Ford PK PJ Ranger 2006-2011 Workshop Repair Service Manual 2000 Page

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CONTENTS
Title
GENERAL INFORMATION
DIMENSIONS
FOREWORD
This manual has been prepared to

provide information covering normal
service repairs and maintenance for the
wanger.
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 Motor Company
APPLICATION:
This manual is applicable to vehicles
beginning with the Vehicle Identification
Numbers (VIN), and related materials shown
on the following page.
GENERAL INFORMATION
00
SECTION
._------------------------------GENERAL INFORMATION ... 00-00
00-00
GENERAL INFORMATION
HOW TO USE THIS MANUAL ........ . 00-00-2
ABBREVIATION . .................. . 00-00-4
VEHICLE IDENTIFICATION NUMBER

(VIN) CODE . ..................... 00-00-1
VEHICLE IDENTIFICATION NUMBERS
(VIN) . ........................... 00-00-1
VEHICLE IDENTIFICATION NUMBER (VIN) CODE
MNBBS1 01 06W123456
==I==I=I=l
DCFOOOOOOOOOB05
~I____
1 - ._ _ _ _ _ _ _ _ _ _
-..:...P..:.:la:..:.;..nt W=A. A. Thailand
Production year
No meaning
L--_ _ _ _ _ _ _ _ _ _ _...:E:;,;n:o!:gii:.:..:.ne~tyJ:.PEe:_
L--_ _ _ _ _ _ _ _ _--..::G::..ro:.::s:.:.s...:.ve:::.:h.:::ic::.:le:...w:.:.:e::::ig~h:.:..t
L--_ _ _ _ _ _ _ _ _ _ _ _ _
Serial No.
Bodv stvle
~~~~
L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ Product
sorce
~~~~
L--_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _..:..A.::.:.ir..,::b=a
World manufacturer identification
6= 2006
7= 2007
0
1=WL-C (2.5 L-DI)
2= WL-3 (2.5 L Diesel-Emission Turbo)
9= WE-C (3.0 L-DI)
D= 2268-2721 kg {5001--6000 Ibs}
E= 2722-3175 kg {6001-7000 Ibs}
A= Regular cab.-without box
B= Regular cab.-with box
E= Double cab.-without box
F= Double cab.-with box
1= Stretch cab.
(with Rear Access System) -without box
2= Stretch cab.
(with Rear Access System) -with box
S= Japan (for Thailand)
B= Seatbelt only
D= with Air bag (Driver side) .~
L= with Air bag (Driver and Passenger)
U= with Air bag (Driver, Passenger and Side air bag)
MNB= FORD (Thailand)
DCFOOOZWB001
00-00-1
GENERAL INFORMATION
HOW TO USE THIS MANUAL

DCFOOOOOOOOOB03
This manual contains frame and cabin dimensions. An explanation of how to read the dimensional drawing is given
~~
How To Read Frame Dimensions

Frame dimensions are the dimensions measured by projecting certain reference points onto a plane surface.
When there are no specific indications, the sta ndard pOints and dimensions are symmetrical in regard to the
center of the vehicle.
The hypothetical lines may differ according to the vehicle model.
The outline drawing shows the figure that projected vehicle from the upper side.
Example
DIMENSIONS
FRAME
DIMENSIONS~ Shows box size
IPay Load:2t Engine:SL Mission:5MT
f-- Shows applicable vehicle
Shows dimension
Flat-plane dimensions
84{22.99 t 1
489
358
150
( .4 )\ (19.25) (14.09l/
.91
172{6.77) 131{5.16)
171{6.73)
223
365
598 23.54)
8.78 I{ 4.3 ) \
95{3.74) 27{1.06) 85{3.35)
'j
I{
Shows imaginary reference line

Straight-line dimensions
8
Shows point name

Point
symbol
I Designation I
Hole diameter
or boll or nut
size mm{ln}
Point
symbol
"
Front spring hanger rear

Crossmember No.4 side hole
Side member outer front end
Crossmember No.1 guide pipe

Side member standard hole
Air duct bracket
ct>14.5 {O.57}
ct>10 {O.39}
ct>10 {O.39}
L
M
N
Front spring hanger front

Cross member No.2 side hole
ct>19 {O.75}
ct> 54 {2.13}
ct>10 {O.39}
C
D
E
F
G
H
I
J
Radiator guide bracket

Dumper mountinQ hole
Cabin mounting bracket
II
ct>40 {1.57}
ct>13 {O.51}
l;jXlo
IO.51xO.591
Hole diameter
Designation
o
p
ct>13.7 {O.54}
ct>10{O.39}
R
S
Rear s rin han er rear

Side member standard hole
I-- Shows slot
ct>33 {1.30}
ct>67 {2.64}
ct>19 {O.75}
DBG0980B1
00-00-2
GENERAL INFORMATION
How To Rear Cabin Dimensions
e Cabin dimensions are the actual dimensions between two standard points.
.r.
I:!.
Y
9
center of the vehicle.
_e_W--=.h_e_n_t_h_e_re_a_r_e_n_o_s_pe_c_i_fic_in_d_ic_a_t_io_n_s_,
_th_e_s_t_a_n_d_ar_d_p_o_i_nt_s_a_n_d_d_im_e_n_s_io_n_s_a_r_e_s__m_m_e_tr_ic_a_l_in_re__a_r_d_to_th_e---,.'.
Example
"j
Shows vehicle section
FRONT
BODY~TRAIGHT-LINE DIMENSIONS (1)

mm{in}
Shows point symbol

(Right side of
vehiCle)-H~~E;~~g=::bb(~r~~~;t~~~R~~~~1J
Shows point symbol

(Left side of vehicle)
Shows detail
drawing of points
Shows point name

Hole diameter
or bolt or nut
size mm {in}
Point
symbol
A
B
C
Shroud panel datum hole

fJ7 {O.28}
fJ7 {O.28}
fJ7{O.28}
Point
symbol
D
E
F
Designation
Crossmember datum hole
Hole diameter
or bolt or nut
size mm {in}
fJ7{O.28}
fJ6.2 {O.24}
fJ10 {O.39}
DBG0980B101
00-00-3
GENERAL INFORMATION
Symbols of Body Dimensions
The following 8 symbols are used to iQdicate the standard points.
MEANING
SYMBOL
G)6iJ
./
Center of circular hole
SYMBOL
(arrow only)
MEANING
Bolt tip
Center elliptical hole
Center of rectangular-shaped hole
Notch
Edge of rectangular-shaped hole
Panel seam, bead, etc.
MZZ2010B016
ABBREVIATION
CM
Ctr
DSC
Fr
HU
LH
M
MC
RH
Rr
Control module
Center
Dynamic stability control
Front
Hydraulic unit
Left
Metallic
Mica
Right
Rear
00-00-4
DCFOOOOOOOOOB04
BODY & ACCESSORIES
QT~ 1
41-----------------------------------------BODY STRUCTURE
[DIMENSIONS] ........... 09-800
09-800
BODY STRUCTURE [DIMENSIONS]
FRAME DIMENSIONS (UNDERBODY

REGULAR CAB 2WD) ....... 09-80D-2
DOUBLE CAB 2WD) .. 09-80D-4
STRETCH CAB {WITH REAR ACCESS
SYSTEM} 2WD) ....... 09-80D-6
SYSTEM} HI-RIDER) ... 09-80D-8
DOUBLE CAB 4WD) .. 09-80D-10
SYSTEM} 4WD) ....... 09-80D-12
FRONT BODY STRAIGHT-LINE
DIMENSIONS (1) ....... 09-80D-14
FRONT BODY STRAIGHT-LINE

DIMENSIONS (2) .... 09-80D-15
CABIN SIDE FRAME STRAIGHT-LINE
DIMENSIONS (REGULAR CAB) . 09-80D-17
DIMENSIONS (DOUBLE CAB) . 09-80D-18
DIMENSIONS (STRETHC CAB
{WITH REAR ACCESS SYSTEM},
HI-RIDER) .... 09-80D-19
ROOM STRAIGHT-LINE DIMENSIONS
(REGULAR CAB) .. 09-80D-21
(DOUBLE CAB) . : . 09-80D-22
(STRETHC CAB {WITH REAR ACCESS
SYSTEM}, HI-RIDER) .... 09-80D-24
09-800-1
6,
CD
:11
CD
.....
.....
~~
!Jl .....
......
1\3
...
coOl
~U)
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......
oS
~oo
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00 .....
oS
'l31\)
~~
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W
CO
oS
(,)
I\)
'i\)
co
-.,J
0
0
Ol
0>
00
.....
Ol
.s
......
Ol
"""
U)
':j;;:
Co
-.,J
......
.....
'ill....
85 {15.16}
69 {1 0.59}
id
61 old
n----
':~
II
bII ..
1,140{44.88}
~o~
00 {15.75}
1,1.11
85 {15.16}---I1I;1o==~n-----L-----I~
00 {15.75}
..,.
._
or
75 {6.89}_1~"D<'"
48 {5.83}
50 {9.84}-...
25 {4.92}
60 {6.30}
II
s:
'T1
:0
l>
c_
zen
_
::::I
III
o
l>
m
N
:E
c
:0
en
......
IZ
en
o-
-cs::
m
......
-I
C
::D
C
0
@
-I
!t: ::D
en
:0
OJ
0
g-<m
:0
en
C
Z
C
!!. 0
o Z
::::I
(J)
Q.
_. s:
m
(J)
::::I
iii m
"C
'T1

mm{in}
271
{1 D.67}
Point
symbol
Designation
or bolt or nut
size mm {in}
Point
symbol
Designation
K
K'
Box bracket No.2
Box bracket No.3
Box bracket No.3
Box mounting hole

