . . . . . . . . . . . . . . . . . . . ROOF ANTENNA REMOVAL . . . . . . . . . . . . . . . ROOF ANTENNA INSTALLATION . . . . . . . . . . ROOF ANTENNA INSPECTION . . . . . . . . . . . . ANTENNA FEEDER REMOVAL/INSTALLATION . . . . . . . . . . . . . . . ANTENNA FEEDER INSPECTION . . . . . . . . . . CONDENSER REMOVAL/INSTALLATION . . . T24 T24/25 T25 T25 T25 T25 T25 T25/26 T26 T26 T26 T26 T26 T26/27 T27 T27 T27 T27/28 T28 T28 T28
CONTINUED
T2
TO. MODEL .INDEX
POWER SYSTEM
POWER SYSTEM
FUSE SERVICE CAUTION Caution D Determine and correct the cause of the burnt fuse before replacing it with the specified type. If the fuse is replaced before doing this, it may burn again. MAIN FUSE REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
G6, WL, WL TURBO, F2 CIS
IGNITION SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the ignition switch connectors. 3. Inspect for continuity between the ignition switch terminals using an ohmmeter. : Continuity
Ignition g key y position LOCK ACC ON START Terminal 2A 2B 1D 1C 1B 1A
2A START
2B
2B
123456567
2A
START LOCK LOCK ON ON ACC ACC 1A 1B 1C 1D
1C 1D
1A 1B
F2 CARB
4. If not as specified, replace the ignition switch. KEY REMINDER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the key reminder switch connector. 4. Remove the key reminder switch.
KEY REMINDER SWITCH
1 2 3
Nut Bolt Main fuse

STEERING LOCK
IGNITION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the ignition switch connectors. 4. Remove the screw to remove the ignition switch.
IGNITION SCREW SWITCH CONNECTOR
IGNITION SWITCH
CONTINUED
T3
TO. MODEL .INDEX
POWER SYSTEM
KEY REMINDER SWITCH INSPECTION 1. Remove the column cover. 2. Disconnect the key reminder switch connector. 3. Inspect for continuity between the key reminder switch terminals using an ohmmeter. : Continuity
Key position Inserted Removed
A
Socket Removal Note 1. Pry up the stopper with a tape-wrapped screwdriver. 2. Pull the socket by prying up the stopper.
Terminal A B
CIGARETTE LIGHTER INSPECTION D Verify that the cigarette lighter plug will move normally within 1020 seconds, after pressing the plug into the socket. If the plug does not move, replace the cigarette lighter.
4. If not as specified, replace the key reminder switch. CIGARETTE LIGHTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the center panel. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2 3 4
Cigarette lighter plug Connector Socket + Removal Note Ring
CONTINUED
T4
TO. MODEL .INDEX
EXTERIOR LIGHTING SYSTEM

FRONT COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the headlight aiming. (Refer to HEADLIGHT AIMING.)
If it is difficult to remove front combination light with pliers D Remove the adjusting screws and the screw by loosening them.
ADJUSTING SCREW SCREW
ADJUSTING SCREW
HEADLIGHT AIMING 1. Adjust the tire air pressure to the specification. 2. Position the unloaded vehicle on a level surface. 3. Seat one person in the drivers seat. 4. Start the engine and charge the battery fully. 5. Position the vehicle straight ahead and perpendicularly to a wall. 6. Set the headlights 7.6 m {25 ft} from the wall. 7. While adjusting one headlight, disconnect the connector of the other.
1 2 3 Front combination light connector Front combination light + Removal Note Spring
Front Combination Light Removal Note Removal with pliers Caution D When pressing the hook of the adjusting screws and the screw with the pliers, do not damage the front combination light mounting. 1. Press the hook of the adjusting screws and the screw with the pliers. 2. Pull the front combination light out of the adjusting screws and the screw.
Caution D Always tighten the adjusting screws last. When loosening the adjusting screws, loosen the screws first and then tighten them. If the adjusting screws are tightened first, then loosened, they will continue to loosen when the vehicle is in motion and may cause the headlights to become misaligned. 8. Adjust the headlights by turning the adjusting screws as shown in the figure. Loosen the screws first, then tighten them.
OUTWARD INWARD
ADJUSTING SCREW
HOOK SCREW
UP DOWN
HEADLIGHT BULB REMOVAL/INSTALLATION Caution D A halogen bulb generates extremely high heat when it is used. If the surface of the bulb is soiled, excessive heat will build up and the lights life will be shortened. When replacing the bulb, hold the metal flange, not the glass.
FRONT COMBINATION LIGHT MOUNTING
CONTINUED
T5
TO. MODEL .INDEX

1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 1 2 3 Headlight bulb connector Cover + Installation Note Headlight bulb 3
Screw Front turn light Front turn light connector
Cover Installation Note D Align the TOP mark with top side.
TOP MARK
FRONT TURN LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Socket Front turn light bulb
PARKING LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FRONT SIDE TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
FRONT
1 2
Socket Parking light bulb 1 2 3 4

REAR
FRONT TURN LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Front side turn light Front side turn light connector Socket Front side turn light bulb
CONTINUED
T6
TO. MODEL .INDEX

REAR COMBINATION LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. REAR FOG LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
WITHOUT REAR BUMPER
1 2 3
Screw Rear combination light Rear combination light connector
1 2 3 4
Rear fog light connector Nut Spring washer Rear fog light
REAR COMBINATION LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the rear combination light. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
WITH REAR BUMPER
1 2 3 1 2 3 4 5 Screw Lens + Removal Note Rear turn light bulb Back-up light bulb Brake light/taillight bulb
Rear fog light connector Screw Rear fog light
REAR FOG LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Lens Removal Note D Push the hook upward with your finger.
HOOK
1 2 3
Screw Lens Rear fog light bulb
CONTINUED
T7
TO. MODEL .INDEX

LICENSE PLATE LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. COMBINATION SWITCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3 4 5
Screw License plate light License plate light bulb Socket License plate light connector
1 2 3 4
Screw Windshield wiper and washer switch Light switch Body
COMBINATION SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. For vehicles without air bag system, remove the horn cap. For vehicles with air bag system, remove the driver-side air bag module. (Refer to AIR BAG SYSTEM, DRIVER-SIDE AIR BAG MODULE REMOVAL/INSTALLATION.) 3. Remove the steering wheel. (Refer to section N, MANUAL STEERING, STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION.) 4. For vehicles with air bag system, remove the clock spring. (Refer to AIR BAG SYSTEM, CLOCK SPRING REMOVAL/INSTALLATION.) 5. Remove the column cover. 6. Remove in the order indicated in the table. 7. Install in the reverse order of removal.
LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
1 2 3
Light switch connector Screw Light switch
LIGHT SWITCH INSPECTION Headlight Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.) Note D When the flash-to-pass switch is on, the contact of the low-high switch is at neutral. 2. Inspect for continuity between the light switch terminals using an ohmmeter.
1 2 3
Screw Combination switch Combination switch connector
CONTINUED
T8
TO. MODEL .INDEX

: Continuity
Switch position Light OFF TNS HeadHead light Dimmer Low High
(J) F
3. If not as specified, replace the light switch. HAZARD WARNING SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
Terminal P (B) D (N) L (H) F (J) H (L)
Flashto-pass Off On Off On Off On
( ): Light switch right side lever

(N) D HOOK
OFF OFF TNS FLASH -TO -PASS HIGH HEADLIGHT TNS LOW
HEADLIGHT
Hazard warning switch
H (L)
L (H)
P (B)
HAZARD WARNING SWITCH INSPECTION 1. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Inspect for continuity between the hazard warning switch terminals using an ohmmeter. : Continuity : Bulb
(*)
* (O) P (*)
* (M) N
* (K) L * (J) H
(*)
(*)
Switch position Off On
Terminal F D B A C I K H J
F (*)
* (B)
( ): LIGHT SWITCH RIGHT SIDE LEVER
3. If not as specified, replace the light switch. Turn Switch 1. Remove the light switch. (Refer to LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the light switch terminals using an ohmmeter. : Continuity
Switch position Right Off Left
J A C I B H K F D
Terminal C (M) A (K) E (O)
( ): Light switch right side lever

(M) C K * * * * (M) (O) (K) * H P N L (J) (*) A E
(*)
I J H F
C D
A B
F (*)
(*)
* (B)
(*)
3. If not as specified, replace the hazard warning switch.
(K) (O) ( ): LIGHT SWITCH RIGHT SIDE LEVER
CONTINUED
T9
TO. MODEL .INDEX

REAR FOG LIGHT SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the rear fog light switch and pull it forward to remove it. 3. Disconnect the connector to remove the rear fog light switch. HEADLIGHT LEVELING SWITCH REMOVAL 1. Disconnect the negative battery cable. 2. Insert your hand under the dashboard near the fuse block, grasp the hooks of the headlight leveling switch and pull it forward to remove it. 3. Disconnect the connector to remove the headlight leveling switch.
HOOK CONNECTOR REAR FOG LIGHT SWITCH
HOOK
CONNECTOR HEADLIGHT LEVELING SWITCH
REAR FOG LIGHT SWITCH INSTALLATION 1. Connect the rear fog light switch connector. 2. Insert the rear fog light switch in the hole to install it. 3. Connect the negative battery cable. REAR FOG LIGHT SWITCH INSPECTION 1. Remove the rear fog light switch. (Refer to REAR FOG LIGHT SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the rear fog light switch terminals using an ohmmeter. : Continuity
Switch position Off Neutral On Terminal A D F
HEADLIGHT LEVELING SWITCH INSTALLATION 1. Connect the headlight leveling switch connector. 2. Insert the headlight leveling switch in the hole to install it. 3. Connect the negative battery cable. HEADLIGHT LEVELING SWITCH INSPECTION 1. Remove the headlight leveling switch. (Refer to HEADLIGHT LEVELING SWITCH REMOVAL/INSTALLATION.) 2. Inspect for continuity between the headlight leveling switch terminals using an ohmmeter. : Continuity : Resistance : Bulb
Switch position 0 1 Terminal C D A B
R1+ R2+ R3 R2+R3 R3
2
A F D
3 R1:1600
A
2:
560
3:300
3. If not as specified, replace the rear fog light switch.
3 * C * * D A B * B
R1 R2 R3
3. If not as specified, replace the headlight leveling switch.
CONTINUED
T10
TO. MODEL .INDEX

BACK-UP LIGHT SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
2534 {2.53.4, 1924}
FLASHER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Nm {kgfm, ftlbf}
DRIVER-SIDE FRONT SIDE TRIM
1 2 3
Back-up light switch connector Back-up light switch Gasket
BACK-UP LIGHT SWITCH INSPECTION 1. Disconnect the back-up light switch connector. 2. Inspect for continuity between the back-up light switch terminals using an ohmmeter. : Continuity
Shift lever position Reverse Other Terminal A B 1 2 3 Nut Flasher unit Flasher unit connector
3. If not as specified, replace the back-up light switch.
CONTINUED
T11
TO. MODEL .INDEX

FLASHER UNIT INSPECTION 1. Measure the voltage at the flasher unit terminals as indicated below. 2. Disconnect the flasher unit connector before inspecting for continuity at terminal C. 3. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses. 4. If the parts and wiring harnesses are okay but the system still does not work properly, replace the flasher unit. Terminal Voltage List (Reference) B+: Battery positive voltage
A C B
Terminal
Signal
Connection
Test condition Hazard warning switch on
Voltage (V) /Continuity Alternates B+ and 0 B+ 0 B+ B+ 0 Yes
Inspection area
Flasher unit out ut output
Hazard warning switch
Hazard warning switch off
Ignition switch at ON position Ignition switch at LOCK or ACC position Ignition switch at ON position Ignition switch at LOCK or ACC position
D Hazard
warning switch
D Turn signal
light
Hazard warning switch on B Power supply su ly Hazard warning switch
D HAZARD 10 A
fuse
D METER 15 A
Hazard warning switch off
fuse
D Hazard
warning switch GND
Flasher unit ground
GND
Constant: inspect for continuity to ground
HEADLIGHT LEVELING ACTUATOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the radiator grille. (Refer to section S, EXTERIOR ATTACHMENT, RADIATOR GRILLE REMOVAL/INSTALLATION.) 3. Remove the front turn light. (Refer to FRONT TURN LIGHT REMOVAL/INSTALLATION.) 4. Remove the front combination light. (Refer to FRONT COMBINATION LIGHT REMOVAL/INSTALLATION.) 5. Remove the headlight leveling actuator connector from the bracket. 6. Disconnect the headlight leveling actuator connector. 7. Remove the nuts. 8. Remove the headlight leveling actuator.
HEADLIGHT LEVELING ACTUATOR
HEADLIGHT LEVELING ACTUATOR CONNECTOR
CONTINUED
T12
TO. MODEL .INDEX

HEADLIGHT LEVELING ACTUATOR INSPECTION 1. Measure the voltage at the headlight leveling actuator terminals as indicated below. Note D Because the headlight leveling actuator connector is waterproof, it is impossible to measure the voltage at the headlight leveling actuator terminals. When inspecting, measure the voltage at the terminal of the part which is connected to the headlight leveling actuator. (1) To measure the voltage at the terminal A of the headlight leveling actuator, remove the column cover and measure the voltage at the terminal N of the light switch connector. (Refer to LIGHT SWITCH INSPECTION.) (2) To measure the voltage at the terminal B of the headlight leveling actuator, remove the headlight leveling switch with the connector connected and measure the voltage at the terminal C of the headlight leveling switch connector. (Refer to HEADLIGHT LEVELING SWITCH INSPECTION.) (3) Disconnect the headlight leveling actuator connector before inspecting for continuity at terminal C. 2. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses. 3. If the parts and wiring harnesses are okay but the system still does not work properly, replace the headlight leveling actuator. Terminal Voltage List (Reference) B+: Battery positive voltage
Terminal
Signal Headlight leveling g actuator power supply
Connection
Test condition Headlight illuminated Headlight unilluminated Headlight leveling switch at 0
Voltage ( V ) /Continuity B+
Inspection area
Combination switch
Combination switch 0 6.2 4.2 Headlight leveling switch 2.1 0
Headlight leveling switch position
g Headlight leveling switch
g Headlight switch on
Headlight leveling switch at 1 Headlight leveling switch at 2 Headlight leveling switch at 3
Headlight leveling actuator ground
GND
Constant : inspect for continuity to ground
Yes
GND
CONTINUED
T13
TO. MODEL .INDEX

REAR FOG LIGHT RELAY REMOVAL/INSTALLATION Note D Because the lock section of the relay is damaged easily, do not remove the relay from the bracket unless replacement is necessary. Always perform an inspection of the rear fog light relay before removal. 1. Disconnect the negative battery cable. 2. Disconnect the rear fog light relay connector. 3. Remove the rear fog light relay by prying the lock section of the upper part with a flathead screwdriver. RUNNING LIGHT RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the washer tank from the bracket. 3. Remove the running light relay with the cover attached.
NUT
RUNNING LIGHT RELAY WITH COVER
REAR FOG LIGHT RELAY
4. Remove the cover. 5. Disconnect the running light relay connector.

COVER
BRACKET
REAR FOG LIGHT RELAY CONNECTOR
RUNNING LIGHT RELAY
4. Install in the reverse order of removal. REAR FOG LIGHT RELAY INSPECTION 1. Remove the bracket and pull it toward you. 2. Inspect for continuity between the rear fog light relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
Step 1 2 B+ GND Terminal A B C D
RUNNING LIGHT RELAY CONNECTOR
6. Install in the reverse order of removal. RUNNING LIGHT RELAY INSPECTION 1. Remove the running light relay. (Refer to RUNNING LIGHT RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the running light relay terminals using an ohmmeter. : Continuity : Diode
Test cond condi tion Constant Terminal A B C D E F
A C D A B
B B C A
3. If not as specified, replace the rear fog light relay.

E F C D A B
CONTINUED
T14
TO. MODEL .INDEX

3. Connect the terminal A to the positive battery terminal and the terminal D to the negative battery terminal. 4. Verify that there is continuity between terminals A and E, and that there is no continuity between terminals B and F.
B C A
E F
C D
A B
5. Connect the terminal C to the positive battery terminal and the terminal D to the negative battery terminal. 6. Verify that there is no continuity between terminals B and F, and between terminals A and E.
B C A
E F
C D
A B
7. If not as specified, replace the running light relay.
CONTINUED
T15
TO. MODEL .INDEX
INTERIOR LIGHTING SYSTEM

INTERIOR LIGHT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
ALL VEHICLES EXCEPT REGULAR CAB
Interior Light Installation Note Regular cab Note D The spacer acts as a ground. If the spacer is not installed in the position shown in the figure, the interior light may not illuminate.
REGULAR CAB
1. Tighten the screw fully. (More than 4 mm {0.2 in} of thread should be exposed.) 2. Install the interior light.
SCREW
4.0 mm {0.2 in}
1 2 3 4 5 6
Lens + Removal Note Interior light bulb Screw Spacer Interior light + Installation Note Interior light connector
SPACER INTERIOR LIGHT
INTERIOR LIGHT INSPECTION 1. Remove the interior light. (Refer to INTERIOR LIGHT REMOVAL/INSTALLATION.) 2. Inspect for continuity between the interior light terminals using an ohmmeter. : Bulb
Step ON DOOR OFF
B
Lens Removal Note All vehicles except regular cab 1. Insert a tape-wrapped flathead screwdriver into the lens. 2. Twist the screwdriver to remove the lens.
Terminal A B Body GND
A OFF DOOR ON
Regular cab D Push the areas indicated by the arrows to pull out the lens.
3. If not as specified, replace the interior light.
CONTINUED
T16
TO. MODEL .INDEX

DOOR SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
Panel light control switch
1 2 3
Screw Door switch Door switch connector
DOOR SWITCH INSPECTION 1. Remove the door switch. 2. Inspect for continuity between the door switch terminals using an ohmmeter. : Continuity
Switch condition Pressed Released Terminal A Body GND
BODY GND
3. If not as specified, replace the door switch. PANEL LIGHT CONTROL SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
HOOK
CONTINUED
T17
TO. MODEL .INDEX

PANEL LIGHT CONTROL SWITCH INSPECTION 1. Remove the meter hood without disconnecting the panel light control switch connector. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 2. Measure the voltage at the panel light control switch as indicated below. 3. Disconnect the panel light control switch connector before inspecting for continuity at terminal G. 4. If not as specified, inspect the parts listed under Inspection area and the related wiring harnesses. 5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the panel light control switch. Terminal Voltage List (Reference) B+: Battery positive voltage
G H F D A B
Terminal A B D F G H
Signal Panel light control output Power supply Panel light control switch ground
Connection Each illumination Not used g switch Light Not used GND Not used
Test condition Inspect using an oscilloscope + A terminal inspection Headlight switch at TNS or headlight position Headlight switch at OFF position Constant: Inspect for continuity to ground
Voltage (V)/ Continuity B+ 0 Yes
Inspection area Each illumination

D Light switch D TAIL 10 A fuse
GND
A Terminal Inspection 1. Measure the wave pattern of the A terminal on the panel light control switch using an oscilloscope.
PANEL LIGHT CONTROL SWITCH
OSCILLOSCOPE
2. Set the headlight switch to either the TNS or headlight position. 3. Set the panel light control switch to the brightest position. 4. Verify that the pattern of the screen is as shown in the figure.
5. Verify that the pattern on the screen matches the pattern shown in the figure as the panel light control switch is gradually turned to the darkest position.
V B+ 0
13.2 ms 515.4 ms
CONTINUED
T18
TO. MODEL .INDEX
WIPER AND WASHER
WIPER AND WASHER

WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Loosen the bolts. 4. Pull the windshield wiper motor forward until the connection between the windshield wiper motor and windshield wiper link is in the engine room. 5. Pry off the connection between the windshield wiper motor and windshield wiper link. 6. Remove the windshield wiper motor.
WINDSHIELD WIPER MOTOR
WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION 1. Remove in the order indicated in the table. 2. Install in the reverse order of removal. 3. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)
1619 {1.62.0, 1214}
Nm {kgfm, ftlbf}
CONNECTOR
1
WINDSHIELD WIPER LINK
Cap Nut Windshield wiper arm + Installation Note Windshield wiper blade Rubber brush
2
BOLT
4.06.8 {4070, 3560} Nm {kgfcm, inlbf}
3 4
7. Install in the reverse order of removal. WINDSHIELD WIPER MOTOR INSPECTION 1. Disconnect the windshield wiper motor connector. 2. Connect battery positive voltage and inspect the operation of the windshield wiper motor as indicated below.
Terminal A C Operation High Low
Windshield Wiper Arm Installation Note D Clean the windshield wiper arm connector shafts with a wire brush before installing the windshield wiper arms.
WINDSHIELD WIPER ARM CONNECTOR SHAFT
A B
C D
3. Connect battery positive voltage to terminal C of the windshield wiper motor to operate the windshield wipers at low speed. 4. Disconnect battery positive voltage from terminal C of the motor while the wipers are operating. 5. Verify that the wipers do not stop in the park position. 6. Short between terminal C and B of the motor, and connect battery positive voltage to terminal D of the motor. 7. Verify that the wipers operate at low speed again, then stop in the park position. 8. If not as specified, replace the windshield wiper motor.
WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT 1. Operate the windshield wiper motor to set the windshield wipers in the park position. 2. Align both ends of the wiper blades to the marks on the ceramic section.
CERAMIC SECTION
MARK
CONTINUED
T19
TO. MODEL .INDEX
WIPER AND WASHER

WINDSHIELD WIPER LINK REMOVAL/INSTALLATION 1. Remove the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE REMOVAL/INSTALLATION.) 2. Remove the cowl grille. 3. Remove the windshield wiper motor. (Refer to WINDSHIELD WIPER MOTOR REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. 6. Adjust the windshield wiper arm and blade. (Refer to WINDSHIELD WIPER ARM AND BLADE ADJUSTMENT.)
6.879.80 {70100, 60.886.7}
1 2
Windshield washer motor Grommet
WINDSHIELD WASHER MOTOR INSPECTION 1. Disconnect the windshield washer motor connector. 2. Connect battery positive voltage to terminal B and ground to terminal A of the motor. 3. Verify that the windshield washer motor operates.
B
Nm {kgfcm, inlbf}
1 2
Bolt Windshield wiper link
M A
WINDSHIELD WASHER TANK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Disconnect the windshield washer pipe from the windshield washer motor. 4. Pull the windshield washer tank up and slide it off the bracket.
B A
4. If the motor does not operate, replace the windshield washer motor. WINDSHIELD WASHER NOZZLE REMOVAL 1. Disconnect the windshield washer pipe from the windshield washer nozzle. 2. Remove the windshield washer nozzle using a 10 mm {0.4 in} deep socket wrench from underneath the bonnet.
DEEP SOCKET WRENCH WINDSHIELD WASHER NOZZLE
WINDSHIELD WASHER TANK
CONNECTOR WINDSHIELD WASHER PIPE
BRACKET
5. Install in the reverse order of removal. WINDSHIELD WASHER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the windshield washer tank. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
WINDSHIELD WASHER NOZZLE INSTALLATION 1. Connect the windshield washer pipe to the windshield washer nozzle. 2. Push the windshield washer nozzle into the installation hole. 3. Adjust the windshield washer nozzle. (Refer to WINDSHIELD WASHER NOZZLE ADJUSTMENT.)
CONTINUED
T20
TO. MODEL .INDEX
WIPER AND WASHER

WINDSHIELD WASHER NOZZLE ADJUSTMENT D Insert a needle or equivalent tool into the spray holes of the windshield washer nozzle and adjust the nozzle direction as shown.
SCREW
CENTER
WINDSHIELD WIPER AND WASHER SWITCH
320 {12.6}
390 {15.4}
CONNECTOR
100 100 {3.9} {3.9}
6. Install in the reverse order of removal. WINDSHIELD WIPER AND WASHER SWITCH INSPECTION 1. Remove the column cover. 2. Remove the windshield wiper and washer switch. 3. Inspect for continuity between the windshield wiper and washer switch terminals using an ohmmeter. : Continuity
Switch position Onetouch Off On Terminal L(F) G(E ) M(C ) N(D ) C(M )
290 {11.4} 290 {11.4}
270 {10.6}
180 {7.1}
MOLDING END LINE
WINDSHIELD GLASS END LINE
123
mm {in}
OFF Wiper switch INT LO HI Washer switch On
WINDSHIELD WASHER PIPE REMOVAL/INSTALLATION 1. Disconnect the windshield washer pipe from the windshield washer nozzle and the windshield washer motor. 2. Remove the clips. 3. Remove the windshield washer pipe.
( ): Wiper and washer switch left side lever

(D) N ONE-TOUCH WIPER SWITCH HI OFF LO INT
HI LO CLIP WINDSHIELD WASHER PIPE INT RELAY H (J) L (F)
OFF INT
4. Install in the reverse order of removal. WINDSHIELD WIPER AND WASHER SWITCH REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the column cover. 3. Disconnect the connector. 4. Remove the screws. 5. Remove the windshield wiper and washer switch.
M (C)
G (E)
C (M) WASHER SWITCH
0 (*) *
M N (*) L (*) * (J)
G (*) H (*)
* (E) * (F)
C * (D)
* (A) *
( ): WIPER AND WASHER SWITCH LEFT SIDE LEVER
4. If not as specified, replace the windshield wiper and washer switch.
CONTINUED
T21
TO. MODEL .INDEX
WARNING AND INDICATOR SYSTEM

INSTRUMENT CLUSTER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
INSTRUMENT CLUSTER INSPECTION Speedometer 1. Adjust the tire air pressure to the specification. 2. Using a speedometer tester, verify that the speedometer indication is within the allowable range indicated in the table.
Speedometer tester p indication (km/h) 20 40 60 80 100 120 140 160 180 Allowable range (km/h) 1822 3644 5466 7288 90110 108132 126154 144176 162198
1 2 3
Screw Instrument cluster connector Instrument cluster
3. Verify that fluctuation of the speedometer needle is within the allowable range. Needle fluctuation allowable range Within 0.5 km/h 4. If the speedometer needle does not move or if the indication is outside of the allowable range, inspect the vehicle speedometer sensor and related wiring harness. 5. If the vehicle speedometer sensor and related wiring harness are normal, replace the instrument cluster. Tachometer Using the SSTs (NGS kit) or a dwell tacho tester Caution D If the engine speed exceeds the allowable range, the engine could be damaged. Therefore, when inspecting the tachometer, do not allow the engine speed to exceed the allowable range indication on the tachometer. 1. Follow the appropriate procedure for using the SSTs (NGS kit) or dwell tacho tester.
INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY Caution D If the print plate on the back of the instrument cluster is damaged, the system will not operate properly and it may become the cause of trouble or malfunction. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
1 2 3 4 5
Screw Bulb Alarm Front lens Instrument cluster
Using the SSTs (NGS kit) (1) Connect the SSTs (NGS kit) to the data link connector and battery.
DIAGNOSTIC PROGRAM CARD
NGS KIT
CONTINUED
T22
TO. MODEL .INDEX

(2) Select VEHICLE & ENGINE SELECTION and press TRIGGER. (Select the model and specifications of the vehicle you are testing.) (3) Select PCM-POWERTRAIN CTRL MODULE and press TRIGGER. (4) Select PID/DATA MONITOR AND RECORD and press TRIGGER. (5) Select RPM and press TRIGGER. (6) Press START. Using a dwell tacho tester D Connect a dwell tacho tester to the terminals K and B of the PCM connector. 2. Verify that the tachometer indication is within the allowable range indicated in the table.
Dwell tacho tester indication (rpm) 650 1000 2000 3000 4000 Allowable range (rpm) 583705 9261060 19542120 29803180 40084240
: Resistance
Step 1 2 Terminal FUEL + FUEL R1 R2 GND COM
R1, R2: 140200
GND FUEL+ COM FUEL
12. Verify that the difference in resistance between R1 and R2 is less than 6 . 13. If not as specified, replace the instrument cluster. Water Temperature Gauge 1. Disconnect the water temperature sender unit connector. 2. Turn the ignition switch to ON position. 3. Verify that the needle is below C. 4. Ground terminal A of the water temperature sender units vehicle side connector.
3. If the tachometer needle does not move or if the indication is outside of the allowable range, inspect the PCM and related wiring harness. 4. If the PCM and related wiring harness are normal, replace the instrument cluster. Fuel Gauge 1. Disconnect the fuel gauge sender unit connector. 2. Connect the red lead of SST (Fuel And Thermometer checker) to terminal B of the fuel gauge sender unit connector and black lead to ground. 3. Set the resistance of SST (Fuel And Thermometer checker) to 180 .
49 N088 0A0 49 0839 285
*
5. Verify that the needle is above H. 6. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 7. Measure the resistance between the water temperature gauge terminals using an ohmmeter. : Resistance
Step 1 2 Terminal TEMP + TEMP R1 V+ COM R2
4. Turn the ignition switch to ON position. 5. Verify that the needle is below E. 6. Turn the ignition switch to LOCK position. 7. Set the resistance of SST (Fuel And Thermometer checker) to 10 . 8. Turn the ignition switch to ON position. 9. Verify that the needle is above F. 10. If the needle does not move or moves irregularly, remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 11. Measure the resistance between the fuel gauge terminals using an ohmmeter.
R1, R2: 140200
CONTINUED
T23
TO. MODEL .INDEX

WARNING AND INDICATOR LIGHT BULB REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the instrument cluster. (Refer to INSTRUMENT CLUSTER REMOVAL/INSTALLATION.) 3. Turn the socket counterclockwise to remove the bulb as shown in the figure.
TEMP
TEMP+ COM
V+
8. Verify that the difference in resistance between R1 and R2 is less than 6 . 9. If not as specified, replace the instrument cluster. INSTRUMENT CLUSTER REPAIR Note D The needle of speedometer or tachometer may continue to rotate clockwise until it rests on the mask plate. If a customer complains of this concern, repair the needle position according to the following steps. 1. Verify the concern.
TACHOMETER SPEEDOMETER
BULB
4. Install in the reverse order of removal. FUEL GAUGE SENDER UNIT INSPECTION 1. For G6, F2 CIS, or F2 Carb engine vehicles, remove the fuel pump unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) For WL or WL Turbo engine vehicles, remove the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) 2. Using an ohmmeter, measure and verify that the resistance between terminals B and C (WL, WL Turbo) or A and B (G6, F2 CIS, F2 Carb) of the fuel gauge sender unit is as shown in the following chart while slowly moving the unit arm from empty to full.
Measuring point Resistance () 18.426.4 81.593.5 136154
* DOUBLE CAB 2WD, STRETCH CAB 2WD
2. Turn the ignition switch to LOCK position. 3. Remove the ROOM fuse, then wait for 10 minutes or more until the power supply in the instrument cluster is spent. 4. Turn the ignition switch to ON position. 5. Verify that the needle returns to zero.
TACHOMETER SPEEDOMETER
Full 1/2 Empty
WL, WL TURBO
87.0 {3.43} * 65.5 {2.58}
FULL
169.7 {6.681} * 158.1 {6.224}
1/2
253.7 {9.988}
* B C
mm {in}
EMPTY
6. After the needle returns to zero, install the ROOM fuse with the ignition switch at ON position. If the needle does not return to zero, remove the front lens and carefully move the needle to zero by hand. (Refer to INSTRUMENT CLUSTER DISASSEMBLY/ASSEMBLY.)
CONTINUED
T24
TO. MODEL .INDEX

WATER TEMPERATURE SENDER UNIT INSPECTION 1. Remove the water temperature sender unit. 2. Place the sender unit in a container of water. 3. Heat the water gradually. 4. Using an ohmmeter, measure and verify that the resistance between terminal of the sender unit and the sender unit body is as shown below.
A B
mm {in}
G6, F2 CIS, F2 CARB

67.5 {2.66}
FULL
160.1 {6.303}
1/2
255.7 {10.067}
Water temperature (C {F }) 49.850.2 {121.7122.3}
Resistance () 189.4259.6
EMPTY
3. If not as specified, replace the fuel gauge sender unit. (Refer to section F2, FUEL SYSTEM, FUEL TANK REMOVAL/INSTALLATION.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT DISASSEMBLY/ASSEMBLY.) (Refer to section F2, FUEL SYSTEM, FUEL PUMP UNIT REMOVAL/INSTALLATION.) WATER TEMPERATURE SENDER UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Disconnect the connector. 3. Remove the water temperature sender unit.
CONNECTOR
5. If not as specified, replace the water temperature sender unit. OIL PRESSURE SWITCH INSPECTION 1. Verify that the oil pressure warning light illuminates when the ignition switch is turned to ON position. 2. Verify that the oil pressure warning light goes off when the engine is started. 3. If the oil pressure warning light does not illuminate or remains illuminated, inspect the oil pressure warning light bulb and related wiring harness. 4. If the oil pressure warning light bulb and related wiring harness are normal, inspect the oil pressure. (Refer to section D, LUBRICATION SYSTEM, OIL PRESSURE INSPECTION.) 5. If the oil pressure is normal, replace the oil pressure switch. HORN REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Disconnect the horn connector. 3. Remove the bolt. 4. Remove the horn.
WATER TEMPERATURE SENDER UNIT
WATER TEMPERATURE SENDER UNIT INSTALLATION 1. Apply sealant from the third thread to the top thread.
BOLT THIRD THREAD

68 {0.240.31}
mm { in }
2. Install the water temperature sender unit. Tightening torque 11.817.6 Nm {120180 kgfcm, 105156 inlbf} 3. Connect the water temperature sender unit connector. 4. Connect the negative battery cable.
HORN
HORN CONNECTOR
5. Install in the reverse order of removal. HORN RELAY REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.)
T25
CONTINUED
TO. MODEL .INDEX
WARNING AND INDICATOR SYSTEM, AUDIO