Front spring hanger
N
0
Box bracket No.2
Dumper bracket
Dumper bracket
Rear spring hanger
Hole diameter
or bolt or nut
size mm {in}
016 {0.63}
020 {0.79}
016 x 23
{0.63 x 0.91}
020 {0.79}
020 {0.79}
014 {0.55}
M12 {0.47}
M12 {0.47}
032 {1.26}
09-800-3
~
@
~
~
<0 oo.J
'i\31
Co ~
~I
oo.J
~ I~
C11
~ l::l
..... 0 ) .
~~--i
1:":1
.... 385 {15.16}
F::::'::: .
400 {15.75}
400 {15.75}
81 {3.19}
'1.
5:
10
1_
I,
1 ,230 {48.43}
".
c
o
-<
en
-<
OJ
l_
~l
f6:111
EI
1I1:6~
40{44.SS1
1,024 {40.31}
..
1,130{44.49}-.....fOl
1,290 {50.79}
EI
JJ
I\)
g
0
......
0
~
m
s:
Z
-c
~ .......
m
-
! ~
a
-I
OJ
l>
I~I! ~
_ .
c:
1/1_
"-
T"Tl/
!e. 0
o z
::s en
~o
175 {6.89}-+1&1!:\S.
148 {5.83}
s:
!2
3-' m
Z
Co
l>
:c
~~
a-
~1~:;;JJ,883l34'70}~
1::309{12.17}~'
..
1. . . .
!. . . .
.... 250 {9.84}
.... 125 {4.92}
160 {6.30}
"?3
CD
."..CD
~~~~237
{9.33}
.... 310 {12.20}
9."..
.-.
6,
0
CD

mm{in}
239
{9.41}
DBG0980B004
Point
symbol
Designation
Cabin mounting bracket No.1
Bumper stay bracket

Tie down hook mounting hole
Front suspension bracket
tension rod
Rebound stopper bracket
C
D
E
F
G
H
I

Hole diameter
or bolt or nut
size mm {in}
027 {1.06}
015 {0.59}
013.5 {0.53}
025 {0.98}
012.5 {0.49}
016 {0.63}
012.5 {0.49}
060 {2.36}
065 {2.56}
030 {1.18}
Point
symbol
Designation
Box bracket No.1
K'
Box bracket No.1
Box bracket No.3
Box bracket No.3
Box mounting hole

N
0
Front spring hanger
Dumper bracket
Dumper bracket
Rear spring hanger
Hole diameter
or bolt or nut
size mm {in}
016 {0.63}
020 {0.79}
016 x 23
{0.63 x 0.91}
020 {0.79}
020 {0.79}
048.5 {1.91}
014 {0.55}
M12 {0.47}
M12 {0.47}
032 {1.26}
09-800-5
do
o
U)
"""'-
0>
(,)
I\)
EJ
1\3"
COOl
~~
c.u
Ol
.j>.
.j>.
I\)
00
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......
CO
--
Ol
0>
.j>.
00
CO
0
-.J
!D '0
(;)
~
.!:S
EJ
0>
f- a,
.j>.
Q)
00
-.J
--
EJc.u ....;;;:::
.j>.~
.2l
BS{1S.16}
00 {1S.7S}--~
III
BS{1S.16}
Jd#
"1J
"
IilPI
1,140 {44.BB}
1,140 {44.BB}
~
....... ,... ..
r ............
JI
I~I
;1~lr_
~: 69{10.S9}~
....
~,
I;---
40{9.4S}~1--"""""
~. 00 {1S.7S}
....
....
4B {S.B3}
--2:
3
3
~L'
e,
()
ro
'"
0
OJ
0
'"ro~
:i.E
c
I \)
==
-I
en
en
en
-<
en
::E:
::D
."
0
<D
-f
C
::D
-f
::D
C
~
en
OJ
en
......
m
......
C
m s:
m
::D
Z
0 en
i:::j
::E:
-I
::D
-I
~
en
::D
en
::I
tIl_
....
1,224 {4B.19}
_
en
!!!.o
o Z
::I
CD
c..
_. ==
m
3 z
_
C
==
m
::D
e:
SO{9.B4}~
2S{4.92}
60 {6.30}
CD
::I
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*"iii
.....
........
~ ________________________________________________________________________________________________- 4
ro
oOJ
(;)00
~oo
00
~f\)
---
.2l
~~
"T1 "T1
.J

mm{in}
1,645
{64.76}------I~
257
{10.12}
DBG0980B006
Point
symbol
A
B
C
D
E
F
G
H
Designation
Bumper stay bracket
tension rod
Cabin mounting bracket NO.3
Hole diameter
or bolt or nut
size mm {in}
027 {1.06}
015 {0.59}
013.5 {0.53}
025 {0.98}
012.5 {0.49}
016 {0.63}
012.5 {0.49}
060 {2.36}
065 {2.56}
Point
symbol
Designation
J
J'
Box bracket No.1

Box bracket No.1
Box bracket NO.3
K'
L
M
N
Box bracket No.3

Box mounting hole
Front spring hanger
Dumper bracket
Dumper bracket
Rear spring hanger
0
P
Hole diameter
or bolt or nut
size mm {in}
016 {0.63}
020 {0.79}
016 x 23
{0.63 x 0.91}
020 {0.79}
020 {0.79}
014 {0.55}
M12 {0.47}
M12 {0.47}
032 {1.26}
09-800-7
cb
cb
CD
'"
~
CXl
.j>.
....
.j>.
(0
......
....
m
tn
'"(0
&>
?3
....
(0
(Xl
.j>.
-..J
'0
....
(Xl
I\)
.j>.
I\)
CXl
a;
tn
.j>.
(Xl
:-l
....
......
....
0
$
......
....
---
385 {15.16}
_3BSIIS.16)
"-269 {1 0.59}
1. . . .
_4061IS.9B)
,:
.
:;>\
=!L~O
J[)
.
240 {9.45}~
'.... 406 {15.98}
1. . . .
..<:iD1
1,140{44.88}
1,224 {48.19}
IItJ
Ico-" I
.a:
......
3
3
-=~
::c
::c
c
m
::c
'i'"
: :t
Q)
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;:;
ex>
0
ex>
0
CD
3:
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en
en
en
-<
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l>
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:::j
-:e
."
0
c:
0
l>
OJ
-0
en
......
en
-s:C
m
......
:D
c:
-I
:D
::t
-I
en
-I
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OJ
~
en
-I
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c
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tIl_
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CD en
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'2,3:
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"TI "TI
!!jjIW&l~~~#y*~1!WI1!i!IIII1f
-~ ______________________________________________________________________________________________
gLI
~(O
~tn
~~
......
f> ....
(Xl ....
$
!=>I\)
~~
"""""'~',''''"'~'-,~,'''''''''''''' """"""""'~'''''~'''''~'''''~'~'''~~'~''''''~'''''~~~'''C;~'5S~~","'iilf,~~

mm{in}
,;a
.
257
{10.12}
DBG0980B010
Point
symbol
A
B
C
D
E
F
G
H
"I
I'
Designation
Bumper stay bracket
Box bracket No.1
Box bracket No.1
Hole diameter
or bolt or nut
size mm {in}
027 {1.06}
015 {0.59}
013.5 {0.53}
012.5 {0.49}
016 {0.63}
012.5 {0.49}
060 {2.36}
065 {2.56}
016 {0.63}
020 {0.79}
Point
symbol
Designation
Box bracket No.3
J'
Box bracket No.3

Box mounting hole
K
L
M
N

Front spring hanger

Dumper bracket
P
Q
Dumper bracket
Rear spring hanger
Hole diameter
or bolt or nut
size mm {in}
016 x 23
{0.63 x 0.91}
020 {0.79}
020 {0.79}
016.5 {0.65}
040 {1.57}
014 {0.55}
M12 {0.47}
M12 {0.47}
032 {1.26}
09-800-9
@
Gl
I~
1,290 {50.79}
JII
-. . . .
0",,"
...... 0>
~~
~m
~m
-.J
-.J
-.J
406 {15.98}
406 {15.98}
-<en0
"""
~
385 {15.16}
269 {1 0.59}
-1--.......1-385 {15.16}
(3
1.1e~
I I
r-
:0
IA
10
~:\ ~u
118
309 {12.17}
400 {15.75}
dJ
il~
.w
... m
","AA
An'
.......
::J
~. 0
=""0
"""
w
CD
.:::J
-. m
3z
::::J _
~ c
~~
....
C
I
~
VJ
VJ
.j:a,
@
en
-I
......
en
-oZ
-c
::c
~ ......
m
tIl
l>
~ ~
m
0
g en
~
c
tIl
m
~
cZ
~C
::::J
Co
~~
~m
l>
-~
:....."""
~~

mm{in}
H .
II
fl
239
{9.41 }
DBG0980B008
Point
symbol
A
B
C
D
E
F
G
H
" I
J
J'
Designation
Bumper stay bracket
Box bracket No.1
Box bracket No.1
Hole diameter
or bolt or nut
size mm {in}
027 {1.06}
015 {0.59}
013.5 {0.53}
012.5 {D.49}
016 {0.63}
012.5 {D.49}
060 {2.36}
065 {2.56}
030 {1.18}
016 {D.63}
020 {D.79}
Point
symbol
Designation
Box bracket No.3
K'
L
M
N
Box bracket NO.3

Box mounting hole
Front spring hanger
Dumper bracket
Dumper bracket
Rear spring hanger
0
P
Q
R
Hole diameter
or bolt or nut
size mm {in}
016 x 23
{0.63 x 0.91}
020 {D.79}
020 {D.79}
016.5 {0.65}
040 {1.57}
014 {D.55}
M12 {0.47}
M12 {D.47}
032 {1.26}
09-800-11
I\)
I
.....
&,
o(,0
-.J(J1
~(O
J.j>.
-.J
......
.j>.
O'l
ro
(Xl
~
....... ~
(0
-.
......
(J1
(0
(Xl
.j>.
m '"00-.J
......
W
(0
......
$
'ji)
~ ro
.j>.
Ul
(J1
en
......
-.......
(Xl
.j>.
o __________________________________________________________________________________________________
gLI
ro
ro
O'l
-.......
---
.22
-.
.j>. ......
0
(Xl ......
91\)
.22
~~

mm{in}
A
257
{10.12}
DBG0980B010
Point
symbol
f_
.,
Designation
Bumper stay bracket
C
D
Tie do~n hook mounting hole


F
G
H
. I
I'

Box bracket No.1
Box bracket No.1
Hole diameter
or bolt or nut
size mm {in}
027 {1.06}
015 {0.59}
013.5 {0.53}
012.5 {0.49}
016 {0.63}
012.5 {0.49}
060 {2.36}
065 {2.56}
016 {0.63}
020 {0.79}
Point
symbol
Designation
Box bracket No.3
J'
K
L
Box bracket NO.3

Box mounting hole

Front spring hanger
Dumper bracket
Dumper bracket
Rear spring hanger
P
Q
Hole diameter
or bolt or nut
size mm {in}
016 x 23
{0.63 x 0.91}
020 {0.79}
020 {0.79}
016.5 {0.65}
040 {1.57}
014 {0.55}
M12 {0.47}
M12 {0.47}
032 {1.26}
09-800-13

FRONT BODY STRAIGHT-LINE DIMENSIONS (1)
DCF098053020B01
mm{in}
550
~---{21.65}---~~
o.
1,410
~-----------{55.51}-----------iOIoI
DBG0980B011
Point
symbol
A
B
C
Designation
09-800-14
Hole diameter
or bolt or nut
size mm {in}
07 {0.28}
07 {0.28}
07 {0.28}
Point
symbol
D
E
F
Designation
Crossmember datum hole
Hole diameter
or bolt or nut
size mm {in}
07 {0.28}
06.2 {0.24}
010 {0.39}

FRONT BODY STRAIGHT-LINE DIMENSIONS (2)
DCF098053020B02
09-800-15
~'
II
~i
111
li
II
II
it
II'I
I
Ii
I
11
Ii
i'
Ii
II
I'
11
1~
H
1:
I:
11
jj
Ji
Ii
I
Ii
Ii
Point
symbol
Designation
Windshield garnish installation

square hole

square hole
C
0
Bonnet hinge installation hole

Front fender installation hole
11
il!
09-800-16
Hole diameter
or bolt or nut
size mm {in}
Point
symbol
608 x 608
{0027 x 0027}
608 x 608
{0027 x 0027}
012 {0.47}
010 {0039}
Shroud gusset datum hole
Cowl panel datum slot
F'
G
Cowl panel datum hole

Designation
Hole diameter
or bolt or nut
size mm {in}
014 {0055}
0602 x 8
{0024 x 0031}
0602 {0024}
010 {0039}

CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (REGULAR CAB)
DCF098070010BOl
mm{in}
~.u;~~ttiTl\tt---- 1,090
{42.91}
DBG0980B015
Point
symbol
A
B
Designation
Wheel apron panel front
datum hole
square hole
Hole diameter
or bolt or nut
size mm {in}
Point
symbol
012 {O.47}
D
E
07 {O.28}
x 6.8
{O.27 x O.27}
6.8
F
G
Designation
Door hinge installation hole
Side frame outer connection
Side frame outer datum hole
Hole diameter
or bolt or nut
size mm {in}
012 {O.47}
012 {O.47}
03.2 {O.13}
09-800-17

CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (DOUBLE CAB)
DCF098070010B02
mm{in}
--
Fr
Fr
~T
DBG0980B018
Point
symbol
A
B
Designation
datum hole

square hole
D
E

09-800-18
Hole diameter
or bolt or nut
size mm {in}
012 {O.47}
07 {O.28}
x 6.8
{O.27 x O.27}
6.8
012 {O.47}
012 {O.47}
Point
symbol
F
G
H
J
K
Designation
Hole diameter
or bolt or nut
size mm {in}
012 {O.47}
012 {O.47}
03.2 {O.13}
-.
CABIN SIDE FRAME STRAIGHT-LINE DIMENSIONS (STRETHC CAB {WITH REAR ACCESS SYSTEM}, HIRIDER)
DCF098070010B03
mm{in}
1,197
1--------{47.13}-------I
G
DBG0980B019
mm{in}
1,098
{43.23}
1,724
\\~~F=====~{67.87}----+-++--~~
1,195
{47.05}
G
DBG0980B020
09-800-19
fr=~

B
0
]--I
0
o~
IA
~?ij I~~
Point
symbol
A
B
:$
Designation
datum hole

square hole
D
E

Fr
~
o~
==
---E!
JL.~
:$
Hole diameter
or bolt or nut
size mm {in}
012 {O.47}
07 {O.28}
6.8 x6.8
{O.27 x O.27}
012 {O.47}
012 {O.47}
Point
symbol
F
G
H
I
-=::
t~~
~
II
rn --ErJ
~
:$
1=1
011
II~~
i1
--Er-
//~,l
J!~t
~
Designation
Striker installation hole
Rear access panel hinge
installation hole
installation hole
--ErDBG0980B021
Hole diameter
or bolt or nut
size mm {in}
07 {O.28}
013 {O.51}
05 {O.20}
012 {O.47}
012 {O.47}
09-800-20

ROOM STRAIGHT-LINE DIMENSIONS (REGULAR CAB)
DCF098070001 B01
DBG0980B022
Fr
Point
symbol
"
A
B
C
D
E
0~1
00
DBG0980B023
Designation
Harness installation hole
Front pillar inner datum hole
Cowl side panel datum hole
Tunnel reinforcement
installation hole
Rear pillar inner datum hole
Hole diameter
or bolt or nut
size mm {in}
07 {0.28}
010 {0.39}
012 {0.47}
07 {0.28}
012 {0.47}
Point
symbol
Designation
Rear pillar inner datum slot
Striker installation slot
Hole diameter
or bolt or nut
size mm {in}
012 {0.47}
08 x 12
{0.31 x 0.47}
08.2 x7.6
{0.32 x 0.30}
09-800-21

ROOM STRAIGHT-LINE DIMENSIONS (DOUBLE CAB)
DCF098070001802
09-800-22

A
DBG0980B025
Designation
Point
symbol
Designation
Rear pillar inner datum slot
J
K

Striker installation slot
Hole diameter
or bolt or nut
size mm {in}
012 {0.47}
07x9
{0.28 x 0.35}
06 {0.24}
010.2 {0.40}
08.2 x 7.6
{0.32 x 0.30}
09-800-23

ROOM STRAIGHT-LINE DIMENSIONS (STRETCH CAB {WITH REAR ACCESS SYSTEM}, HI-RIDER)
DCF098070001803
09-800-24
DBG0980B027
Designation
Point
symbol
Designation

Pillar trim datum hole
Pillar trim datum slot
Tunnel reinforcement datum

hole
Hole diameter
or bolt or nut
size mm {in}
012 {0,47}
06 {0.24}
010 x 20
{0.39 x 0.79}
07 {0.28}
010 {0.39}
09-800-25
l
D
DBG0980B028
Point
symbol
A
B
Designation
C
D
E
Harness installation hole

Front pillar inner datum hole
Cowl side panel datum hole
Trim installation hole
Trim installation slot
09-800-26
Hole diameter
or bolt or nut
size mm {in}
07 {0.28}
010 {0.39}
012 {0.47}
010 {0.39}
07 {0.28}
010 x 15
{0.39 x 0.59}
Designation
Pillar trim datum slot
Crossmember No.3 datum

hole
Hole diameter
or bolt or nut
GENERAL INFORMATION
GENERAL INFORMATION ... 00-00
00-00
GENERAL INFORMATION
AIM OF DEVELOPMENT ............ 00-00-1

(VIN) CODE . ..................... 00-00-12
AIM OF DEVELOPMENT

(VI N) . ........................... 00-00-12
UNITS . .......................... . 00-00-13
NEW STANDARDS . ................ . 00-00-14
dcfOOOOOOOOOt01
External View
DCFOOOZWB002
"
Vehicle Outline
Engine
Mechanical
A roller has been adopted to the rocker arm to reduce rolling resistance. Due to this, fuel economy has
been improved. (WL-C, WE-C)
Valve lift has been increased (high lift), improving intake and exhaust efficiencies. Due to this, engine
torque and power have been improved. (WL-C, WE-C)
A timing belt auto tensioner has been adopted to reduce timing belt deterioration. (WL-C, WE-C)
A DOHC type valve system has been adopted for improved engine torque and power. (WL-C, WE-C)
Due to the bifurcated oil pan bottom, vibration in the oil pan has been reduced for improved engine noise
suppression. (WL-C, WE-C)
A hard-plastic oil strainer has been adopted for weight reduction.
A cover has been installed on the upper part of the engine for improved appearance and engine noise
suppression. (WL-C, WE-C)
A balance shaft has been adopted for reduced vibration and noise. (G
Intake/exhaust and fuel supply systems
Superior high-output, noise suppression, and low fuel consumption have been realized due to the adoption
of a direct injection type common rail. (WL-C, WE-C)
Smooth driveability has been realized due to the adoption of a variable induction turbocharger which
achieves a balance between the air charging pressure providing responsive rise from low speed and the air
charging pressure at the high speed range. (WL-C, WE-C)
A water-cooling type EGR cooler with excellent cooling capability has been adopted for improved intake air
charging efficiency, recirculating more exhaust gas. Due to this, NOx has been reduced for improved
exhaust em~sion performance.
.
':.~-fItr--
00-00-1
GENERAL INFORMATION
--------------------------------------------------------------------------------~,
Suspension and steering

Front suspension
The double wishbone suspension, which has I-shape lower arms and tension rods, is used for the front
suspension of 4x2 models.
The double wishbone suspension, which has A-shape lower arms, is used for the front suspension of 4x2
(Hi-Rider) and 4x4 models. A-shape lower arms have high rigidly and durability.
The torsion bar springs are used for both 4x2 and 4x4 models.
4x2
FRONT SHOCK ABSORBER
UPPER ARM
FRONT STABILZIER
TENSION ROD
LOWER ARM
DBG213ZTB001
4x2 (Hi-Rider)
UPPER ARM
FRONT STABILIZER
LOWER ARM
DBG213ZTB002
00-00-2
GENERAL INFORMATION
4x4
SHOCK ABSORBER
TORSION BAR SPRING
LOWER ARM
DBG213ZTB003
00-00-3
GENERAL INFORMATION
Rear suspension
The rigid axle suspension with leaf spring is used for the rear suspension.
To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the
right side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias
mount).ln order to increase the rigidity in the lateral direction, wide shackle plates are used in the frame
mounting.
For 4x4 models, the rear springs are mounted on top of the axle housing to raise the center of gravity.
Thus, the shock absorbers attach directly to brackets welded to the axle housing.
4x2 EXCEPT
Hi-Rider
Hi-Rider, 4x4
DCF214ZTBOOl
00-00-4
..
(
GENERAL INFORMATION
Power steering
With the adoption of an engine speed sensing power steering mechanism, handling stability has been
improved.
With the adoption, for all vehicles, of a steering column with a tilt mechanism, operability has been
improved. (Some models)
With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.
RESERVE TANK
STEERING COLUMN AND SHAFT
POWER STEERING
OIL PUMP
STEERING GEAR AND LINKAGE
DBR614ZWB801
00-00-5
GENERAL INFORMATION
Remote Freewheel (RFW)
The PCM receives signals from the transfer case switch and other switches. It then activates one of two
solenoids, causing a vacuum from the vacuum pump to be applied to the RFW actuator, and switching the
remote freewheel (RFW) unit to lock or free.
To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-way
check valve.
The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front
differential.
The RFW operation is controlled by PCM.
FRONT DIFFERENTIAL
SLEEVE
DRIVE PINION GEAR

RFW ACTUATOR
DBG314ZTB012
00-00-6
GENERAL INFORMATION
4x4 control
Remote Freewheel (RFW)
A special 4x4 control module has been adopted for the 4x4 control system control, and it operates the
transfer motor according to the signals from the speed sensor, 4x4 switch, and digital TR sensor to perform
shifting between 2H, 4H and 4L.
The 4x4 CM receives signals from the transfer case sensor and other switches. It then activates one of two
To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum
pump, such as during acceleration or at high altitude operation, the actuation system includes a one-wcy
check valve.
The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front
differential.
The RFW operation is controlled by 4x4 CM.
FRONT DIFFERENTIAL
OUTPUT SHAFT
DRIVE PINION GEAR

RFW ACTUATOR
arnffn00000092
00-00-6a
GENERAL INFORMATION
Brakes
A tandem-type master cylinder has been adopted, improving braking force.
A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force.
A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
A two-piston type front disc brake caliper has been adopted, improving braking force. (Hi-Rider, 4x4)
A wide width lining for the rear brake drum has been adopted, improving braking force.
An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability.
A vacuum pump has been adopted, improving braking force.
LOAD SENSING
PROPORTIONING VALVE (LSPV)
REAR BRAKE (DRUM)
FRONT BRAKE (DISC)
VACUUM PUMP
DCF411ZTBOOl (
.i
00-00-7
GENERAL INFORMATION
ABS [REAR ABS]
The ASS is a one sensor, 1-channel control system, which provides dual control for the rear wheels.
This system continuously monitors rear wheel speed via a sensor mounted on the differential. When the teeth
~\
on the sensor rotor, mounted on the ring gear, pass the sensor pickup, AC voltage is induced in the sensor
circuit with a frequency proportional to the average rear wheel speed. If a rear wheel is judged likely to lockup
during braking, the ASS modulates hydraulic pressure to the rear brakes, inhibiting lockup.
~ ASS CONTROL MODULE (CM)
ABSRELAY/
DCF413ATB001
00-00-8
GENERAL INFORMATION
ABS [4W-ABS]
The ABS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,
resulting in size and weight reduction.

I
Select-low controlled-4-wheel anti-lock brake system with 4-sensor and 3-channel has been adopted, and has .
the following features.
i .
The integrated ABS Hydraulic Unit/Control Module (HU/CM) system is compact, lightweight and highly
reliable.
INSTRUMENT CLUSTER
G SENSOR (Hi-Rider, 4x4)
FRONT ASS WHEEL-SPEED

SENSOR
DCF413BTB001
00-00-9
GENERAL INFORMATION
Transmission
~
Automatic transmission [5R55S]

Five forward speeds automatic transmission has been adopted.
A water-cooling type and an air-cooling type AT oil cooler has been adopted.
An adaptive learn strategy system has been adopted.
An engine-transaxle total control system has been adopted.
FLUID
PUMP
TSS SENSOR
ISS SENSOR
LOW/REVERSE
ONE-WAY CLUTCH
OSSSENSOR
LOW/REVERSE
BRAKE
OVERDRIVE
BRAKE
OVERDRIVE ONEWAY CLUTCH
INTERMEDIATE
BRAKE
CONTROL VALVE
BODY
arnffn00000345
00-00-10
GENERAL INFORMATION
Manual transmission [S15M-D, S15MX-D]
A linked, triple-cone synchronizer mechanism has been adopted for 1st and 2nd gears.
A linked, double cone synchronizer mechanism has been adopted for 3rd gear.
A cam-type reverse lockout mechanism has been adopted.
III
S15M-D
2ND GEAR
S15MX-D
r-------------------COUNTER REVERSE GEAR
REVERSE IDLER GEAR
____________________ JI
DCG5118T8001
Safety
An immobilizer system has been adopted. This anti-theft device prevents the engine from being started unless
the encrypted identification code, transmitted from a special electronic chip embedded in the key, corresponds
with the identification code registered in the v e h i c l e . "
Side air bags that effectively protect the chest area have been adopted for the seats.
Pre-tensioner and load limiter mechanisms have been adopted for the seat belts.
00-00-11
'
GENERAL INFORMATION
Transfer [5R55S]
A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during
4x2 driving.
Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
TRANSFR
SPEED SENSOR
arnffn00000335
00-00-11a
GENERAL INFORMATION
l_______
MNBBS1D106123456
====1=1-1--
Serial No.
Algeria:
Others:
Plant
ModelYesr
Production year
Gulf:
Algeria:
Others:
Check Digit
Plant
No meaning
Engine type
Gulf only
Gross vehicle weight
1=
2=
Gulf only
8=
3=
Body style
2=
Product sorce
Air bag
mark
W=A. A. Thailand
7= 2007, 8=2008, 9=2009 .. .
6= 2006, 7=2007, 8=2008 .. .
o to 9, X
W= A. A. Thailand
o
6= F2E (2.2 EGI)

1=WL-C (2.5 L-DI)
9= WE-C (3.0 L-DI)
4= WL-Turbo (2.5L Diesel turbo)
7= G6E (2.6 EGI)
Other
D= 2268-2721 kg {5001-6000 Ibs}
E= 2722-3175 kg {6001-7000 Ibs}
Others
1= Stretch cab.
2= Stretch cab.
M= Thailand (for Europe (L.H.D.))
S= Japan (for Australia, General (R.H.D.),
General (L.H.D.), Gulf)
B= Seatbelt only
D= with Air bag (Driver side)
WFO=FORD (European (L.H.D.))
MNA=FORD (Australian)
MNB=FORD (General (R.H.D.))
MNC=FORD (General (L.H.D.), Gulf)
: This mark is used only for Algerian model, in order to identify the manufacturer.
arnffn00000261
Australian specs.
MNA
MNA
MNA
MNA
BS"""
OS"""
LS"""
US"""
arnffw00001612
00-00-12
GENERAL INFORMATION
UNITS
Electrical current
Electric power
Electric resistance
Electric voltage
Length
Negative pressure
A (ampere)
W (watt)
ohm
V (volt)
mm (millimeter)
in (inch)
kPa (kilo pascal)
mmHg (millimeters of mercury)
inHg (inches of mercury)
kPa (kilo pascal)
Positive pressure
kgf/cm 2 (kilogram force per square

centimeter)
psi (pounds per square inch)
Nm (Newton meter)
kgfm (kilogram force meter)
Torque
kgfcm (kilogram force centimeter)

ftlbf (foot pound force)
inlbf (inch pound force)
L (liter)
Volume
US qt (U.S. quart)
Imp qt (Imperial quart)
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fI oz (fluid ounce)
Weight
g (gram)
oz (ounce)
Conversion to SI Units (Systeme International d'Unites)

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 as the 81 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 81 unit value is
an upper limit and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
unit value may differ after conversion. For example, consider 2.7 kgf/cm 2 in the following specifications:
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}
270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
The actual converted values for 2.7 kgf/cm 2 are 265 kPa and 38.4 psi. In the first specification, 2.7 is used as
an upper limit, so the converted values are rounded down to 260 and 38. In the second specification, 2.7 is
used as a lower limit, so the converted values are rounded up to 270 and 39.
00-00-13
GENERAL INFORMATION
NEW STANDARDS
dcfOOOOOOOOOt05
Following is a comparison of the previous standard and the new standard.

New Standard
Abbreviation
Name
Previous Standard
Abbreviation
Accelerator Pedal
Accelerator Pedal
APP
ACL
Accelerator Pedal Position
Air Cleaner

Air Cleaner
AlC
Air Conditioning
Barometric Pressure
Air Conditioning
Atmospheric Pressure
B+
Battery Positive Voltage
VB
Battery Voltage
Brake Switch
AP
BARO
Calibration Resistor
CMP sensor Camshaft Position Sensor
-
LOAD
Calculated Load Voltage
CAC
CLS
Charge Air Cooler

Closed Loop System
Closed Throttle Position
CTP
CPP
CIS
Clutch Pedal Position

Continuous Fuel Injection System
Control Sleeve Sensor
CS sensor
CKP sensor Crankshaft Position Sensor
EGI
CSP sensor
-
Stoplight Switch
Corrected Resistance
Crank Angle Sensor
Intercooler
Feedback System
Fully Closed
Clutch Position
Electronic Gasoline Injection System
Control Sleeve Position Sensor
Crank Angle Sensor 2
Diagnosis Connector
Diagnostic Trouble Code(s)

Distributor Ignition
Test Mode
Service Code(s)
Distributorless Ignition
EI
ECT
Electronic Ignition
Engine Coolant Temperature
EM
Engine Modification
Engine Speed Input Signal
DI
DLI
EVAP
EGR
FC
FF
4GR
-
FSO
solenoid
GEN
Evaporative Emission
Spark Ignition
Direct Ignition
Electronic Spark Ignition
Water Thermo
Exhaust Gas Recirculation
Fan Control

Fan Control
Flexible Fuel
Fourth Gear
Flexible Fuel
Overdrive
Fuel Pump Relay
Circuit Opening Relay
#3
Fuel Cut Valve
#6
Fuel Shut Off Solenoid
FCV
Alternator
Ground/Earth
Oxygen Sensor
Idle Air Control

IDM Relay
Incorrect Gear Ratio
Injection Pump
FIP
Fuel Injection Pump
InputlTurbine Speed Sensor

Intake Air Temperature
IAT
Pulse Generator
Intake Air Thermo
KS
MIL
Knock Sensor
Malfunction Indicator Lamp
MAP
Manifold Absolute Pressure
Intake Air Pressure
Mass Air Flow

Airflow Sensor
lAC
MAF
Mass Air Flow
MAF sensor Mass Air Flow Sensor
MFL
OBD
OL
#2
Engine Modification
Engine RPM Signal
Ground
Heated Oxygen Sensor
H02S
#6
#1
Generator
GND
#6
Data Link Connector

Diagnostic Test Mode
DLC
DTM
DTC
Remark
Name
Multiport Fuel Injection

On-Board Diagnostic
Open Loop
00-00-14
With heater
Idle Speed Control

Spill Valve Relay
#6
-
Knock Sensor
Malfunction Indicator Light

Diagnosis/Self Diagnosis
Open Loop
#6
\.
GENERAL INFORMATION
Previous Standard
New Standard
Abbreviation
-
OC
02S
PNP
PID
-
PSP
Name
Output Speed Sensor
Oxidation Catalytic Converter
Abbreviation
-
Name
Vehicle Speed Sensor 1
Catalytic Converter
Oxygen Sensor
Park/Neutral Range
Oxygen Sensor
Park/Neutral Position
Parameter Identification
PCM Control Relay
Main Relay
Power Steering Pressure

Powertrain Control Module
Pressure Control Solenoid
Engine Control Unit

Line Pressure Solenoid Valve
Pulsed Secondary Air Injection
Secondary Air Injection System
Pump Speed Sensor

Random Access Memory
NE Sensor
RAM
AIR
Secondary Air Injection
Secondary Air Pulse Valve
Sequential Multipoint Fuel Injection
Reed Valve
Sequential Fuel Injection
1-2 Shift Solenoid Valve
PCM
PAIR
-
SAPV
SFI
-
Shift Solenoid A
Shift Solenoid B
Shift Solenoid C
Third Gear
Three Way Catalytic Converter
3GR
TWC
TB
TP
TP sensor
TCV
TCC
TCM
-
TR
TC
Throttle Body
Transmission (Transaxle) Control

Module
Transmission (Transaxle) Fluid
Temperature Sensor
Transmission (Transaxle) Range
EC-AT Control Unit
ATF Thermosensor
Turbocharger
Inhibitor Position
Turbocharger
Wide Open Throttle
Vehicle Speed Sensor

IC Regulator
Air Flow Sensor
Catalytic Converter
Fully Open
Pulsed
injection
#6
Injection
with air
pump
Throttle Sensor
Timing Control Valve
Lockup Position

Voltage Regulator
VR
VAF sensor Volume Air Flow Sensor
Warm Up Three Way Catalytic
WUTWC
Converter
TCV
#4
Shift B Solenoid Valve

3--4 Shift Solenoid Valve
Throttle Position
Throttle Position Sensor
Timer Control Valve
Torque Converter Clutch
#6
Shift A Solenoid Valve

3rd Gear
Catalytic Converter
Throttle Body
VSS
WOT
ECU
Remark
#6
#5
#1: Diagnostic trouble codes depend on the diagnostic test mode

#2: Controlled by the PCM
#3:'ln some models, there is a fuel pump relay that controls pump speed. That relay is now called the fuel pump
relay (speed).
#4: Device that controls engine and powertrain
#5: Directly connected to exhaust manifold
#6: Part name of diesel engine
00-00-15
ENGINE
OUTLINE .................
ON-BOARD DIAGNOSTIC
[WL-3] . . . . . . . . . . . . . . . . . .
ON-BOARD DIAGNOSTIC
[WL-C, WE-C] . . . . . . . . . . . .
MECHANICAL [WL-3] .......
MECHANICAL
[WL-C, WE-C] ............
LUBRICATION [WL-3] .......
LUBRICATION
[WL-C, WE-C] . . . . . . . . . . . .
COOLING SYSTEM [WL-3]. . .
COOLING SYSTEM
[WL-C, WE-C] ............
INTAKE-AIR SYSTEM
[WL-3] . . . . . . . . . . . . . . . . . .
01-00
01-00
01-02A
01-028
01-10A
01-108
01-11A
01-11 B
01-12A
01-128
01-13A
ENGINE ABBREVIATIONS
ABDC
ABS
After Bottom Dead Center
ACC
ATDC
Accessories
After Top Dead Center
Before Bottom Dead Center
CCM
Comprehensive Component Monitor
CM
Control Module
DC
DLC-2
Drive Cycle
Data Link Connector-2
DOHC
Double Overhead Camshaft
DSC
EX
Exhaust
IN
KOEO
dcf01000200Ot01
Bottom Dead Center

Before Top Dead Center
Controller Area Network
HU
ENGINE SPECIFICATION [WL-3] ..... . 01-00-3

ENGINE SPECIFICATION
[WL-C, WE-C] . ................... . 01-00-5
Antilock Brake System
BTDC
CAN
FFD
INTAKE-AIR SYSTEM
[WL-C, WE-C] ............. 01-13B
FUEL SYSTEM [WL-3] ....... 01-14A
FUEL SYSTEM
[WL-C, WE-C] ............. 01-14B
EXHAUST SYSTEM [WL-3] ... 01-15A
. EXHAUST SYSTEM
[WL-C, WE-C] ............. 01-15B
EMISSION SYSTEM [WL-3] ... 01-16A
EMISSION SYSTEM
[WL-C, WE-C] ............. 01-16B
CHARGING SYSTEM
[WL-3, WL-C, WE-C] ....... 01-17
STARTING SYSTEM
[WL-3, WL-C, WE-C] ....... 01-19
CONTROL SYSTEM [WL-3] ... 01-40A
CONTROL SYSTEM
[WL-C, WE-C] ............. 01-40B
OUTLINE
ENGINE ABBREViATIONS ........... 01-00-1

ENGINE FEATURES
[WL-3, WL-C, WE-C]. . . . . . . . . . . . . .. 01-00-2
BBDC
BDC
I(lll
Dynamic Stability Control

Freeze Frame Data
Hydraulic Unit
Intake
KOER
Key On Engine Off

Key On Engine Running
M
MRE
Motor
Magneto Resistance Element
01-00-1
OUTLINE
MT
PATS
Manual Transmission
OFF
ON
Switch on
switch off
PC
PCV
Pending Code
Positive Crankcase Ventilation
Passive Anti-theft System
PID
PIS
Power Steering
SOHC
SST
Single Overhead Camshaft

Special Service Tool
TDC
VBC
Top Dead Center

Variable Boost Control
ENGINE FEATURES [WL-3, WL-C, WE-C]

Mechanical
Improved engine performance
Coated pistons have been adopted (WL-C, WE-C)

Swirl type combustion chamber (WL-3)
DOHC with 4 valves per cylinder (WL-C, WE-C)
3 valves per cylinder (WL-3)
An eight counter weight crankshaft has been adopted

A crankshaft pulley cover has been adopted (WL-C, WE-C)
An engine cover with insulator has been adopted (WL-C, WE-C)
Full-floating cylinder head cover mounting
Torsional damper pulley
An auto tensioner that automatically adjusts the timing belt tension has been adopted
(WL-C, WE-C)
Reduced engine noise and

vibration
Improved serviceability
Improved design
,An engine cover has been adopted (WL-C, WE-C)
Lubrication
Gear type oil pump adopted

Oil jet valves adopted
Water-cooled type oil cooler adopted
Plastic oil strainer adopted

Oil pan baffle plate adopted (WL-C, WE-C)
Down flow type radiator with aluminum core and plastic tank adopted
Thermo-modulation type cooling fan adopted
Longer-life new engine coolant (type FL22) adopted
Power efficiency, performance,

and fuel economy
A variable geometry turbocharger has been adopted (WL-C, WE-C)
Improved emission gas

purification
Small size turbocharge has been adopted (WL-3)
Electronic control type fuel injection pump adopted
Improved lubricity
Reduced weight
Reduced engine noise
Cooling System
Reduced weight
Miniaturization
Reduced noise
Built-in type water pump adopted
Intake air System
Fuel System
purification
Exhaust gas purification
Emission System
Improved exhaust gas purification
Improved reliability
Common rail injection system adopted (WL-C, WE-C)
EGR system adopted

EGR cooler adopted
Oxidation catalytic converter adopted
Rollover valve adopted
Charging System
IImproved reliability
01-00-2
dcfD1000200Qt02
I Generator with built-in battery sensing type IC regulator adopted
OUTLINE
Starting System
IImproved startability
Reduction type starter adopted
Control System
purification
Intake shutter valve control adopted (WL-C, WE-C)

Fuel injection control changed
EGR control adopted
ENGINE SPECIFICATION [WL-3]
dcf01000200Ot03
Specification
Specifications
WL-3
Item
MECHANICAL
Type
Cylinder arrangement and number
Combustion chamber
Valve system
Displacement
Bore x stroke
Compression ratio
Diesel, 4-cycle
In-line, 4 cylinder
Swiri type
SOHC, timing gear and belt driven, 12-valve
(ml {cc, cu in})
2,499 {2,499, 152.4}
93.0 x 92.0 {3.66 x 3.62}
(mm {in})
21.6
Compression pressure
IN
Valve timing
EX
Valve clearance
[Engine cold]
(kPa {kgf/cm2, psi} [rpm])

BTDC (0)
Open
ABDC (0)
Close
BBDC (0)
Open
ATDC (0)
Close
IN
(mm {in})
EX
2,942 {30.0, 427} [200]

8
23
61
9
0.05-0.15 {0.0020-0.0059}
0.15-0.25 {0.0060-0.0098}
LUBRICATION SYSTEM
Type
Oil pressure (reference value)
[after warm up]
Type
Oil pump
Relief valve opening pressure
(reference value)
Type
Oil cooler
Type
Oil filter
Bypass pressure
Force-fed type
2
(kPa {kgf/cm , psi} [rpm])
Gear type
(kPa {kgf/cm 2, psi})
580-700 {5.9-7.1, 84.1-1 01.5}

Water-cooled
Full-flow, paper element
(kPa {kgf/cm 2 , psi})

(L {US qt, Imp qt})
(L {US qt, Imp qt})
(L {US qt, Imp qt})
Total (dry engine)

Oil replacement
Oil and oil filter replacement
COOLING SYSTEM
Type
Coolant capacity (approx. quantity)
(L {US qt, Imp qt})
Type
Water pump
Type
(OC {OF})
Opening temperature
Thermostat
(OC
{OF})
Full-open temperature
(mm {in})
Full-open lift
Radiator
Type
Cap valve
Cooling system cap
opening
(kPa {kgf/cm2, psi})
pressure
Type
Number of blades
Cooling fan
Outer diameter
(mm {in})
Oil capacity
(approx.
quantity)
410-570 {4.19-5.81 , 59.6-82.6} [2,500]
80-120 {0.82-1.22, 11.6-17.4}

6.7 {7.1, 5.9}
5.5 {5.8, 4.8}
6.2 {6.6, 5.5}
Water-cooled, forced circulation
8.8 {9.3, 7.7}
Centrifugal, V-belt driven
Wax, bottom-bypass
80-84 {176-183}
95 {203}
8.5 {0.33} or more
Corrugated fin
93.2-122.6 {0.95-1.25, 13.5-17.8}
Thermo-modulation type
10
440 {17.3}
01-00-3
OUTLINE
Specifications
Item
WL-3
INTAKE AIR SYSTEM

Turbocharger type
Small size turbocharger

Dry type (Non-woven fabric)
Air cleaner element

Glow plug type
Ceramic type
FUEL SYSTEM
Fuel injection pump
Bosch VE distributor (Electronic control)
Fuel tank capacity (reference)
(L {US gal, Imp gal})
63 {17, 14}*1, 70 {18, 15}*2
EMISSION SYSTEM
EGR valve type
Catalytic converter type
Vacuum
Oxidation catalytic converter
CHARGING SYSTEM
Voltage
Battery
Type and capacity

(5-hour rate)
Output
Regulated voltage
Generator
(V)
12
(Ah)
65031 R (56)
(V-A)
12-70
14.1-14.7
(V)