3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
AUDIO
AUDIO UNIT REMOVAL 1. Disconnect the negative battery cable. 2. With the beveled parts of the SST (Removing tool) facing inward, insert them into the unit. 3. Pull the SST (Removing tool) outward and rearward to slide out the unit.
49 D066 801A
1 2 3
Nut Horn relay connector Horn relay
HORN RELAY INSPECTION 1. Remove the horn relay. (Refer to HORN RELAY REMOVAL/INSTALLATION.) 2. Inspect for continuity between the horn relay terminals using an ohmmeter. : Continuity B+: Battery positive voltage
4. Disconnect the connectors and antenna jack. AUDIO UNIT INSTALLATION Caution D If the harness or the antenna feeder is caught between the unit and dashboard, it may become the cause of trouble or malfunctions. Make certain that the wiring harness and antenna feeder are not caught between the unit and dashboard. 1. Connect the connectors and antenna jack. 2. Insert the unit until each clip clicks. 3. Connect the negative battery cable.
A C D A B
SPEAKER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the front door trim. (Refer to section S, TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.) Caution D When removing or installing a speaker, touching the radio cone paper could cause poor sound quality. When removing or installing a speaker, hold the speakers bracket and handle with care. 3. Remove in the order indicated in the table. 4. Install in the reverse order of removal.
3. If not as specified, replace the horn relay. CLOCK REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the meter hood. (Refer to section S, DASHBOARD AND CONSOLE, METER HOOD REMOVAL/INSTALLATION.) 3. Remove the screws and remove the clock.
SCREW CLOCK SCREW
CONTINUED
T26
TO. MODEL .INDEX
AUDIO
1 2 3
Screw Speaker + Installation Note Connector
SCREW
Speaker Installation Note D When installing the speakers, position the speakers so that the terminals face downward.
ROOF ANTENNA
SPEAKER INSPECTION 1. Remove the speaker. (Refer to SPEAKER REMOVAL/INSTALLATION.) 2. Inspect for resistance between the speaker terminals using an ohmmeter. : Resistance
Test condition Constant Terminal A B R
ROOF ANTENNA INSTALLATION 1. Tape the antenna jack to the antenna drain hose.
R: 4
123456567
3. Touch the leads of an ohmmeter to the speaker terminals and verify that the speaker clicks. Range 1 4. If not as specified, replace the speaker. ROOF ANTENNA REMOVAL 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeder.
2. Pass the roof antenna and antenna drain hose through the A-pillar from the hole in the roof. 3. Connect the antenna feeder. 4. Install the screws. 5. Install the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 6. Connect the negative battery cable. ROOF ANTENNA INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the roof antenna and the antenna feeeder. 4. Verify that there is no continuity between roof antenna terminals A and B using an ohmmeter. 5. Inspect for continuity between the roof antenna terminals using an ohmmeter. : Continuity
Step 1 2 Terminal A B C D
ANTENNA FEEDER
C D
ROOF ANTENNA B A
4. Remove the screws and pull out the roof antenna.
123456567
CONTINUED
T27
TO. MODEL .INDEX
AUDIO
6. If not as specified, replace the roof antenna. ANTENNA FEEDER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal. CONDENSER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
IGNITION COIL
1 2 3 4
Screw Clip Nut Condenser
1 2
Clip Antenna feeder
ANTENNA FEEDER INSPECTION 1. Disconnect the negative battery cable. 2. Remove the driver-side front side trim. (Refer to section S, TRIM, FRONT SIDE TRIM REMOVAL/INSTALLATION.) 3. Disconnect the connection between the antenna feeder and the roof antenna. 4. Verify that there is no continuity between the antenna feeder terminals A and B using an ohmmeter. 5. Inspect for continuity between the antenna feeder terminals using an ohmmeter. : Continuity
Step 1 2 Terminal A B C D
B D A C
123456567
6. If not as specified, replace the antenna feeder.
CONTINUED
T28
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
HEATER AND AIR CONDITIONER SYSTEMS

SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . U 2 STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U19 HANDLING REFRIGERANT . . . . . . . . . . . . . . . . U 2 MAGNETIC CLUTCH STORING REFRIGERANT . . . . . . . . . . . . . . . . . U 2 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U20 SERVICE CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . U 2 MAGNETIC CLUTCH CLEARANCE HANDLING COMPRESSOR OIL . . . . . . . . . . . . U 2 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U20/21 REFRIGERANT SYSTEM SERVICE MAGNETIC CLUTCH INSPECTION . . . . . . . . . U21 PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3 A/C RELAY No.1 MANIFOLD GAUGE SET INSTALLATION . . . . U 3 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U21 RECOVERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3 A/C RELAY No.1 INSPECTION . . . . . . . . . . . . . U22 CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 3/5 A/C RELAY No.2 REFILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 5/6 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U22 REFRIGERANT CHARGE CHECK . . . . . . . . . . U 6/7 A/C RELAY No.2 INSPECTION . . . . . . . . . . . . . U22 REFRIGERANT PRESSURE CHECK . . . . . . . U 7 REFRIGERANT PRESSURE SWITCH PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . U 7 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U22 BASIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . U 8 REFRIGERANT PRESSURE SWITCH STRUCTURAL VIEW . . . . . . . . . . . . . . . . . . . . . . U 8/9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . U23 BLOWER UNIT REMOVAL/INSTALLATION . . U10 THERMOSWITCH INSPECTION . . . . . . . . . . . U23/24 BLOWER UNIT DISASSEMBLY/ASSEMBLY . U10 BLOWER MOTOR COOLING UNIT REMOVAL/INSTALLATION . . U10/11 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U24 COOLING UNIT DISASSEMBLY/ASSEMBLY . U12 BLOWER MOTOR INSPECTION . . . . . . . . . . . U24 EVAPORATOR INSPECTION . . . . . . . . . . . . . . U13 RESISTOR REMOVAL/INSTALLATION . . . . . . U24 HEATER UNIT REMOVAL/INSTALLATION . . . U13 RESISTOR INSPECTION . . . . . . . . . . . . . . . . . . U25 HEATER UNIT DISASSEMBLY/ASSEMBLY . . U14 CLIMATE CONTROL UNIT REMOVAL . . . . . . U25 HEATER CORE INSPECTION . . . . . . . . . . . . . . U15 CLIMATE CONTROL UNIT INSTALLATION . . U25 A/C COMPRESSOR CLIMATE CONTROL UNIT REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U15 DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . U25/26 CONDENSER REMOVAL/INSTALLATION . . . U16 CLIMATE CONTROL UNIT WIRE CONDENSER INSPECTION . . . . . . . . . . . . . . . U16 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . U26/27 RECEIVER/DRIER CLIMATE CONTROL UNIT INSPECTION . . . . U27 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U16/17 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . U28 REFRIGERANT LINES FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U28 REMOVAL/INSTALLATION . . . . . . . . . . . . . . . U17/18 TROUBLESHOOTING INDEX . . . . . . . . . . . . . . U28 CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . U19 SYMPTOM TROUBLESHOOTING . . . . . . . . . . U28/39
CONTINUED
U1
TO. MODEL .INDEX
SERVICE WARNINGS, SERVICE CAUTIONS
SERVICE WARNINGS
HANDLING REFRIGERANT D Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and throat. If accidental system discharge occurs, ventilate work area before resuming service. D Do not pressure test or leak test R-134a service equipment and/or vehicle air conditioning system with compressed air. Some mixtures of air and R-134a have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. D Do not allow the refrigerant to leak near fire or any kind of heat. A poisonous gas may be generated if the refrigerant gas contacts fire or heat such as from cigarettes and heaters. When carrying out any operation that can cause refrigerant leakage, extinguish or remove the above-mentioned heat sources and maintain adequate ventilation. D Handling liquid refrigerant is dangerous. A drop of it on the skin can result in localized frostbite. When handling the refrigerant, wear gloves and safety goggles. If refrigerant splashes into the eyes, immediately wash them with clean water and consult a doctor. STORING REFRIGERANT D The refrigerant container is highly pressurized. If it is subjected to high heat, it could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Store the refrigerant at temperatures below 40 !C {104 !F}.
SERVICE CAUTIONS
HANDLING COMPRESSOR OIL D Use FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil for this vehicle. Using a PAG oil other than FD46XG (G6, WL, WL turbo) or ZXL 100PG compressor oil can damage the A/C compressor. D Do not spill compressor oil on the vehicle. A drop of compressor oil on the vehicle surface can eat away at the paint. If oil gets on the vehicle, wipe it off immediately. D FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil (PAG oil) has a higher moisture absorption efficiency than the previously used mineral oil. If moisture mixes with the compressor oil, the refrigerant system could be damaged. Therefore, install caps immediately after using the compressor oil or removing refrigerant system parts to prevent moisture absorption.
FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) COMPRESSOR OIL
MINERAL OIL
TIME MOISTURE ABSORPTION
CONTINUED
U2
TO. MODEL .INDEX
REFRIGERANT SYSTEM SERVICE PROCEDURES

MANIFOLD GAUGE SET INSTALLATION 1. Fully close the valves of the SST (49 C061 001). 2. Connect the SSTs (49 C061 002, 49 C061 003) to the high- and low-pressure side joints of the SST (49 C061 001). 3. Connect the SSTs (49 C061 006A, 49 C061 007) to the ends of the SSTs (49 C061 002, 49 C061 003). 4. Connect the SSTs (49 C061 006A, 49 C061 007) to the charging valves.
49 C061 001 49 C061 002 49 C061 003 49 C061 007
CAP CHARGING VALVE OF LOW-PRESSURE SIDE
TAP PIN SIDE
AIR PURGE VALVE
49 C061 001 49 C061 005 49 C061 004

REFRIGERANT TANK SCALE VACUUM PUMP
7. Open all the valves of the SST (49 C061 001). Caution D Close the SST (49 C061 001) valve immediately after stopping the vacuum pump. If the valve is left open, the vacuum pump oil will flow back into the refrigeration cycle and cause a decrease in the efficiency of the air conditioner. 8. Start the vacuum pump and let it operate for 15 minutes.
49 C061 001
49 C061 006A
CAP
CHARGING VALVE OF HIGH-PRESSURE SIDE
RECOVERY Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturers instructions. CHARGING Charging Recycled R-134a Refrigerant Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturers instructions. Charging New R-134a Refrigerant Caution D Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts. 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank. 6. Place the refrigerant tank on the scale. Regular amount of refrigerant 550 g {19.4 oz}
CLOSE
9. Verify that high- and low-pressure side readings of the SST (49 C061 001) are at 101 kPa {760 mmHg, 29.9 inHg}. Close each valve of the SST (49 C061 001).
49 C061 001
10. Stop the vacuum pump and wait for 5 minutes. 11. Check the high- and low-pressure side readings of the SST (49 C061 001). If the reading has changed, inspect for leakage and then repeat from step 7. If the reading has not changed, go to step 12. 12. Open the valve of the refrigerant tank. 13. Weigh the refrigerant tank.
CONTINUED
U3
TO. MODEL .INDEX

Warning D If the refrigerant system is charged with a large amount of refrigerant when checking for gas leakage, and if any leakage should occur, the refrigerant will be released into the atmosphere. In order to prevent the accidental release of refrigerant which can destroy the ozone layer in the stratosphere, follow the proper procedures and charge with only a small amount of refrigerant when checking for gas leakage. D If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 14. Open the high-pressure side valve of the SST (49 C061 001).
49 C061 001
OPEN
Warning D If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 17. Open the high-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the weight of refrigerant tank has decreased 300 g {10.6 oz} from the amount in step 13.
49 C061 001
OPEN
18. Close the high-pressure side valve of the SST (49 C061 001).
49 C061 001
15. When the low-pressure side reading increases to 0.098 MPa {1.0 kgf/cm2, 14 psi}, close the high-pressure side valve of the SST (49 C061 001).
49 C061 001
16. Inspect for leakage from the cooler pipe/hose connections using the SST (Gas leak tester). If there is no leakage, go to step 17. If a leakage is found at a loose joint, tighten the joint and inspect for leakage again. If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the charging procedure from step 7. If there is no leakage after tightening the joint, go to step 17.
Warning D If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running. 19. Start the engine and actuate the A/C compressor. 20. Open the low-pressure side valve of the SST (49 C061 001) and charge with refrigerant until the refrigerant tank is empty.
CONTINUED
U4
TO. MODEL .INDEX

AIR PURGE VALVE
49 C061 001
OPEN
TAP PIN SIDE
49 C061 001 49 C061 005
49 C061 004
REFRIGERANT TANK
VACUUM PUMP
21. Close the low-pressure side valve of the 6. Open only the center valve of the SST (49 C061 SST (49 C061 001) and the valve of the refrigerant tank. (49 C061 001). 22. Stop the engine and A/C compressor. 23. Inspect for leakage using the SST (Gas leak Caution tester). If there is no leakage, go to step 24. If D Close the SST (49 C061 001) valve leakage is found at a loose joint, tighten the joint immediately after stopping the vacuum and inspect for leakage again. If there is still a leak pump. If the valve is left open, the vacuum at the same joint, discharge the refrigerant and pump oil will flow back into the refrigeration then repair the joint. Repeat the charging cycle and cause a decrease in the efficiency procedure from step 7. If there is no leakage after of the air conditioner. tightening the joint, go to step 24. 24. Disconnect the SSTs (49 C061 006A, 7. Start the vacuum pump and let it run for 1 minute. 49 C061 007) from the charging valves. 49 C061 001 25. Install the caps to the charging valves.
CLOSE
49 C061 006A 49 0061 007

CAP
CAP
8. Close the center valve of the SST (49 C061 001). REFILLING Caution D Do not exceed the specification when charging the system with refrigerant. Doing so will decrease the efficiency of the air conditioner or damage the refrigeration cycle parts. 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49 C061 001). 3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001). 4. Connect the SST (49 C061 005) to the vacuum pump. 5. Connect the SST (49 C061 004) to the refrigerant tank.
49 C061 001
9. Stop the vacuum pump. 10. Open the valve of the refrigerant tank. Warning D If charging the system with refrigerant using service cans, running the engine with the high-pressure side valve open is dangerous. Pressure within the service cans will increase and the cans could explode, scattering metal fragments and liquid refrigerant that can seriously injure you. Therefore, do not open the high-pressure side valve while the engine is running.
CONTINUED
U5
TO. MODEL .INDEX

11. Start the engine and actuate the A/C compressor. 12. Open the low-pressure side valve of the SST (49 C061 001).
49 C061 001
OPEN CAP
49 C061 007
49 C061 006A
CAP
REFRIGERANT CHARGE CHECK Caution D The FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil will separate from refrigerant at high temperatures of 50 C {122 F} or more. If this happens, the sight glass will change to a milky-white color, and there is a possibility that you might mistakenly believe the refrigerant amount to be insufficient and recharge with additional refrigerant. If the system is overcharged with refrigerant, the sight glass will become clear and give a false indication. You will mistakenly believe that the refrigerant amount is correct. Therefore, when checking the refrigerant amount, verify the refrigerant pressure and cooler pipe temperature in addition to the sight glass condition. 1. Warm up the engine and run it at a constant 1,500 rpm. 2. Set the fan switch at 4th. 3. Set the temperature control dial to MAX COLD. 4. Close all the doors and windows. 5. Check the refrigerant amount condition according to the following table.
13. Refer to refrigerant charge check and refill with refrigerant.

L.H.D.
SIGHT GLASS
R.H.D. (WL, G6, F2 Cab)
SIGHT GLASS
R.H.D. (WL turbo)
SIGHT GLASS
14. Close the low-pressure side valve of the SST (49 C061 001) and the valve of the refrigerant tank. 15. Stop the engine and the A/C compressor. 16. Disconnect the SSTs (49 C061 006A, 49 C061 007) from the charging valves. 17. Install the caps to the charging valves.
CONTINUED
U6
TO. MODEL .INDEX
Amount
Condition of sight glass
Other conditions
D High-pressure side cooler
Mpa {kgf/cm2, psi} 2.0 {21, 299} 1.5 {15, 213} 1.0 {10, 142}
HIGH-PRESSURE SIDE
Insufficient Bubbles
pipe is warm; low-pressure side cooler pipe is cool. D High- and low-pressure side readings are lower than normal. D Air cooling ability is low.
0.2 {2.0, 28}
LOW-PRESSURE SIDE
Clear Correct
Milky white
pipe is hot; low-pressure side cooler pipe is cold. D High- and low-pressure side readings are normal. * If sight glass is milky-white, pour water into condenser for approximately 20 seconds to cool it off, then the sight glass will clear.
0.1 {1.0, 14}
PRESSURE READING OF MANIFOLD GAUGE

20 {68} 25 {77} 30 {86} 35 {95} 40 C {104} {F}
AMBIENT TEMPERATURE
Over Clear
pipe is hot; low-pressure side cooler pipe is cold. D High- and low-pressure side reading are higher than normal. D Air cooling ability is low.
9. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.) PERFORMANCE TEST Note D After servicing the refrigerant system, the test is performed. 1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Record center ventilator right side temperature. 8. Determine and record ambient temperature. 9. Verify that the temperature reading is in the shaded zone.
C {F} 6 {43} 5 {41} 4 {39} 3 {37} 2 {36} 1 {34} 0 {32} 20 {68} 25 {77} 30 {86} 35 {95}
6. If not as specified, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.) REFRIGERANT PRESSURE CHECK 1. Install the SSTs (Manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Open the bonnet. 3. Close all the doors and windows. 4. Warm up the engine and run it at a constant 1,500 rpm. 5. Set the fan switch at 4th. 6. Set the temperature control dial to MAX COLD. 7. Measure the ambient temperature and the highand low-pressure side reading of the SST (49 C061 001). 8. Verify that the intersection of the pressure reading of the SST (49 C061 001) and ambient temperature is in the shaded zone.
40 C {104} {F}
CENTER VENTILATOR TEMPERATURE
AMBIENT TEMPERATURE
10. If the performance is not within the shaded zone, troubleshoot the refrigerant system. (Refer to TROUBLESHOOTING.)
CONTINUED
U7
TO. MODEL .INDEX
BASIC SYSTEM
BASIC SYSTEM
STRUCTURAL VIEW
L.H.D. (G6) BLOWER UNIT COOLING UNIT HEATER UNIT
COOLER PIPE (LOW) COOLER PIPE (HIGH)
HEATER HOSE A/C COMPRESSOR
COOLER HOSE (LOW) CONDENSER
L.H.D. (WL, WL turbo) BLOWER UNIT COOLING UNIT HEATER UNIT
RECEIVER/DRIER
COOLER PIPE (LOW) COOLER PIPE (HIGH) A/C COMPRESSOR
HEATER HOSE
COOLER HOSE (HIGH) CONDENSER
L.H.D. (F2, F2 Cab) BLOWER UNIT COOLING UNIT HEATER UNIT
RECEIVER/DRIER
COOLER PIPE (LOW)
HEATER COOLER HOSE PIPE A/C (HIGH) COMPRESSOR COOLER HOSE (HIGH)
CONDENSER
RECEIVER/DRIER
CONTINUED
U8
TO. MODEL .INDEX
BASIC SYSTEM
R.H.D. (G6) HEATER UNIT HEATER HOSE A/C COMPRESSOR COOLER HOSE (LOW) COOLING UNIT
BLOWER UNIT
COOLER PIPE (HIGH)
CONDENSER RECEIVER/DRIER COOLER HOSE (HIGH)
R.H.D. (WL, WL turbo) HEATER UNIT HEATER HOSE A/C COMPRESSOR COOLER HOSE (LOW) COOLING UNIT
BLOWER UNIT
COOLER PIPE (HIGH)
SIGHT GLASS
CONDENSER
R.H.D. (F2 Cab)
RECEIVER/DRIER HEATER UNIT HEATER HOSE COOLING UNIT
COOLER HOSE (HIGH)
WL turbo
A/C COMPRESSOR COOLER HOSE (LOW)
BLOWER UNIT
COOLER PIPE (HIGH) CONDENSER RECEIVER/DRIER
CONTINUED
U9
TO. MODEL .INDEX
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 4. Remove the passengers side front side trim (L.H.D. only.) 5. Remove as indicated in the table. 6. Install in the reverse order of removal.
R.H.D.
B C A A B C
1 2 3 4 5 6 7 1 2 Connector Blower unit 8 9 10 11
Blower motor Resistor Blower harness Polyurethane protector Inlet duct case (front) Inlet duct case (rear) Blower case (upper) Blower case (lower) Air intake door Air intake link Air intake crank
BLOWER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
L.H.D.
COOLING UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the glove compartment. 4. Disconnect the air intake wire from the cooling unit. (Refer to CONTROL SYSTEM, CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle.
B C A B C A
CONTINUED
U10
TO. MODEL .INDEX
BASIC SYSTEM
5. Remove in the order indicated in the table. Do not allow compressor oil to spill. 6. Install in the reverse order of removal. 7. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
L.H.D.
Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note Cooler pipe (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Removal Note + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note Connector Cooling unit + Removal Note + Installation Note
1521 Nm {1.52.2 kgfm, 130.2190.9 inlbf}
6.99.8 Nm {0.71.0 kgfm, 60.886.7 inlbf}
3 4
R.H.D.
2029 Nm {2.03.0 kgfm, 1521 ftlbf}
Cooling Unit Removal Note (R.H.D. only) D Turn the cooling unit 90 degrees to the right, and remove the cooling unit.
R
9.8119.61 Nm {100200 kgfcm, 86.8173.5 inlbf}
Cooling Unit Installation Note D When installing a new cooling unit (evaporator), add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplement amount 40 ml {40 cc, 1.4 fl oz}
CONTINUED
U11
TO. MODEL .INDEX
BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
L.H.D.
1 2 3 4 5 6 7
Cooler case (upper) Cooler case (lower) Thermoswitch clip Thermoswitch + Assembly Note Evaporator Expansion valve + Assembly Note High pressure pipe
Expansion Valve Assembly Note D Replace the O-rings at the expansion valve joints and apply compressor oil to the O-rings and connect the joints. D Tighten the joint to the specified torque using two open-end wrenches. D Assemble the heat-sensing tube as shown in the figure.
2024 Nm {2.02.5 kgfm, 1518 ftlbf}
R.H.D.
11.814.7 Nm {120150 kgfcm, 105130 inlbf}
HEAT-SENSING TUBE
Thermoswitch Assembly Note 1. Insert the thermoswitch probe in location as shown in the figure.
EVAPORATOR
40 mm {1.6 in}
CONTINUED
U12
TO. MODEL .INDEX
BASIC SYSTEM
EVAPORATOR INSPECTION 1. Remove the cooling unit. (Refer to COOLING UNIT REMOVAL/INSTALLATION.) 2. Remove the evaporator from the cooling unit. 3. Inspect for cracks, damage, and oil leakage. If any problems are found, replace the evaporator. 4. Inspect for bent fins. If they are bent, use a flat-head screwdriver to straighten them. HEATER UNIT REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.) (With heater core only) 3. Remove the dashboard. (Refer to section S, DASHBOARD AND CONSOLE, DASH BOARD REMOVAL/INSTALLATION.) 4. Remove in the order indicated in the table. 5. Install in the reverse order of removal.
WITH HEATER CORE ONLY
1 2
Heater hose Heater unit
CONTINUED
U13
TO. MODEL .INDEX
BASIC SYSTEM
HEATER UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
* * * WITH HEATER CORE ONLY
1 2 3 4 5 6 7 8
Heater core Air mix rod Air mix link Air mix crank (1) Air mix crank (2) Air mix shaft Airflow mode main link Airflow mode crank (1)
9 10 11 12 13 14 15 16
Airflow mode crank (2) Airflow mode crank (3) Airflow mode crank (4) Airflow mode sub link (1) Airflow mode sub link (2) Heater case (1) Heater case (2) Heater case (3)
CONTINUED
U14
TO. MODEL .INDEX
BASIC SYSTEM
HEATER CORE INSPECTION 1. Remove the heater unit. (Refer to HEATER UNIT REMOVAL/INSTALLATION.) 2. Remove the heater core from the heater unit. 3. Inspect for cracks, damage, and coolant leakage. If any are found, replace the heater core. 4. Inspect for bent fins. If any are bent, use a flathead screwdriver to straighten them. 5. Verify that the heater core inlet and outlet are not distorted or damaged. Repair with pliers if necessary. A/C COMPRESSOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the drive belt (P/S + A/C). 4. Remove the air cleaner and air hose. (WL turbo only) (Refer to section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM REMOVAL/INSTALLATION.) 5. Loosen the A/C compressor bolts, then slide the A/C compressor. (WL turbo only) Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Adjust the drive belt (P/S + A/C). (Refer to section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT.) 9. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
F2, F2 Cab R
3039 {3.04.0, 2228}
G6, WL, WL turbo

1521 {1.52.2, 1115}
2435 {2.43.6, 1826}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
1 2
Connector Cooler hose (high) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note Cooler hose (low) + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note A/C compressor + Installation Note
A/C Compressor Installation Note D Remove the following amount of compressor oil from the new A/C compressor when replacing the A/C compressor. Compressor oil to be removed = 180 ml {180 cc, 6.08 fl oz} [compressor oil from old A/C compressor + 15 ml {15 cc, 0.5 fl oz} ]
CONTINUED
U15
TO. MODEL .INDEX
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION Condenser Installation Note D When installing a new condenser, add FD46XG 1. Disconnect the negative battery cable. (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) 2. Discharge the refrigerant from the system. compressor oil into the refrigeration cycle. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE Supplemental amount PROCEDURES, CHARGING.) 30 ml {30 cc, 1.0 fl oz} 3. Remove the radiator grille. 4. Remove the charge air cooler and air hose. (WL CONDENSER INSPECTION turbo only) 1. Inspect for cracks, damage, and oil leakage. If any (Refer to section F2, INTAKE-AIR SYSTEM, problems are found, replace the condenser. INTAKE-AIR SYSTEM 2. Inspect for fins clogged by dust. If any are clogged, REMOVAL/INSTALLATION.) remove the dust from the fins. 5. Remove the receiver/drier. 3. Inspect for bent fins. If any are bent, use a flathead (Refer to RECEIVER/DRIER REMOVAL/INSTALLATION.) screwdriver to straighten them. Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.) RECEIVER/DRIER REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille. Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 4. Remove in the order indicated in the table. Do not allow compressor oil to spill. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
6.859.80 Nm {70100 kgfcm, 60.886.7 inlbf}
1521 Nm {1.52.2 kgfm, 1115 ftlbf}
B C C A D D R R
Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note Bonnet lock stay Condenser + Installation Note
2 3
CONTINUED
U16
TO. MODEL .INDEX
BASIC SYSTEM
Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 3. Remove the radiator grille. 4. Remove the front bumper. (Refer to section S, BUMPER, FRONT BUMPER REMOVAL/INSTALLATION.) 5. Remove the radiator. (WL turbo only) 6. Remove in the order indicated in the table. Do not allow compressor oil to spill. 7. Install in the reverse order of removal. 8. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
1 2
Connector Cooler pipe + REFRIGERANT LINES REMOVAL/INSTALLATION, Refrigerant Lines Installation Note Condenser + CONDENSER REMOVAL/INSTALLATION, Condenser Installation Note Receiver/drier + Installation Note
Receiver/drier Installation Note D When installing a new receiver/drier, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount 35 ml {35 cc, 1.2 fl oz} REFRIGERANT LINES REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.)
L.H.D.
B C D F R D F
B R
R R C B A R R R B A
B A A C
CONTINUED
U17
TO. MODEL .INDEX
BASIC SYSTEM
R.H.D.
B R E B R B C A R A B R A C
R D
D C
A: 6.859.80 Nm {70100 kgfcm, 60.886.7 inlbf} B: 1521 Nm {1.52.2 kgfm, 1115 ftlbf} C: 2029 Nm {2.03.0 kgfm, 1521 ftlbf} D: 9.8119.61 Nm {100200 kgfcm, 86.8173.5 inlbf} E: 2435 Nm {2.43.6 kgfm, 1826 ftlbf}
Cooler hose (low) + Removal Note + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note Cooler hose (high) + Removal Note + Refrigerant Lines Installation Note Cooler pipe (high) + Refrigerant Lines Removal Note + Refrigerant Lines Installation Note
Refrigerant Lines Installation Note 1. When installing a new cooler pipe or hose, add FD46XG (G6, WL, WL turbo) or ZXL 100PG (F2, F2 Cab) compressor oil into the refrigeration cycle. Supplemental amount Cooler hose (low): 8 ml {8 cc, 0.3 fl oz} Cooler hose (high): 5 ml {5 cc, 0.2 fl oz} Cooler pipe: 3 ml {3 cc, 0.1 fl oz} 2. Apply compressor oil to the O-rings and connect the joints. 3. Tighten the joints. (1) Tighten the nut or bolt of the joint by hand. (2) Tighten the joint to the specified torque. If it is a nut joint, tighten the nut using a spanner and torque wrench.
Cooler Hose Removal Note WL turbo only D Loosen the A/C compressor bolts, then slide the A/C compressor, and remove the cooler hose bolt from the A/C compressor. Refrigerant Lines Removal Note D Loosen the nut using two spanners, then remove the cooler pipe or hose.
CONTINUED
U18
TO. MODEL .INDEX
CONTROL SYSTEM
CONTROL SYSTEM
STRUCTURAL VIEW
L.H.D. A/C RELAY No.2* REFRIGERANT PRESSURE SWITCH
A/C RELAY No.1
MAGNETIC CLUTCH
CLIMATE CONTROL UNIT
THERMOSWITCH RESISTOR
BLOWER MOTOR
R.H.D.
REFRIGERANT PRESSURE SWITCH MAGNETIC CLUTCH A/C RELAY No.2*
A/C RELAY No.1
CLIMATE CONTROL UNIT
THERMOSWITCH
RESISTOR BLOWER MOTOR
CONTINUED
* F2 Cab only
U19
TO. MODEL .INDEX
CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly. 3. Adjust the magnetic clutch clearance. (Refer to MAGNETIC CLUTCH CLEARANCE ADJUSTMENT.)
10.115.0 N {102153 89132 kgf inlbf}
Stator Removal Note D Set a straight-socket (17 mm {0.67 in}) on the shaft of the A/C compressor to protect it. D Remove the stator using a pulley puller as shown in the table.
STRAIGHT-SOCKET (17 mm {0.67 in})
Stator Installation Note D Install the stator perpendicularly using the SST and a pulley puller as shown in the table.
49 H061 005
1 2 3 4 5 6
Bolt + Removal/Installation Note Pressure plate + Installation Note Shim Snap ring A/C compressor pulley Stator + Removal Note + Installation Note
Pressure Plate Installation Note D When installing the pressure plate, carry out magnetic clutch clearance adjustment. MAGNETIC CLUTCH CLEARANCE ADJUSTMENT G6, WL, WL turbo Only 1. Set the A/C compressor on a level block. 2. Turn on the magnetic clutch by connecting the battery positive voltage to the magnetic clutch connector terminal and the ground to the A/C compressor body. 3. Fix a dial gauge on a magnetic base and set the measuring probe onto point A on the pressure plate surface.
Bolt Removal/Installation Note D When removing or installing the bolt, hold the pressure plate in place as shown in the table.
BOLT A/C COMPRESSOR
CONTINUED
U20
TO. MODEL .INDEX
CONTROL SYSTEM
4. Turn off the magnetic clutch by disconnecting the ground from the A/C compressor body, then measure the dial gauge readings. 5. Measure the clearance for point B and C on the pressure plate surface by repeating the above steps 2 through 4. Clearance 0.350.75 mm {0.0140.029 in}
MEASURING POINT A B
3. If not within the specification, remove the pressure plate and adjust the clearance by changing the shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5 mm {0.020 in}) or the number of shims. MAGNETIC CLUTCH INSPECTION 1. Disconnect the magnetic clutch connector. 2. Connect battery positive voltage to terminal A of magnetic clutch and ground to the A/C compressor body.
6. If the clearance is not as specified, adjust it by changing the shim. Note D The seven shim sizes from 0.7 mm {0.028 in} to 1.3 mm {0.051 in} differ in 0.1 mm {0.004 in} increments.
3. Verify that the magnetic clutch operates. 4. If not as specified, replace the stator. A/C RELAY No.1 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal. F2, F2 Cab Only 1. Measure the clearance around the entire circumference between the pressure plate and A/C compressor pulley using a thickness gauge.
1 2
Connector A/C relay No.1
2. Verify that the clearance is within the specification. Clearance 0.30.6 mm {0.010.02 in}
CONTINUED
U21
TO. MODEL .INDEX
CONTROL SYSTEM
A/C RELAY No.1 INSPECTION 1. Remove the A/C relay No.1. 2. Inspect for continuity between the A/C relay No.1 terminals using an ohmmeter. : Continuity B+: Battery positive voltage
C D D B
B C A
A C D A B
3. If not as specified, replace the A/C relay No.2. REFRIGERANT PRESSURE SWITCH REMOVAL/ INSTALLATION 1. Disconnect the negative battery cable. 2. Discharge the refrigerant from the system. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, RECOVERY.) (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, CHARGING.) 3. Remove the radiator grille. Caution D If moisture or foreign material enters the refrigeration cycle, cooling ability will be lowered and abnormal noise will occur. Always immediately plug all open fittings after removing any refrigeration cycle parts to keep moisture or foreign material out of the cycle. 4. Remove as indicated in the table. 5. Install in the reverse order of removal. 6. Carry out the refrigerant system performance test. (Refer to REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST.)
B
123456567
3. If not as specified, replace the A/C relay No.1. A/C RELAY NO.2 REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove in the order indicated in the table. 3. Install in the reverse order of removal.
1 2 Connector A/C relay No.2