Self diagnosis function
Equipped
STARTING SYSTEM
Type
Output
Starter
Coaxial reduction
(kW)
2.2
CONTROL SYSTEM
IAT sensor No.2 (Inside MAF)
Thermistor
Hot-wire
MAF sensor
IAT sensor No.1
Boost sensor
Thermistor
Piezoelectric element
ECT sensor
Thermistor
Magnetic pickup
CKP sensor
APP sensor
EGR valve position sensor
Potentiometer
Potentiometer
BARO sensor (built into PCM)

Fuel temperature sensor
CS sensor
Magnetic pickup
Thermistor
Timer position sensor

Fuel pump speed sensor
Magnetic pickup
Magnetic pickup
Neutral switch
ON/OFF
ON/OFF
CPP switch
Idle switch
*1 :
*2 :
ON/OFF
Double cab, freestyle cab

Regular cab
Recommended engine oil

Item
Grade
Viscosity (SAE)
01-00-4
Specification
API CD/CE/CF--4 or ACEA B1/B3/B5
5W-30, 10W-30
:'
OUTLINE
ENGINE SPECIFICATION [WL-C, WE-C]
dcf010002000to4
Specification
Item
Compression pressure
IN
Valve timing
EX
Valve clearance
[engine cold]
IN
(mm {in})
EX
(mm {in})
Oil pressure (reference value)

[after warm up]
Oil pump
0.10-0.16 mm {0.00400.0062 in}

0.17-0.23 mm {0.00670.0090 in}
0.10-0.16 mm {0.00400.0062 in}

0.17-0.23 mm {0.00670.0090 in}
(kPa {kgf/cm 2 , psi}
410-570 {4.19-5.81, 59.6-82.6} [2,500]
580-700 {5.9-7.1, 84.1-101.5}
80-120 {0.82-1.22, 11.6-17.4}
7.0 {7.4, 6.2}
Centrifugal, V-belt driven
( C { F})
80-84 {176-183}
Thermostat
95 {203}
93.2-122.6 {0.95-1.25, 13.5-17.8}
Cooling system cap
Cooling fan
(mm {in})
450 {17.7}
01-00-5
OUTLINE
Specifications
Item
WL-C
Air cleaner element

Glow plug type
WE-C
Dry type
Stainless type
FUEL SYSTEM
Supply pump
Electronic control
Fuel injector
Electromagnetic control
Fuel tank capacity

(reference)
70 {18, 15}
EMISSION SYSTEM
EGR valve type
Vacuum

CHARGING SYSTEM

Voltage
8attery
Type and capacity

(5-hour rate)
Output
Regulated voltage
Self diagnosis function
Generator
(V)
(A-Ji
(V-A)
(V)
12
65D31R (56)
95D31 R (64)
12-70
14.1-14.7
Equipped
STARTING SYSTEM
Type
Starter
Output
(kW)
Coaxial reduction
2.2
CONTROL SYSTEM
MAF sensor
IAT sensor No.1
800st sensor
Thermistor
Hot-wire
Thermistor
ECT sensor
Thermistor
Hall element type
CMP sensor
CKP sensor
APP sensor
Magnetic pickup

8ARO sensor (built into PCM)
Fuel pressure sensor
Neutral switch
CPP switch
Idle switch
Potentiometer
Potentiometer
Thermistor
ON/OFF
ON/OFF
ON/OFF

Item
Grade
Viscosity (SAE)
01-00-6
Specification
API CD/CE/CF-4 or ACEA 81/83/85
5W-30, 10W-30
ON-BOARD DIAGNOSTIC [WL-C, WE-C]
01-02B ON-BOARD DIAGNOSTIC [WL-C, WE-C]

ON-80ARD DIAGNOSTIC OUTLINE
[WL-C, WE-C] .................... 01-028-1
DIAGNOSTIC SYSTEM
WIRING DIAGRAM [WL-C, WE-C] .... 01-028-2
DTC TEST MODE [WL-C, WE-C] ...... 01-028-6
DTC DETECTION LOGIC AND

CONDITIONS [WL-C, WE-C] ......... 01-028-9
PID/DATA MONITOR AND RECORD
[WL-C, WE-C] .................... 01-028-15
SIMULATION TEST [WL-C, WE-C] ..... 01-028-16
KOEO/KOER SELF-TEST
[WL-C, WE-C] ..................... 01-028-16
ON-80ARD DIAGNOSTIC OUTLINE [WL-C, WE-C]

Features
DTCs adopted
KOEO/KOER self-test function adopted
PID/DATA monitor function adopted
Simulation test function adopted
810ck Diagram
PCM
OBD SYSTEM
r------------------------------------------I
I
I
I
I
I
I
I
:>
TESTER
DETECTION
FUNCTION
:> COMMUNICATION
{}
~---11---
MIL
{}
MEMORY
FUNCTION
I
I
I
I
I
I
I
I
I
MALFUNCTION
INDICATION
FUNCTION
PID DATA
MONITOR
FUNCTION
--------
DLC-2 (CAN)
M-MDS
I
I
SIMULATION
TEST
FUNCTION
'I
FUNCTION
------------
------
FAIL-SAFE
FUNCTION
INPUT DEVICE
L--
ENGINE CONTROL SYSTEM
OL1TPL1T DEVICE
D8G1028T8001
01-028-1

DIAGNOSTIC SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf010200000l14
With Immobilizer System
-f--t-+LOCK
ACC
IG1
-I::--t---{E
IG2
DLC
STA
IG-
FEN
KLN
TEN
DLC-2
KLN
' - - - - I TEN
GLOW INDICATOR
LIGHT
.,---.j--------1I----------f
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY01
01-028-2
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR I '-'-+--_~
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKP SENSOR
PCM
D
F
Tl--+--o
0--+--1-...
BLOWER ' - - - - '

MOTOR
REFRIGERANT
PRESSURE
SWITCH (LOW)
~r--~~ o-~~~
AlC
COMPRESSOR
GLOW
PLUG
RELAY
- ---------------------------,
VARIABLE SWIRL :
CONTROL
:
SOLENOID VALVE :
AlC RELAY
AlC
:SWITCH
,,
THERMO SWITCH
' WITH
AlC ~
DBG102BWBY02
01-028-3

Without Immobilizer System
.J-4----(E
STA
DLC
r------~-~--~~-------~~---------~IG-
FEN
KLN
TEN
DLC-2
'------l KLN
'-----iTEN
GLOW INDICATOR
LIGHT
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.4
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-028-4
RFWLOCK
SOLENOID
1---1--+"" VALVE
APP
SENSOR
RFW FREE
SOLENOID
1----+"" VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR ~I----r
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
D--+--o o--+--+-...
BLOWER ' - - - - - '
MOTOR
.~~------
GLOW
PLUG
RELAY
-------------------------------REFRIGERANT
PRESSURE
SWITCH (LOW)
~r--~~ O-~~~
AlC
COMPRESSOR
.. .. ................................................ .. -,
VARIABLE SWIRL :
CONTROL
I
SOLENOID VALVE :
I
I
I
. . . . . . oo ...
AlC RELAY
THERMO SWITCH
- - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - - - ~
DBG102BWBY02
01-028-5

DTC TEST MODE [WL-C, WE-C]
dcf01020000ot15
Sending Diagnostic Data

PID data monitor
The PID data monitor items are shown below.
PID data monitor table
-: Not applicable
Unit
Full names
Monitor status since DTCs cleared

Calculated LOAD value
Engine coolant temperature
Intake manifold absolute pressure
kPa
Engine speed
rpm
I
I
km/h
Vehicle speed
Intake air temperature
Air flow rate from mass air flow sensor
gls
OBD requirement according to vehicle design

Time Since Engine Start
Distance travelled while MIL is activated
km
kPa
EGR valve control signal

Number of warm-ups since DTCs cleared
PCM power supply voltage

Ambient air temperature
Accelerator pedal position (sensor No.1)
km
V
C
01-028-6
of
-: Not applicable
Unit
DTC that caused required Freeze Frame Data storage

Calculated LOAD value
Fuel rail pressure

Barometric Pressure
miles
%
%
Full names
Intake air temperature

Air flow rate from mass air flow sensor
miles
kPa
Sending Freeze Frame Data

The Freeze Frame Data monitor items are shown below.
Freeze Frame Data monitor table
Engine speed
Vehicle speed
of

Intake manifold absolute pressure
mph
Fuel rail pressure
Distance travelled since DTCs cleared

Barometric Pressure
of
%
C
of
kPa
rpm
km/h
C
I
I
gls
kPa
kPa
%
%
mph
of

Sending Emission-related Malfunction Code
The DTCs are shown below.
MIL
POO46
POO47
POO48
Variable boost control (VBC) solenoid valve circuit rangel

performance malfunction
Variable boost control (VBC) solenoid valve control circuit low
input
Variable boost control (VBC) solenoid valve control circuit high
input
DC
Self-test
*1
ON
C/O/R
ON
C/O/R
ON
C/O/R
01-028-7

DTC
P0403
P0404
P0405
P0406
P0489
P0490
P0500
P0562
P0563
P0602
P0606
P0607
P0610
P0627
P0628
P0629
P0642
P0643
P0652
P0653
P0660
P0661
P0662
P0663
P0664
P0665
P0685
P0698
P0699
P1196
P1259
P1260
P1391
P1392
P1528
P1602
P1603
P1604
P1621
P1622
P1623
P1624
P1675
P1676
P2008
P2009
P2010
P2135
P2136
P2143
P2144
P2145
ondition
EGR solenoid valve circuit malfunction

EGR valve stuck
EGR valve position sensor circuit low input
EGR valve position sensor circuit high input
EGR solenoid valve control circuit low input
EGR solenoid valve control circuit high input
VSS circuit malfunction
Battery voltage low input
Battery voltage high input
PCM programming error
PCM malfunction
PCM performance problem
PCM vehicle options error
Fuel metering valve control circuit open
Fuel metering valve control circuit low input
Fuel metering valve control circuit high input
Fuel pressure sensor and boost sensor 5 V circuit low input
Fuel pressure sensor and boost sensor 5 V circuit high input
CMP sensor and APP sensor 5 V circuit low input
CMP sensor and APP sensor 5 V circuit high input
Intake shutter solenoid valve (half) control circuit open
Intake shutter solenoid valve (half) control circuit low input
Intake shutter solenoid valve (half) control circuit high input
Intake shutter solenoid valve (full) control circuit open
Intake shutter solenoid valve (full) control circuit low input
Intake shutter solenoid valve (full) control circuit high input
Main relay control circuit open
EGR valve position sensor 5 V circuit low input
EGR valve position sensor 5 V circuit high input
Key off voltage high input
IMMOBILIZER to PCM signal error
Theft detected Vehicle immobilizer
Glow plug control circuit low input
Glow plug control circuit high input
Exhaust shutter solenoid valve circuit problem
Immobilizer/PCM communication error
10 Number Unregistered
Code word unregistered
Immobilizer code word does not match
Immobilizer 10 does not match
Immobilizer code wordllO number write failure
Anti-theft system
Injection quantity adjustment value writing error
Injection quantity adjustment value checksum error
Variable swirl control (VSC) solenoid valve circuit open
Variable swirl control (VSC) solenoid valve circuit low input
Variable swirl control (VSC) solenoid valve circuit high input
Accelerator pedal position (APP) sensor No.1 INo.2 voltage
correlation problem
Accelerator pedal position (APP) sensor No.1/idle switch voltage
correlation problem
EGR control solenoid valve control circua open
EGR control solenoid valve control circuit low input
EGR control solenoid valve control circuit high input
01-028-8
MIL
DC
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
1
2
1
1
ON
ON
ON
ON
1/2
1/2
2
1
1
1
1
1/2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
-
Self-test
type*1
Memory
function
CIOIR
CIR
CIOIR
CIOIR
CIO
CIO
C
ClaiR
ClaiR
ClaiR
ClaiR
CIR
CIR
C/R
ClaiR
ClaiR
ClaiR
CIOIR
cia
CIO
cia
CIO
CIO
CIO
-
1
1
1
1
1
C/O/R
CIOIR
-
cia
CIO
cia
cia
CIO
cia
cia
CIO
CIO
CIO
CIO
cia
a
a
ON
ON
ON
ON
ON
1
1
1
1
1
cia
CIO
CIO
ON
ClaiR
ON
CIOIR
ON
ON
ON
1/2
1/2
1/2
cia
C/O/R
ClaiR

DTC
Condition
MIL
P2146
Fuel injector No.1 and No.4 power supply circuit malfunction
ON
P2147
P2148
Fuel injector No.1 and No.4 power supply circuit low input
Fuel injector No.1 and No.4 power supply circuit high input
ON
ON
P2149
P2150
Fuel injector No.2 and NO.3 power supply circuit malfunction

Fuel injector No.2 and NO.3 power supply circuit low input
ON
ON
P2151
Fuel injector No.2 and NO.3 power supply circuit high input
BARO sensor circuit range/performance malfunction
ON
P2227
P2228
P2229
BARO sensor circuit low input

BARO sensor circuit high input
P2263
Air charging system performance malfunction
P2530
PCM (engine switch circuit) malfunction
DC
Self-test
type*1
Memory
function
C/R
C/R
C/R
C/R
C/R
C/R
C
ON
ON
ON
C/O/R
C/O/R
ON
*1 : C; CMDTe self test, 0; KOEO self test, R; KOER self test
Sending Continuous Monitoring System Test Results

These appear when a problem is detected in a monitored system.
1-drive cycle type
If any problems are detected in the first drive cycle, confirmed DTCs will be stored in the peM memory.
2-d rive cycle type
The code for a failed system is stored in the PCM memory in the first drive cycle. If the problem is not found in
the second drive cycle, the PCM determines that the system returned to normal or the problem was mistakenly
detected, and deletes the pending code. If the problem is found in the second drive cycle too, the PCM
determines that the system has failed, and stores the DTCs.
After pending codes are stored, if the PCM determines that the system is normal in any future drive cycle, the
PCM deletes the pending codes.
DTC DETECTION LOGIC AND CONDITIONS[WL-C, WE-C]
id0102c4100300
P0016 CKP-CMP correlation

The PCM monitors the input pulses from the CKP and CMP sensors. If the pick-up timing input pulses do not
match each other, the peM determines that the camshaft position does not coincide with the crankshaft
position.
P0045 Variable boost control (VeC) solenoid valve control circuit open
The PCM monitors the VBC solenoid valve control signal. If the VBC solenoid valve control voltage is less than
5 V for 2 s when the VBC solenoid valve is off, the PCM determines that there is a VBC solenoid valve control
circuit malfunction (open circuit).
P0046 Variable boost control (VeC) solenoid valve circuit range/performance malfunction
The PCM monitors the driver IC temperature of the VBC solenoid valve. If the temperature of the VBC solenoid
valve driver IC in the PCM exceeds 150 C{320 F} while the VBC solenoid valve is operating, the PCM
determines that there is a VBC solenoid value malfunction.
P0047 Variable boost control (VeC) solenoid valve control circuit low input
The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve off but the
voltage at PCM terminal 178 still remains low, the PCM determines that the VBC solenoid valve circuit has a
malfunction (circuit short to ground).
P0048 Variable boost control (VeC) solenoid valve control circuit high input
The peM monitors the VBC solenoid valve control signal. If the peM turns VBC solenoid valve on but the
current at peM terminal 178 still remains high, the PCM determines that the VBC solenoid valve circuit has a
malfunction (circuit short to power supply).
P0088 Fuel pressure system too high
The PCM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
running. If the fuel pressure is more than the preprogrammed criteria, the PCM determines that the fuel
pressure is too high.
P0093 Fuel system leak detection
The peM monitors the fuel pressure in the common rail from the fuel pressure sensor while the engine is
running. If the fuel pressure is lower than the preprogrammed criteria, the PCM determines that there is
leakage in the fuel system.
01-028-9

P0097 Intake air temperature (IAT) sensor No.2 circuit low input
The PCM monitors the input signal from intake air temperature sensor NO.2. If the voltage from intake air
temperature sensor No.2 is less than 0.1 V for 2 s, the PCM determines that there is a malfunction in the
intake air temperature sensor No.2 circuit.
P0098 Intake air temperature (I AT) sensor No.2 circuit high input
The PCM monitors the input signal from intake air temperature sensor NO.2. If the voltage from intake air
temperature sensor No.2 is more than 4.6 V for 1 s, the PCM determines that there is a malfunction in the
P0101 Mass airflow (MAF) sensor range/performance malfunction
The PCM monitors the ratio between calculated air mass flow and actual air mass flow under the programmed
condition.
If the ratio is more than or less than the programmed criteria the PCM determine that there is a malfunction in
the MAF sensor.
P0102 Mass airflow (MAF) sensor circuit low input
The PCM calculates the intake air flow amount based on the airflow sensor. If the calculated intake air flow
amount is below 0.44 g/s {0.058 Ib/min} for 2.0 s while the engine is running, the PCM determines that the
airflow sensor signal input is low.
P0103 Mass airflow (MAF) sensor circuit high input
amount is above 170 g/s {22 Ib/min} for 1.5 s while driving other than under a fully open throttle condition, and
the fuel injection quantity based on the engine speed is below the specification, the PCM determines that the
airflow sensor signal input is high.
P0106 Boost sensor range/performance malfunction
The PCM monitors and compares the intake manifold internal pressure via the boost sensor with the
atmospheric pressure via the barometric pressure sensor (built into PCM) while the engine is not running. lithe
difference of these pressure is above 11 kPa {0.11 bar, 1.6 psi}, the PCM determines that there is a boost
sensor characteristic malfunction.
P0107 Boost sensor circuit low input
The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is less than 0.24
V for 2.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
P0108 Boost sensor circuit high input
The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is more than 4.9
V for 1.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.
P0111 Intake air temperature (IAT) sensor No.1 range/performance malfunction
The PCM monitors the input signal from the IAT sensor No.1. If the difference between the maximum and
minimum value of the IAT sensor No.1 is less than 1 C {1.8 OF}, the PCM determines that there is a
malfunction in the IAT sensor NO.1.
P0112 Intake air temperature (IAT) sensor No.1 circuit low input
The PCM monitors the input signal from IAT sensor NO.1. If the voltage from IAT sensor No.1 is less than 0.14
V for 2.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
P0113 Intake air temperature (IAT) sensor No.1 circuit high input
The PCM monitors the input signal from IAT sensor NO.1. If the voltage from IAT sensor No.1 is more than 4.90
V for 1.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
P0116 Engine coolant temperature (ECT) sensor range/performance malfunction
Minimum engine coolant temperature rise is not achieved within the specified time limit from when the engine
was started.
P0117 Engine coolant temperature (ECT) sensor circuit low input
The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is less than 0.20
V for 2.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
P0118 Engine coolant temperature (ECT) sensor circuit high input
The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is more than 4.91
V for 1.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
P0122 Accelerator pedal position (APP) sensor No.1 circuit low input
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 .is less than
0.29 V for 0.5 s when the APP sensor No.1 power supply voltage is normal, the PCM determines that there is
a malfunction in the APP sensor No.1 circuit.
P0123 Accelerator pedal position (APP) sensor No.1 circuit high input
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is more than
P0182 Fuel temperature sensor circuit low input
The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel temperature
sensor is less than 0.2 V, the PCM determines that there is a malfunction in the fuel temperature sensor
circuit.
01-028-10
(.
.\
P0183 Fuel temperature sensor circuit high input

The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel temperature
sensor is more than 4.9 V, the PCM determines that there is a malfunction in the fuel temperature sensor
circuit.
P0191 Fuel pressure sensor range/performance malfunction
The PCM monitors the fuel pressure in the common rail and input signal from the fuel pressure sensor while
the engine is running. If all of the following conditions is met, the PCM determines that there is malfunction in
the fuel pressure sensor range/performance malfunction.
The PCM calculates the difference between the actual fuel pressure and the target fuel pressure. If the
pressure difference is more than 5 MPa {51 kgf/cm 2 , 726 psi}.
The PCM monitors the input signal from the fuel pressure sensor. If the difference between the maximum
and minimum voltage of the fuel pressure sensor is less than 0.01 V.
P0192 Fuel pressure sensor circuit low input
The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the input
voltage from the fuel pressure sensor is less than 0.2 V, the PCM determines that there is a malfunction in the
fuel pressure sensor circuit.
P0193 Fuel pressure sensor circuit high input
voltage from the fuel pressure sensor is more than 4.8 V, the PCM determines that there is a malfunction in
the fuel pressure sensor circuit.
P0201 Fuel injector No.1 circuit open/short
The PCM monitors each cylinder fuel injector control signal current while the engine is running. If the PCM
detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that the
fuel injector at No.1 cylinder has an open or short circuit.
detects a control signal current of more or less than the preprogrammed criteria, the PCM determine that the
.
fuel injector at NO.3 cylinder has an open or short circuit.
P0222 Accelerator pedal position (APP) sensor No.2 circuit low input
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is less than
P0223 Accelerator pedal position (APP) sensor No.2 circuit high input
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is more than
4.80 V for 0.5 s when the APP sensor no.2 power supply voltage is normal, the PCM determines that there is a
malfunction in the APP sensor No.2 circuit.
P0227 Idle switch circuit low input
The PCM monitors the input voltage from APP sensor No.1 when the idle switch is off. If the input voltage is
less than 0.86 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
P0228 Idle switch circuit high input
The PCM monitors the input voltage from APP sensor No.1 when the idle switch is on. If the input voltage is
more than 1.35 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
P0300 Random misfire detected
The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the interval
time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the PCM detects
a misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires and
calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can affect emission performance, has occurred.
P0301, P0302, P0303, P0304 Cylinder No.1 No.2 No.3 No.4 misfire detection
The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the interval
time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the PCM detects
a misfire in the corresponding cylinder. While the engine is running, the PCM counts the number of misfires and
calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the preprogrammed criteria, the
PCM determines that a misfire, which can affect emission performance, has occurred.
01-028-11

P0335 Crankshaft position (CKP) sensor circuit malfunction
The PCM monitors the input signal from the CKP sensor while the engine is running. If the following conditions
are detected, the PCM determines that the CKP circuit has a malfunction.
- The PCM receives no pulse from the CKP sensor
- The PCM receives an improper pulse number from the CKP sensor
P0340 Camshaft position (CMP) sensor circuit malfunction
The PCM monitors the input signal from the CMP sensor while the engine is running. If the following conditions
are detected, the PCM determines that the CMP circuit has a malfunction.
- The PCM receives no pulse from the CMP sensor
- The PCM receives an improper pulse number from the CMP sensor
P0380 Glow plug relay circuit malfunction
The PCM monitors the glow plug relay control signal. If the following conditions are detected, the PCM
determines that the glow plug relay circuit has a malfunction.
- The PCM turns the glow plug relay off but the voltage remains low
- The PCM turns the glow plug relay on but the voltage remains high
- The PCM internal driver IC temperature is more than 150 C {320 F} when the glow plug relay is on
P0401 EGR flow insufficient detected
The PCM monitors the difference between the target air amount and intake air amount while the EGR system is
operating at EGR feedback control. If the difference between the target air amount and the intake air amount is
less than the threshold, the PCM determines that there is a malfunction in the EGR system.
P0402 EGR flow excessive detected
The PCM monitors the difference between the target air amount and intake air amount while the EGR system is
operating at EGR feedback control. If the difference between the target air amount and the intake air amount is
more than the threshold, the PCM determines that there is a malfunction in the EGR system.
P0403 EGR solenoid valve circuit malfunction
The PCM monitors the EGR solenoid valve control signal. If the following conditions are detected, the PCM
determines that the EGR solenoid valve circuit has a malfunction (open circuit).
- The PCM turns the EGR solenoid valve off but the voltage remains low
- The PCM internal driver IC temperature is more than 150 C {320 F} when the EGR solenoid valve is on
P0404 EGR control circuit range/performance
The PCM monitors the difference between target EGR valve lift and actual EGR valve lift under the
programmed condition.
If the difference is more or less than the programmed criteria the PCM determines that there is a malfunction in
the EGR control circuit.
P0405 EGR valve position sensor circuit low input
The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the input
voltage is less than 0.1 V, the PCM determines that the EGR valve position sensor circuit has a malfunction.
P0406 EGR valve position sensor circuit high input
The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the input
voltage is more than 4.9 V, the PCM determines that the EGR valve position sensor circuit has a malfunction.
P0489 EGR solenoid valve control circuit low input
,
The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve off but the
voltage remains low, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit short to
ground).
P0490 EGR solenoid valve control circuit high input
The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve on but the
voltage remains high, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit short to
power supply).
P0500 VSS circuit malfunction
The PCM monitors the input signal from the instrument cluster during set conditions. If the input signal is less
than 0 km/h {O mph} for 25 s, the PCM determines that there is a VSS circuit malfunction.
P0562 Battery voltage low input
The PCM monitors the battery voltage. If the battery voltage is less than 8 V, the PCM determines that there is
a malfunction in the battery and the battery signal system.
P0563 Battery voltage high input
The PCM monitors the battery voltage. If the battery voltage is more than 16 V, the PCM determines that there
is a malfunction in the battery charging system.
P0602 PCM programming error
No configuration data in the PCM
P0606 PCM malfunction
PCM internal malfunction.
P0607 PCM performance problem
P061 0 PCM vehicle options error
PCM data configuration error
01-028-12
(
\

P0627 Fuel metering valve control circuit open
The PCM monitors the fuel metering valve driver IC temperature in the PCM and the control voltage while the
engine is running. If either of the following conditions is met, the PCM determines that there is a malfunction in
the fuel metering valve range/performance.
The PCM monitors the fuel metering valve driver IC temperature in the PCM. If the fuel metering valve
driver IC temperature is more than 150 C {320 F} during the fuel metering valve operation, the PCM
determines that the fuel metering valve has a malfunction
The PCM monitors the fuel metering valve control voltage at the PCM terminals. If fuel metering valve
control voltage is less than 5 V when fuel metering valve is not operating, the PCM determines that the fuel
metering valve has a malfunction (open circuit)
P0628 Fuel metering valve control circuit low input
The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects that
the circuit voltage is low when the fuel metering valve is off, the PCM determines that there is a malfunction in
the fuel metering valve circuit (circuit short to ground).
P0629 Fuel metering valve control circuit high input
The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the peM detects that
the circuit voltage is high when the fuel metering valve is on, the PCM determines that there is a malfunction in
the fuel metering valve circuit (circuit short to power supply).
P0642 Fuel pressure sensor and boost sensor 5 V circuit low input
The PCM monitors the fuel pressure sensor and the boost sensor 5 V circuit. If the fuel pressure sensor and
boost sensor power voltage is lower than 4.9 V, the peM determines that there is a fuel pressure sensor and
boost sensor 5 V circuit malfunction.
P0643 Fuel pressure sensor and boost sensor 5 V circuit high input
The PCM monitors the fuel pressure sensor and boost sensor 5 V circuit. If the fuel pressure sensor and boost
sensor power voltage is higher than 4.9 V, the PCM determines that there is a fuel pressure sensor and boost
sensor 5 V circuit malfunction.
P0652 CMP sensor and APP sensor 5 V circuit low input
The PCM monitors the CMP sensor and APP sensor 5 V circuit. If the CMP sensor and APP sensor power
voltage is lower than 4.9 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
malfunction.
P0653 CMP sensor and APP sensor 5 V circuit high input
voltage is higher than 5.1 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
malfunction.
P0660 Intake shutter solenoid valve (half) control circuit open
The PCM monitors the intake shutter solenoid valve (half) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (half) control circuit has a malfunction.
The PCM turns the intake shutter solenoid valve (half) off, but the intake shutter solenoid valve (half) control
voltage is less than 5 V for 2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 C {320 F} when the intake shutter solenoid
valve (half) is on
P0661 Intake shutter solenoid valve (half) control circuit low input
The peM monitors the intake shutter solenoid valve (half) control signal at peM terminal 152. If the peM turns
the intake shutter solenoid valve (half) off but the voltage at PCM terminal 152 remains low, the peM
determines that intake shutter solenoid valve (half) circuit has a malfunction (circuit short to ground).
P0662 Intake shutter solenoid valve (half) control circuit high input
The PCM monitors the intake shutter solenoid valve (half) control signal at peM terminal 152. If the peM turns
the intake shutter solenoid valve (half) on but the voltage at PCM terminal 152 remains high, the PCM
determines that the intake shutter solenoid valve (half) circuit has a malfunction (circuit short to power supply).
P0663 Intake shutter solenoid valve (full) control circuit open
The PCM monitors the intake shutter solenoid valve (full) control signal. If the following conditions are detected,
the PCM determines that the intake shutter solenoid valve (full) control circuit has a malfunction.
The peM turns the intake shutter solenoid valve (full) off, but the intake shutter solenoid valve (full) control
voltage is less than 5 V for 2 s (open circuit)
- The peM internal driver IC temperature is more than 150 C {320 F} when the intake shutter solenoid
valve (full) is on
P0664 Intake shutter solenoid valve (full) control circuit low input
The PCM monitors the intake shutter solenoid valve (full) control signal at peM terminal 155. If the PCM turns
the intake shutter solenoid valve (full) off, but the voltage at PCM terminal 155 remains low, the peM
determines that intake shutter solenoid valve (full) circuit has a malfunction (circuit short to ground).
P0665 Intake shutter solenoid valve (full) control circuit high input
The PCM monitors the intake shutter solenoid valve (full) control Signal at PCM terminal 155. If the PCM turns
the intake shutter solenoid valve (full) on, but the voltage at PCM terminal 155 remains high, the PCM
determines that the intake shutter solenoid valve (full) circuit has a malfunction (circuit short to power supply).
01-028-13
ON-BOARD DIAGNOSTIC [WL-C, WE-C] ,

P0685 Main relay control circuit open
The PCM monitors the power supply to the PCM. If the power supply is shut down several times when the
engine switch is turned to the ON position, the PCM determines that there is a power circuit malfunction (open
circuit).
P0698 EGR valve position sensor 5 V circuit low input
The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is lower than
4.9 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
P0699 EGR valve position sensor 5 V circuit high input
The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is higher
than 5.1 V, the PCM determines that there is a EGR position sensor 5 V circuit malfunction.
P1196 Key off voltage high input
The PCM monitors whether the main relay opens after 2 s when the engine switch is turned to the off position.
If the main relay does not open after 2 s, the PCM determines that there is malfunction in the main relay circuit.
P1259 IMMOBILIZER to PCM signal error
The PCM does not complete target 10 transfer.
P1260 Theft detected Vehicle immobilizer
Immobilizer system malfunction
P1391 Glow plug control circuit low input
The PCM monitors the output signal to the glow plug relay when the glow plug relay is on. If the glow plug relay
voltage is less than 2 V for 1 s when the glow plug relay is operating, The PCM determines that there is a
malfunction in the glow plug relay circuit.
P1392 Glow plug control circuit high input
The PCM monitors the output signal to the glow plug relay when the glow plug relay is off. If the glow plug relay
voltage is more than 2 V for 1 s when the glow plug relay is off, The PCM determines that there is a
malfunction in the glow plug relay control circuit.
P1528 Exhaust shutter solenoid valve circuit problem
The PCM monitors the input voltages from the exhaust shutter solenoid valve. If the voltage remains low or
high, the PCM determines that the exhaust shutter solenoid valve circuit has malfunction.
P1602 Immobilizer/PCM communication error
PCM internal malfunction
P160310 Number Unregistered
P1604 Code word unregistered
P1621 Immobilizer code word does not match
Cord word stored in immobilizer system and PCM does not to match.
10 number stored in immobilizer system and PCM does not to match.
P1622 Immobilizer 10 does not match
P1623 Immobilizer code wordllO number write failure
P1624 Anti-theft system
P1675 Injection quantity adjustment value writing error
The fuel injector compensation data configuration has not been completed.
P1676 Injection quantity adjustment value checksum error
The fuel injector compensation data check sum error.
P2008 Variable swirl control (VSC) solenoid valve control circuit open