R
5.97.8 Nm {6080 kgfcm, 5369 inlbf}
A/C RELAY NO.2 INSPECTION 1. Remove the A/C relay No.2. 2. Inspect for continuity between the A/C relay No.2 terminals using an ohmmeter. : Continuity B+: Battery positive voltage
Step 1 2 B+ GND Terminal B D A C 1 2
Connector Refrigerant pressure switch + Installation Note
Refrigerant Pressure Switch Installation Note D Apply compressor oil to the O-ring and connect the joint.
CONTINUED
123456567
U22
TO. MODEL .INDEX
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION 1. Install the SSTs (manifold gauge set). (Refer to MANIFOLD GAUGE SET INSTALLATION.) 2. Disconnect the refrigerant pressure switch connector. 3. Verify the high-pressure side reading of the SST (Manifold gauge). 4. Inspect for continuity between the terminals of the refrigerant pressure switch using an ohmmeter.
0.180.21 {1.82.2, 2631} 3.03.3 {3034, 427483}
WITH HEATER CORE A B C
WITHOUT HEATER CORE A B
CONTINUITY
7. If not as specified, inspect on/off points of the thermoswitch. To Inspect On/Off Points of the Thermoswitch 1. Disconnect the negative battery cable. 2. Remove the cooling unit (Refer to BASIC SYSTEM, COOLING UNIT REMOVAL/INSTALLATION.) 3. Remove the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) 4. Connect the negative battery cable. 5. Connect the thermoswitch connector to the wiring harness connector. 6. Turn the ignition switch to ON position. 7. Turn the A/C switch on. 8. Turn the fan switch on. 9. Immerse the sensor part of thermoswitch in a container of ice water. 10. Connect the positive (+) and negative () probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. 11. Inspect the voltage as shown below.
WITH HEATER CORE
NO CONTINUITY
0.02 {0.25, 3.56} OR LESS 0.40.7 {4.08.0, 57113} MPa { kgf/cm2 , psi }
5. If not as specified, replace the refrigerant pressure switch. THERMOSWITCH INSPECTION To Determine if the Switch is Functioning 1. Remove the glove compartment. 2. Start the engine. 3. Turn the fan switch on. 4. Turn the A/C switch on. 5. Connect the positive (+) and negative () probes of the voltmeter to terminal A and terminal B of the thermoswitch respectively. (The wiring harness connector must be connected to the thermoswitch connector.) 6. Inspect the voltage as shown below.
WITH HEATER CORE
: Continuity
Water temperature temperat re 3C {37F} or more 1C {34F} or less WITHOUT HEATER CORE Terminal A C
: Continuity
Temperature control dial position MAX COLD 1/2 MAX WARM Water temperature temperat re 03C {3237F} 3C {37F} or more 711C {4552F} 11C {52F} or more
123456567
Terminal A B
: Continuity
Magnetic clutch cl tch On Off WITHOUT HEATER CORE Terminal A C
1418C {5764F} 18C {64F} or more
: Continuity
Magnetic clutch cl tch On Off
123456567
Terminal A B
123456567
CONTINUED
U23
TO. MODEL .INDEX
CONTROL SYSTEM
BLOWER MOTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the blower motor connector. 3. Connect battery positive voltage to terminal B and ground to terminal A of the blower motor, and verify its operation.
WITH HEATER CORE A B C
WITHOUT HEATER CORE A B
12. If not as specified, replace the thermoswitch. (Refer to BASIC SYSTEM, COOLING UNIT DISASSEMBLY/ASSEMBLY.) BLOWER MOTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
4. If not as specified, replace the blower motor. RESISTOR REMOVAL/INSTALLATION 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Remove as indicated in the table. 4. Install in the reverse order of removal.
1 2
Connector Blower motor
1 2
Connector Resistor
CONTINUED
U24
TO. MODEL .INDEX
CONTROL SYSTEM
RESISTOR INSPECTION 1. Remove the glove compartment. 2. Disconnect the resistor connector. 3. Verify that the resistance between the terminals of the resistor is as shown in the table.
Terminal 1A1B (2A) 1A1C 1C1D Resistance () R1: 0.430.47 R2: 1.041.16 R3: 1.471.63
CLIMATE CONTROL UNIT INSTALLATION 1. Connect the climate control unit connectors. 2. Insert the climate control unit until each clip clicks.
R3
R2
R1
1C 1D
1A 1B
3. Adjust the wire of the climate control unit. (Refer to CLIMATE CONTROL UNIT WIRE ADJUSTMENT.) 4. Install the glove compartment. 5. Connect the negative battery cable. Climate Control Unit Removal/Installation Note With heater core D Set the temperature control dial at MAX COLD, the airflow mode control dial at DEF. CLIMATE CONTROL UNIT DISASSEMBLY/ASSEMBLY 1. Disassemble in the order indicated in the table. 2. Assemble in the reverse order of disassembly.
WITH HEATER CORE
1D
1C
1A
1B
2A
2A
4. If not as specified, replace the resistor. CLIMATE CONTROL UNIT REMOVAL 1. Disconnect the negative battery cable. 2. Remove the glove compartment. 3. Disconnect the air intake wire from the blower unit. 4. Disconnect the air mix wire and airflow mode wire from the heater unit. 5. With the beveled parts of the SST facing inward, insert them into the climate control unit. 6. Pull the SST outward and rearward to slide out the climate control unit.
49 D066 801A
7. Disconnect the climate control unit connectors.
CONTINUED
U25
TO. MODEL .INDEX
CONTROL SYSTEM
WITHOUT HEATER CORE
CLIMATE CONTROL UNIT WIRE ADJUSTMENT Air Intake Wire 1. Set the air intake lever at FRESH. 2. Set the air intake link to FRESH in the direction of the arrow and insert a screwdriver into the set hole.
L.H.D.
AIR INTAKE WIRE
SET HOLE
R.H.D. AIR INTAKE WIRE
1 2 3 4 5 6 7 8 9 10 11 11 13
Dial Knob + Removal Note A/C switch Panel Fan switch Climate control unit harness Illumination bulb A/C amplifer Air mix wire Airflow mode wire Air intake wire Cap Body
SET HOLE
3. Connect the air intake wire to the air intake link. 4. Clamp the air intake wire to wire clamp. 5. Verify that the air intake lever moves its full stroke. Air Mix Wire (With heater core only) 1. Set the temperature control dial at MAX COLD. 2. Set the air mix link to MAX COLD in the direction of the arrow and insert a screwdriver into the set hole.
SET HOLE
Knob Removal Note D Use a wire to push the knob from the reverse side and remove it as shown in the figure.
WIRE KNOB
AIR MIX WIRE
3. Connect the air mix wire to the air mix link. 4. Clamp the air mix wire to wire clamp. 5. Verify that the temperature control dial moves its full stroke.
CONTINUED
U26
TO. MODEL .INDEX
CONTROL SYSTEM
Airflow Mode Wire 1. Set the airflow mode control dial at DEF. 2. Set the airflow mode link to DEF in the direction of the arrow and insert a screwdriver into the set hole.
SET HOLE
Fan Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the fan switch terminals using an ohmmeter. : Continuity
Switch position 0 1 2 3 4 Terminal A B C D E F
AIRFLOW MODE WIRE
3. Connect the airflow mode wire to the airflow mode link. 4. Clamp the airflow mode wire to wire clamp. 5. Verify that the airflow mode control dial moves its full stroke. CLIMATE CONTROL UNIT INSPECTION A/C Switch 1. Remove the climate control unit. (Refer to CLIMATE CONTROL UNIT REMOVAL.) 2. Inspect for continuity between the A/C switch terminals using an ohmmeter. : Continuity
Switch position OFF ON Terminal A B
B C
1 0
123456567 E C A
3. If not as specified, replace the fan switch.
3. Connect battery positive voltage to terminal C and 123456567 ground to the terminal A. 4. Turn the A/C switch on. 5. Verify that the LED illuminaltes. 6. If not as specified, replace the A/C switch.
CONTINUED
U27
TO. MODEL .INDEX
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD D Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly perform the procedures. D When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while doing the inspection to discover whether poor contact points are the cause of any intermittent malfunctions. If there is a problem, check to make sure connectors, terminals and wiring harnesses are connected correctly and undamaged. D The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area. TROUBLESHOOTING INDEX
No. 1 2 3 4 5 6 7 8 Malfunction symptom Insufficient blown air volume and/or no blown air depending on airflow mode. No blown air in any airflow mode. Blown air volume does not change at any fan speed. Airflow mode does not change. Improper air circulation and/or no air circulation. No temperature control.(For climate control unit without variable thermistor only) Air from vent not cold enough. No cool air. Noise while operating A/C system.
1 Insufficient blown air volume and/or no blown air depending on airflow mode. TROUBLESHOOTING HINTS 1 Malfunction in VENT mode system Steps 14 2 Malfunction in HEAT mode system Step 5 3 Malfunction in DEFROSTER mode system Steps 68 STEP 1 INSPECTION When airflow mode control dial is operated, is appropriate resistance felt and can it be moved throughout its full range? Does air blow out when in VENT mode? Is vent clogged? Is duct in dashboard properly installed? Yes No Yes No 3 4 Yes No Yes No 5 6 Does air blow out when in HEAT mode? Does air blow out when in DEFROSTER mode? Yes No Yes No 7 8 Is vent clogged? Is defroster duct properly installed? Yes No Yes No Go to next step. Go to Step 1 of troubleshooting index No. 3. Go to Step 5. Go to next step. Remove obstruction, then go to Step 9. Go to next step. Inspect duct for clogging, deformity and air leakage, then go to Step 9. Install duct securely in the proper position, then go to Step 9. Go to next step. Inspect vent for clogging, then go to Step 9. Operation is okay. Recheck malfunction symptoms. Go to next step. Remove obstruction, then go to Step 9. Go to next step. Inspect duct for clogging, deformity, and air leakage, then go to next step. Install duct securely in the proper position, then go to next step. ACTION
CONTINUED
U28
TO. MODEL .INDEX
CONTROL SYSTEM
STEP 9 Does air blow out?
INSPECTION Yes No
ACTION Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
No blown air in any airflow mode. Blown air volume does not change at any fan speed.
TROUBLESHOOTING HINTS 1 Blower motor, resistor, fan switch malfunction Step 1 2 Blower unit malfunction Steps 24 STEP 1 INSPECTION Inspect the following systems and electrical parts: D Blower motor, resistor, fan switch. Are they okay? Turn ignition switch to ON position. Turn fan switch on. on Is noise coming from blower unit? Inspect fan in blower unit. D Is fan free of interference from blower unit case? D Is fan free of foreign material and obstructions? Is fan okay? Is blower unit intake vent clogged? Yes No Yes No Yes No Go to next step. Repair or replace malfunctioning part, then go to Step 5. Go to next step. Go to Step 4. Go to next step. Remove obstruction, repair or replace fan and blower unit case, then go to Step 5. Remove obstruction, then go to next step. Inspect if there are any obstructions in passage between blower unit and heater unit, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs. ACTION
Yes No
Does air blow out?
Yes No
Airflow mode does not change.
TROUBLESHOOTING HINTS 1 Malfunction in heater units airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow mode wire or wire clamp Steps 1, 2 2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction Step 3 3 Malfunction in one or more heater unit doors Steps 4, 5 STEP 1 INSPECTION Inspect heater units airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub links, airflow mode wire and wire clamp. D Is there g grease on airflow mode main link, , airflow mode cranks and airflow mode sub links? D Are airflow mode main link, airflow mode rod, airflow mode cranks, and airflow mode sub links installed securely and in the proper position? D Is wire clamp free of deformation? Are above items all okay? Yes Go to next step. ACTION
No
Apply grease or install airflow mode main link, airflow mode rod, airflow mode cranks and airflow mode sub links securely in their proper positions, repair wire clamp, then go to Step 6.
CONTINUED
U29
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 2
INSPECTION Is airflow mode wire positioned securely and correctly in relation to the heater units airflow mode main link? Inspect climate control unit. D Is bevel g gear set properly y engaged? g g D Is airflow mode wire properly installed in correct direction on bevel gear? D Is wire clamp free of deformation? Are above items okay? Is there any foreign material or obstruction in any of heater units doors? Are all doors within heater unit securely and properly positioned? Yes No Yes No Go to next step.
ACTION Adjust airflow mode wire or install it correctly, then go to Step 6. Go to next step. Properly engage bevel gear set or install airflow mode wire in correct direction, repair or replace wire clamp, then go to Step 6. Remove obstruction, then go to Step 6. Go to next step. Inspect each door for cracks or damage, then go to next step. Install malfunction doors securely in proper position, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
4 5
Yes No Yes No
Does airflow mode change?
Yes No
Improper air circulation and/or no air circulation.
TROUBLESHOOTING HINTS 1 Malfunction in blower units air intake crank, air intake link, air intake wire or wire clamp Steps 1, 2 2 Climate control unit air intake wire or wire clamp malfunction Step 3 3 Blower unit air intake door malfunction Steps 4, 5 STEP 1 INSPECTION Inspect blower units air intake crank, air intake link and wire clamp. D Is there grease g on air intake crank and air intake link? D Are air intake crank and air intake link securely and properly positioned? D Is wire clamp free of deformation? Are above items okay? Is air intake wire positioned securely and correctly in relation to the blower units air intake link? Inspect climate control unit. D Is air intake wire properly installed in correct direction in relation to the air intake lever of climate control unit? D Is wire clamp free of deformation? Are above items okay? Is there any foreign material or obstruction in blower units air intake door? Is blower units air intake door securely and properly positioned? Yes Go to next step. ACTION
No
Apply grease or install air intake crank and air intake link properly and securely, repair wire clamp, then go to Step 6.
Yes No Yes No
Go to next step. Adjust air intake wire or install securely in correct position, then go to Step 6. Go to next step. Install air intake wire securely in correct position, repair or replace wire clamp, then go to Step 6. Remove obstruction, then go to Step 6. Go to next step. Inspect air intake door for cracks or damage, then go to next step. Install air intake door securely in proper position, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
4 5
Yes No Yes No
Does air circulate?
Yes No
CONTINUED
U30
TO. MODEL .INDEX
CONTROL SYSTEM
No temperature control.(Without variable thermistor in climate control unit only)
TROUBLESHOOTING HINTS 1 Malfunction in heater units air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp Steps 2, 3 2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction Step 4 3 Heater unit air mix door malfunction Steps 5, 6 STEP 1 2 INSPECTION Is coolant sufficiently warmed up? Inspect heater units air mix rod, air mix link, air mix cranks, air mix shaft and wire clamp. D Is there grease g on air mix rod, , air mix link and air mix cranks? D Are air mix rod, air mix link, air mix cranks, and air mix shaft securely installed in their proper positions? D Is wire clamp free of deformation? Are above items okay? Is air mix wire securely installed in the correct position in relation to heater units air mix link? Inspect climate control unit. D Is bevel g gear set properly y engaged? g g D Is air mix wire properly installed in correct position in relation to bevel gear? D Is wire clamp free of deformation? Are above items okay? Is there any foreign material or obstruction in heater units air mix door? Is heater units air mix door securely and properly installed? Yes No Yes Go to next step. Warm engine up, then go to Step 7. Go to next step. ACTION
No
Apply grease or install air mix rod, air mix link, air mix cranks, and air mix shaft securely in their proper positions, repair wire clamp, then go to Step 7.
Yes No Yes No
Go to next step. Adjust air mix wire or install securely in correct position, then go to Step 7. Go to next step. Properly engage bevel gear set or install air mix wire in correct position, repair or replace wire clamp, then go to Step 7. Remove obstruction, then go to Step 7. Go to next step. Inspect door for cracks or damage, then go to next step. Install door securely in proper position, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
5 6
Yes No Yes No
Does unit operate in every temperature setting?
Yes No
Air from vent not cold enough.
TROUBLESHOOTING HINTS 1 Drive belt malfunction Step 1 2 Malfunction in blower unit or condenser Steps 4, 5 3 Malfunction in receiver/drier or expansion valve (valve closes too much) Steps 8, 9 4 Malfunction in refrigerant lines Steps 10, 11 5 Malfunction in piping connections Steps 1, 2, 13 6 A/C compressor system malfunction, insufficient compressor oil Steps 15, 16 7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system Steps 1720
CONTINUED
U31
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 1
INSPECTION Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION Yes No Go to next step.
ACTION Adjust or replace drive belt, then go to Step 21. + Section B2, DRIVE BELT, DRIVE BELT ADJUSTMENT
Is it okay? 2 Carry out refrigerant system performance test. + REFRIGERANT SYSTEM SERVICE PROCEDURES PERFORMANCE TEST PROCEDURES, Is operation normal? Are refrigerants high-pressure and low-pressure values both high? Is blower unit intake clogged? Yes No Yes No Yes Operation is normal. (Recheck malfunction symptoms.) Go to next step. Go to next step. Go to Step 6. Remove obstruction, then go to Step 21. (If air does not reach evaporator within cooling unit, heat exchange does not occur and refrigerant pressure rises. Therefore, removal of obstruction is necessary.) Go to next step. Add or subtract refrigerant to make specified amount, then go to Step 21. (Excessive amount of refrigerant.) Replace condenser, or repair and clean condenser fins, then go to Step 21. Go to next step. Go to Step 14. Go to next step. Go to Step 10. Go to next step. Start vacuum pump for 30 minutes and replace receiver/drier, then go to Step 21. (Since receiver/drier has become saturated with water, replacement is necessary.) Replace expansion valve, then go to Step 21. (Since valve closes too much, replacement is necessary.) Install heat-sensing tube securely in proper position, then go to Step 21. Go to next step.
3 4
No 5 Inspect condenser. + BASIC SYSTEM, CONDENSER INSPECTION Is it okay? Yes
No 6 7 Are refrigerants high-pressure and low-pressure values both low? Immediately after A/C compressor operates, does refrigerants high-pressure value momentarily g g y rise to correct value, then fall and stay below it? (Is there negative pressure on low-pressure side?) Turn A/C switch off and let air conditioner stop for 10 minutes min tes. Start engine. Turn both A/C switch and fan switch on. Does malfunction occur after A/C compressor turns on? Is expansion valve heat-sensing tube within cooling unit securely installed in proper position? Yes No Yes No Yes No
Yes
No 10 Inspect refrigerant lines. D Is piping free of damage and cracks? D Are piping connections free of oil grime? (Visual inspection) D Are piping connections free of gas leakage? D Are piping installation points on condenser free of gas g leakage? g D Are piping installation points on receiver/drier free of gas leakage? D Are piping installation points on A/C compressor free of gas leakage? D Are piping installation points on cooling unit free of gas leakage? *Perform gas leak inspection using gas leak tester. Are above items okay? Yes
No
If piping or an A/C component is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to Step 13.
CONTINUED
U32
TO. MODEL .INDEX
CONTROL SYSTEM
STEP 11
INSPECTION Are piping connections for evaporator in cooling unit free of gas leakage? Yes
ACTION If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Add or subtract refrigerant to make specified amount, then go to Step 21. If piping is damaged or cracked, replace it. Then go to Step 21. If there is no damage, go to next step. Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21. Tighten connections to specified torque. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Tighten connections to specified torque, add or subtract refrigerant to make specified amount, then go to Step 21. If the A/C compressor is making noise, add 10 ml {10 cc, 0.34 fl oz} of compressor oil and verify that malfunction does not occur. Replace O-ring on piping, add or subtract refrigerant to make specified amount, then go to Step 21. Go to next step. (Pressure hardly increases.) Go to Step 17. Return to Step 3. Go to next step. Troubleshooting completed. (Explain to customer that cause was insufficient compressor oil.) Replace A/C compressor, then go to Step 21. (Cause is defective A/C compressor.) Go to Step 20. Go to next step. Go to next step. Repair or install air mix rod, air mix link, air mix cranks and air mix shaft securely in proper position, then go to Step 21.
No
12
Are piping connections for evaporator in cooling unit loose?
Yes
No
13
Are piping connections loose?
Yes
No
14 15 16
Does refrigerants high-pressure value hardly increase? When engine is racing, does high-pressure value increase? After compressor oil is replenished each 10 ml {10 cc, 0.34 fl oz}, does high-pressure value increase? Is only refrigerant low-pressure value high? Are heater units air mix rod, air mix link, air mix cranks and air mix shaft securely and properly installed?
Yes No Yes No Yes No Yes No Yes No
17 18
CONTINUED
U33
TO. MODEL .INDEX
TROUBLESHOOTING
STEP 19 1. 2. 3. 4. 5. 6.
INSPECTION Set the fan switch at 4th position. Turn the A/C switch on. Set to FRESH mode. Set the temperature control to MAX COLD. Set to VENT mode. Run engine at a constant 1,500 rpm for 10 minutes. 7. Run engine at idle speed for 1 minute. 8. 1 engine speed cycle is defined as going from idle speed to 4,000 rpm and back to idle speed over a period of 12 seconds. Perform 5 cycles. 9. Run engine at idle speed for 30 seconds. 10. Remove all compressor oil from A/C compressor and verify that it is 105 ml {105 cc, 3.55 fl oz}. 11. If it is more than 105 ml {105 cc, 3.55 fl oz}, put only 105 ml {105 cc, 3.55 fl oz} back into A/C compressor. 12. Carry out above steps 1 to 10 again and verify that compressor oil is 105 ml {105cc, 3.55 fl oz}. Is there 105 ml {105 cc, 3.55 fl oz} of compressor oil in A/C compressor? Is expansion valve heat-sensing tube within cooling unit securely installed in proper position? Yes Go to Step 21.
ACTION
No
Carry out 1 to 10 of step 19 again until compressor oil is 105 ml {105 cc, 3.55 fl oz}.
20
Yes
Replace expansion valve, then go to next step. (Since valve opens too much, replacement is necessary.) Install heat-sensing tube securely in proper position, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
No 21 Does cool air blow out? (Are results of refrigerant system performance test okay?) Yes No
No cool air.
TROUBLESHOOTING HINTS 1 A/C compressor system malfunction Step 2 2 Incorrect amount of refrigerant Step 3 3 A/C switch indicator light malfunction Steps 46 4 A/C relay system malfunction (WL, WL turbo, F2 Cab) Steps 7, 1113 (G6, F2) Steps 7, 11, 12 5 Refrigerant pressure switch malfunction Step 8 6 PCM A/C cut-off control system (WL, WL turbo) Steps 9, 26 (G6, F2) Step 9 7 PCM (IG1 signal) system malfunction Steps 10, 25 8 Magnetic clutch system malfunction Step 14 9 PCM (A/C signal) system malfunction (WL, WL turbo) Steps 15, 20 (G6, F2) Steps 15, 19, 20 (F2 Cab) Step 15 10 Thermoswitch, A/C switch malfunction (WL, WL turbo, G6, F2) Steps 2124 (F2 Cab) Steps 1618
CONTINUED
U34
TO. MODEL .INDEX
CONTROL SYSTEM
STEP 1 2 Does air blow out?
INSPECTION Yes No Start engine. Turn both A/C switch and fan switch on on. Does A/C compressor operate? Inspect refrigerant amount. + REFRIGERANT SYSTEM SERVICE PROCEDURES, PERFORMANCE TEST Is it okay? Does A/C switch indicator light illuminate? Turn ignition switch to ON position. (With air mix wire) Remove airflow mode wire, air intake wire and air mix wire. Remove climate control unit. (Without air mix wire) Remove airflow mode wire and air intake wire. Remove climate control unit. Remove A/C switch from climate control unit and connect A/C switch connector. Test voltage at A/C switch terminal C (IG2 signal). Is voltage approximately 12 V? Inspect A/C switch. + CONTROL SYSTEM, CLIMATE CONTROL UNIT INSPECTION Is it okay? Are A/C relay power supply fuses okay? Yes No Yes No Yes No Yes Go to next step.
ACTION Go to Step 1 of troubleshooting indexes 1, 2. Go to Step 1 of troubleshooting index 6. Go to next step. Go to next step. Add or subtract refrigerant to specified level, then go to Step 27. Go to Step 7. Go to next step Go to next step.
4
*5
No
Repair wiring harness between fuse block and A/C switch, then go to Step 27.
*6
Yes No Yes No
Inspect wiring harness between A/C switch and resistor, then go to Step 27. Replace A/C switch, then go to Step 27. Go to next step. Check for a short to ground on blown fuses circuit. Repair or replace as necessary. Install appropriate amperage fuse. Inspect refrigerant pressure switch, then go to Step 27. WL for ISRAEL: Undo short, reconnect refrigerant pressure switch connector, then go to Step 10. Other models: Undo short, reconnect refrigerant pressure switch connector, then go to next step. Go to appropriate inspection procedure. (The engine coolant temperature sensor (DTC 09) or throttle position sensor (DTC 0120), which sends the PCMs A/C cut off control input signal, may be the cause of the trouble.)
*8
Remove radiator grille. Disconnect refrigerant pressure switch connector. When refrigerant pressure switch connector terminals A and B (on wiring harness side) are shorted, does cool air blow out?
Yes No
*9
Check the DTC for the PCM ON-BOARD DIAGNOSTIC SYSTEM. Are the following DTCs displayed? D DTC 09 (WL or WL turbo) D DTC 0120 (F2 or G6) + Section F2, ON-BOARD DIAGNOSTIC SYSTEM, DIAGNOSTIC TROUBLE CODE INSPECTION
Yes
No
Go to next step.
*10
Turn ignition switch to ON position. Does magnetic clutch operate when A/C relay connector terminal B (IG2 signal) is grounded?
Yes No
Go to Step 15. Go to next step.
CONTINUED
U35
TO. MODEL .INDEX
TROUBLESHOOTING
STEP
*11
INSPECTION Turn ignition switch to ON position. Test voltage at the following A/C relay connector terminals: D Terminal A (IG2 signal) D Terminal C (A/C control signal) Is voltage approximately 12 V? Test voltage at A/C relay terminal D (A/C control signal). Is voltage approximately 12 V? Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector (on wiring harness side) terminal A (A/C control signal). Is voltage approximately 12 V? Test voltage at magnetic clutch connector terminal A (A/C control signal). Is voltage approximately 12 V? Yes No Go to next step.
ACTION
Repair wiring harness between fuse block and A/C relay, then go to Step 27. G6 or F2: Go to Step 14. Other models: Go to next step. Inspect A/C relay, then go to Step 27. Reconnect refrigerant pressure switch connector, then go to next step. Repair wiring harness between A/C relay and refrigerant pressure switch, then go to Step 27. Inspect magnetic clutch, then go to Step 27. G6 or F2: Repair wiring harness between A/C relay and magnetic clutch, then go to Step 27. Other models: Repair wiring harness between refrigerant pressure switch and magnetic clutch, then go to Step 27. F2 Cab: Go to next step. Other models: Go to Step 21. F2 Cab: Repair wiring harness between A/C relay and thermoswitch, then go to Step 27. G6 or F2: Go to Step 19. Other models: Go to Step 20. Undo short, then go to next step.
*12
*13
*14
*15
Turn A/C switch off. Remove glove compartment. Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminal (A/C signal): D Terminal B (with variable thermistor in climate control unit) D Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V? Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals shorted does cool (on wiring harness side) are shorted, air blow out? D Terminal AC (with variable thermistor in climate control unit) D Terminal BC (without variable thermistor in climate control unit) Turn ignition switch to ON position. Test voltage at the following thermoswitch connector terminals (IG2 signal): D Terminal B (with variable thermistor in climate control unit) D Terminal A (without variable thermistor in climate control unit) Is voltage approximately 12 V? Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V? Disconnect refrigerant pressure switch connector. Test voltage at refrigerant pressure switch connector ( (on wiring g harness side) ) terminal A (A/C control signal). Is voltage approximately 12 V?
Yes
No
*16
Yes
No
Undo short, then go to Step 18.
*17
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
*18
Yes
Inspect wiring harness between thermoswitch and A/C switch, then go to Step 27. Inspect A/C switch, then go to Step 27. Repair wiring harness between thermoswitch and refrigerant pressure switch, then go to Step 27. Go to next step.
No Yes
*19
No
CONTINUED
U36
TO. MODEL .INDEX
CONTROL SYSTEM
STEP
*20
INSPECTION Turn ignition switch to ON position. Test voltage at the following PCM connector terminals (A/C signal): D Terminal G (WL or WL turbo) D Terminal Q (G6 or F2) Is voltage approximately 12 V? Turn ignition switch to LOCK position. Disconnect thermoswitch connector. Start engine. Turn both A/C switch and fan switch on. When following thermoswitch connector terminals (on wiring harness side) are shorted, shorted does cool air blow out? D Terminal BC (without variable thermistor in climate control unit) D Terminal AC (with variable thermistor in climate control unit) Turn ignition switch to ON position. Test voltage at the following thermoswitch ( g ) connector terminals (IG2 signal): D Terminal A (without variable thermistor in climate control unit) D Terminal B (with variable thermistor in climate control unit) Is voltage approximately 12 V? Turn ignition switch to ON position. Turn A/C switch on. Turn fan switch off. Test voltage at A/C switch connector terminal A (A/C signal). Is voltage approximately 12 V? Test voltage at thermoswitch connector terminal C (A/C signal). Is voltage approximately 12 V? Test voltage at the following PCM connector terminals (A/C signal): D Terminal L (WL or WL turbo) D Terminal J (G6 or F2) Is voltage approximately 12 V? Inspect the following input signal components: D Engine coolant temperature sensor and PCM wiring harness (A/C cut-off control). Are they okay? Does cool air blow out? (Is refrigerant system performance test result correct?) Yes
ACTION G6 or F2: Repair wiring harness between PCM and refrigerant pressure switch, then go to Step 27. Other models: Repair wiring harness between PCM and thermoswitch, then go to Step 27. Inspect PCM, then go to Step 27. Undo short, then go to next step.
No Yes
*21
No
Go to Step 23.
22
Yes
Inspect thermoswitch, then go to Step 27.
No
Repair wiring harness between fuse block and thermoswitch, then go to Step 27.
*23
Yes
Go to next step.
No
Inspect A/C switch, then go to Step 27.
*24
Go to next step. Repair wiring harness between thermoswitch and A/C switch, go to Step 27. WL or WL turbo: Go to next step. Other models: Recheck malfunction symptoms. Repair wiring harness between A/C relay and PCM, then go to Step 27. Recheck malfunction symptoms. Replace input signal components, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
*25
*26
27
CONTINUED
U37
TO. MODEL .INDEX
TROUBLESHOOTING
Noise while operating A/C system.
TROUBLESHOOTING HINTS 1 Magnetic clutch operation noise Step 3 2 A/C compressor operation noise Steps 48 3 A/C compressor slippage noise Steps 911 4 Hose or refrigerant line interference noise Step 12 STEP 1 2 3 INSPECTION Is there a squeaking or whirling sound (A/C compressor slippage noise)? Is there a rattling or vibrating sound (interference noise)? Is there a clicking sound (magnetic clutch operation noise)? Yes No Yes No Yes Go to Step 9. Go to next step. Go to Step 12. Go to next step. Adjust clearance between magnetic clutch pressure plate and A/C compressor pulley, then go to Step 13. + CONTROL SYSTEM, MAGNETIC CLUTCH CLEARANCE ADJUSTMENT Go to next step. Go to next step. Condition is normal. (Noise normally occurs for 23 seconds immediately after A/C compressor turns on.) Go to next step. ACTION
No 4 Is noise heard continuously for more than 3 seconds after A/C compressor comes on? Yes No
Inspect idle speed. + Section F2, ENGINE TUNE-UP, IDLE SPEED ADJUSTMENT
Yes
No
Adjust idle speed, then go to Step 13.
Is it okay? 6 7 Drain compressor oil. Is it contaminated with metal particles? Is compressor oil whitish and mixed with water? Yes No Yes No 8 Is compressor oil darker than normal and contaminated with aluminum chips? Yes Go to next step. Replace A/C compressor, then go to Step 13. Replace entire A/C system (excluding heater), then go to Step 13. Go to next step. Replace A/C compressor and receiver/drier, then go to Step 13. (Since A/C compressor may be worn and receiver/drier may be clogged, replacement of receiver/drier is necessary.) Condition is normal. Recheck malfunction symptoms. Go to next step.
No 9 Inspect drive belt. + Section B2, DRIVE BELT, DRIVE BELT INSPECTION Yes
No Is it okay? 10 Is drive belt worn? Does it have foreign material imbedded in it, or have oil on it? Yes No
Adjust or replace drive belt, then go to Step 13.
Remove obstruction, remove oil, or replace drive belt, then go to Step 13. Go to next step.
CONTINUED
U38
TO. MODEL .INDEX
CONTROL SYSTEM
STEP 11
INSPECTION Inspect magnetic clutch. + CONTROL SYSTEM, MAGNETIC CLUTCH INSPECTION Is it okay? Is noise coming from A/C compressor? Yes
ACTION Replace A/C compressor (excluding pressure plate, A/C compressor pulley, and stator), then go to Step 13. Replace magnetic clutch, then go to Step 13. Visually inspect A/C compressor, replace appropriate parts if necessary, then go to next step. If noise is coming from refrigerant lines, repair any detached or missing clips, tighten loose bolts, then go to next step. Troubleshooting completed. Explain repairs to customer. Recheck malfunction symptoms, then repeat from Step 1 if malfunction recurs.
No Yes
12
No
13
Has A/C compressor noise stopped?
Yes No
CONTINUED
U39
BACK.TO.MAIN.INDEX
TO. MODEL .INDEX
TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . TD 1 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 1/3 LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . TD 4 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD 4 FUEL AND EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD 5/6 ENGINE ELECTRICAL SYSTEM . . . . . . . . . TD 6/10 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD10 MANUAL TRANSMISSION . . . . . . . . . . . . . . . TD10/11 PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . . TD11 FRONT AND REAR AXLES . . . . . . . . . . . . . . TD11 STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . TD12 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . TD12 SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . TD13/14 BODY ELECTRICAL SYSTEM . . . . . . . . . . . TD14/15 HEATER AND AIR CONDITIONER SYSTEMS . . . . . . . . . . . . . TD15
TECHNICAL DATA
ENGINE
Item Generator Drive belt deflection [Applied pressure [ 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) }) P/S A/C Generator Drive belt tension (N {kgf, lbf}) P/S A/C Compression (kPa {kgf/cm2, psi} [rpm]) New Used New Used New Used New Used New Used New Used Standard Minimum (mm {in}) (mm {in}) Engine G6 10.012.0 {0.400.47} 12.014.0 {0.480.55} 6.67.2 {0.260.28} 7.28.0 {0.290.31} 8.510.0 {0.340.39} 10.011.5 {0.400.45} 491588 {5060, 110132} 393490 {4050, 88110} 412470 {4248, 93105} 354402 {3641, 8090} 557641 {56.765.4, 125143} 471556 {48.056.7, 106124} 1255 {12.8, 182} [270] 882.6 {9.0, 128} [270] 00.7 {00.027} 00.5 {00.019}
Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
CONTINUED
TD1
TO. MODEL .INDEX
TECHNICAL DATA
Item New Generator Drive belt deflection [A li d pressure 98 [Applied kgf 22 lbf}] N {10 kgf, ( (mm { {in}) }) Used Limit New A/C (meas (measuring ring point oint a) Used Limit New A/C (meas (measuring ring point oint b) Used Limit New Generator Drive belt tension (N {kgf, lbf}) A/C Used Limit New Used Limit IN Valve clearance [Engine cold] (mm {in}) EX Compression (kPa {kgf/cm2, psi} [rpm]) Standard Minimum Standard Standard Minimum Standard Minimum (mm {in}) (mm {in}) (mm {in})
Engine WL, WL Turbo 7.09.0 {0.280.35} 8.010.0 {0.320.39} 16.0 {0.63} 5.06.2 {0.200.24} 6.06.5 {0.240.25} 11.3 {0.44} 9.511.8 {0.380.46} 11.012.5 {0.440.49} 18.0 {0.71} 442637 {4565, 99143} 383539 {3955, 86121} 177 {18, 40} 403519 {4153, 91116} 354431 {3644, 8096} 181 {18.5, 41} 0.050.15 {0.00200.0059} (0.10"0.05 {0.0039"0.0020}) 0.15 {0.0059} [Engine hot (Reference)] 0.150.25 {0.00600.0098} (0.20"0.05 {0.0079"0.0020}) 0.25 {0.0098} [Engine hot (Reference)] 2,942 {30, 427} [200] 2,648 {27, 384} [200] 9.010.0 {0.360.39} 101.2101.8 {3.9854.007} 102.5 {4.035} 113.2113.8 {4.4574.480} 114.5 {4.508} 0.51.0 {0.020.03} 00.4 {00.01} 00.5 {00.01}
Timing belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Bolt head mark W Cylinder y head bolt length (mm {in}) Bolt head mark N
Camshaft oil seal tapping amount Front oil seal tapping amount Rear oil seal tapping amount
CONTINUED
TD2
TO. MODEL .INDEX
TECHNICAL DATA
Item Generator Drive belt deflection [Applied pressure [ 98 N {10 kgf, 22 lbf}] ( (mm {i {in}) }) P/S A/C Generator Drive belt tension (N {kgf, lbf}) P/S A/C Compression (kPa {kgf/cm2, psi} [rpm]) New Used New Used New Used New Used New Used New Used Standard Minimum New Used (mm {in}) (mm {in})
Engine F2 CARB 7.08.0 {0.280.31} 8.09.0 {0.320.35} 5.06.0 {0.200.23} 5.56.5 {0.220.25} 10.012.0 {0.400.47} 12.014.0 {0.480.55} 510588 {5260, 115132} 432509 {4452, 97114} 393490 {4050, 88110} 344441 {3545, 7799} 373490 {3850, 84110} 275372 {2838, 6283} 1196 {12.2, 173} [300] 837 {8.54, 121} [300] 1226 {12.5, 178} [300] 858 {8.75, 124} [300] F2 CIS
Timing g belt deflection [Applied pressure 98 N {10 kgf, 22 lbf}] (mm {in}) Pushing distance of the front oil seal (from the edge of the chain cover) Pushing distance of the rear oil seal (from the edge of the rear cover)
8.09.0 {0.320.35} 9.010.0 {0.360.39} 0 {0} 00.5 {00.019}
CONTINUED
TD3
TO. MODEL .INDEX
TECHNICAL DATA
LUBRICATION SYSTEM
Item Engine F2 {kgf/cm2, 295392 {3.04.0, 4356} [3000] 3.9 {4.1, 3.4} 4.2 {4.4, 3.7} 4.6 {4.9, 4.0} G6 305402 {3.14.1, 4558} [3000] 4.5 {4.8, 4.0} 4.7 {5.0, 4.4} 5.5 {5.8, 4.8} WL 452529 {4.65.4, 6676} [3000] WL Turbo 402480 {4.14.9, 5969} [3000]
Oil pressure
(kPa
psi} [rpm])
Oil replacement Oil capacit capacity (L {US qt, qt lmp lm qt}) Engine oil Above 30_C {86_F} 0!C40_C {32_F104!F} 10!C20_C {14_F68!F} Above 25_C {13_F} Viscosity Above 10_C {14_F} Below 20_C {4_F} Below 0_C {32_F} 15!C40_C {5_F104!F} Oil and oil filter replacement Total (dry engine)
5.6 {5.9, 4.9} 6.3 {6.7, 5.5} 6.7 {7.1, 5.9} API service CD
API service SG SAE 40 SAE 30 SAE 20W-20 SAE 10W-30*, 10W-40, 10W-50 SAE 20W-40, 20W-50 SAE 5W-20 SAE 5W-30*
SAE 10W-30 SAE 5W-30
Below 10_C {50_F} D European specification vehicles use only those oils marked with an asterisk
COOLING SYSTEM
Item Coolant capacity ca acity (L {US qt, qt lmp lm qt}) With heater Without heater Engine F2 G6 7.5 {7.9, 6.6} 6.9 {7.3, 6.1} Sub: 83.586.5 {183187} Main: 86.589.5 {188193} Sub: 1.5 {0.06} min. Main: 8.0 {0.31} min. WL WL Turbo 9.4 {9.9, 8.3} 8.8 {9.3, 7.7}
Opening temperature Thermostat Full-open temperature Full-open lift
(_C {_F})
83.589.5 {183193}
8084 {176183}
(_C {_F}) (mm {in})
100 {212} 8.5 {0.33} min. 74102 {0.751.05, 10.714.9}
95 {203} 8.5 {0.33} min.
Radiator cap
Cap valve opening pressure (kPa {kgf/cm2, psi})
94122 {0.951.25, 13.517.7}
CONTINUED
TD4
TO. MODEL .INDEX
TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS CIS vehicles
Item Idle speed Injection timing
1 Idle speed*1
Engine G6 (rpm) (BTDC !/rpm) 730770 (750"20) 46/750 700800 (750"50) 700800 (750"50) Within the regulation Within the regulation F2 730770 (750"20) 57/750 780880 (830"50)
(rpm)
A/C P/S
ON*2 ON*3
CO concentration HC concentration Fuel pressure (kPa {kgf/cm2, psi}) Hold pressure Fuel pump maximum pressure Fuel leakage (drop/2 minutes) Fuel injector Injection volume (ml {cc, fl oz}/15 sec.) Resistance (") [20!C {68!F}] Pressure regulator
*1: *2: *3: *4:
More than 340 {3.5, 50} 500630 {5.06.5, 7292} Less than 1 5571 {5571, 1.92.3} 4660 {4660, 1.62.0}
1216 210250 {2.12.6, 3036} 270310 {2.73.2, 3945}
Fuel pressure (at vacuum ON) (kPa {kgf/cm2, psi}) Fuel pressure (at vacuum OFF*4) (kPa {kgf/cm2, psi})
Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on. A/C switch and fan switch are turned on. Steering wheel is fully turned. Hot condition at start.
DIESEL vehicles
Item Idle speed Injection timing Boost relief pressure (kPa {kgf/cm2, psi}) When A/C is operated Idle-up Idle u s speed eed (rpm) Injection pump When P/S is operated When engine is cold Cam lift (mm {in}) Injection starting pressure (MPa {kgf/cm2, psi}) Nozzle leakage Diesel smoke
*1: *2: *3:
Engine WL Turbo (rpm) 760800 700740 (720"20)*2 ATDC 10! 107115 {1.091.18, 15.516.8} 825875 (850"25) 12001500 (1350"150) 2.48 {0.098} New: 11.412.2 {116124, 16501760} Inspection: More than 10.0 {102, 1450} No leakage when pressure of 8.8 MPa {90 kgf/cm2, 1280 psi}) is applied. (%) Within the regulation 805855 (830"25) 825875 (850"25)*3 (780"20)*1 WL 700740 (720"20)
Injection nozzle
General (L.H.D.) Europe and UK Europe
CONTINUED
TD5
TO. MODEL .INDEX
TECHNICAL DATA
CARB vehicles
Item Idle speed Injection timing (rpm) (BTDC) A/C Operated Idle up speed Idle-up (rpm) P/S Operated D/P Operated T/P Operated CO concentration HC concentration Fuel pump um Discharge pressure Discharge amount Float level (mm {in}) (kPa {kgf/cm2, H L () (%) (ppm) psi}) cc {cu in} min. Engine F2 CARB 800850 (800 +50 0 ) 57 (6"1) 14001600 (1500"100) 19002100 (2000"100) 10501250 (1150"100)
1 2 2.02.5 (2.0 +0.5 0 )* , 2.03.0 (2.5"0.5)*
2025 {0.20.25, 2.83.6} 1150 {70.2} 89 {0.3150.354} 4445 {1.7321.772} 4852 {50"2}
Carburetor
*1: *2:
Primary throttle opening angle
GULF General
ENGINE ELECTRICAL SYSTEM