The PCM monitors the VSC solenoid valve control signal. If the following conditions are detected, the PCM
determines that the VSC solenoid valve control circuit has a malfunction.
- The PCM turns the VSC solenoid valve off, but the VSC solenoid valve control voltage is less than 5 V for
2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 C {320 F} when the VSC solenoid valve is on
P2009 Variable swirl control (VSC) solenoid valve circuit low input
The PCM monitors the output signal to the VSC solenoid valve. If the voltage of the VSC solenoid valve is low
even if the VSC solenoid valve is off, the PCM determines that there is a malfunction in the VSC solenoid valve
control circuit.
P2010 Variable swirl control (VSC) solenoid valve circuit high input
The PCM monitors the output signal to the VSC solenoid valve. If the voltage of the VSC solenoid valve is high
even if the VSC solenoid valve is on, the PCM determines that there is a malfunction in the VSC solenoid valve
control system.
01-028-14
.. )
" . '.
P2135 Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
The PCM monitors the input signals from accelerator pedal position sensor No.1 and accelerator pedal position
sensor NO.2. If the difference between accelerator pedal position sensor No.1 and accelerator pedal position
sensor No.2 is more than 0.9 V for 0.5 s, the PCM determines that there is a malfunction in the accelerator
pedal position sensor characteristic.
P2136 Accelerator pedal position (APP) sensor No.lIidle switch voltage correlation problem
The PCM compares the input voltage from APP sensor No.1 with the input voltage from the idle switch when
the accelerator pedal is released (idle switch is on). If the difference is more than 1.35 V for 0.5 s, the PCM
determines that there is an APP sensor No.1/idle switch angle correlation problem.
P2143 EGR control solenoid valve control circuit open
The PCM monitors the EGR control solenoid valve control signal. If the following conditions are detected, the
PCM determines that the EGR control solenoid valve circuit has a malfunction.
- The PCM turns the EGR control solenoid valve off but the voltage remains low (open circuit).
- The PCM internal driver IC temperature is more than 150 C {320 F} when the EGR control solenoid valve
is on.
P2144 EGR control solenoid valve control circuit low input
The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control solenoid
valve off but the voltage remains low, the PCM determines that the EGR control solenoid valve circuit has a
malfunction (circuit short to ground).
P2145 EGR control solenoid valve control circuit high input
The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control solenoid
valve on but the voltage still remains high, the PCM determines that the EGR control solenoid valve circuit has
a malfunction (circuit short to power supply).
P2146 Fuel injector No.1 and No.4 power supply circuit malfunction
The PCM monitors the fuel injector No.1 and No.4 power supply voltage when the engine is running. If the
following conditions are detected 5 times, the PCM determines that the fuel injector No.1 and No.4 power
supply circuit has a malfunction.
Fuel injector No.1 and No.4 power supply voltage is less than 43 V
Fuel injector No.1 and No.4 power supply voltage is 53 V or above
P2147 Fuel injector No.1 and No.4 power supply circuit low input
The PCM monitors the fuel injector No.1 and No.4 power supply current when the engine is running. If the
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or above,
the PCM determines that the fuel injector No.1 and No.4 power supply current is too high.
P2148 Fuel injector No.1 and No.4 power supply circuit high input
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.1 and No.4 power
supply current is too high.
P2149 Fuel injector No.2 and No.3 power supply circuit malfunction
The PCM monitors the fuel injector No.2 and NO.3 power supply voltage when the engine is running. If the
following conditions are detected 5 times, the PCM determines that the fuel injector No.2 and NO.3 power
Fuel injector No.2 and NO.3 power supply voltage is less than 43 V
Fuel injector No.2 and No.3 power supply voltage is 53 V or above
P2150 Fuel injector No.2 and No;3 power supply circuit low input
The PCM monitors the fuel injector No.2 and NO.3 power supply current when the engine is running. If the
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or above,
the PCM determines that the fuel injector No.2 and No.3 power supply current is too high.
P2151 Fuel injector No.2 and No.3 power supply circuit high input
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.2 and NO.3 power
supply current is too high.
P2227 BARO sensor circuit range/performance malfunction
The PCM monitors the input signal from the barometric pressure sensor. If the difference between the
barometric pressure input from the barometric pressure sensor and the boost pressure is more than 11 kPa
{0.11 bar, 1.6 psi}, the PCM determines that there is a malfunction in the barometric pressure sensor.
P2228 BARO sensor circuit low input
The PCM monitors the input signal for the barometric pressure. If the voltage from the barometric pressure
sensor is less than 2.2 V for 1 s, the PCM determines that there is a malfunction in the barometric pressure
sensor signal system.
P2229 BARO sensor circuit high input
sensor is more than 4.8 V for 1 s, the PCM determines that there is a malfunction in the barometric pressure
sensor signal system.
01-028-14a

P2263 Air charging pressure performance malfunction
The peM monitors the air charging pressure. If the air charging pressure is not within the specification for the
peM control target, the peM determines that there is a malfunction in the air charging system.
P2530 PCM (engine. switch circuit) malfunction
peM internal malfunction.
PID/DATA MONITOR AND RECORD [WL-C, WE-C]
dcf010200000l17
The PID/DATA monitor items are shown below.
PID/DATA 'T'onitor item table

Monitor item
Definition
AAT
AC_REQ
ACCS
APP
Ambient temperature
APP1
Accelerator pedal position sensor No.1
APP2
Accelerator pedal position sensor No.2
AlC request signal

Air conditioning compressor cycling switch
Accelerator pedal position
ARPMDES
Target engine speed

,
BARO
Barometric pressure
BOO
CPP
DTCCNT
Brake switch
Clutch pedal position switch
DTC count (includes those needing no action)
ECT
EGRV2
EGR solenoid valve (vent)
FIP _FL
Supply pump flow control
FIP_SCV
FLT
FRP
GP _LMP
GPC
IASV
IASV2
Fuel metering valve

Fuel temperature
Glow indicator light
Glow plug relay
Intake shutter solenoid valve (half)
Intake shutter solenoid valve (full)
IAT
Intake air temperature (IAT sensor No.1)
INGEAR
IVS
LOAD
Load/no load condition

Idle switch
Engine load
MAF
Mass airflow amount
MAP
Boost sensor
MIL
MIL_DIS
RPM
SEGRP DSD
SELTESTDTC
VBCV
VPWR
VSS
WARM SW
Malfunction indicator lamp

The distance travelled since the MIL was activated
Engine speed
Desired EGR valve position
Diagnostic trouble codes
VBC solenoid valve
Module supply voltage
Vehicle speed
Exhaust heating switch
Unit/Condition
C
Off/On
Off/On
%
%
V
%
V
rpm
Pa
V
Off/On
Off/On
No unit
C
V
Off/On
A
%
A
C
Pa
Off/On
Off/On
Off/On
Off/On
C
V
Off/On
Off Idle/Idle
%
g/s
V
Pa
V
Off/On
km/h
rpm
%
No unit
%
V
km/h
Off/On
PCM terminal
239
128
209,222
222
209
-
238
228
-
167
177
179
179
115
140
233
182
152
155
141
240
161
190
189
256
-
193
178
201,203,205
184
-
01-028-15

SIMULATION TEST [WL-C, WE-C]
dcf01020000Ot18
The simulation items are shown below.

C,~imulation item table
Item
: Applicable
-: Not applicable
Test condition
Applicable component
Unit/condition
ACCS
EGRV2
GP _LMP
Air conditioning compressor cycling switch
Off/On
EGR solenoid valve (vent)

Off/On
Glow plug relay

Off/On
Off/On
GPC
Off/On
Off/On
IASV
IASV2
INJ_1

Fuel injector No.1
INJ_2
INJ_3
Fuel injector No.2

Fuel injector No.3
INJ_4
Fuel injector No.4

VBC solenoid valve
SEGRP
VBCV
WARM_SOL
01-028-16
Exhaust shutter solenoid valve
Off
Off
Off
Off
KOEO
KOER
PCM terminal
128
177
233
182
152
155
125, 174
102, 149
101,173
126, 150
0/0
0/0
Off/On
116
178

KOEO/KOER SELF-TEST[WL-C, WE-C]
id01 02c41 00400
: Applicable
- : Not applicable
OTC
Condition
POO16
CKP-CMP correlation
POO45
Variable boost control (VBC) solenoid valve control circuit open
POO46
Variable boost control (VBC) solenoid valve circuit range/performance

malfunction
POO47
POO48
Variable boost control (VBC) solenoid valve control circuit low input
POO88
POO93
Fuel pressure system too high

Fuel system leak detection
POO97
POO98
Intake air temperature (IAT) sensor No.2 circuit low input

Intake air temperature (IAT) sensor No.2 circuit high input
P0101
P0102
P0103
Variable boost control (VBC) solenoid valve control circuit high input
KOEO
KOER
Mass airflow (MAF) sensor range/performance malfunction

Mass airflow (MAF) sensor circuit low input
Mass airflow (MAF) sensor circuit high input
P0106
Boost sensor range/performance malfunction
P0107
P0108
Boost sensor circuit low input

Boost sensor circuit high input
P0111
P0112
Intake air temperature (IAT) sensor No.1 range/performance malfunction

P0113
P0116
P0117
P0118
Engine coolant temperature (ECT) sensor range/performance malfunction

Engine coolant temperature (ECT) sensor circuit low input
P0122
Engine coolant temperature (ECT) sensor circuit high input

Accelerator pedal position (APP) sensor No.1 circuit low input
P0123
P0182
Accelerator pedal position (APP) sensor No.1 circuit high input

Fuel temperature sensor circuit low input
P0183
P0191
Fuel temperature sensor circuit high input
P0192
P0193
Fuel pressure sensor circuit low input

Fuel pressure sensor circuit high input
Fuel injector No.1 circuit open/short
P0201
Fuel pressure sensor range/performance malfunction
P0202
P0203
P0204

P0222
P0223
P0227
P0228
Idle switch circuit low input

Idle switch circuit high input
P0300
P0301
Random misfire detected

Cylinder No.1 misfire detection
P0302
P0303
P0304
P0335
Crankshaft position (CKP) sensor circuit malfunction
P0340
P0380
Camshaft position (CMP) sensor circuit malfunction

Glow plug relay circuit malfunction
P0401
EGR flow insufficient detected
01-028-17
....

DTC
P0402
P0403
P0404
P0405
P0406
P0489
P0490
P0500
P0562
P0563
P0602
P0606
P0607
P0610
P0627
P0628
P0629
P0642
P0643
P0652
P0653
P0660
P0661
P0662
P0663
P0664
P0665
P0685
P0698
P0699
P1196
P1259
P1260
P1391
P1392
P1528
P1602
P1603
P1604
P1621
P1622
P1623
P1624
P1675
P1676
P2008
P2009
P2010
P2135
P2136
P2143
P2144
P2145
P2146
ndition
Co
EGR flow excessive detected
EGR control circuit range/performance
EGRvalve position sensor circuit low input
PCM malfunction
10 Number Unregistered
Immobilizer 10 does not match
Immobilizer code word/IO number write failure
Anti-theft system
Variable swirl control (VSC) solenoid valve control circuit open
Variable swirl control (VSC) solenoid valve circuit low input
Variable swirl control (VSC) solenoid valve circuit high input
Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
Accelerator pedal position (APP) sensor No.1 /idle switch voltage correlation
problem
EGR control solenoid valve control circuit open
KOEO
KOER
01-028-18

OTC
P2147
P2148
P2149
P2150
P2151
P2227
P2228
P2229
P2263
P2530
Condition
Air charging pressure performance malfunction
01-02C-19
KOEO
KOER
MECHANICAL [WL-C, WE-C]
01-108 MECHANICAL [WL-C, WE-C]

ENGINE STRUCTURAL VIEW
[WL-C, WE-C] .. ,...............
CYLINDER HEAD COVER
CONSTRUCTION [WL-C, WE-C] .....
CYLINDER HEAD CONSTRUCTION
[WL-C, WE-C] .................
CYLINDER HEAD GASKET
CONSTRUCTION [WL-C, WE-C] ...
CYLINDER BLOCK
CONSTRUCTION [WL-C, WE-C] ....
CRANKSHAFT, MAIN BEARING
CRANKSHAFT PULLEY
PISTON CONSTRUCTION
[WL-C, WE-C] ..................
01-10B-1
01-10B-1
01-10B-2
01-10B-2
01-10B-2
01-10B-3
01-10B-4
01-10B-4
CONNECTING ROD,
CONNECTING ROD BEARING
CONSTRUCTION [WL-C, WE-C] .... 01-10B-5
DRIVE BELT CONSTRUCTION
[WL-C, WE-C] ............... 01-10B-5
VALVE MECHANISM STRUCTURAL
VIEW [WL-C, WE-C] ............. 01-10B-6
TIMING GEAR CONSTRUCTION
[WL-C, WE-C] ................. 01-1 OB-6
CAMSHAFT CONSTRUCTION
[WL-C, WE-C] .............. 01-1 OB-8
AUTO TENSIONER CONSTRUCTION
[WL-C, WE-C] ................. 01-10B-8
VALVE, ROCKER ARM
CONSTRUCTION [WL-C, WE-C] ...... 01-10B-9
ENGINE MOUNT STRUCTURAL
VIEW [WL-C, WE-C] ................ 01-10B-9
ENGINE STRUCTURAL VIEW [WL-C, WE-C]
dcf011002000t02
DGB110BTB001
CYLINDER HEAD COVER CONSTRUCTION [WL-C, WE-C]
dcf011 01 022Ot02
The cylinder head cover is made of aluminum alloy.

The cylinder head cover is made of aluminum alloy with a baffle plate on its lower side for blow-by gas
separation.
01-108-1

CYLINDER HEAD CONSTRUCTION [WL-C, WE-C]
dcf011 01 010Ot02
A lightweight aluminum alloy cylinder head with good thermal conductivity has been adopted.
A plastic region bolt has been adopted as a cylinder head bolt providing constant high axial force (tightening
force).
Due to the adoption of 4 valves, the opening area has been increased and the charging efficiency improved.
The smooth curved intake port reduces intake resistance.
DBG110BTB801
CYLINDER HEAD GASKET CONSTRUCTION [WL-C, WE-C]
dcf011010271to2
A steel-laminated gasket has been adopted for the cylinder head gasket.
CYLINDER BLOCK CONSTRUCTION [WL-C, WE-C]
dcf011 01 030Ot02
A special cast iron liner-less type cylinder block has been adopted to provide a thin-walled cylinder block. In
addition, a curve-shaped, deep-skirt cylinder block has been adopted to heighten the cylinder block rigidity.
The engine coolant passage has been equipped by cross-drilling in the bore, improving the cooling
performance and reducing oil consumption.
SECTION A-A
CROSS DRILL HOLE
DGB110BTB002
01-108-2

CRANKSHAFT, MAIN BEARING CONSTRUCTION [WL-C, WE-C]
dcf011 011301 t02
Structure
A five axle-hole, 8 counter weight steel crankshaft has been adopted.
An oil line for supplying oil to each journal is provided in the crankshaft. Crank pins and fillets on both sides of
.
the journal are rolled to bear heavy loads.
Upper and lower main bearings are made of aluminum alloy and thrust bearings are used at the No.3 journal.
The upper main bearing has oil grooves and oil holes.
LOWER THRUST BEARING
FILLET ROLL AREA
OIL PASSAGE
DBG110BTB004
01-108-3

CRANKSHAFT PULLEY CONSTRUCTION [WL-C, WE-C)
dcfD11011371t02
Structure
A torsional damper pulley is used for the crankshaft pulley to reduce torsional vibration noise.
The pulley installation area has a pulley cover for reduction of engine noise.
TORSIONAL DAM PAR
PULLEY COVER
DBG110BTB802
PISTON CONSTRUCTION [WL-C, WE-C)
dcf011 011 01 0102
Structure
In accordance with the adoption of the common rail injection system, the piston head shape (combustion
chamber) has been changed.
A reduction in friction has been achieved by the coating of the skirt area together with a compression rating
setting of 18.0.
To realize high combustion efficiency, the diffusion area of the hotspot at combustion has been expanded by
the change in the shape of the combustion chamber and the spray pattern of fuel injectors. Exhaust emission
and combustion noise have been reduced through smooth and uniform combustion.
COMBUSTION CHAMBER
COATING
DBG110BTB803
01-108-4
: ..

CONNECTING ROD, CONNECTING ROD BEARING CONSTRUCTION [WL-C, WE-C]
dcf011011211t02
Structure
Connecting rods are made of forget manganese steel.
Dowel pins are used to position the rod cap to the connecting rod.
Connecting rod caps are secured with plastic region bolts.
The connecting rod bearing is mode of aluminum alloy.
BUSH
, , " ' - _ - - - CONNECTING ROD
CONNECTING ROD UPPER BEARING
CONNECTING ROD CAP
uv-------"CONNECTING ROD CAP BOLT

DBG110BTB804
DRIVE BELT CONSTRUCTION [WL-C, WE-C]
dcf01101580Dt01
Structure
A V-belt has been adopted which consists of three belts including generator and water pump operation belts
(two belts), and an AIC compressor operation belt.
DRAIVEBELT
(V-BELT)
GENERATOR
PULLEY
IDLER
WATER PUMP
PULLEY
AlC COMPRESSOR
PULLEY
CRANKSHAFT
PULLEY
DGB110BTB003
01-108-5

VALVE MECHANISM STRUCTURAL VIEW [WL-C, WE-C]
dcf011 012111 101
RARM
TIMING BELT
BALANCE SHAFT
DBG110BTB805
TIMING GEAR CONSTRUCTION [WL-C, WE-C]
dcf011012111to2
Supply Pump Gear

The gears are helical. Supply pump gear is combined with a scissors gear.
The scissors gear, through the force of the scissors gear spring, prevents the teeth of the supply pump gear
from moving back and forth (backlash) between the teeth of the No.2 idler gear, with which the supply pump
gear is meshed, and thus reduces gear noise.
When removing the supply pump gear, fix the scissors gear to the supply pump gear using a lock bolt (M6 x
1.0, length under the bolt head is approximately 10 mm {0.63 in} to prevent the scissors gear from rotating
under the spring force.
01-108-6
MECHANICAL [WL-C, WE-C)
\
SUPPLY PUMP GEAR
(NO.2 IDLER GEAR
SCISSORS GEAR (DOTTED LINE)
SUPPLY PUMP GEAR
SCISSORS GEAR SPRING
BALL BEARING
SCISSORS GEAR
FRICTION GEAR
HELICAL GEAR
NO.3 IDLE GEAR
FRICTION GEAR
DBG110BTB806
01-108-7

CAMSHAFT CONSTRUCTION [WL-C, WE-C)
dcf011 012111 103
The camshaft is made of cast iron alloy.

A hollow type,camshaft with five bearings has been adopted. In addition, the hollow area is provided as the oil
passage.
The camshaft No. 1 journal has a hexagonal shaped surface around the rear of the shaft to prevent rotation
during servicing.
Thrust force is received at the front of the No. 1 journal.
HOLLOW (OIL PASSAGE)
THRUST FORCE RECEIVING AREA
EXH
INT
HEXAGONAL SHAPED SURFACE
HOLLOW (OIL PASSAGE)

DBG110BTBR01
AUTO TENSIONER CONSTRUCTION [WL-C, WE-C)
dcf011 012111 104
A hydraulic timing belt auto tensioner has been adopted for timing belt adjustment so that the timing belt
tension is maintained constantly.
PLUNGER
BALL
c::t-t--+--OIL
PLUNGER SPRING
DBG110BTBRR2
01-108-8

VALVE, ROCKER ARM CONSTRUCTION [WL-C, WE-C]
dcf011012111t05
The valves are operated by rocker arms.

Valve clearance is adjusted by the adjust screw and nut of the rocker arm.
CAMSHAFT
VALVE STEM
DBG110BTB807
ENGINE MOUNT STRUCTURAL VIEW [WL-C, WE-C]
dcf01103900Ot02
4x4
DBG110BTB809
01-108-9
LUBRICATION [WL-C, WE-C]
01-11B LUBRICATION [WL-C, WE-C]

LUBRICATION SYSTEM OUTLINE
[WL-C, WE-C] ................
LUBRICATION SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] ............
LUBRICATION SYSTEM
. FLOW DIAGRAM [WL-C, WE-C] ...
OIL FILTER CONSTRUCTION
[WL-C, WE-C] ................
01-11B-1
01-11B-2
01-11B-3
01-11B-3
OIL COOLER, OIL FILTER BODY

CONSTRUCTION [WL-C, WE-C] ..... 01-11B-4
OIL PAN CONSTRUCTION
[WL-C, WE-C] .............. ; ... 01-11 B-4
OIL STRAINER CONSTRUCTION
[WL-C, WE-C} .................' 01-11 B-5
OIL PUMP CONSTRUCTION
[WL-C, WE-C] .................. 01-11B-5
OIL JET VALVE CONSTRUCTIONI
OPERATION [WL-C, WE-C] ........ 01-11 B-6
LUBRICATION SYSTEM OUTLINE [WL-C, WE-C]
Features
Improved lubricity
Reduced weight
Reduced engine noise
Gear type oil pump adopted

Oil jet valves adopted
Water-cooled type oil cooler adopted
Plastic oil strainer adopted
Oil pan baffle plate adopted
01-118-1

LUBRICATION SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf011100000105
OIL JET VALVE
OIL COOLER
O-RING
All:J~A
--A
II
OILPUMP
.,../
GASKET
AA
OIL STRAINER
O-RING
OIL COOLER AND OIL

FILTER BODY
COMPONENT
OIL OUTLET PIPE
OIL FILTER
r;:-J----O-RING
~
A
'7
OIL PAN
L_
-
:}
---~OIL PAN DRAIN PLUG

GASKET
DCG111 ZTB008
01-11 B-2

LUBRICATION SYSTEM FLOW DIAGRAM [WL-C, WE-C]
dcf01110000Ot06
. . . . . - - - - - - - - - - - - - ..
CAMSHAFT, ROCKER ARM
~+----------------------------~----~
OIL PRESSURE SWITCH
VACUUM PUMP
r8J ORIFICE
~~r----------------r~f~~--+-~
~:
OIL FILTER BODY~
I"---
BALANCESHAFT
I---I-r--""T"'""+--L..--+!:: MAIN BEARING
I
OIL
FILTER
'- -----:
!
~,
CRANKSHAFT
'---_ _--'/<IIf-L-Il----+-~::.-I1 OIL PUMP
,,
,
,,
,
- - - - . OIL PASSAGE
--. OIL RELIEF PASSAGE
- . OIL BYPASS PASSAGE
,,
,,
e;z ..
L..J "-1\1...--4-1-~-----------'
I I
I CONN~TING I I
I
ROD BEARING
:~-~I'b~h
I
PISTON
OIL JET VALVE
.:TURBOCHARGER
I
TIMING GEAR
...
, , ,
OIL PAN
OIL STRAINER
DCG111 ZTB006
OIL FILTER CONSTRUCTION [WL-C, WE-C]
dcf01111430Ot02
A full-flow paper element type oil filter has been adopted.

The oil filter is installed on the oil filter body. (Left surface (vehicle left) of the cylinder block)
HEIGHT
OUTER
DIAMETER
DCG111ZTB001
Oil filter specification

Item
Outer diameter
Height
Specification (mm {in})

73.7 {2.90}
100 {3.94}
01-118-3

OIL COOLER, OIL FILTER BODY CONSTRUCTION [WL-C, WE-C]
dcf011114700t02
A water-cooled, 5-layered type oil cooler has been adopted to reduce engine oil degradation.
The oil cooler, oil cooler bypass valve, and oil pressure control valve are built into the oil filter body.
..
'.
OIL PRESSURE CONTROL

VALVE COMPONENT
OIL FILTER BODY
rr~
ir ~
@.
0J
v-
OIL COOLER
BYPASS VALVE
COMPONENT
'ff',~
l1---C@-0IL FILTER
DCG111ZTB007
Oil filter body specification

Specification (kPa {kgf/cm 2 , psi})
[oil temperature: 120C {248 OF}]
Item
164-200
,400-480
Oil cooler bypass valve opening pressure

Oil pressure control valve opening pressure
OIL PAN CONSTRUCTION [WL-C, WE-C]
dcf01111004Ot02
A steel oil pan has been adopted.

A silicon sealant with excellent sealing qualities has been adopted. Also, sealing slots have been adopted on
the oil pan attachment side to improve sealing performance.
An oil baffle plate has been installed inside the oil pan to bifurcate the oil pan bottom. Due to this, the vibrations
at the oil surface and in the oil pan have been reduced for improved engine noise suppression.
EXTERNAL VIEW
DCG111ZTB010
,.;
01-118-4

OIL STRAINER CONSTRUCTION [WL-C, WE-C]
dcf01111424ot02
A plastic oil strainer with a resin filter in the middle of the strainer has been adopted for weight reduction.
A-A SECTIONAL VIEW
EXTERNAL VIEW
RESIN FILTER
OIL STRAINER
OIL STRAINER
RESIN FILTER
OIL SUPPLY INLET
OIL PUMP CONSTRUCTION [WL-C, WE-C]
dcf011114100to2
A gear type oil pump with superior heat resistance and noise reduction has been adopted, ensuring stable
discharge performance.
The oil pump consists of the oil pump body, oil pump drive gear, driving gear, driven gear, relief valve, and oil
pump cover.
The oil pump is driven by the crankshaft through the timing gear and oil pump drive gear.
The relief valve is built into the oil pump body.
OIL PUMP DRIVE GEAR
DRIVING GEAR
OIL PUMP BODY
DCG111 ZTB005
Oil pump specification

Item
Oil discharge pressure (reference value)
[after warm up]
Relief valve opening pressure (reference value)
Engine speed [rpm]
Specification (kPa {kgf/cm 2 , psi})
At idling
100-330 {1.02-3.36, 14.5-47.7}

410-570 {4.19-5.81, 59.6-82.6}
580-700 {5.9-7.1, 84.1-101.5}
2,500
01-118-5

OIL JET VALVE CONSTRUCTION/OPERATION [WL-C, WE-C)
dcf01111073ot02
Construction
The oil jet valves are installed in the cylinder block. The oil jet valve nozzles are installed pointed toward the
back surface of each piston.
The oil jet valves are designed to maintain optimum oil pressure in the engine by controlling the oil injection
according to the oil pressure applied to the check ball in the oil jet valves.
o
CYLINDER BLOCK
MAIN GALLERY
TO BACK SURFACE
OF PISTON
ENGINE OIL
NOZZLE
OIL JET VALVE
CYLINDER BLOCK
DCG111ZTB003
Operation
Oil pressure applied to the check-ball in the oil jet valve opens and closes the oil passage-way to the nozzle
and controls oil injection starting and stopping.
Oil pressure greater than the specified value applied to the check-ball in the oil jet valve opens the oil passage
to the spring-pressed nozzle, starting injection. Conversely, oil pressure less than the specified value applied to
the check-ball blocks the oil passage by spring force, stopping injection.
~------------------------------------.
SECTIONAL VIEW
OIL PASSAGE
CHECK BALL
--1---111.
SPRING
OIL PASSAGE
(TO NOZZLE)
DCG111ZTB004
01-118-6
COOLING SYSTEM [WL-C, WE-C]
01-128 COOLING SYSTEM [WL-C, WE-C]

COOLING SYSTEM OUTLINE
[WL-C, WE-C] ................... 01-12B-1
COOLING SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] ........... 01-12B-1
COOLING SYSTEM
FLOW DIAGRAM [WL-C, WE-C] . 01-12B-2
RADIATOR, COOLING SYSTEM CAP

CONSTRUCTION [WL-C, WE-C] ..... ~01-12B-2
THERMOSTAT CONSTRUCTION!
OPERATION [WL-C, WE-C] ......... 01-12B-3
WATER PUMP CONSTRUCTION!
OPERATION [WL-C, WE-C] ......... 01-12B-3
COOLING FAN CONSTRUCTION
[WL-C, WE-C] ................. 01-12B-4
COOLING SYSTEM OUTLINE [WL-C, WE-C]

Features
COOLING SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf01120000Dt05
COOLING
SYSTEM CAP
COOLING FAN
COOLANT
RESERVE TANK
DCG112ZTB005
01-128-1

COOLING SYSTEM FLOW DIAGRAM [WL-C, WE-C]
IEGR
COOLER
COOLANT
RESERVE
TANK
1\
CYLINDER HEAD
.,.
RADIATOR
III
I
I
dcf011200000t06
-.
r-'
WATER PUMP
CYLINDER BLOCK
THERMOSTAT
I
+-
TURBOCHARGER
r+
r--1
OIL COOLER
-+COOLANT
FLOW
DIRECTION
*: IF EQUIPPED
J
I
I
HEATER*
I
I
arnffn00000142
RADIATOR, COOLING SYSTEM CAP CONSTRUCTION [WL-C, WE-C]
A corrugated fin type radiator has been adopted.

The radiator tanks are made of plastic and the
core is made of aluminum for weight reduction.
The down-flow direction of water inside the
radiator causes air to bleed from the cooling
system easier.
Four mounting rubbers are utilized to decrease
vibration.
A low-pressure type cap has been adopted for the
cooling system. It is installed on the radiator.
dcf011215200t02
8WII
~[(O)D~
COOLING SYSTEM
TANK
CA~
(\l
CORE
DCG112ZTB001
01-128-2

THERMOSTAT CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf011215171t02
Construction
A wax-type thermostat with a jiggle-pin has been adopted.
The thermostat body is made of stainless steel with excellent corrosion resistance.
Operation
When the engine coolant temperature reaches
80-84 C {176-183 OF}, the valve starts
opening to allow engine coolant to flow from the
radiator stabilizing the engine coolant
temperature. When the engine coolant
temperature decreases to approx. 77 C {171F},
the valve closes to stop the engine coolant flow
from the radiator.
LOWER RADIATOR
HOSE SIDE
ENGINE
SIDE
. . . ENGINE COOLANT
FLOW DIRECTION
WATER PUMP CONSTRUCTION/OPERATION [WL-C, WE-C]

Construction
The aluminum alloy water pump with the impeller built into the cylinder block has been adopted for size
reduction.
A highly reliable integrated water seal has been adopted.
The water pump is not serviceable and must be replaced as a single unit if it has a malfunction.
EXTERNAL VIEW
SEC.A-A
WATER SEAL
IMPELLER
A
DCG 112ZTB003
Operation
The water pump is driven by the drive belt.
01-128-3

COOLING FAN CONSTRUCTION [WL-C, WE-C]
dcf01121514ot02
A thermo-modulation type cooling fan has been adopted which operates the cooling fan only when necessary.
Due to this, the following effects have been obtained.
Reduced noise
- Improved heating performance
Rapid engine warming-up
The cooling fan consists of the fan blades and fan drive.
Noise (wind noise) which occurs during fan operation has been reduced due to the nonuniform positioning of
the fan blades.
The fan blades are made of plastic for weight reduction.
The cooling fan is driven by the drive belt.
FAN BLADE
DCG112ZTB004
Cooling fan specification

Item
Specification
Thermo-modulation type
Type
Number of blades
Outer diameter
01-128-4
(mm {in})
9
450 {17.7}
INTAKE-AIR SYSTEM [WL-C, WE-C]
01-138 INTAKE-AIR SYSTEM [WL-C, WE-C]

INTAKE AIR SYSTEM OUTLINE
[WL-C, WE-C] .................
INTAKE AIR SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] ..........
INTAKE AIR SYSTEM HOSE
ROUTING DIAGRAM
[WL-C, WE-C] .................
INTAKE AIR SYSTEM DIAGRAM
[WL-C, WE-C] ...........
AIR CLEANER CONSTRUCTION
[WL-C, WE-C] ..............
VARIA8LE 800ST CONTROL (V8C)
SOLENOID VALVE FUNCTION
[WL-C, WE-C] ................
VARIA8LE 800ST CONTROL (V8C)
SOLENOID VALVE CONSTRUCTION
[WL-C, WE-C] .................
AIR CHARGING SYSTEM OUTLINE
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . .
AIR CHARGING SYSTEM DIAGRAM
[WL-C, WE-C] .................
AIR CHARGING SYSTEM OPERATION
[WL-C, WE-C] ...................
TUR80CHARGER FUNCTION
[WL-C, WE-C] ..................
01-138-1
01-138-2
01-138-2
01-138-3
01-138-3
01-138-3
01-138-3
01-138-4
01-138-4
01-138-4
01-138-5
TUR80CHARGER CONSTRUCTIONI
OPERATION [WL-C, WE-C] ........ 01-138-5
CHARGE AIR COOLER
CONSTRUCTION [WL-C, WE-C] .... 01-138-6
ACCELERATOR PEDAL COMPONENT
GLOW SYSTEM OUTLINE
[WL-C, WE-C] ................... 01-138-6
GLOW SYSTEM CONSTRUCTION
[WL-C, WE-C] ................. 01-138-6
GLOW SYSTEM OPERATION
[WL-C, WE-C] .................. 01-138-6
GLOW PLUG FUNCTION
[WL-C, WE-C] ............... 01-138-6
GLOW PLUG CONSTRUCTION
[WL-C, WE-C] ................. 01-138-7
GLOW PLUG RELAY OPERATION
[WL-C, WE-C] ............ 01-138-7
VACUUM CHAM8ER FUNCTION
[WL-C, WE-C] ................. 01-138-7
VACUUM CHECK VALVE FUNCTION
[WL-C, WE-C] .................... 01-138-7
VACUUM CHECK VALVE
INTAKE AIR SYSTEM OUTLINE [WL-C, WE-C]

Features
IPower efficiency, performance, and fuel economy
dcf011300000to5
A variable geometry turbocharger has been adopted
Specification
Item
Turbocharger type
Air cleaner element
Glow plug type
WL-C, WE-C
Variable geometry turbocharger
Dry type
Stainless type
01-138-1

INTAKE AIR SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf01130000ot06
VACUMM CHECK VALVE
(
BLADE ACTUATOR
DUCT
GLOW PLUG RELAY
DBGl13BTBB05
INTAKE AIR SYSTEM HOSE ROUTING DIAGRAM [WL-C, WE-C]
dcf01130000ot07
VACUUM CHECK VALVE

AIR FILTER
EGRVALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)
INTAKE SHUTTER VALVE
EGR CONTROL
SOLENOID VALVE
VACUUM PUMP
DBGl13BWB305
01-138-2

INTAKE AIR SYSTEM DIAGRAM [WL-C, WE-C]
dcf01130000Qt08
CHARGE AIR COOLER
INTAKE MANIFOLD
*:TOPCM
DGB113BTB001
AIR CLEANER CONSTRUCTION [WL-C, WE-C]
dcf011313300t02
Consists of the air cleaner case, air cleaner element, and fresh-air duct.
A dry type air cleaner element has been adopted.
r---------------------,
DGB113BTB002
VARIABLE BOOST CONTROL (VB C) SOLENOID VALVE FUNCTION [WL-C, WE-C]
dcf011318748t01
Switches the vacuum passage between the vacuum chamber and the guide blade actuator.
Vacuum is applied to the guide blade actuator using the VBC solenoid valve.
As a result, the variable guide vanes of the turbocharger are adjusted based on the signals from the PCM.
VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE CONSTRUCTION [WL-C, WE-C]
dcf011318748to2
Construction
Consists of the solenoid coil, spring, and plunger.
PORT A (VACUUM CHAMBER)
PORT B (GUIDE BLADE ACTUATOR)
DBG113BTB311
01-138-3

AIR CHARGING SYSTEM OUTLINE [WL-C, WE-C]
dcf01131370ot04
A variable boost (variable geometry) type turbocharger has been adopted. By changing the opening angle of
the guide blades and changing the exhaust pressure that acts on the turbine impellers, the optimum boost
pressure according and fuel consumption have been improved in every driving range.
AIR CHARGING SYSTEM DIAGRAM [WL-C, WE-C]
dcf01131370ot05
VACUUM CHECK VALVE

CHAMBER
VACUUM PUMP
-
*:TOPCM
DBG113BTB702
AIR CHARGING SYSTEM OPERATION [WL-C, WE-C]
dcf01131370ot06
When the VBC solenoid valve is operated according to the duty signal from the PCM, the vacuum passage is
opened and vacuum is applied to the guide blade actuator of the turbocharger. Due to this, the rod of the guide
blade actuator is pulled and the opening angle of the guide blades changes.
When the duty signal is on for a long time, the vacuum that acts on the guide blade actuator is reduced and the
guide blades move in the closing direction.
When the duty signal is off for a long time, the vacuum that acts on the guide blade actuator is reduced and the
guide blades move in the opening direction.
When the guide blades are moved in the closing direction, the passages that lead the exhaust gas to the
turbine impellers become narrow and the flow rate of the exhaust gas increases. Due to this, the exhaust gas
pressure is increased and the boost pressure is also increased. On the other hand, when the guide blades are
moved in the opening direction, the passages that lead the exhaust gas to the turbine impellers become wide.
Due to this, the exhaust gas pressure is reduced and the boost pressure is also reduced.
01-138-4
c'

GUIDE BLADE OPEN
(BOOST PRESSURE HIGH)
GUIDE BLADE CLOSED

(BOOST PRESSURE IS LOW)
TURBINE IMPELLER
TURBOCHARGER FUNCTION [WL-C, WE-C]
dcf011313700t07
The turbocharger uses the exhaust gas pressure to compress the intake air.
TURBOCHARGER CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01131370Dt08
A variable geometry turbocharger has been adopted.

The turbocharger consists of mainly a turbine wheel, a compressor wheel, guide blades, and a guide blade
actuator.
When the exhaust gas flows to the turbine wheel, the turbine wheel and the compressor wheel that is on the
same axis as the turbine wheel rotate to compress the intake air.
The opening angle of the guide blades changes according to the movement of the guide blade actuator rod.
0+
o
INTAKE AIR FLOW
EXHAUST GAS FLOW

DBG113BTB396
01-138-5

CHARGE AIR COOLER CONSTRUCTION [WL-C, WE-C]
dcf011313560t02
An aluminium-alloy intercooler has been adopted.

Compressed and heated intake air is cooled by the intake air charger to increase air density, enhancing the
charging efficiency.
DGB113BTB003
ACCELERATOR PEDAL COMPONENT CONSTRUCTION [WL-C, WE-C]

Consists of the accelerator pedal and accelerator
pedal position (APP) sensor.
dcf01134160Ot02
ACCELERATOR
PEDAL POSITION
(APP) SENSOR
IDLE SWITCH
ACCELERATOR
PEDAL
DGB113BTB004
GLOW SYSTEM OUTLINE [WL-C, WE-C]
dcf011318601t07
The glow system warms up the combustion chamber at engine start to improve ignitability.
GLOW SYSTEM CONSTRUCTION [WL-C, WE-C]
dcf011318601t08
The glow system consists of the glow plug relay, glow plug lead, and glow plug.
GLOW SYSTEM OPERATION [WL-C, WE-C]
dcf011318601t09
When the PCM energizes the glow plug relay, the glow plug activates, the circuit from the battery to the glow
plug is established, and power is supplied to the glow plug via the glow plug lead. Due to this, the glow plug is
heated and the combustion chamber is warmed up.
GLOW PLUG
DGB113BTB005
GLOW PLUG FUNCTION [WL-C, WE-C]

The glow plug warms up the air inside the combustion chamber by generating heat.
01-138-6
dcf011318601t10
;,.', .
\ .-

GLOW PLUG CONSTRUCTION [WL-C, WE-C]
dcf011318601t11
Installed to the cylinder head.

A stainless type glow plug has been adopted.
q@L--J..I-!!1---IL-l!-------l~
~~
HEAT-GENERATING AREA
GLOW PLUG RELAY OPERATION [WL-C, WE-C]
dcf011318601t12
The glow plug relay activates according to the glow control signal from the peM, and supplies/cuts the power to
the glow plug.
DBG113ATB105
VACUUM CHAMBER FUNCTION [WL-C, WE-C]

The vacuum chamber improves vacuum
efficiency by reducing the pulsation generated
when the air is drawn.
dcf011320330101
TO VACUUM PUMP
TOEGR
SOLENOID VALVE
VACUUM CHAMBER
DBG 113BTB302
VACUUM CHECK VALVE FUNCTION [WL-C, WE-C]
dcf01134291 0101
The one-way check valve prevents vacuum pressure inside the vacuum pump from flowing back to the vacuum
chamber.
01-138-7

VACUUM CHECK VALVE CONSTRUCTION [WL-C, WE-C]
Mainly consists of the valve.
dcf011342910to2
t
SEC. A-A
TO
VACUUM"
PUMP
~AIRFLOW
DBG113BTB301
01-138-8
FUEL SYSTEM [WL-C, WE-C]
01-148 FUEL SYSTEM [WL-C, WE-C]

FUEL SYSTEM OUTLINE
[WL-C, WE-C] ....................
FUEL SYSTEM STRUCTURAL VIEW
[WL-C, WE-C] ....................
FUEL SYSTEM DIAGRAM
[WL-C, WE-C] ....................
COMMON RAIL INJECTION
SYSTEM FUNCTION
[WL-C, WE-C] ....................
FUEL TANK CONSTRUCTION
[WL-C, WE-C] ....................
FUEL FILTER FUNCTION
[WL-C, WE-C] ....................
FUEL FILTER CONSTRUCTION/
OPERATION [WL-C, WE-C] .........
SUPPLY PUMP FUNCTION
[WL-C, WE-C] ....................
01-148-1
01-148-2
01-148-3
01-148-4
01-148-4
01-148-4
01-148-5
01-148-5
SUPPLY PUMP CONSTRUCTION/

OPERATION [WL-C, WE-C] .......... 01-148-5
FUEL METERING VALVE
FUNCTION [WL-C, WE-C] ........... 01-148-9
FUEL METERING VALVE
CONSTRUCTION/OPERATION
[WL-C, WE-C] .................... 01-148-9
COMMON RAIL FUNCTION
[WL-C, WE-C] ..................... 01-148-1 0
COMMON RAIL CONSTRUCTION
[WL-C, WE-C] .................... 01-148-10
FUEL INJECTOR FUNCTION
[WL-C, WE-C] ..................... 01-148-10
FUEL INJECTOR CONSTRUCTION
[WL-C, WE-C] ..................... 01-148-10
FUEL INJECTOR OPERATION
[WL-C, WE-C] ..................... 01-148-12
CHECK VALVE FUNCTION
[WL-C, WE-C] .................... 01-148-13
FUEL SYSTEM OUTLINE [WL-C, WE-C]
dcf01140000Ot04
Features
IImproved exhaust gas purification
Common rail injection system adopted
Specification
WL-C, WE-C
Item
Supply pump
Fuel injector
Fuel tank capacity (reference)
Electronic control
Electromagnetic control
70 {18, 15}
01-148-1

FUEL SYSTEM STRUCTURAL VIEW [WL-C, WE-C)
dcf01140000Ot05
Engine Room Side

CHECK VALVE
FUEL INJECTOR
COMMON RAIL
SEDIMENTOR SWITCH
FUEL METERING VALVE

SUPPLY PUMP
DBG114BTB302
Fuel Tank Side

Double cab 4x2 (except Hi-Rider), Stretch cab 4x2 (with rear access system (except Hi-Rider
FUEL GAUGE SENDER UNIT
FUEL TANK
DBG114BTB330
01-148-2

Regular cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
FUEL SYSTEM DIAGRAM [WL-C, WE-C]
*:TOPCM
- - - . - : FUEL FLOW
DBGl14BTB301
01-148-3

COMMON RAIL INJECTION SYSTEM FUNCTION [WL-C, WE-C]
dcf01140000Dt07
This system stores fuel under high pressure supplied by the supply pump in the common rail, and injects it
through the electromagnetic injectors.
The PCM controls both fuel injection amount and timing by sending a signal to the injector solenoid valve coil.
Since fuel is highly pressurized by the supply pump and stored in the common rail, injection pressure is
constantly assured even at low speed since engine speed and load have no influence on the injection process.
The PCM can precisely control the fuel injection amount and timing due to use of an solenoid valve coil in the
injector that opens and closes the fuel path.
Fuel is injected multiple times, including multiple auxiliary injections previous to the main injection. These
multiple injections help to smooth the fuel combustion process, reducing noise and vibration levels as well as
the amount of NOx in the exhaust.
With the use of 160 MPa {1.632 kgf/cm 2 , 23,206 psi} ultra-high pressure injectors, engine output is improved
and the amount of smoke and particulate matter in the exhaust is greatly reduced.
<::=
......
FUEL PRESSURE LIMITER

FUEL
PRESSURE
SENSOR
COMMON RAIL
FUEL FILTER
t
FUEL INJECTOR
FUEL TANK
=:> RETURN FUEL FLOW
"-------:0
...... MAIN FUEL FLOW

DBG114BTB30B
FUEL TANK CONSTRUCTION [WL-C, WE-C]
dcf011442110to2
Capacity is 70 L {18 US gal, 15 Imp gal}.

Two rollover valves are built-in.
FUEL FILTER FUNCTION [WL-C, WE-C]
The filter part removes foreign material or dirt in the fuel.

The priming pump is a pump to discharge (drain) the accumulated water efficiently.
01-148-4
dcf01142049Dt03

FUEL FILTER CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf011420490t04
The fuel filter consists of the drain plug and the priming pump.
To drain water, loosen the drain plug on the lower side and pump the priming pump on the upper side of the
fuel filter.
The sedimentor switch illuminates the sedimentor warning light to inform the user of the drain timing. The float
rises according to the level of accumulated water. If the water level exceeds the specification, the circuit for the
sedimentor switch is completed.
PRIMING PUMP
FUEL FILTER
CARTRIDGE
SEDIMENTOR
SWITCH
DRAIN PLUG
D8G 1148T8307
SUPPLY PUMP FUNCTION [WL-C, WE-C]
dcf01141335ot01
An electrically controlled supply pump with ultra-high discharge pressure and low-drive torque has been
adopted.
The supply pump intakes the proper fuel amount and pressure feeds the fuel to the common rail.
SUPPLY PUMP CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01141335ot02
The supply pump is driven by the timing belt. The feed pump is driven by the supply pump drive shaft.
The supply pump has three pumping elements with 120 0 offset (displacement pumps).
The fuel metering valve is located in the supply duct between the feed pump and the supply pump, and meters
the quantity of fuel which is to be delivered into the high-pressure chamber in accordance with the current
operating status of the engine.
Any surplus fuel is returned to the fuel tank via the fuel return ..
,-------------------------------------,
FUEL RETURN
SUPPLY
PUMP
. FEED PUMP
D8G 1148T8502
01-148-5

Flow of fuel through fuel pump
PRESSURE RESTRICTION
(ZERO DELIVERY RESTRICTION)
(
HIGH FUEL
PRESSURE
SUPPLY PUMP
r--::=>-L-_OVER FLOW
VALVE
TO FUEL
INJECTOR~-f----+H
FUEL FILTER
FUEL METERING VALVE
FUEL TANK
DBG114BTB509
Feed Pump Operation

The feed pump is designed as a gear pump and delivers the required fuel to the supply pump.
Essential components are two counter-rotating, meshed gear wheels that transport the fuel in the tooth gaps
from the intake side to the pressure side.
The contact line of the gears forms a seal between the intake side and the pressure side and prevents the fuel
from flowing back.
The delivery quantity is approximately proportional to engine speed. For this reason, fuel-quantity control is
required.
For fuel-quantity control purposes, there is an overflow valve incorporated in the supply pump.
INTAKE SIDE
":FUELFLOW
DBG114BTB510
\. ,
01-148-6

Overflow Valve Operation
High-pressure generation (up to 160 MPa {1,632 kgf/cm2, 23,206 psi}) means high thermal load on the
individual components of the supply pump. The mechanical components of the supply pump must also be
lubricated sufficiently to ensure durability.
The overflow valve is designed to ensure optimum lubrication or cooling for all operating conditions.
At lower engine speeds (low feed pump pressure) the control plunger is moved only slightly out of its seat. The
lubrication/cooling requirement is correspondingly low.
A small amount of fuel is released to lubricate/cool the pump via the restriction at the end of the control plunger
The supply pump features automatic venting. Any air in the supply pump is vented through the restriction.
With increasing engine speed (increasing feed pump pressure), the control plunger is moved further against
the compression spring.
Increasing engine speeds require increased cooling of the supply pump. Above a certain pressure, the supply
pump cooling bypass is opened and the flow rate through the supply pump is increased.
At high engine speeds (high feed pump pressure), the control plunger is moved further against the
compression spring. The supply pump cooling bypass is now fully open (maximum cooling).
Excess fuel is transferred via the return bypass to the intake side of the feed pump.
In this way, the internal pump pressure is limited to a maximum of 600 kPa {6.12 kgf/cm2, 87.0 psi}.
FUEL
PUMP
PRESSURE
LOW
ENGINE
SPEED
TIME
FUEL
PUMP
PRESS-'--_ _-.t
URE
TIME
INCREASING
ENGINE
SPEED
LUBRICATION!
COOLINGNENT
ILATIONSUPPLY PUMP
SUPPLY
PUMP
COOLING
BYPASS
SUPPLY
PUMP
COOLING
BYPASS
TO HIGHPRESSURE
CHAMBER
HIGH
ENGINE
SPEED
LUBRICATION!
COOLINGNENT
ILATIONSUPPLY PUMP
RESTRICTION
CONTROL
PLUNGER
FUEL
PUMP
PRESS- '--_ _-..
URE
TIME
RETURN
BYPASS TO
FEED PUMP
TO HIGHPRESSURE
CHAMBER
TO HIGHPRESSURE
CHAMBER
DBG114BTB511
01-148-7

High Pressure Generation
The supply pump is driven via the drive shaft.
An eccentric element is fixed to the drive shaft and moves the three plungers up and down according to the
cam lobes of the eccentric element.
Fuel pressure from the feed pump is applied to the inlet valve. If the feed pump pressure exceeds the internal
pressure of the high-pressure chamber (pump plunger in TOG position), the inlet valve opens.
Fuel is now pressed into the high-pressure chamber, which moves the pump plunger downwards (intake
stroke).
If BOG of the pump plunger is exceeded, the inlet valve closes due to the increasing pressure in the
high"pressure chamber. The fuel in the high-pressure chamber can no longer escape.
As soon as the pressure in the high-pressure chamber exceeds the pressure in the common rail, the outlet
valve opens and the fuel is pressed into the common rail via the high-pressure connection (delivery stroke).
The pump plunger delivers fuel until TOG is reached. After this, the pressure drops so that the outlet valve
closes.
As the pressure on the remaining fuel is reduced, the pump plunger moves downward.
If the pressure in the high-pressure chamber falls below the transfer pressure, the inlet valve reopens and the
process starts again.
HIGH-PRESSURE TO COMMON RAIL
INLET VALVE
~.-...--TAPPET
. . . . FUEL FEED
DBG114BTBR12
01-148-8

Zero Delivery Restriction Operation
The zero-delivery throttle is installed to the supply
pump. The fuel metering unit sends a quantity of
fuel to the plunger even during zero-delivery. To
prevent this, the fuel is returned to the feed pump
inlet via the orifice of the zero-delivery throttle,
ensuring zero fuel delivery to the plunger. Except
during zero-delivery, essentially no fuel is sent to
the orifice due to the throttle effect, instead it is
sent to the plunger.
ZERO DELIVERY THROTTLE

ZERO DELIVERY ORIFICE
FUEL METERING VALVE FUNCTION [WL-C, WE-C]
dcf01141335ot03
By controlling the supply pump intake amount, the fuel metering valve controls the pressure pump feed amount
and the pressure inside the fuel injection pipe.
The intake amount is determined by the total opening size of the valve as controlled by the duty value of the
solenoid actuation current.
The duty solenoid can adjust the open and close time ratio to control the intake amount by changing the OFF
time during a single cycle. For a normally open type fuel metering valve, making the duty ratio larger increases
the intake amount and, conversely, making the duty value smaller decreases the intake amount.
ON (CLOSE)
OFF (OPEN)
il
Duty
'j
j-'---
U U
j
j
1 cycle
.j,-,----i
DBG114BTB514
FUEL METERING VALVE CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf011413350to4
De-energized (open)
The solenoid inner port is opened and fuel is sent
into the high-pressure chamber.
.....FUELFLOW
DBG 114BTB506
01-148-9

Energized (closed)
The solenoid inner port is closed. Fuel siphoned
by the feed pump is returned to the fuel tank
through the overflow valve.
DBG114BTB507
COMMON RAIL FUNCTION [WL-C, WE-C]
dcf011413151t01
Due to constant high-pressure fuel (25-160 MPa {255-1.631 kgf/cm2, 3,626-23,206 psi}) in the rail,
electrically controlled injection is made possible.
COMMON RAIL CONSTRUCTION [WL-C, WE-C]
dcf011413151t02
The PCM constantly maintains optimum pressure by monitoring the fuel pressure measurement signal from the
fuel pressure sensor.
As a consideration to safety, a fuel pressure limiter has been installed to mechanically drain fuel if the pressure
goes above 195 MPa {1.988 kgf/cm2, 28,282 psi}.
CONNECTOR(FUEL INJECTOR SIDE)
CONNECTOR(SUPPLY PUMP SIDE)

DBG114BTB505
FUEL INJECTOR FUNCTION [WL-C, WE-C]
dcf011413250t01
A small sized, energy saving, electromagnetically controlled injector has been adopted.
A multiple fuel injection system has been adopted. The fuel injection amount and timing, as well as the division
of the numerous injections are according to a PCM ON/OFF signal that controls the opening and closing of the
electromagnetic valves.
The construction and material of the electromagnetic valve has been modified to save energy and improve
response.
FUEL INJECTOR CONSTRUCTION [WL-C, WE-C]
dcf01141325Ot02
The fuel injector is composed of: a valve control plunger that controls the nozzle, a control chamber with an
inflow/outflow orifice, and an solenoid valve coil that controls the inflow/outflow of fuel to the control chamber
via an on/off function.
The valve control plunger is connected to the nozzle so that the up and down movement of the plunger results
in the opening and closing of the nozzle.
The control chamber contains a single orifice plate to provide an inflow and outflow path.
01-148-10

RETURN FUEL FLOW (TO FUEL TANK)
t
FUEL FLOW (FROM COMMOMRAIL)
ORIFICE PLATE
VALVE CONTROL PLUNGER
NOZZLE
DBG114BTB500
Fuel Injector Calibration Code

Because the fuel injector corrects the deviation of the fuel injection amount caused by the difference in
mechanical characteristics, if the fuel injector or the PCM is replaced, the injector calibration code (rank
number) programming in the PCM is required.
This is done by inputting the eight digit fuel injector calibration code (or fuel injector calibration bar code) into
the PCM by means of M-MDS and taking into account the corresponding cylinder.
I----r============~
It is not necessary to configure the 9th and 1Oth
digit (AO: WL-C engine, BO: WE-C engine) of the
FUEL INJECTOR
fuel inJector calibration code as it is the fuel
IDENTIFICATION
CODE
injector grade identification code.
(AO : WL-C ENGINE)
(BO : WE-C ENGINE)
FUEL INJECTOR
CALIBRATION
CODE
FUEL
INJECTOR
FUEL INJECTOR
CALIBRATION BAR CODE
DBG 114BTB503
01-148-11

FUEL INJECTOR OPERATION [WL-C, WE-C]
dcf011413250to3
The solenoid valve coil controls inflow/outflow of fuel to the control chamber by opening and closing according
to an ON/OFF signal received from the peM.
De-energized (off)
- When the solenoid valve coil is not energized, the plate is pushed down, closing the control chamber outflow
orifice to valve ball, and causing the pressurized fuel from the fuel injection pipe to fill the control chamber. Due
to this, the nozzle connected to the valve control plunger is closed and injection does not occur.
Energized (on)
When solenoid valve coil energization begins the valve ball and plate are pulled upwards, opening the control
chamber outflow orifice and fuel outflow occurs. As fuel outflow occurs, the control chamber pressure
decreases, drawing the valve control plunger and the nozzle upward, and injection begins. As energization
continues the nozzle is opened even more, providing maximum injection rate. When energization of the
solenoid valve coil ends, the plate once again moves down and the nozzle is closed instantaneously. Since the
coil can be repeatedly energized any number of times, multiple pilot injection is made possible.
ENERGIZED (ON)
RETURN
FUELFrL~O~W~-T'-~__'
PLATE
VALVE BALL
OUTFLOW
ORIFICE
CONTROL
CHAMBER
IN-FLOW
ORIFICE
VALVE CONTROL
PLUNGER
NOZZLE
+: FYEL FLOW
DBG114BTB501
01-148-12

CHECK VALVE FUNCTION [WL-C, WE-C]
dcf011413152t01
The one-way check valve prevents fuel from flowing back to the fuel injector.
CHECK VALVE
FUEL RETURN HOSE
TO FUEL
TANK
FROM
.~. i~~~TOR
: FUEL FLOW
DBG114BTB111
01-148-13
EXHAUST SYSTEM [WL-C, WE-C]
01-158 EXHAUST SYSTEM [WL-C, WE-C]

EXHAUST SYSTEM OUTLINE
[WL-C, WE-C] . ................... 01-158-1
EXHAUST SYSTEM STRUCTURAL

VIEW [WL-C, WE-C] .. ............. . 01-158-1
EXHAUST SYSTEM OUTLINE [WL-C, WE-C]

Features
The exhaust system (including the exhaust manifold) has been laid out as straight as possible in order to
achieve smooth flow of exhaust gas and maintain high power output.
EXHAUST SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
OXIDATION CATALYTIC CONVERTER
TURBOCHARGER
DBGl15BTB401
01-158-1
EMISSION SYSTEM [WL-C, WE-C]
01-168 EMISSION SYSTEM [WL-C, WE-C]

EMISSION SYSTEM OUTLINE
[WL-C, WE-C] ....................
EMISSION SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] .............
EMISSION SYSTEM DIAGRAM
[WL-C, WE-C] ...........
EGR SYSTEM OUTLINE
[WL-C, WE-C] ............
EGR SYSTEM DIAGRAM
[WL-C, WE-C] .............
EGR SYSTEM OPERATION
[WL-C, WE-C] ..............
EGR SYSTEM FUNCTION
[WL-C, WE-C] .................
EGR SYSTEM OPERATION
[WL-C, WE-C] ...................
EGR SORENOID VALVE
FUNCTION [WL-C, WE-C] ..........
EGR SORENOID VALVE
DESCRIPTION [WL-C, WE-C] ....
EGR CONTROL SOLENOID VALVE
FUNCTION [WL-C, WE-C] ........
01-168-1
01-168-2
01-168-3
01-168-4
01-168-4
01-168-4
01-168-4
01-168-5
01-168-5
01-168-5
01-168-5

DESCRIPTION [WL-C, WE-C] ...... 01-168-5
EGR COOLER FUNCTION
[WL-C, WE-C] ................ 01-168-5
EGR COOLER DESCRIPTION
[WL-C, WE-C] ................. 01-168-6
DESCRIPTION [WL-C, WE-C] ...... 01-168-6
INTAKE SHUTTER SOLENOID VALVE
DESCRIPTION [WL-C, WE-C] ....... 01-168-6
OXIDATION CATALYTIC
CONVERTER FUNCTION
[WL-C, WE-C] ................. 01-168-6
CONSTRUCTION [WL-C, WE-C] ... 01-168-7
ROLLOVER VALVE FUNCTION
[WL-C, WE-C] ................... 01-168-7
ROLLOVER VALVE
[WL-C, WE-C] ................... 01-168-7
EMISSION SYSTEM OUTLINE [WL-C, WE-C]
dcf011600000t04
Feature
Improved exhaust gas purification
EGR system adopted

EGR cooler adopted
Oxidation catalytic converter adopted
Specification
Item
EGR valve type
WL-C, WE-C
Vacuum
01-168-1

EMISSION SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf011600000to5
Engine Room Side


INTAKE SHUTTER SOLENOID VALVE (HALF)
INTAKE SHUTTER SOLENOID VALVE (FULL)
DBG116BTB479
Fuel Tank Side

DBG116BTB331
01-168-2

Regular cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
EMISSION SYSTEM DIAGRAM [WL-C, WE-C]
AIR FI
EGR CONTORL SOLENOID VALVE
EGR SOLENOID VALVE
INTAKE SHUTTER SOLENOID---!HI!:,II;li!-*

VALVE (HALF OPEN)
INTAKE SHUTTER SOLE

VALVE (FULL CLOSE)
-*:TOPCM
DBG116BWB332
01-168-3

EGR SYSTEM OUTLINE [WL-C, WE-C]
dcf011600020t06
The EGR cooler cools EGR gas and improves the intake-air charging efficiency, reducing black smoke.
For control of EGR system, refer to CONTROL SYSTEM, EGR CONTROL. (See 01-40B-17 EGR CONTROL
OUTLINE [WL-C, WE-C].) (See 01-40B-17 EGR CONTROL BLOCK DIAGRAM [WL-C, WE-C].) (See 01-40B17 EGR CONTROL OPERATION [WL-C, WE-C].)
EGR SYSTEM DIAGRAM [WL-C, WE-C]
dcf011600020t07
VALVE
EGR VALVE POSITION SENSOR
EGR CONTROL SOLENOID
EGR SOLENOID VALVE
*:TOPCM
DGB116BTB723
EGR SYSTEM OPERATION [WL-C, WE-C]
dcf01160002ot08
To open the EGR valve and increase the EGR amount, increase the EGR solenoid valve control duty valve to
increase the vacuum applied to the EGR valve. To close the EGR valve to decrease the EGR amount, increase
the EGR control solenoid valve control duty valve to decrease the vacuum applied to the EGR valve.
When the PCM energizes the intake shutter solenoid valve during the exhaust gas introduction at low engine
speed, the vacuum passage is opened and vacuum is applied to the intake shutter valve actuator. Due to this,
the intake shutter valve is closed and vacuum is generated downstream of the intake manifold after the intake
shutter valve, realizing easier introduction of the exhaust gas to the combustion chamber.
EGR SYSTEM FUNCTION [WL-C, WE-C]
The EGR valve, installed to the intake manifold, recirculates the exhaust gas to the intake manifold.
01-168-4
dcf011620300t03
-,

EGR SYSTEM OPERATION [WL-C, WE-C]
dcf01162030Ot04
Consists of a diaphragm and valves.

The EGR solenoid valve operates based on the signal from the PCM and changes the valve opening angle to
open the passage leading from the exhaust gas to the intake manifold by inducting the vacuum to the
diaphragm on the upper part of the EGR valve.
DIAPHRAGM
ROD
FILTER
I!!!!!JHI----HOLDER
VALVE
HOUSING ---LL...LJ
EGR SORENOID VALVE FUNCTION [WL-C, WE-C]
dcf011618741t05
EGR solenoid valve open/close the passage which brings vacuum generated in the vacuum pump to the
diaphragm, and control the EGR valve opening.
EGR SORENOID VALVE DESCRIPTION [WL-C, WE-C]
dcf011618741t06
Structure/Operation
Vent side port of solenoid valve is connected to the EGR valve diaphragm through EGR control solenoid valve,
and the vacuum side port of solenoid valve is connected to vacuum pump..
Solenoid valve consists of a solenoid coil, spring, plunger and air filter.
EGR solenoid valve increases the angle of the valve opening by increasing vacuum on EGR valve via the EGR
control signal (duty signal).
EGR solenoid valve decreases the angle of the valve opening by releasing vacuum on EGR valve via the EGR
control signal (duty signal).
EGR CONTROL SOLENOID VALVE FUNCTION [WL-C, WE-C]
dcf011618741t07
EGR valve changes the pressure on the diaphragm of the EGR valve from vacuum to atmospheric pressure.
EGR CONTROL SOLENOID VALVE DESCRIPTION [WL-C, WE-C]
dcf011618741to8
Structure/Operation
EGR control solenoid valve consists of coil, spring, and plunger.
When EGR valve is not energized, the passage between the diaphragm and atmospheric air side is open.
When specified conditions are satisfied, the solenoid coils become energized and electromagnetic, and then
pull the plunger. At this time, the passage between the diaphragm and atmospheric air side is closed and the
passage between the diaphragm and vacuum pump side is opened.
EGR COOLER FUNCTION [WL-C, WE-C]
dcf011600020to9
EGR cooler cools recircurated exhaust gas from the intake manifold.
01-168-5

EGR COOLER DESCRIPTION [WL-C, WE-C]
dcf01160002ot10
Structure/Operation
EGR cooler has an EGR passage and coolant passage.
..../
EGR COOLER
EXHAUST GAS FLOW
EGR PASSAGE
DBG116BTBB02
INTAKE SHUTTER VALVE DESCRIPTION [WL-C, WE-C]
dcf01160000ot07
Function
When the exhaust gas recirculation system is operated, the intake shutter valve closes, vacuum is generated in
the intake manifold, and EGR gas is efficiently transported to the combustion chamber. As a result, NOx is
reduced.
When the engine is idling, the intake shutter valve closes and reduces air intake noise.
Structure/Operation
When the exhaust gas recirculation system is operated and vacuum is applied to the diaphragm of the intake
shutter valve actuator, internal lever is pulled and the intake shutter valve closes.
,---------------==----~--------------.
INTAKE MANIFOLD
DBG116BTBB01
INTAKE SHUTTER SOLENOID VALVE DESCRIPTION [WL-C, WE-C]
dcf01160000ot08
Function
The intake shutter solenoid valve switches the opening/closing of the passage where the vacuum generated in
the vacuum pump is led to the diaphragm of the intake shutter valve actuator.
Structure
The intake shutter valve consists mainly of a solenoid coil, and a spring, a plunger.
Operation
.
The vacuum passage between the intake shutter valve actuator and the vacuum pump is opened or closed
depending upon whether the intake shutter solenoid valve is energized or de-energized.
OXIDATION CATALYTIC CONVERTER FUNCTION [WL-C, WE-C]
dcf01162050ot04
Purifies contaminants in the exhaust gas by utilizing a chemical reaction in a three way catalytic converter.
The catalytic converter converts the noxious carbon monoxide and hydrocarbon in the exhaust gas to nonnoxious carbon dioxide and water.
01-168-6

OXIDATION CATALYTIC CONVERTER CONSTRUCTION [WL-C, WE-C]
dcf011620500to5
Consists of a three-way catalytic converter and insulator.

A catalytic converter utilizing a platinum-palladium-rhodium system has been adopted.
OXIDATION CATALYTIC CONVERTER OPERATION [WL-C, WE-C]
dcf01162050Ot06
Contaminants in the exhaust gas (HC and CO) are purified by oxidization while passing through the catalytic
converter.
Oxidization process
Noxious hydrocarbon (HC) and carbon monoxide (CO) are bonded to oxygen which is converted to
non-noxious carbon dioxide and water.
O2 + HC + CO ~ CO 2 + H2 0
ROLLOVER VALVE FUNCTION [WL-C, WE-C]
dcf01164272Ot03
The rollover valve prevents fuel flow into the airflow hose during sudden cornering or vehicle rollover.
ROLLOVER VALVE CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01164272Ot04
The rollover valve consists of a float, and spring.

The rollover valve utilizes a combination of float weight, spring force, and buoyancy. When the float is sunk in
the fuel, the float (valve) closes to block the sealing surface of the passage.
FUEL LEVEL
SPRING
...
VEHICLE LEVEL
(NORMAL VEHICLE POSITION)
ROTATED 180 0 (VEHICLE

ROLLOVER)
FLOW OF EVAPORATIVE GAS

DBG116ATB030
01-168-7
CHARGING SYSTEM [WL-3, WL-C, WE-C]
01-17
CHARGING SYSTEM OUTLINE

[WL-3, WL-C, WE-C] ............ 01-17-1
CHARGING SYSTEM STRUCTURAL

VIEW [WL-3, WL-C, WE-C] .......... 01-17-1
GENERATOR CONSTRUCTION
[WL-3, WL-C, WE-C] ............ 01-17-2
CHARGING SYSTEM OUTLINE [WL-3, WL-C, WE-C]
Features
IImproved reliability
Generator with built-in battery sensing type Ie regulator adopted
CHARGING SYSTEM STRUCTURAL VIEW [WL-3, WL-C, WE-C]
BATTERY
DCG117ZTB003
01-17-1

GENERATOR CONSTRUCTION [WL-3, WL-C, WE-C]
dcf01171830Dt01
A battery sensing type IC regulator is built into the generator which directly detects the voltage charged to the
battery. Battery overcharge during light loads and charge voltage decreases during heavy loads have been
prevented, improving battery reliability.
REAR BEARING
FRONT
BEARING
PULLEY
REGULATOR COMPONENT
STATOR COIL
DCG117ZTB001
B
GENERATOR
WARNING LIGHT
STATOR
COIL
S
~-I---H-I---o
E
BATTERY
IC REGULATOR
DCG117ZTB002
An IC regulator with a malfunction diagnosis function is built into the generator. The generator warning light
illuminates if any of the following malfunctions occurs.
No power generation
Overvoltage
Open circuit
Terminal B disconnected
Terminal S disconnected
01-17-2
"J
STARTING SYSTEM [WL-3, WL-C, WE-C]
01-19
STARTING SYSTEM [WL-3, WL-C, WE-C]
STARTING SYSTEM OUTLINE

[WL-3, WL-C, WE-C] .............. 01-19-1
STARTING SYSTEM STRUCTURAL

VIEW [WL-3, WL-C, WE-C] .......... 01-19-1
STARTER CONSTRUCTION
[WL-3, WL-C, WE-C] . .............. 01-19-1
STARTING SYSTEM OUTLINE [WL-3, WL-C, WE-C]

Features
IImproved startability
Reduction type starter adopted
STARTING SYSTEM STRUCTURAL VIEW [WL-3, WL-C, WE-C]
DCG 119ZTB002
STARTER CONSTRUCTION [WL-3, WL-C, WE-C]
dcfOl1918400tol
A high torque coaxial reduction type starter has been adopted.
~--------------------------------,
ENGINE SWITCH
PULL-IN COIL
DCGl19ZTBOOl
01-19-1
CONTROL SYSTEM [WL-C, WE-C]
01-408 CONTROL SYSTEM [WL-C, WE-C]

OUTLINE [WL-C, WE-C] ........... 01-408-2
STRUCTURAL VIEW [WL-C, WE-C] .. 01-408-3
DIAGRAM [WL-C, WE-C] ..... 01-408-4
WIRING DIAGRAM [WL-C, WE-C] .... 01-408-5
8LOCK DIAGRAM [WL-C, WE-C] .... 01-408-9
RELATION CHART [WL-C, WE-C] ... 01-408-10
IDLE SPEED CONTROL OUTLINE
[WL-C, WE-C] ................. 01-408-10
IDLE SPEED CONTROL 8LOCK
DIAGRAM [WL-C, WE-C] .......... 01-408-11
IDLE SPEED CONTROL
OPERATION [WL-C, WE-C] ......... 01-408-11
GLOW CONTROL OUTLINE
[WL-C, WE-C] ............... 01-408-11
GLOW CONTROL
GLOW CONTROL OPERATION
[WL-C, WE-C] ............... 01-408-12
800ST PRESSURE CONTROL
OUTLINE [WL-C, WE-C] ........ 01-408-12
FUEL INJECTION AMOUNT CONTROL
OUTLINE [WL-C, WE-C] ........ 01-408-12
OPERATION [WL-C, WE-C] ....... 01-408-13
FUEL INJECTION TIMING CONTROL
OUTLINE [WL-C, WE-C] ...... 01-408-13
OPERATION [WL-C, WE-C] ..... 01-408-14
MULTIPLE FUEL INJECTION
CONTROL OUTLINE [WL-C, WE-C] .. 01-408-15
MULTIPLE FUEL INJECTION CONTROL
FUEL PRESSURE CONTROL
OUTLINE [WL-C, WE-C] ......... 01-408-16
EGR CONTROL OUTLINE
[WL-C, WE-C] . . . . . . . . . . . . . .. 01-408-17
EGR CONTROL 8LOCK
DIAGRAM [WL-C, WE-C] .......... 01-408-17
EGR CONTROL OPERATION
[WL-C, WE-C] . . . . . . . . . . . . . . . .. 01-408-17
AlC CUT-OFF CONTROL
OUTLINE [WL-C, WE-C] .......... 01-408-18
AlC CUT-OFF CONTROL

8LOCK DIAGRAM [WL-C, WE-C] .. 01-408-18
AlC CUT-OFF CONTROL
IMM081L1ZER SYSTEM
OUTLINE [WL-C, WE-C] ......... 01-408-19
IMM081L1ZER SYSTEM 8LOCK
DIAGRAM [WL-C, WE-C] ............ 01-408-19
IMM081L1ZER SYSTEM
PCM FUNCTION [WL-C, WE-C] ....... 01-408-19
PCM CONSTRUCTION [WL-C, WE-C] .. 01-408-19
MASS AIR FLOW (MAF) SENSOR
FUNCTION [WL-C, WE-C] ........... 01-408-20
[WL-C, WE-C] ................ 01-408-20
INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 FUNCTION
[WL-C, WE-C] .................. 01-408-21
SENSOR NO.2 CONSTRUCTION/
OPERATION [WL-C, WE-C] ....... 01-408-21
SENSOR NO.1 FUNCTION
[WL-C, WE-C] ................ 01-408-21
800ST SENSOR FUNCTION
[WL-C, WE-C] ................. 01-408-22
800ST SENSOR CONSTRUCTION/
ACCELERATOR PEDAL POSITION
(APP) SENSOR FUNCTION
[WL-C, WE-C] ................. 01-408-23
(APP) SENSOR DESCRIPTION
[WL-C, WE-C] ................ 01-408-23
IDLE SWITCH FUNCTION
[WL-C, WE-C] ............... 01-408-23
IDLE SWITCH DESCRIPTION
[WL-C, WE-C] ............... 01-408-24
FUEL TEMPERATURE SENSOR
FUNCTION [WL-C, WE-C] .......... 01-408-24
[WL-C, WE-C] ................. 01-408-24
FUEL PRESSURE SENSOR
FUNCTION [WL-C, WE-C] ......... 01-408-24
[WL-C, WE-C] ................ 01-408-25
ENGINE COOLANT TEMPERATURE
(ECT) SENSOR FUNCTION
[WL-C, WE-C] ................ 01-408-25
(ECT) SENSOR CONSTRUCTION/
CAMSHAFT POSITION (CMP) SENSOR
FUNCTION [WL-C, WE-C] ........ 01-408-25
01-408-1

[WL-C, WE-C] . ...................
CRANKSHAFT POSITION (CKP)
SENSOR FUNCTION [WL-C, WE-C] ..
SENSOR CONSTRUCTION/
OPERATION [WL-C, WE-C] .........
FUNCTION [WL-C, WE-C] ..........
01-408-26
01-408-26
01-408-27
CLUTCH PEDAL POSITION (CPP)

SWITCH FUNCTION [WL-C, WE-C] .. . 01-408-27
SWITCH DESCRIPTION
[WL-C, WE-C] . ................... . 01-408-28
NEUTRAL SWITCH FUNCTION
[WL-C, WE-C] . ................... . 01-408-28
NEUTRAL SWITCH CONSTRUCTION/
01-408-27
ENGINE CONTROL SYSTEM OUTLINE [WL-C, WE-C]
dcf01400000ot22
Features
Improved emission gas purification
Fuel injection control changed

EGR control (and intake shutter valve control) adopted
Specification
Item
MAF sensor
IAT sensor No.1
Boost sensor
Specification
Thermistor
Hot-wire
Thermistor
ECT sensor
Thermistor
CMP sensor
CKP sensor
Hall element type

Magnetic pickup
APP sensor
BARO sensor (built into PCM)
Neutral switch
Potentiometer
Potentiometer
Thermistor
ON/OFF
CPP switch
ON/OFF
Idle switch
ON/OFF
01-408-2

ENGINE CONTROL SYSTEM STRUCTURAL VIEW [WL-C, WE-C]
dcf01400000ot23
GLOW
INDICATOR
LIGHT
APP SENSOR
CPPSWITCH
IDLE
SWITCH
BRAKE SWITCH
CKP SENSOR
PCM (BUILT INTO BARO

SENSOR)
MAF SENSOR!
IAT SENSOR NO.2
AlC RELAY
GLOW PLUG RELAY
SUPPLY PUMP
BOOST SENSOR!
IAT SENSOR NO.1
DBG140BTB001
01-408-3

ENGINE CONTROL SYSTEM DIAGRAM [WL-C, WE-C]
dcf014000000t24
J:
:;:J:
()
[jd:~
0:3;
UJ
...J
zUJ
:;;:~
,Cl
:2_
0:
*:TOPCM
TACHOMETER ---':
~:FUELFLOW
GLOW INDICATOR LIGHT -j
.. ____
L__
Z
w
UJ
C\I
~,. 0,
, ,
...J
...J
~
1___ -
I,
l.
Cl
Ci)
0
W
W
(L
, , w
z, ,,, ,,,
,, ,, ,, J:
,
, ," , w
,___ _ ,
,, ,, , ,---_ >..,
,-1--,-'-'-.!......I--'-:";:
f::J
,z
, w
,,
,,
J:
()
f;:: ;:: e.
f-
UJ
...J
()
___ I
UJ
::J
III
~
()
,,
,,
,,
-----,
---- CPP SWITCH
---- AlC RELAY
EGRVALVE
AIRFI
EGR SOLENOID
TO GLOW PLUG
INTAKE SHUTTER SOLENOI
VALVE (HALF OPEN)
INTAKE SHUTTER SOLENOID
VALVE (FULL CLOSE)
APP
IDLE
SENS~CH
\
P SENSOR
ACCELERATOR
PEDAL
BOOST SENSOR/IAT SENSOR NO.1

TO VACUUM RESERVER TANK
FOR BRAKE SYSTEM
DBG140BTB002
01-408-4
"
..,

ENGINE CONTROL SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf014000000t25
-r--t--tLOCK
ACC
IG1
-r--t----{E
IG2
STA
DLC
IG-
FEN
KLN
TEN
DLC-2
KLN
'----;TEN
GLOW INDICATOR
LIGHT
r--+-----t---------{
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.4
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY01
01-408-5
)--+-+.1'
APP
SENSOR
RFWLOCK
SOLENOID
VALVE
RFW FREE
SOLENOID
.)---+.1' VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR ~I--_-I.
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
BLOWER
MOTOR
CKP SENSOR
PCM
L--_----I
REFRIGERANT
PRESSURE
SWITCH (LOW)
~)---t-o
AlC
~~~-~~~~~~~~~--------------I
VARIABLE SWIRL:
CONTROL
,
SOLENOID VALVE :
COMPRESSOR
AlC RELAY
AlC
:SWITCH
,,
THERMO SWITCH
'- -- - - - - - - - - - - - - - WITH AlC- - - - - - - - - - - - - - --
DBG102BWBY02
01-408-6
(0
...,