Item Electrolyte gravity Back-up current *1 Test load chart Battery Slow charge (A) Quick charge (A/30 min.) (A) Battery type Battery type (5-hour rate) Battery type (5-hour rate) Standard Minimum Standard Minimum Ignition switch ON Standard voltage g (V) Idle [20_C {68_F}] Generated current*2 (Reference) (A)
*1:
Engine G6 1.271.29 (mA) 80D26R 80D26R (55) 80D26R (55) ( ) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) B Terminal L S B Terminal L S 1000 (r (rpm) m) 2000 Approx. 062 Max. 20 195 5.56.5 35 3.74.4 18.5 {0.73} 5.0 {0.20} 4.86.0 {0.480.62, 1.061.36} 2.2 {0.22, 0.48} B+ Approx. 1 B+ 14.114.7 13.014.0 14.114.7 Approx. 043
Rotor resistance (Between slip rings) Brush length Brush s spring ring force
Generator
Engine speed s eed
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. *2: Must not be 0 A. CONTINUED
TD6
TO. MODEL .INDEX
TECHNICAL DATA
Item Ignition g coil Resistance [20_C {68_F}] Primary coil Secondary coil NGK Type Ty e DENSO Spark S plug Plug gap Resistance Tightening torque (k) NGK DENSO (Nm {kgfm, ftlbf}) No.1 lead High Hightension l d lead No.2 lead Resistance (k ) [20 _C {68 _F}] No.3 lead No.4 lead Center lead Commutator diameter Brush length Starter spring Brush s ring force Pinion gap No load test
*3:
Engine G6 ( ) (k) 0.810.99 1016 ZFR5F11*3, *5, ZFR6F11*4, *5, BKR5E*3, BKR6E*4 KJ16CR11*3, *5, KJ20CR11*4, *5 K16PRU*3, K20PRU*4 (mm {in}) 1.01.1 {0.0400.043}*5, 0.70.8 {0.0280.031} 3 07 5 3.07.5 1522 {1.52.3, 1116} 2.97.7 4.310.8 5.413.5 6.616.2 4.511.2 29.4 {1.16} 28.8 {1.14} 12.3 {0.48} 7.0 {0.28} 180243 {18.324.8, 40.354.5} 57.7 {5.88, 12.9} 3.0 {1.118} 11.5 Below 100 (mm {in}) (mm {in}) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) (mm {in}) (V) (A)
Standard Minimum Standard Minimum Standard Minimum Voltage Current
Standard plug *4: Cold type plug *5: Europe
CONTINUED
TD7
TO. MODEL .INDEX
TECHNICAL DATA
Item Electrolyte gravity Back-up current Test load chart Battery Slow charge g (A) Quick charge g (A/30 min.) (A)
*1
Engine F2 CARB 1.271.29 (mA) Max. 20 110 180 3.04.0 4.55.5 20 30 ( ) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) B Terminal L S B 3.74.4 18.5 {0.73} 5.0 {0.20} 4.86.0 {0.480.62, 1.061.36} 2.2 {0.22, 0.48} B+ Approx. 1 B+ 14.114.7 13.014.0 14.114.7 Approx. 043 Approx. 062 1.0351.265 1016 02/1200, 913/2200, 1923/6000 02/20 {150, 5.9}, 1115/53.3 {400, 15.7} BKR5E*5 BKR6E*3 BKR7E*4 K16PRU*5 K20PRU*3 K22PRU*4 (mm {in}) (k) NGK DENSO (Nm {kgfm, ftlbf}) No.1 lead No.2 lead 0.70.8 {0.0280.031} BPR5ES11*3 BPR6ES11*4 W16EXRU11*3 W20EXRU11*4 1.01.1 {0.0400.043} 0.810.99 34B19R 55D23R 34B19R (27) 55D23R (48) 34B19R (27) 55D23R (48) F2 CIS
Battery ty type e Battery y type y (5-hour rate) Battery y type y (5-hour rate) Standard Minimum Standard Minimum Ignition switch ON
Rotor resistance (Between slip rings) Brush length spring Brush s ring force
Generator Standard voltage g (V)
Idle [20_C {68_F}] Generated current*2 (Reference) (A) Ignition g coil Resistance [20_C {68_F}]
Terminal
L S 1000
Engine speed s eed Primary coil Secondary coil
(r m) (rpm) 2000 ( ) (k) /rpm /kPa {mmHg, inHg} NGK
Centrifugal spark advance Distributor Vacuum spark advance
Type Ty e Spark plug lug Plug gap Resistance Tightening torque DENSO
30 75 3.07.5 1522 {1.52.3, 1116} 2.757.07 4.1910.43 4.3810.88 5.7314.08 2.005.33 3.99.9
High Hightension l d lead