-I:-+----{ E
DLC
r-------t-,--~~+_-----~~--------~IG-
FEN
KLN
TEN
DLC-2
KLN
L----ITEN
GLOW INDICATOR
LIGHT
,..--+-----+---------(
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-408-7
J---+-+-.z'
APP
SENSOR
RFWLOCK
SOLENOID
VALVE
\..
RFW FREE
SOLENOID
.J---+-.z' VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR L!:::I----{
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
IJ--+--o o--I--+-.... GLOW

BLOWER
MOTOR
L...-_----'
REFRIGERANT
PRESSURE
SWITCH (LOW)
~~-~~ o-~~~
PLUG
RELAY
EGR CONTROL
SOLENOID VALVE
VARIABLE SWIRL:
CONTROL
:
SOLENOID VALVE :
AlC
COMPRESSOR
AlC RELAY
AlC
!SWITCH
,,
,,
THERMO SWITCH
'- - - - - - - - - - - - - - - WITH AlC' - - - - - - - - - - - - - - -
DBG102BWBY02
01-408-8

ENGINE CONTROL SYSTEM BLOCK DIAGRAM [WL-C, WE-C]
dcf014000000t26
PCM
BATTERY
CPPSWITCH
NEUTRAL SWITCH
~
~
~
APP SENSOR
I~
IDLE SWITCH
MAF SENSORIIAT SENSOR NO.2

IAT SENSOR NO.1
ECT SENSOR
BAROSENSOR
BOOST SENSOR
CMPSENSOR
CKPSENSOR
VEHICLE SPEED SIGNAL
AlC SWITCH
I~
~
~
~
~
~
~
~
~
~
~
IDLE SPEED CONTROL
GLOW CONTROL
BOOST PRESSURE
CONTROL
FUEL INJECTION AMOUNT
CONTROL
FUEL METERING VALVE

FUEL INJECTOR
VBC SOLENOID VALVE
EGR SOLENOID VALVE
FUEL INJECTION TIMING

CONTROL
MULTIPLE FUEL
INJECTION CONTROL

VALVE
(HALF, FULL)
GLOW INDICATOR LIGHT
FUEL PRESSURE
CONTROL
EGR CONTROL
GLOW PLUG RELAY
AlC RELAY
IMMOBILIZER-RELATED
INFORMATION
AlC CUT-OFF CONTROL
MIL
IMMOBILIZER SYSTEM
IMMOBILIZER-RELATED
INFORMATION
DBG140BTBOO3
01-408-9

ENGINE CONTROL SYSTEM RELATION CHART [WL-C, WE-C]
dcf01400000Ot27
x: Applicable
Item
e"E
0
()
"0
Q)
Q)
e"E
0
()
e"E
0
Co
()
Q)
(/)
:J
(/)
(/)
Co
"lii
0
0
(()
e"E
0
()
e"E
0
"E
()
E
ell
c:
U
Q)
13Q)
:~
:~
Q)
Q)
LL
LL
:J
:J
Ol
c:
+='
c:
0
:J
e"E
0
()
c:
0
U
Q)
:~
e"E
0
()
Q)
:J
Q)
.2
(/)
(/)
e"E
>-
(/)
a;
C!J
.E
x
x
x
x
x
Q)
rr.
LL
:J
:!=
:c0
:2
"S
()
-5
a.
+='
Co
e"E
()
()
Input device
Battery
CPP switch
Neutral switch
APP sensor
x
x
x
x
Idle switch
MAF sensor/lAT sensor No.2
IAT sensor No.1
ECT sensor

BARO sensor
x
x
Boost sensor
CMP sensor
CKP sensor
Vehicle speed signal
AlC switch
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

Immobilizer-related information
Output device
Fuel metering valve
Fuel injector
x
x
x
VBC solenoid valve

EGR solenoid valve
Glow plug relay
x
x
x
x
x
EGR control solenoid valve

Intake shutter solenoid valve (half,
full)
x
x
x
x
x
AlC relay
Immobilizer-related information
IDLE SPEED CONTROL OUTLINE [WL-C, WE-C]
x
x
dcf014000000t28
The peM feedback controls the idle speed by calculating the fuel injection amount so that the idle speed is at
the target idle speed corresponding to the driving conditions .
. 01-408-10

IDLE SPEED CONTROL BLOCK DIAGRAM [WL-C, WE-C]
CPP SWITCH
NEUTRAL SWITCH
AlCSWITCH
APPSWITCH
ECTSWITCH
CKPSWITCH
I
I
I
I
I
I
I
I
I
I
I
dcf014000000t29
.......
....
....
....
...
........
.......
........
VEHICLE SPEED
SIGNAL
.......
FUEL PRESSURE
SENSOR
.......
PCM
.....1
""I
FUEL INJECTOR
DBG140BTB850
IDLE SPEED CONTROL OPERATION [WL-C, WE-C]
dcf01400000Ot30
Feedback Control
If there is a difference between the target idle speed and the actual idle speed, the PCM controls the fuel
injection amount so that the actual idle speed corresponds to the target idle speed.
Target idle speed
No load: 720 rpm
AlC ON: 750 rpm
Engine Speed Control while Warming Up
Controls engine speed based on the input signal from the engine coolant temperature sensor (below 0 C {32
OF}) so that the engine speed while warming up corresponds to the target engine speed.
Engine speed while warming up control
720-1,000 rpm
Engine Speed Fluctuation Prevention Control for Each Cylinder
The PCM detects the engine speed fluctuation while idling and corrects the fuel injection amount per each
cylinder. Due to this, the variance in fuel injection amount caused by ununiformity of the cylinders (such as fuel
injectors) and engine vibration while idling are reduced.
GLOW CONTROL OUTLINE [WL-C, WE-C]
dcf01400000Ot31
Heating of the glow plug is controlled by the PCM through the glow plug relay to improve engine startability.
Energization time to the glow plug is determined according to the engine coolant temperature and engine
starting conditions.
GLOW CONTROL BLOCK DIAGRAM [WL-C, WE-C]
I
I
ECT SENSOR
CMP SENSOR
CKP SENSOR
I
I
I
I
.......
........
....
...
dcf014000000t32
PCM
~I
GLOW INDICATOR
LIGHT
GLOW PLUG RELAY
DBG140BTB851
01-408-11

GLOW CONTROL OPERATION [WL-C, WE-C]
dcf014000000t33
The glow plug relay operates under the following conditions:

During preheating timer operation
During engine cranking
- While outer glow is operating
Preheating Timer
The PCM operates the glow plug relay for several seconds after the engine switch is turned to the ON position
according to the engine coolant temperature. The higher the engine coolant temperature, the shorter the period
of the timer operation.
The glow indicator light illuminates during the preheating timer operation to inform the driver that the glow
system is operating.
Glow Continuation Timer
The PCM operates the glow plug relay for 120 s (max.). after the engine has been started with the engine
coolant temperature lower than 32C {89.6 OF}. When the engine coolant temperature reaches 32C {89.6 OF}
or more, the glow continuation timer is cancelled.
BOOST PRESSURE CONTROL OUTLINE [WL-C, WE-C]
dcf01400000Ot34
The PCM duty-controls the VBe solenoid valve.

By changing the opening angle of the guide blades (variable vanes) around the turbine impellers according to
the engine driving conditions, turbocharger response, vehicle acceleration performance, and fuel consumption
have been improved in every driving range.
BOOST PRESSURE CONTROL BLOCK DIAGRAM [WL-C, WE-C]
BATTERY
APP SENSOR
ECT SENSOR
BARO SENSOR
BOOST SENSOR
CKP SENSOR
I
I
dcf01400000Ot35
....
..
...
......
....
PCM
~I VBC SOLENOID VALVE I
......
..
DBG140BTB852
BOOST PRESSURE CONTROL OPERATION [WL-C, WE-C]
dcf01400000Ot36
The VBC solenoid valve is controlled by the variable boost control signal (duty signal) from the PCM. The
longer the valve is ON, the higher the boost pressure becomes.
The PCM performs feedback control by determining the period that the VBC solenoid valve is ON based on the
engine speed and the fuel injection amount so that the optimum boost pressure can be obtained.
Under driving conditions where more boost pressure is needed, the PCM sends the variable boost control
signal to extend the ON period of the VBC solenoid valve, moving the guide blades in the turbocharger in the
closing direction.
Under driving conditions where less boost pressure is needed, the PCM sends the variable boost control signal
to shorten the ON period of the VBC solenoid valve, moving the guide blades in the turbocharger in the
opening direction.
FUEL INJECTION AMOUNT CONTROL OUTLINE [WL-C, WE-C]
dcf01400000Ot37
The fuel injection amount is controlled by the opening of the nozzle in the fuel injector based on the signal from
the PCM.
The PCM corrects the variation in the fuel injection amount of each cylinder by inputting the fuel injector
calibration code (or fuel injector calibration bar code) into the PCM.
01-408-12

FUEL INJECTION AMOUNT CONTROL BLOCK DIAGRAM [WL-C, WE-C]
CPP SWITCH
NEUTRAL SWITCH
APP SENSOR
IDLE SWITCH
MAF SENSOR/IAT
SENSOR NO.2
I
I
I
I
I
........
......
.......
ECT SENSOR
........
......
......
FUEL TEMPERATURE
SENSOR
BARO SENSOR
......
.......
IAT SENSOR NO.1
I
I
PCM
.....J
..... 1
FUEL INJECTOR
....
....
...
FUEL PRESSURE
SENSOR
CMP SENSOR
......
CKP SENSOR
....
....
VEHICLE SPEED
SIGNAL
dcf01400000ot38
......
DBG140BTB853
FUEL INJECTION AMOUNT CONTROL OPERATION [WL-C, WE-C]
dcf01400000ot39
Basic Injection Amount

Operation
Fuel injection amount is controlled based on the fuel injector nozzle opening period.
Injection amount calculation
The PCM calculates the optimum fuel injection amount according to engine operation conditions.
The following two amount values are compared and the one of less amount is selected for the final injection
amount.
Basic injection amount
. The logically necessary injection amount is calculated based on the accelerator opening angle and engine
speed.
Maximum injection amount
The maximum injection amount is calculated by correcting the basic injection amount based on driving
conditions such as mass air flow, intake air temperature, and barometric pressure, intake air temperature and
engine coolant temperature.
FUEL INJECTION TIMING CONTROL OUTLINE [WL-C, WE-C]
dcf01400000ot40
The PCM determines and controls the optimum fuel injection timing according to engine operation conditions
based on the signals from each input sensor.
01-408-13

FUEL INJECTION TIMING CONTROL BLOCK DIAGRAM [WL-C, WE-C]
......
CPP SWITCH
I
NEUTRAL SWITCH
I
I
APP SENSOR
MAF SENSOR/
IAT SENSOR NO.2
IAT SENSOR NO.1
ECT SENSOR
.....
......
...
JII""
.....
.....
.. I
PCM
FUEL INJECTOR
111"""1
-I
....
FUEL TEMPERATURE
SENSOR
"..
.......
CMP SENSOR
I
I
.....
CKP SENSOR
BARO SENSOR
dcf01400000Ot41
"..
.......
DBG140BTB854
FUEL INJECTION TIMING CONTROL OPERATION [WL-C, WE-C]
dcf01400000Ot42
Fuel injection start timing is determined based on the fuel injection amount and crank angle signals input from
the crankshaft position sensor.
TDC
CRANK ANGLE BASIC POSITION
CKP INPUT SIGNAL

FUEL INJECTION STARTS
---.JhL__~--i------~
INJECTION SIGNAL _ _ _ _ _ _ _ _ _ _ _ _
PILOT INJECTION PERIOD
INJECTOR LIFT
"I
_ _ _ __
I"
1I
CORRECTIO~
.:1:1
IL_ _---.ll
:~7'
INTERVAL
-: ~.
L -_ _ __
MAIN INJECTION TIMING

DBG140BTB860
Determination of Fuel Injection Timing

The peM calculates the optimum fuel injection timing based on the predetermined target fuel injection timing
and input signals from each sensor.
Target Fuel Injection Timing
Target fuel injection timing is calculated based on engine speed and fuel injection amount.
Injection Timing Correction
Actual fuel injection timing is corrected based on the input signals from each sensor such as intake air
temperature, engine coolant temperature, and barometric pressure.
01-408-14

MULTIPLE FUEL INJECTION CONTROL OUTLINE [WL-C, WE-C]
dcf01400000ot43
Pilot injection: To reduce noise and NOx, the peM performs multiple fuel injections before the main injection
according to the vehicle driving conditions.
MULTIPLE FUEL INJECTION CONTROL BLOCK DIAGRAM [WL-C, WE-C]
CPP SWITCH
NEUTRAL SWITCH
I
I
APP SENSOR
.......
......
......
.......
......
BARO SENSOR
....
....
CMP SENSOR
CKP SENSOR
MAF SENSOR/IAT
SENSOR NO.2
ECT SENSOR
I
I
dcf01400000ot44
....
....
PCM
FUEL INJECTOR
......
.......
DBG140BTB855
MULTIPLE FUEL INJECTION CONTROL OPERATION [WL-C, WE-C]
dcf01400000ot45
Function
In single injection, ignition delay becomes longer and much fuel is injected before ignition since the ignition has
started. Therefore, the fuel is combusted rapidly at a high temperature and a high pressure, resulting in
increased noise and NOx.
To prevent this, the peM performs multiple fuel injection. Due to this, the fuel is combusted slowly and the
occurrence of noise and NOx is suppressed.
SINGLE INJECTION
MULTIPLE INJECTION
INJECTION PATTERN
INJECTION PATTERN
FUEL INJECTION DELAY
FUEL INJECTION DELAY

CRANK ANGLE ..L-_-'--------'L-----'-
CRANK ANGLE
TOC
TPC
DBG140BTB861
Operation
Injection patterns of the multistage injection control according to the combination of injection times are shown in .
the figure. The peM selects the optimum injection pattern based on the vehicle conditions and performs
injection for 3 times at maximum.
While in a driving condition at low engine speed and low engine load, the fuel injection time is increased up to 3
times to reduce knocking noise which occurs during combustion.
While in a driving condition at high engine speed and high engine load, the fuel injection time is reduced to one
time at minimum to improve output and fuel economy.
01-408-15

-BASIC CRANK ANGLE
TOC
r:\
CKPSIGNAL
n n n
PILOT INJECTION
PILOT INJECTION
L-__--J:
3-STAGE
INJECTION - T - - - - - - - - - '
----'nL______________
---lnL______________
: MAIN INJECTION
---JnL-_______
_________
INJECTION
SINGLE
L--_ _ _ _ _ _ _ _ _ _ _ _ __
PILOT INJECTION
2-STAGE
MAIN INJECTION
: MAIN INJECTION
___________________
INJECTION
:
I
DBG140BTB862
Operation condition
The PCM determines the number of times fuel injection occurs based on the engine speed, fuel injection
amount, and signals from each sensor.
When the engine is started, the PCM calculates the number of times fuel injection occurs based on the engine
coolant temperature, engine speed and fuel injection amount.
FUEL PRESSURE CONTROL OUTLINE [WL-C, WE-C]
dcf01400000ot46
The PCM performs the feedback control of the fuel pressure in the common rail to gain optimum fuel injection
pressure according to engine operation conditions.
Because the fuel pressure can be controlled regardless of engine operation conditions, high pressure fuel
injection even with low engine speed is possible. Due to this, generation of NOx and particulate matter can be
reduced.
FUEL PRESSURE CONTROL BLOCK DIAGRAM [WL-C, WE-C]
APP SENSOR
I
I
MAF SENSOR/IAT
SENSOR NO.2
ECTSENSOR
FUEL TEMPERATURE
SENSOR
BAROSENSOR
FUEL PRESSURE
SENSOR
CKPSENSOR
I
I
I
I
I
I
I
I
I
dcf01400000ot47
....
...
.....
.....
.....
PCM
....
-JIll"
FUEL METERING VALVE
....
.....
.....
DBG140BTB856
FUEL PRESSURE CONTROL OPERATION [WL-C, WE-C]
dcf01400000ot48
The PCM calculates the target fuel pressure based on the engine speed and fuel injection amount.
The PCM operates the fuel metering valve which is installed to the supply pump to adjust the fuel pressure in
the common rail to the target fuel pressure.
By controlling the amount of pumped fuel from the supply pump with the fuel metering valve, the fuel pressure
in the common rail is controlled and a constant, optimum injection pressure has been realized.
01-408-16

EGR CONTROL OUTLINE [WL-C, WE-C]
dcf014000000t49
The PCM controls duty-cycle type solenoid valves and an ON/OFF type solenoid valve to control the EGR
valve in order to obtain the optimum EGR amount for the actual engine operating condition. Due to this,
emission performance and driveability has been improved.
When introducing the exhaust gas during low engine speed, the PCM controls the intake shutter solenoid valve
(half) to control the intake shutter valve opening angle. Thus the exhaust gas is channelled into the combustion
chamber efficiently. Due to this, emission performance and driveability has been improved. (WE-C)
As the MAF sensor deteriorates and an error margin is created between the target and the actual intake air
amount, the PCM conducts learning and correction.
EGR CONTROL BLOCK DIAGRAM [WL-C, WE-C]
CPP SWITCH
.......
NEUTRAL SWITCH
I
I
I
I
........
........
APP SENSOR
IDLE SWITCH
.......
II
.......
MAF SENSOR/IAT
SENSOR NO.2
ECT SENSOR
BAROSENSOR
FUEL PRESSURE
SENSOR
CKP SENSOR
dcf01400000Ot50
.......
EGR SOLENOID
VALVE
.......
EGRCONTROL
SOLENOID VALVE
......
.......
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
......
.......
INTAKE SHUTTER
SOLENOID VALVE
(FULL)
.......
.......
VEHICLE SPEED
SIGNAL
.......
EGRVALVE
POSITION SENSOR
......
PCM
DBG140BTB857
EGR CONTROL OPERATION [WL-C, WE-C]
dcf01400000ot51
EGR Valve Operation

To improve emission performance, target EGR valve position is decided based on intake air flow, engine
speed, engine coolant temperature and fuel injection amount.
The flow amount of the EGR is calculated from the difference between the following amounts.
- Target intake air amount that is mainly calculated from engine speed and fuel injection amount
Actual intake air amount that is mainly detected by MAF sensor/IAT sensor No.2
The PCM controls the vacuum applied to the EGR valve by opening and closing a two-duty solenoid valve.
Intake Shutter Valve Operation
Close condition
The PCM turns on the intake shutter solenoid valve (half) and the intake shutter solenoid valve (full) in order to
close the intake shutter valve when the engine switch is at OFF.
01-408-17

Halfway open condition (WE-C)
The PCM turns the intake shutter solenoid valve (half) on when all of the following conditions are met.
Engine coolant temperature is above threshold level.
Intake air temperature is threshold level.
Barometric pressure is above threshold level.
Engine speed is below threshold level.
Vehicle speed is below threshold level.
Fuel injection amount is below threshold level.
Full open condition
For conditions other than closed and halfway open, the PCM turns off the intake shutter solenoid valve (half)
and the intake shutter solenoid valve (full) in order to open the intake shutter valve.
MAF Learning
After learning is initiated, the PCM calculates the actual intake air amount for the complete learning period.
The PCM calculates the deviation between the target and actual intake air amount, then, based on the
deviation, derives the learning factor. The PCM stores the learning factor and uses it to correct the intake air
amount. Due to this, the error margin of the MAF sensor is resolved. If the deviation factor is less than the
specified amount, the PCM does not calculate nor update the learning factor.
The PCM stores the learning factor until the next time the factor is updated. The factor is erased using the
M-MDS.
Using the M-MDS for learning
By using the M-MDS, the learning function can be freely controlled. Due to this, even if the PCM or MAF
sensor/lAT sensor No.2 is replaced, the learning factor can be stored again.
When using the M-MDS to control the MAF learning function, learning is performed at the following three
engine speed levels.
720 rpm
- 1,850 rpm
- 2,500 rpm
Without using the M-MDS for learning
By shorting circuit the DLC terminal TEN five times within 5 s, the learning function can be freely controlled.
Due to this, even if the PCM or MAF sensor/lAT sensor No.2 is replaced, the learning factor can be stored
again.
The glow indicator light illuminates while MAF learning is performed, and flashes five times after it is
completed.
AlC CUT-OFF CONTROL OUTLINE [WL-C, WE-C]
dcf01400000ot52
The AlC relay is turned on and off according to engine operation conditions to improve drivability.
AlC CUT-OFF CONTROL BLOCK DIAGRAM [WL-C, WE-C]
I
I
I
I
APP SENSOR
ECT SENSOR
VSS
CKP SENSOR
I
I
I
I
I
I
dcf01400000ot53
....
.....
....
...
....
....
PCM
~I
AlC RELAY
DBG140BTB858
AlC CUT-OFF CONTROL OPERATION [WL-C, WE-C]
dcf01400000ot54
When the accelerator opening angle is 87.5 % or more, the PCM cuts the power supply to the A/C relay for 3 s.
When the engine coolant temperature is 113C {235 OF} or more, the PCM turns off the power supply to the AI
C relay until the engine coolant temperature is less than 110C {230 OF}.
01-408-18

IMMOBILIZER SYSTEM OUTLINE [WL-C, WE-C]
dcf01400000Ot55
While the immobilizer system is operating, the PCM cuts off fuel delivery and stops pressure feeding fuel to the
common rail.
IMMOBILIZER SYSTEM BLOCK DIAGRAM [WL-C, WE-C]
dcf01400000ot56
I-----I~
IMMOBILIZERRELATED
INFORMATION
PCM
FUEL METERING VALVE
FUEL INJECTOR
IMMOBILIZERRELATED
INFORMATION
DBG140BTBB59
IMMOBILIZER SYSTEM OPERATION [WL-C, WE-C]
dcf01400000ot57
When the immobilizer system is activated, the following controls are carried out.
Fuel injector: OFF (Set fuel quantity to zero.)
Fuel metering valve: ON (Set minimum common rail pressure.)
PCM FUNCTION [WL-C, WE-C]
dcf01401 BBBOto3
Function Table
Control descriptions are as follows:
Function
Idle speed control
Glow control
Boost pressure control
Contents
Performs feedback control of idle speed by calculating fuel injection amount so that idle speed
is at target idle speed corresponding to driving conditions.
Controls glow plug operation time via glow plug relay to improve engine startability.
Controls turbocharger guide blade angle according to engine operation conditions to improve
turbocharger response, acceleration performance, and fuel economy.
Fuel injection amount control
Performs optimum fuel injection according to engine operation conditions by controlling signals
to open/close fuel injector nozzle.
Fuel injection timing control

Multiple fuel injection control
Controls optimum fuel injection timing according to engine operation conditions.

Performs multiple fuel injection according to engine operation conditions to reduce noise and
NOx.
Fuel pressure control

Intake shutter valve control
Adjusts to optimum fuel pressure according to engine operation conditions.

Adjusts intake shutter valve to optimum opening angle according to engine operation
conditions.
Controls EGR valve so that EGR volume is optimized according to engine operation conditions.
EGR control
AlC cut-off control
Immobilizer system
Controls operation of AlC according to engine operation conditions to assure drivability.

Inhibits engine starting by cutting fuel injection and pressure feeding fuel to common rail when
immobilizer system is activated.
PCM CONSTRUCTION [WL-C, WE-C]
dcf01401 BBBOto4
A 154-pin (two block) PCM connector has been adopted.

The PCM has a built into piezoelectric element BARO sensor.
01-408-19

MASS AIR FLOW (MAF) SENSOR FUNCTION [WL-C, WE-C]
dcf014013215to3
Detects the intake air amount (mass airflow amount).
( ..
MASS AIR FLOW (MAF) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014013215to4
Installed to the air cleaner.

With built-in IAT sensor No.2
Converts the mass intake airflow amount to voltage.
When the temperature of the metal decreases, the resistance decreases. Using this characteristic, the hot wire
captures heat from the flow of intake air and converts the intake airflow amount to voltage.
The cold wire converts intake air density to voltage from the ambient temperature of the cold wire, using the
characteristic of air whereby the intake air density decreases due to the increase in intake air temperature.
The voltages obtained by the hot wire (intake
MAF
airflow amount) and the cold wire are compared
SENSOR
and the electric potential becomes stable by
supplying the difference in voltage to the
transistor. The voltage supplied to the hot wire is
output as the mass intake airflow amount.
HOT WIRE
INTAKE AIR
DBG140ATB303
MAF SENSOR CHARACTERISTIC (REFERENCE)
(V)
5
HOTWIRE
PCM
MAF SENSOR
......... v~
FIXED RESISTANCE
01
10
20
50 100 200 (g/8)
MASS AIRFLOW AMOUNT

DBG140ATB304
01-408-20
..,

INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 FUNCTION [WL-C, WE-C]
dcf014018842to5
Detects the intake air temperature, and sends it to the PCM as an intake air temperature signal.
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 CONSTRUCTION/OPERATION [WL-C, WE-C]
Installed to the air cleaner.
Built into the mass airflow sensor.
The thermistor type IAT sensor No.2 changes
resistance according to the intake air
temperature.
The resistance decreases if the intake air
temperature increases and, conversely,
increases if the intake air temperature decreases.
MAF SENSOR
IAT SENSOR NO.2
IAT SENSOR NO.2 CHARACTERISTIC (REFERENCE)

30
20
PCM
IAT SENSOR NO.2
~
I
0
-l
g
w
~
(f)
1i:i
w
10
7
5
3
2
0.7
a: 0.5
0.3
~
!~
13.6-18.4
KILOHM
I\.'\.
I'\.'\.'\.
"&.
~~
~
0.493 0.667
KILOHM
I
I
2.21-2.69
KILOHM
~
I",
~
0.2 -20
0
20
40
60
80
{-4} {32} {68} {104} {140} {176}
INTAKE AIR TEMPERATURE (OC ("F})
DBG140ATB306
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 FUNCTION [WL-C, WE-C]
dcf014018842to7
The IAT sensor No.1 detects the intake air temperature which has passed through the charge air cooler, and
sends it to the PCM as an intake air temperature signal.
01-408-21

INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018842t08
Built into the boost sensor.

The boost sensor is installed to the intake manifold.
The thermistor type IAT sensor No.1 changes resistance according to the intake air temperature.
The resistance decreases if the intake air
temperature increases and, conversely,
BOOST SENSOR (BUILT INTO IAT SENSOR NO.1)
increases if the intake air temperature decreases.
DBG140BTB551

18
PCM
IAT SENSOR NO.1
16
,?14
.J::
012
CPU
:2
~10
~ 6
(f)
ffi 4
rr.
2
0_
10 20
30
40
50 60
70
80
20 -10
0
{-4} {14} {32} {50} {68} {86} {104}{122}{140}{158}{176}
INTAKE AIR TEMPERATURE (OC {OF} )
DBG140BTB302
BOOST SENSOR FUNCTION [WL-C, WE-C]
dcf014018212t03
The boost sensor detects the intake air pressure as an absolute pressure, and sends it to the peM as an intake
air pressure signal.
BOOST SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018212t04
The boost sensor is installed to the intake manifold.