*1: *2: *3: *4: *5:
Resistance (k ) [20 _C {68 _F}]
No.3 lead No.4 lead Center lead
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition switch is at OFF position and the ignition key is removed. Must not be 0 A. Standard plug Cold type plug Hot type plug
CONTINUED
TD8
TO. MODEL .INDEX
TECHNICAL DATA
Item Commutator diameter Brush length Starter spring Brush s ring force Pinion gap No load test Voltage Current Standard Minimum Standard Minimum Standard Minimum (mm {in}) (mm {in}) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) (mm {in}) (V) (A)
Engine F2 CARB 32.0 {1.26} 31.4 {1.24} 17.0 {0.67} 11.5 {0.46} 19.2 {1.95, 4.25} 8.83 {0.90, 1.98} 0.52.0 {0.0200.078} 11.5 Below 60 Engine WL, WL Turbo 1.271.29 (mA) 75D26L 20 max. 195 195 250 5.56.5 5.56.5 6.58.0 35 35 40 ( ) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) B A S I B 2.50 17.9 {0.70} 5.0 {0.20} 2.65 {0.27, 0.59} 1.18 {0.12, 0.26} B+ B+ 0 2.04.0 14.0514.85 14.0514.85 7.0257.425 13.0014.85 Approx. 058 Approx. 074 F2 CIS
Item Electrolyte gravity Back-up current *1 Test load chart (A) Battery Slow charge (A) Battery type (5-hour rate) Battery type 75D26R 95D31R 75D26L (52) 75D26R (52) 95D31R (64) 75D26L (52) Quick charge (A/30 min.) min ) Battery type (5-hour rate) 75D26R (52) 95D31R (64) Rotor resistance (Between slip rings) Brush length Brush s spring ring force Standard Minimum Standard Minimum Engine g switch ON G Generator Standard voltage g (V) Idle [20_C {68_F}] Terminal
Terminal
A S I Terminal B current Terminal B current
Generated current*2 (Reference) (A)

*1: Back-up
Engine g speed (rpm)
1000 2000
current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine switch is at OFF position and the engine key is removed. *2: Must not be 0 A.
CONTINUED
TD9
TO. MODEL .INDEX
TECHNICAL DATA
Item Commutator diameter Brush length Starter spring Brush s ring force Pinion gap No load test Voltage Current Standard Minimum Standard Minimum Standard Minimum (mm {in}) (mm {in}) (mm {in}) (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) (mm {in}) (V) (A)
Engine WL, WL Turbo 29.5 {1.16} 27.3 {1.07} 17.7 {0.70} 8.7 {0.34} 27.033.0 {2.753.37, 6.057.41} 3.0 {0.12} 11 Below 130
CLUTCH
Item Clutch pedal Height Pedal free play Clutch disc Runout limit Clutch fluid Type SAE J1703 or FMVSS116 DOT-3 or DOT-4 (mm {in}) 0.7 {0.027} max. (mm {in}) (mm {in}) 241.6246.6 {9.529.70} 3.08.0 {0.120.31} Specification
MANUAL TRANSMISSION M15M-D

Item Type All-season Transmission oil Viscosity Capacity Above 10 _C {50 _F} (L {US qt, lmp qt}) Specification API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.0 {2.1, 1.8}
M15MX-D
Item Type All-season Transmission oil Viscosity Capacity Type All-season Transfer oil Viscosity Capacity Above 10 _C {50 _F} (L {US qt, lmp qt}) Above 10 _C {50 _F} (L {US qt, lmp qt}) Specification API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.5 {2.6, 2.2} API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.0 {2.1, 1.8}
R15M-D
Item Type All-season Transmission oil Viscosity Capacity Above 10 _C {50 _F} (L {US qt, lmp qt}) Specification API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.8 {3.0, 2.5}
CONTINUED
TD10
TO. MODEL .INDEX
TECHNICAL DATA
R15MX-D
Item Type All-season Transmission oil Viscosity Capacity Type All-season Transfer oil Viscosity Capacity Above 10 _C {50 _F} (L {US qt, lmp qt}) Above 10 _C {50 _F} (L {US qt, lmp qt}) Specification API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 3.2 {3.4, 2.8} API service GL-4 or GL-5 SAE 75W-90 SAE 80W-90 2.0 {2.1, 1.8}
PROPELLER SHAFT
Item Runout limit (mm {in}) Propeller shaft (4 0.4 {0.016} 0.31.1 {3.012.0, 2.710.4} 2) Front propeller shaft (4 4) 0.4 {0.016} 0.30.7 {3.08.0, 2.76.9} Rear propeller shaft (4 4) 0.4 {0.016} 0.31.1 {3.012.0, 2.710.4}
Starting torque of universal (Nm {kgfcm, inlbf})
FRONT AND REAR AXLES

Item Play Preload Front axle Wheel bearing (Nm {kgfcm, inlbf}) Pull scale reading (N {kgf, lbf}) Rear axle Drive shaft Wheel bearing play Shaft length g (mm {in}) Pinion height Left side Right side (mm {in}) Front Rear Front Rear Front Rear (mm {in}) (mm {in}) 4 2 0 {0} 0.40.7 {4.08.0, 3.56.9} 5.910.7 {0.61.1, 1.42.4} 0.050.25 {0.0020.010} 551.0561.0 {21.722.0} 619.0629.0 {24.424.7} 0.0320.032 {0.0010.001} 0.2540.254 {0.0100.010} 00.1 {00.003} 0.91.3 {9.014.0, 7.912.1} 1.82.6 {18.027.0, 15.723.4} 0.090.11 {0.00360.0043} [Front] 0.120.20 {0.0050.008} [Rear] 0.05 {0.002} [Front], 0.12 {0.008} [Rear] 0.07 {0.003} [Front], 0.08 {0.005} [Rear] API service GL-5 Front Rear Capacity (L {US qt qt, lmp qt}) Grade LSD Viscosity Capacity (L {US qt, lmp qt}) 1.40 {1.48, 1.23} Front Rear 1.40 {1.48, 1.23} SAE 90 1.85 {1.96, 1.63} Above-18_C {0_F}: SAE 90 Below-18_C {0_F}: SAE 80 SAE 90 1.20 {1.27, 1.06} [MFW] 1.50 {1.59, 1.32} [RFW] 1.85 {1.96, 1.63} API service GL-6 4 4
Backlash of side gear g and differential pinion (mm {in}) Drive pinion inion preload reload (Nm {kgfcm, {kgfcm inlbf}) Backlash of drive pinion inion and ring gear (mm {in}) Differential Standard Minimum Allowance variation Grade Viscosity y Standard Oil
CONTINUED
TD11
TO. MODEL .INDEX
TECHNICAL DATA
STEERING SYSTEM
Item Steering wheel Play Effort Backlash Steering gear Worm shaft preload (mm {in}) (Nm {kgfcm, inlbf}) (mm {in}) (Nm {kgfcm, inlbf}) 1.01.3 {1014, 8.712.1} API service GL-4, SAE 90 (L {US qt, lmp qt}) 0.34 {0.36, 0.30} Manual steering Engine speed sensing power steering 7.8 {80, 69} max. 0 {0} 0.71.2 {6.512.5, 5.710.8} 8.99.3 {9095, 12801350} ATF M-III or equivalent (e.g. DexronRII) 1.1 {1.2, 1.0} 8.99.3 {9095, 12801350}
030 {01.18} 45 {460, 399} max.
Gear housing pressure (MPa {kgf/cm2, psi}) Oil Power steering oil pump Grade Capacity
Oil pump fluid pressure (MPa {kgf/cm2, psi})
BRAKING SYSTEM
Item Brake pedal Brake pedal height Brake pedal play Brake pedal-to-floor clearance Power brake unit Fluid pressure when pedal depressed at 196 N {20 kgf ,44 lbf}) (kPa {kgf/cm2, psi}) Vacuum pump Vacuum specification [In 20 seconds] [When engine speed 1,500 rpm] (kPa {mmHg, in Hg}) Maximum vacuum [When engine speed 3,000 rpm] (kPa {mmHg, in Hg}) Braking force control device Type Rear fluid pressure when front pressure is 4,900 kPa {50 kgf/cm2, 711 psi} (kPa {kgf/cm2, psi}) Front disc brake Disc pad thickness limit Disc plate late Thickness limit Runout limit (mm {in}) (mm {in}) (mm {in}) (mm {in}) (mm {in}) 271.5 {10.68} 2.0 {0.08} 22 {0.87} 0.05 {0.002} 1.0 {0.04} 296.5 {11.67} LSPV 2,550 {26, 370} 73.3 {550, 21.7} Power brake unit at 0 kPa {0 mmHg, 0 in Hg} Power brake unit at 66.7 kPa {500 mmHg, 19.7 in Hg} 790 {8, 114} min. (mm {in}) (mm {in}) (mm {in}) L.H.D.: 214219 {8.438.81} R.H.D.: 219224 {8.638.81} 38 {0.120.31} 105 {4.2} min. 4 2 F2, G6 WL, WL Turbo 4 4
8,240 {84, 1,200} min.
93.3 {700, 27.6}
Rear drum brake Brake lining thickness limit Drum maximum diameter Parking brake Parking brake lever stroke [When pulled at 98 N {10 kgf, 22 lbf}] (notches) Brake fluid Type SAE J1703 or FMVSS116 DOT-3 or DOT-4 17
TD12
CONTINUED
TO. MODEL .INDEX
TECHNICAL DATA
SUSPENSION Suspension
Item Total toe-in Front wheel alignment li [unloaded*1] Inner Outer (mm {in}) (Degree) 0_16 "16 +2_ 35_00 3_ 33_00 +2_ 3_ 0_56"30 1_37"45 (mm {in}) (N {kgf, lbf}) (N {kgf, lbf}) (mm {in}) 68 {0.240.31} 1444 {0.74.5, 1.69.9} 3.432.5 {0.43.2, 0.97.0} 1821 {0.710.82} 4 2 3"3 {0.12"0.12} 0_14 "14 33_30 +2_ 3_ 30_00 +2_ 3_ 1_ 06"30 2_02"45 4 4
Maximum steering angle Camber angle Caster angle*2
Exposed thread of shock absorber piston Lower arm ball joint rotation torque (Pull scale reading) Upper arm ball joint rotation torque (Pull scale reading) Exposed thread of stabilizer control link bolt
*1:
Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in designated positions. Adjust to the median when carrying out wheel alignment. *2: Difference between left and right must not exceed 45.
Wheels and Tires Europe

Item Size Front Rear Front Tire Air pressure ressure (kPa {kgf/cm2, psi}) Rear Wear limit Size Wh l Wheel Offset Pitch circle diameter Tightening torque (Nm {kgfcm, inlbf}) Wheel and tire Runout limit (mm {in}) Imbalance limit Horizontal Vertical (g {oz}) (mm {in}) (mm {in}) Up to full passenger Full loaded Up to full passenger Full loaded (mm {in}) 14 5J 14 5 1/2J 4 2 195R14C-8PR 205/75R14C 200 {2.0, 28} 8 26} 180 {1 {1.8, 220 {2.2, 31} 180 {1.8, 26} 200 {2.0, 28} 180 {1.8, 26} 250 {2.5, 35} 1.6 {0.06} 14 5 1/2J 15 6 1/2JJ 25 {0.98} 139.7 {5.45} Standard wheel: 89117 {912, 6586} Styled wheel (16 6JJ): 118147 {1215, 87108} 2.0 {0.078} 1.5 {0.059} 10 {0.35} 16 6JJ 35 {1.38} 8 26} 180 {1 {1.8, 200 {2.0, 28} 180 {1.8, 26} 450 {4.5, 63} 4 4 235/75R15 105S 205R16C-8PR 180 {1.8, 26}
450 {4.5, 63}
40 {1.57}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on either side of the wheel.
CONTINUED
TD13
TO. MODEL .INDEX
TECHNICAL DATA
General
Item Size Front Rear Unloade d (Up to full Front passenger ) Loaded (Full loaded) Unloade d (Up to full Rear passenger ) Loaded (Full loaded) Wear limit Size Wheel Offset Pitch circle diameter Tightening torque (Nm {kgfcm, inlbf}) Wheel Horizontal and tire Runout limit (mm {in}) Vertical Imbalance limit (g {oz}) (mm {in}) (mm {in}) (mm {in}) 14 5J 14 5J 14 5 1/2J 450 {4.5, 63} 200 {2.0, 28} 4 2 185R14C 185R14C8PR 195R14C 195R14C8PR 4 4 205R16C 235/75R15 P235/75R1 P235/75R1 205R16C8PR 105S 5 105S 5 106S
180 {1.8, 26}
180 {1.8, 26} 180 {1.8, 26} 200 {2.0, 28}
Tire
Air pressure ressure (kPa {kgf/cm2, psi})
180 {1.8, 26}
250 {2.5, 35} 1.6 {0.06} 16 6JJ 35 {1.38} 139.7 {5.45}
240 {2.4, 34}
260 {2.6, 36}
15 6 1/2JJ 25 {0.98}
40 {1.57}
Standard wheel: 89117 {912, 6586} Styled wheel (16 6JJ): 118147 {1215, 87108} 2.0 {0.078} 1.5 {0.059} 10 {0.35}
D One balance weight: max. 60 g {2.1 oz}. D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim. D Do not use more than two balance weights on the inner or outer side of the wheel.

Item Headlight Parking light Front turn light Exterior light bulb capacity ca acity (W) Brake light/taillight Rear turn light Back-up light Rear fog light License plate light Interior light bulb capacity (W) Interior light Stretch cab, Double cab Regular cab High beam/Low beam* Specification 60/55 2 5 2 21 2 21/5 2 21 2 21 2 21 1 5 2 10 1 8 1 3.4 4
Instrument cluster illumination
CONTINUED
TD14
TO. MODEL .INDEX
TECHNICAL DATA
Oil pressure warning light Generator warning light Sedimentor warning light Brake system warning light Warning and indicator light bulb capacity Rear window defroster indicator light (W) Glow indicator light High beam indicator light Turn indicator light Air bag system warning light 4 4 indicator light LOCK indicator light
1.4 1 1.4 1 1.4 1 1.4 1 1.4 1 1.4 1 1.4 1 1.4 2 1.4 1 1.4 1 1.4 1
*: Also remains illuminated when high beam turned on. HEATER AND AIR CONDITIONER SYSTEMS
Item Refrigerant Regular amount Lubricating oil A/C compressor com ressor (g {oz}) Sealed volume (ml {cc, fl oz}) Specification G6, WL 550 {19.4} 180 {180, 6.08} 0.350.75 {0.0140.029} 0.30.6 {0.0120.023} F2
Magnetic clutch clearance (mm {in})
CONTINUED
TD15
BACK TO MAIN INDEX
TO. MODEL .INDEX
SPECIAL TOOLS
SPECIAL TOOLS.............................................. ST-1 ENGINE ........................................................ ST-1 LUBRICATION SYSTEM ............................... ST-1 COOLING SYSTEM ...................................... ST-2 FUELAND EMISSION CONTROL SYSTEMS ................................. ST-2 CLUTCH ....................................................... ST-2 PROPELLER SHAFT .................................... ST-3 FRONT AND REAR AXLES ......................... ST-3/5 STEERING SYSTEM ................................... ST-6 BRAKING SYSTEM ...................................... ST-7 SUSPENSION .............................................. ST-7 BODY ........................................................... ST-7 BODY ELECTRICAL SYSTEM ..................... ST-8 HEATER AND AIR CONDITIONER SYSTEMS ...................... ST-8
SPECIAL TOOLS
ENGINE 49 S013 1A1 Compression gauge set 49 9200 020A Belt tension gauge 49 S011 103 Oil seal installer
CONTINUED
49 8010301 Oil seal installer
49 S011 102A Crankshaft lock tool
49 B025 001 Body
49 G033 107A Dust cover installer
49 S120 710 Coupling flange holder
49 P005 204 Oil seal installer
49 H011 101A Crankshaft lock tool
LUBRICATION SYSTEM 490187280 Oil pressure gauge 49 G014 001 Oil filter wrench
CONTINUED
ST-1
TO. MODEL .INDEX
SPECIAL TOOLS
COOLING SYSTEM 49 9200 145 Radiator cap tester adapter set FUEL AND EMISSION CONTROL SYSTEMS 49 8120 215B Pulley puller 49L018901 Injector checker Self-diagnosis checker 49 B019 9A0 System selector 499140074 Cam lift measuring device 49 T088 0A3* 2 49 T088 0A5* NGS set
1
49H01S9A1A
Program card
SST No. for Program card varies with language 49 T088 030E (English & French) 49 T088 031 E (English & German) 49 T088 032E (English & Dutch) 49 T088 033E (English & Swedish) 49 T088 034C (English & Spanish) 49 T088 035C (English & Portuguese) 49 T088 036C (English & Italian)
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only CLUTCH 49 0259 770B Flare nut wrench 49 E011 1A0 Ring gear brake set 49 SE01 310A Clutch disc centering tool
49 1285 071 Needle bearing puller
CONTINUED
ST-2
TO. MODEL .INDEX
SPECIAL TOOLS
PROPELLER SHAFT 49 0259 440 Mainshaft holder 49 S 120 440 Mainshaft holder
FRONT AND REAR AXLES 49 T028 3A0 Ball joint puller set 49 T028 303 Body (Part of 49 T028 3A0) 49 B025 001 Body 49 T028 304 Attachment (Part of 49 T028 3A0) 49 F019 001 Oil seal installer
49 H033 101 Bearing remover
49 S231 635 Front hub locknut wrench
49 S231 660 Needle bearing puller
49 S033 108 Bearing installer
49 F027 007 Attachment 72
49 S120 645A Rear shaft holder
49 0603 635A Rear shaft nut wrench
49 S 120 748 Attachment
49 U027 003 Oil seal installer
CONTINUED
ST-3
TO. MODEL .INDEX
SPECIAL TOOLS
49 H025 001 Bearing installer 49 M005 561 Differential hanger carrier 49 0727 570 Pinion height gauge body
49 8531 565 Drive model pinion
49 0305 555 Gauge block
49 0259 720 Differential side bearing adjust nut wrench
49 0839 425C Bearing puller set
49 F027 005 Attachment 62 (Part of 49 F027 0A1)
49 S120 710 Coupling flange holder
49 H027 002 Bearing remover
49 G030 795 Oil seal installer
49 G030 338 Attachment E
49 F401 331 Body (Part of 49 F401 330B)
49 S026 2A1 Rear shaft bearing puller
49 S026 204 Plate (Part of 49 S026 2A1)
49 S026 205 Rod (Part of 49 S026 2A1)
49 S026 208 Attachment (Part of 49 S026 2A1)
49 0710 520 Bearing puller
49 W027 0A0 Oil seal installer set
49 W027 001 Body (Part of 49 W027 0A0)
49 U027 004 Oil seal remover
49 M005 795 Oil seal installer
49 U027 005 Bearing installer
CONTINUED ST-4
TO. MODEL .INDEX
SPECIAL TOOLS
49 U027 007 Oil seal installer 49 0813 215A Tubular dowel puller 49 F028 204 Bushing installer
49 M005 796 Body (Part of 49 M005 795) 49 UN27 004 Collar B
49 U027 0A0
49 UN27 003 Collar A
L.S.D. replacer set 49 U027 008 Gauge block 49 F027 009 Attachment 68 & 77
49 U027 009 Oil seal installer
49 UB71525 Bearing installer
49 0107 680A Engine stand
49 U027 011 Shaft (Part of 49 U027 0A0)
49 U027 012 Attachment A (Part of 49 U027 0A0)
49 U027 013 Attachment B (Part of 49 U027 0A0)
49 U027 014 Bolt (Part of 49 U027 0A0)
CONTINUED
ST-5
TO. MODEL .INDEX
SPECIAL TOOLS
STEERING SYSTEM 49 T028 3A0 Ball joint puller set 49 T028 303 Body (Part of 49 T028 3A0) 49 1232 672 Gauge (Part of 49 1232 670A) 49 T028 304 Attachment (Part of 49 T028 3A0) 49 1232 673 Valve body (Part of 49 1232 670A)
491232670A Power steering gauge set
49 H002 671 Adapter
49 0180 510B Preload measuring attachment
49 U032 3A0 Pitman arm puller
49 B032 304 Adapter
491243785A Dust boot installer
49 U034 209 Clip guide
49 U032 201 Locknut wrench
49 G032 354 Adjust wrench
49 G032 3A4 Power steering gauge adapter set
CONTINUED
ST-6
TO. MODEL .INDEX
SPECIAL TOOLS
BRAKING SYSTEM 49 U043 0A0 Oil pressure gauge set 49 U043 004 Oil pressure gauge (Part of 49 U043 0A0) 49 0259 770B Flare nut wrench 49 U043 005 Joint (Part of 49 U043 0A0) 49 B043 001 Adjust gauge
49 U043 006 Hose (Part of 49 U043 0A0) 49 0221 600C Disc brake expand tool
49 E043 003A Turning lock tool
49 0208 701 A Boot air out tool
49 B043 004 Socket wrench
SUSPENSION 49 T028 3A0 Ball joint puller set 49 0180 510B Preload measuring attachment 49 U034 208 Clip guide
49 UB39 615 Bushing puller & installer set
49 U034 2A0 Lower arm bushing puller & installer set
49 U034 209 Clip guide
BODY 49 0305 870A Window tool set 49 0259 866A Window inserting tool
CONTINUED
ST-7
TO. MODEL .INDEX
SPECIAL TOOLS
BODY ELECTRICAL SYSTEM 49 H066 002 Deployment tool 49 D066 002 Adapter harness 49 0839 285 Fuel And Thermometer checker (OLD) 49 T088 0A3* 49 T088 0A5*2 NGS set
1
49 N088 0A0 Fuel And Thermometer checker (NEW)
49 D066 801 A Removing tool
Program card
SST No. for Program card varies with language 49 T088 030E (English & French) 49 T088 031E (English & German) 49 T088 032E (English & Dutch) 49 T088 033E (English & Swedish) 49 T088 034C (English & Spanish) 49 T088 035C (English & Portuguese) 49 T088 036C (English & Italian)
49 T088 037B (English & Danish) 49 T088 038B (English & Norwegian) 49 T088 039B (English & Czech) 49 T088 041 B (English & Greek) 49 T088 042B (English & Hungarian) 49 T088 043B (English & Polish) 49 T088 044B (English & Spanish) 49 T088 045B (English & Portuguese)
*1: Except Europe *2: Europe only HEATER AND AIR CONDITIONER SYSTEMS 49 C061 0A0A Manifold gauge set (R-134a) 49 C061 012 Anti-back flow valve (R-134a) 49 C061 013 Gas leak tester (R-134a)
49 D066 801A Removing tool
49 H061 005 Attachment
ST-8

Ranger Drifter Repair Manual F161!10!99a

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Ranger Drifter Repair Manual F161!10!99a

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BACK.TO.MODEL.

VIEW MAIN INDEX TO MODEL INDEX

Ranger / Drifter Repair Manual

Ford/Mazda Motor Company

BACK TO FOREWORD & ENGINE INDEX

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

Ranger / Drifter Repair Manual

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

VEHICLE IDENTIFICATION NUMBERS (VIN)

General specs. (L.H.D.)

General specs. (R.H.D.)

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

HOW TO USE THIS MANUAL

SHOWS PROCEDURE ORDER FOR SERVICE

SHOWS TIGHTENING TORQUE SPECIFICATIONS

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

HOW TO USE THIS MANUAL

SHOWS EXPENDABLE PARTS

SHOWS DETAILS SHOWS TIGHTENING TORQUE UNITS

SHOWS THERE ARE REFERRAL NOTES FOR SERVICE

SHOWS SPECIAL SERVICE TOOL (SST) NO.

SHOWS REFERRAL NOTES FOR SERVICE

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

HOW TO USE THIS MANUAL

TROUBLESHOOTING PROCEDURE Basic Flow of Troubleshooting

ACTUAL TROUBLESHOOTING PROCEDURES SECTION K ONLY

Apply petroleum jelly

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

HOW TO USE THIS MANUAL

SHOW POINTS REQUIRING ATTENTION IN REGARD TO INSPECTION RESULTS

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HOW TO USE THIS MANUAL

PARTS WHICH MAY BE THE CAUSE OF PROBLEMS

PART WHICH MAY BE THE SYMPTOM

CHOOSE THE ACTUAL SYMPTOM

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

HOW TO USE THIS MANUAL

TROUBLESHOOTING HINTS describes possible point of malfunction.

ACTION describes the appropriate action to take as a result (Yes/No) of INSPECTION.

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

D The actual converted values for 2.7 kgf/cm2 are

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

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RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

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prescribed locations (such as oil seals) before reassembly.

ADJUSTMENT D Use suitable gauges and/or testers when making adjustments.

D Sealant, a gasket, or both should be applied to the

RANG.DRFT.REPAIR MANUAL PAGES. FROM. MANUAL

TO. MODEL .INDEX

FUNDAMENTAL PROCEDURES, INSTALLATION OF RADIO SYSTEM

INSTALLATION OF RADIO SYSTEM

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