The boost sensor is filled with crystal (silicon) and it is the semi-conductor pressure sensor which utilizes the
characteristic of the electrical resistance that changes when the crystal is pressurized.
*Absolute pressure is the pressure when vacuum is set as 0 kPa {O mmHg, 0 inHg}.
With built-in IAT sensor No.2
BOOST SENSOR (BUILT-IN IAT SENSOR NO.1)
BOOST SENSOR
CHARACTERISTIC (REFERENCE)
(V)
20 {150, 5.9}
300 {2,250, 88.6}
PRESSURE KPa {mmHg, inHg}

DBG140BTB301
01-408-22

ACCELERATOR PEDAL POSITION (APP) SENSOR FUNCTION [WL-C, WE-C]
dcf014041609t03
The APP sensor is installed on the accelerator pedal, and detects how much the accelerator pedal is being
depressed from the change in the resistance value (variable resistance).
EXTERNAL VIEW
ACCELERATOR POSITION
SIGNAL (MONITOR)
ACCELERATOR POSITION
SIGNAL (MAIN)
GROUND
DBG140ATB459
ACCELERATOR PEDAL POSITION (APP) SENSOR DESCRIPTION [WL-C, WE-C]
dcf014041609t04
The APP sensor is a potentiometer type and works is the same way as the throttle position sensor.
The APP sensor contains two circuits for detecting accelerator position: main circuit and monitor circuit. The
main circuit is used for the controls operated by the PCM (e.g. fuel injection amount control). The monitor circuit
is used for detecting malfunctions in the APP sensor.
When voltage difference between the main and monitor circuits increases, the PCM determines that the APP
sensor is malfunctioning and stores DTC. Thus, a detection condition item has been added to DTC.
The input voltage characteristic of the APP sensor is as shown.
APP SENSOR CHARACTERISTIC (REFERENCE)
APP SENSOR
PCM
(V)
W
Cl
3.4-3.8
:..J
I-
:::>
0.4-0.8
NOT
ACCELERATED
CLOSE . -
ACCELERATOR
PEDAL POSITION
OPEN
DBG140BTB307
IDLE SWITCH FUNCTION [WL-C, WE-C]
dcf01406647ot03
The idle switch is mounted to the accelerator pedal and inputs to the PCM whether the accelerator pedal is
depressed or released. The PCM detects the idle switch signal as an idle signal.
The idle signal inputted to the PCM is compared with the accelerator opening signal detected from the APP
sensor, and on-board diagnostic of the idle switch and the APP sensor is performed.
IDLE SWITCH
DBG140ATB002
01-408-23

IDLE SWITCH DESCRIPTION [WL-C, WE-C]
dcf01406647Ot04
When the push rod is pushed in (the accelerator pedal is released) a preset amount, the contact of the idle
switch closes, and the PCM determines that the engine is idling. When the contact of the idle switch is open
(OFF), the PCM determines that the engine is not idling.
OFF--i_ON
,
IDLE SWITCH
,,
,,
,-'
I
'-
DBG140ATB455
FUEL TEMPERATURE SENSOR FUNCTION [WL-C, WE-C]
dcf014018843t03
The fuel temperature sensor detects fluctuations in resistance of the thermistor to detect the fuel temperature
which is necessary for the fuel injection amount correction.
FUEL TEMPERATURE SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018843t04
Installed to the supply pump.

The thermistor type fuel temperature sensor changes resistance according to the fuel temperature.
The resistance decreases if the fuel temperature increases and, conversely, increases if the fuel temperature
decreases.
I~(
THERMISTOR
PCM
FUEL TEMPERATURE SENSOR CHARACTERISTIC (REFERENCE)
~
I
g
g
w
()
~
Ci5
CJ)
L-__________~==:=========~
FUEL TEMPERATURE (OC {OF})
DBG140BTB308
FUEL PRESSURE SENSOR FUNCTION [WL-C, WE-C]

Measures the fuel pressure in the common rail.
Measured fuel pressure is used for the fuel pressure control.
01-408-24
dcf014018213t01
(.

FUEL PRESSURE SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018213to2
Installed on the common rail.
COMMON RAIL
Converts the fuel pressure in the common rail to a

voltage signal and outputs it to the PCM.
FUEL PRESSURE SENSOR CHARACTERISTIC (REFERENCE)
5.0
~ 4.0
~ 3.0
0.00
{O,O}
..,../ -
..,../
~
:..J 20
~ 1.0 V
./
40
BO
120
160
200
{4.1,
{B.2,
{12.2, {16.3,
{2.0,
5,B01} 11,603} 17,404} 23,206} 29,007}
FUEL PRESSURE (MPa {kgf/m2, psi})
D8G 1408T8304
ENGINE COOLANT TEMPERATURE (ECT) SENSOR FUNCTION [WL-C, WE-C]
dcf014018841to3
The ECT sensor detects the engine coolant temperature.

ENGINE COOLANT TEMPERATURE (ECT) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf014018841t04
The ECT sensor is thermistor type, and is installed in the cylinder head.
The ECT sensor inputs the thermistor resistance,
~~=;:;;---===:::::--E-C-T-S-EN-S-O-R-C-H-A-R-A-C-T-ER-I-ST-I-C-'
which changes according to the engine coolant
(REFERENCE)
temperature, to the PCM as a voltage.
I
s:!w
IO
Z
~
en
1i5
w
sa:
g~L--_____
ECT SENSOR
.-..
LOW
HIGH
D8G140AT8302
CAMSHAFT POSITION (CMP) SENSOR FUNCTION [WL-C, WE-C]
dcf014018230to1
The CMP sensor detects pulse wheel of intake camshaft pulley rotational signals as cam angle signals.
\
01-408-25

CAMSHAFT POSITION (CMP) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01401823ot02
The CMP sensor is installed on the cylinder head on the front side of engine.
The CMP sensor consists of a Hall element with a magnetic sensor, and a processing circuit that performs
signal amplification and identification.
CMP sensor is a hall-element type and it detects hall voltage generated by the change in magnetic flux of the
magnet inside the sensor and hall element as the camshaft angle signal.
One pulse are detected per one rotation of the camshaft by the projections on the intake camshaft pulley.
If the CMP sensor is removed/installed or replaced, magnetized objects such as metal shavings adhering to the
sensor could cause fluctuation in the magnetic flux of the magneto resistance element, causing abnormal
sensor output which could adversely affect engine control.
PCM
CMP SENSOR
CMP
SENSOR __+---------~---+~
OUTPUT
SIGNAL
PULSE WHEEL
en
INTAKE CAMSHAFT
PULLEY
II
26 0
334
~
DBG140BTB312
CRANKSHAFT POSITION (CKP) SENSOR FUNCTION [WL-C, WE-C]
dcfO 1401822ot03
The CKP sensor detects pulse wheel rotational signals as crank angle signals.
. "')
01-408-26

CRANKSHAFT POSITION (CKP) SENSOR CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01401822Ot04
The CKP sensor is installed to the clutch housing.

The pulse wheel which is installed to the dual-mass flywheel has 58 projections and spaces with 6 of crank
angle between each projection.
The fluctuation in magnetic flux density detected by the magnetic pickup coil in the crankshaft position s'ensor
is input to the PCM as a sensor output signal.
If the crankshaft position sensor is removed/installed or replaced, magnetized objects such as metal shavings
adhering to the sensor could cause fluctuation in the magnetic flux of the magnetic pickup coil, causing
abnormal sensor output which could adversely affect engine control.
FLYWHEEL
DBG140BTB313
EGR VALVE POSITION SENSOR FUNCTION [WL-C, WE-C]
dcf01402030Ot02
The EGR valve position sensor measures EGR valve lift amount and sends signal to the PCM, allowing the
PCM to diagnose a EGR system malfunction when there is a discrepancy between target and actual opening
angles of the EGR valve.
(Umin.)
~ 1,020-1,220 .... -------------~
5
....I
LL
EGRVALVE
i :
-60.0 -i------i----------
30.0-36.6 -
0.54
DBG140ATB311
CLUTCH PEDAL POSITION (CPP) SWITCH FUNCTION [WL-C, WE-C]
dcf014018660to3
The CPP switch detects the clutch connection condition.
01-408-27

CLUTCH PEDAL POSITION (CPP) SWITCH DESCRIPTION [WL-C, WE-C]
dcf01401866Ot04
The CPP switch is mounted to the top of the clutch pedal. When the clutch pedal is depressed, the contact of
the CPP switch closes (ON) and the PCM detects below 1.0V. When the clutch pedal is released, the contact
opens (OFF) and the PCM detects B+.
RELEASED (SWITCH OFF)
ON -:~OFF
I
I
I
I
I
~~
PUSH ROD
CPPSWITCH
;
PCM
CPU
DEPRESSED (SWITCH ON)

DBG140BTB550
NEUTRAL SWITCH FUNCTION [WL-C, WE-C]
dcf01401764Ot03
Detects shift lever neutral position.

NEUTRAL SWITCH CONSTRUCTION/OPERATION [WL-C, WE-C]
dcf01401764Ot04
While the shift lever is in the neutral position, the contact point closes (ON) and the PCM detects below 1.0 V.
While the shift lever is not in the neutral position, the contact point opens (OFF) and the PCM detects B+.
NEUTRAL SWITCH
NOT IN NEUTRAL (SWITCH OFF)
PCM
NEUTRAL (SWITCH ON)
PUSH ON
DBG140BTB305
01-408-28
SUSPENSION
OUTLINE ................. 02-00
WHEEL ALIGNMENT ....... 02-11
WHEEL AND TIRES ........ 02-12
02-00
OUTLINE
SUSPENSION ABBREVIATIONS . ..... 02-00-1

SUSPENSION FEATURES . .......... 02-00-1
SUSPENSION ABBREVIATIONS
14X2
4x4
FRONT SUSPENSION ....... 02-13

REAR SUSPENSION ........ 02-14
SUSPENSION SPECIFICATIONS ..... . 02-00-2
dcf02000000Ot01
14-Wheel 2-Drive
4-Wheel 4-Drive
SUSPENSION FEATURES
Improved driveability
Improved riding comfort
Precision wheel alignment
dcf02000000Ot02
Double wishbone suspension with torsion bar spring (front) has been adopted
Parallel arranged lower arm and tie rod (4x2 models)
Bias mount shock absorber (rear)
Vehicle height adjustment by anchor bolt
Camber and caster adjustment by shims
02-00-1
OUTLINE
SUSPENSION SPECIFICATIONS[Australian Specs.]
id020000100304
SPECIFICATIONS
Suspension
Item
Front suspension
Suspension Type
Spring type
Type
Stabilizer
Diameter
4x2
(mm {in})
Shock absorber type

Maximum
steering angle
Total toe-in
Front wheel
alignment
(Unloaded
condition)
Inner
Outer
(mm {in})
Camber angle
Caster angle
Steering axis inclination
Double wishbone
Torsion bar spring
Torsion bar
Except Hi-Rider: 27 {1.06}
28 {0.94}
Hi-Rider: 28 {0.94}
Cylindrical, double-acting
Except Hi-Rider: 3300'-3700'
31 30'-3530'
Hi-Rider:31 30'-3530'
Except Hi-Rider: 3000'-3500'
2700'-3200'
Hi-Rider:2700'-3200'
2-8 {0.08-0.31}
3-9 {0.12-0.35}
Regular cab: 035' 1
Regular cab and Stretch cab (with
Hi-Rider (Stretch cab (with Rear
Rear Access System): 044' 1
Access System)): 044' 1
Double cab: 045' 1
Hi-Rider (Double cab): 045' 1
Regular cab: 156'1
Rear Access System): 207'1
Access System)): 207'1
Double cab: 206'1
Hi-Rider (Double cab): 206' 1
Regular cab: 825'
Rear Access System): 1037'
Access System)): 1037'
Double cab: 1035'
Hi-Rider (Double cab)): 1035'
Rear suspension
Suspension Type
Spring type
Shock absorber type
4x4
Leaf spring
Semi elliptic leaf spring
Cylindrical, double-acting
: Fuel tank full; engine coolant and engine oil at specified level, and spare tire, jack, and tools in designated
position.
Wheel and tires
Wheel
Tire
Item
Size
Offset
Pitch circle diameter
Material
Size
(mm {in})
(mm {in})
Specification
I 15x61/2J
25 {0.98}
139.7 {5.500}
Steel
Aluminum alloy
Steel
215/70R15C 106/104S
235175R15 109S
15 x 61/2J
20 {0.79}
I
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I
16 x 7J
10 {0.39}
Aluminum alloy
245/70R16 111 S
'.
02-00-2
WHEEL ALIGNMENT
02-11
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT

DESCRiPTION ................... 02-11-1
FRONT WHEEL ALIGNMENT DESCRIPTION
dcf0211 00000101
CAMBER AND CASTER

THE CAMBER ANGLE DECREASES IF
THE SHIM THICKNESS IS INCREASED
.--~~~
DO NOT USE MORE THAN ONE

THE CASTER ANGLE - - - - - - - " 1
DECREASES IF THE SHIM
THICKNESS IS INCREASED
FRONT\::)
DO NOT USE MORE THAN TWO
THE CASTER ANGLE INCREASES IF

THE SHIM THICKNESS IS INCREASED
DBG211ZTB001
To adjust the camber and caster angles, loosen the bolts of the upper arm shaft and insert or remove the
adjustment shims .
The amount of change of the camber and caster due to a 1 mm {0.039 in} shim increase or decrease is as
follows:
Camber: 1 mm {0.039 in} shim = 15'
Caster: 1 mm {0.039 in} shim 30'
02-11-1
WHEEL ALIGNMENT
Shim
For camber
adjustment
For caster
adjustment
Thickness (mm {in})

1.0 {0.039}
1.6 {0.063}
2.0 {0.079}
3.2 {0.126}
4.0 {0.1S7}
1.0 {0.039}
1.6 {0.063}
2.0 {0.079}
3.2 {0.126}
4.0 {0.1S7}
0.6 {0.024}
MAXIMUM STEERING ANGLE

4x2 (EXCEPT Hi-Rider)
Hi-Rider, 4x4
DCF213ZTB001
The maximum steering angle can be adjusted by turning the adjusting bolts.
TOTAL TOE-IN
The total toe-in can be adjusted by turning the tie
rods.
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 turn the
left tie rod by the same amount toward the rear.
One turn of the tie rod (both sides) changes the
toe-in by about 30 mm {1.18 in}.
02-11-2
"
WHEEL AND TIRES
02-12
WHEEL AND TIRES
WHEEL AND TIRES OUTLINE . ....... 02-12-1
WHEEL AND TIRES

STRUCTURAL VIEW . ............. . 02-12-1
WHEEL AND TIRES OUTLINE
dcf02120000Ot01
In consideration of the environment, an adhesive-type balance weight made of steel has been adopted to
reduce amount of lead used in the vehicle (aluminum alloy wheel).
An adhesive-type balance weight is fastened on the inner side of the wheel. Since it is not visible from the
styled side of the wheel, the design of the wheel is favoured.
WHEEL AND TIRES STRUCTURAL VIEW

15-INCH STEEL WHEEL
id0212001042b3
15-INCH ALUMINUM ALLOY WHEEL
16-INCH ALUMINUM ALLOY WHEEL
EFC212ZTD001
02-12-1
FRONT SUSPENSION
02-13
FRONT SUSPENSION
FRONT SUSPENSION OUTLINE ...... 02-13-1

FRONT SUSPENSION
STRUCTURAL VIEW .. ............ 02-13-1
FRONT SUSPENSION DESCRIPTION .. 02-13-3
FRONT LOWER ARM AND TIE ROD

CONSTRUCTION
[4x2 (EXCEPT Hi-Rider)] .......... . 02-13-3
FRONT SUSPENSION OUTLINE
dcf021300000to1
The double wishbone suspension, which has I-shape lower arms and tension rods, is used for the front
suspension of 4x2 models.
The double wishbone suspension, which has A-shape lower arms, is used for the front suspension of Hi-Rider
and 4x4 models. A-shape lower arms have high rigidly and durability.
The torsion bar springs are used for both 4x2 and 4x4 models.
The torsion bar spring is per-coiled in one direction. It therefore gives ample spring performance when installed
correctly, but only half if installed in reverse.
An R (right) or L (left) is marked on the rear end of the bar to distinguish one form the other.
The left and right, and 4x2 and 4x4 torsion bar springs are not interchangeable.
FRONT SUSPENSION STRUCTURAL VIEW

dcf02130000Qt02
4x2 (Except Hi-Rider)
UPPER ARM
FRONT STABILZIER
LOWER ARM
DBG213ZTB001
02-13-1
liD
FRONT SUSPENSION
Hi-Rider
UPPER ARM
FRONT STABILIZER
LOWER ARM
DBG213ZTB002
4x4
TORSION BAR SPRING
LOWER ARM
DBG213ZTB003
02-13-2
FRONT SUSPENSION
FRONT SUSPENSION DESCRIPTION
dcf02130000Ot03
The vehicle height can be adjusted by turning the torsion bar spring anchor bolt. When adjustment is required,
adjust the vehicle height as follows:
1. Place the vehicle on level ground.
2. Inspect the front and rear tire pressure and adjust it if necessary.
3. Measure the distance form the center of each front wheel to the fender brim.
4x2 (Except Hi-Rider): 416-456 mm {16.4-17.9 in}
Hi-Rider: 512-552 mm {20.2-21.7 in}
4x4 (Stretch cab (with Rear Access Systetm)): 512-552 mm {20.2-21.7 in}
4x4 (Double cab): 502-542 mm {19.8-21.3 in}
*Difference between left and right: 10 mm {0.39in} max.
4. If the difference between left and right is not within the specification, adjust the vehicle height by turning the
torsion bar spring anchor bolt.
VEHICLE HEIGHT
4x2
4x4
ANCHOR BOLT
DBG213ZTB004
FRONT LOWER ARM AND TIE ROD CONSTRUCTION [4x2 (EXCEPT Hi-Rider)]
dcf02130000Ot04
To prevent shimmy, the lower arm and tie rod are arranged in parallel.
THE ROD
FORCE.
r;-::..
I
~.>====
II
II
II
- - - -----
r- ... >==---------
I
I
I
LOWER ARM
~:
,_..,,1
DBG213ZTB005
By aligning the lower arm and tie rod in parallel, a change in toe-in, which is the cause of shimmy, does not
occur.
The theory of why the tor-in change does not occur is that when force is applied to the tires form the front, they
move backward, thus resulting in the rectangle (formed by the links) becoming a parallelogram configuration.
As a result, the tires move in parallel to the inside and, although there is a slight change in the vehicle tread
width, there is no change in tor-in.
02-13-3
-.
REAR SUSPENSION
02-14
REAR SUSPENSION
REAR SUSPENSION OUTLINE ....... 02-14-1
REAR SUSPENSION
STRUCTURAL ViEW ............... 02-14-1
REAR SUSPENSION OUTLINE
dcf021400000to1
The rigid axle suspension with leaf spring is used for the rear suspension.
To prevent wind-up of the leaf springs during rapid acceleration or deceleration, the shock absorber on the right
side is mounted at the rear of the axle and the left one is mounted at the front of the axle, (bias mount).ln order
to increase the rigidity in the lateral direction, wide shackle plates are used in the frame mounting.
For Hi-Rider and 4x4 models, the rear springs are mounted on top of the axle housing to raise the center of
gravity. Thus, the shock absorbers attach directly to brackets welded to the axle housing.
REAR SUSPENSION STRUCTURAL VIEW
dcf02140000Ot02
4x2 EXCEPT
Hi-Rider
Hi-Rider, 4x4
DCF214ZTB001
02-14-1
DRIVELINE/AXLE
OUTLINE .... ............ .
ON-BOARD DIAGNOSTIC ....
FRONT AXLE ..............
REAR AXLE ...............
03-00
03-00
03-02
03-11
03-12
DRIVE SHAFT .............. 03-13

DIFFERENTIAL. ............ 03-14
TRANSFER ................ 03-16
4-WHEEL DRIVE ........... 03-18
OUTLINE
DRIVELINEIAXLE ABBREVIATIONS . .. 03-00-1

DRIVELINE/AXLE FEATURES . ....... 03-00-1
DRIVELINEIAXLE SPECIFICATIONS . . . 03-00-2
DRIVELINEIAXLE ABBREVIATIONS
ABS
API
DLC-2
DTC
LSD
OFF
ON
PCM
RFW
SAE
dcf030000000t01

American Petroleum Institute
Data Link Connector-2
Diagnostic Trouble Code
Limited Slip Differential
Switch Off
Switch On
4x2
Remote Freewheel
Society of Automotive Engineers
4-Wheel 2-Drive
4x4
4-Wheel 4-Drive
DRIVELINE/AXLE FEATURES
Improved rigidity, reduced noise
and vibration
dcf03000000Qt02
Improved durability
Improved operability
Improved driveability
Constant velocity joint type rear drive shaft adopted

2-part, 3-joint type propeller shaft with a center bearing support has been adopted (4x2,
4x4 rear)
1-part type propeller shaft has been adapted (4x4 front)
Double offset-shaped constant velocity joint adopted for differential-side joint of front
drive shaft
Bell-shaped constant velocity joint adopted for wheel-side joint of front drive shaft
Unit-design taper roller bearing has been adopted
A spring-tensioned clip-type method of fixing the universal joint has been adopted (4x2,
4x4 rear)
A direct control type transfer shift lever adopted
Remote freewheel (RFW) has been adopted
Electronic control type transfer case adopted
Unit-design taper roller bearing has been adopted
LSD has been adopted
03-00-1
OUTLINE
DRIVELINE/AXLE SPECIFICATIONS
dcf03000000Ot03
Item
Specification
Engine
Transmission type
Vehicle type
Front axle
Bearing type
Rear axle
Bearing type
WL-3
R15M-D
4x2
.,
WE-C
S15MX-D
4x2 Hi-Rider
(mm {in})
(mm {in})
Taper roller bearing

Semi-floating
Banjo type
739 {29.1}
35.0 {1.4}
(Inches)
Hypoid gear
Straight bevel gear
8.9
Grade
Viscosity
Capacity
. (L {US qt, Imp qt})
Front differential
Reduction gear
Differential gear
Ring gear size
Final gear ratio
Differential
Type
oil
S15M-D
4x2
4x4
Support type
Casing
Length
Diameter
Rear differential
Reduction gear
Differential gear
Ring gear size
Final gear ratio
Differential
Type
oil
WL-C
8.0
3.909
1.40
{1.48, 1.23}
3.416
2.45
{2.32, 2.04}
3.727
API service GL-5
SAE 90
2.35 {2.22, 1.96}
Hypoid gear
Straight bevel gear
8.00
3.727
API service GL-5
Above -18C {O OF}:
SAE90
Below -18C {O OF}:
SAE80
(Inches)
Grade
Viscosity
Capacity
(L {US qt, Imp qt})
1.9 {1.8, 1.6}
Front drive shaft

Wheel side
Differential side
(mm {in})
Shaft diameter
Front propeller shaft
L1
(mm {in})
Length (front)
L2
L3
Outer diameter
(mm {in})
D
(front)
Rear propeller shaft
L1
159 {6.26}
Length (rear)
(mm {in})
666.1 {26.22}
L2
L3
956.1 {37.64} 909.8 {35.82}
Outer diameter
(mm {in})
D
(rear)
Joint type
Joint type
03-00-2
Bell joint
Double offset joint
30.0 {1.18}
45.3 {1.78}
552.1 {21.74}
45.3 {1.78}
63.5 {2.50}
163.4 {6.433}
670.6 {26.40}
890.3 {35.05}
63.5 {2.50}
Cross-shaped joint
41.1 {1.62}
443.6 {17.46}
896.3 {35.29}
(.'
OUTLINE
Specification
Item
Engine
Transmission type
Vehicle type
WL-3
WL-C
R15M-D
4x2
R15M-D
WE-C
S15M-D
4x2
S15MX-D
4x2 Hi-Rider
4x4
ef-----:---==1~--+-=:=---1 ~t
i!E3F---------:------------f11S15MX-D 4x4 FRONT
tr=~----~---~S15M-D 4x2 (HI-RIDER) REAR
r:,-[f=-~--~---+~
03-00-3
OUTLINE
Item
Specification
Engine
Transmission type
4x2
Transfer
Type
Oil capacity
(approx.
quantity)
03-00-4
S15M-D
R15M-D
Vehicle type
Transfer oil
WL-C
WL-3
(L {US qt,
Imp qt})
4x2
4x2 Hi-Rider
WE-C
S15MX-D
4x4
Mercon MUltipurpose AFT XT-2QDX
1.85 {1.95, 1.63}
,f
I.
.'
."
OUTLINE
DRIVELINEIAXLE SPECIFICATIONS [RANGER (5R55S)]
Item
Engine
Transmission type
Vehicle type
Front axle
Bearing type
id030000100211
Specification
WL-C
WE-C
5R55S
4x2 Hi-Rider
4x2
4x4
Rear axle
Bearing type

Semi-floating
Support type
Casing
Rear differential
Reduction gear
Differential gear
Ring gear size
Final gear ratio
Differential
Type
oil.
Banjo type
739 {29.1}
(mm {in})
(mm {in})
Length
Diameter
35.0 {1.4}
Hypoid gear
Straight bevel gear
(Inches)
8.9
3.416
Grade
Viscosity
Capacity
(approx. quantity)
(L {US qt, Imp qt})
2.45 {2.32, 2.04}
Front differential
Reduction gear
2.35 {2.22, 1.96}
Grade
Viscosity
Capacity
(approx. quantity)
Differential gear
Ring gear size
(Inches)
Final gear ratio
Differential
Type
oil
3.727
API service GL-5
SAE90
Hypoid gear
Straight bevel gear
8.00
3.727
API service GL-5
Above -18C {O OF}:
SAE90
Below -18C {O OF}:
SAE80
1.9 {1.8, 1.6}
(L {US qt, Imp qt})
Front drive shaft

Joint type
Shaft diameter
Wheel side
Differential side
(mm {in})

Length (front)
,
(mm {in})
Outer diameter
(front)
(mm {in})
Bell joint
Double offset joint
30.0 {1.18}
L1
L2
L3
D
13.2 {0.52}
588.4 {23.17}
34.3 {1.35}
26.5 {1.04}

Length (rear)
Outer diameter
(rear)
Joint type
03-00-4a
(mm {in})
(mm {in})
192.5 {7.579}
L1
L2
677.6 {26.68}
691.6 {27.23}
L3
909.8 {35.82}
890.3 {35.05}
41.1 {1.62}
63.5 {2.50}
Cross-shaped joint
443.6 {17.46}
896.3 {35.29}
OUTLINE
Item
Engine
Transmission type
Vehicle type
Specification
WL-C
WE-C
5R55S
4x2 Hi-Rider
4x2
5R55S 4x2
4x4
L2
L1
5R55S 4x2 (Hi-Rider)
L2
L1
L3
5R55S 4x4 FRONT
L1
1
IlliJfJl-----l-I_--"-'I~
L2
L3
5R55S 4x4 REAR

D
(
L3
Transfer case
High
1.000
Gear ratio t - : - = - - - - - - - - - - - + - - - - - - - - - - - - - - - - - - + - - - - - = - - : - : - : : - - - - - - J
Low
2.480
Type
Mercon V
Transfer
Oil capacity
(L {US qt,
case oil
(approx.
1.2 {1.3, 1.1}
Imp qt})
quantity)
I.
03-00-4b
...;
ON-BOARD DIAGNOSTIC
ON-BOARD DIAGNOSTIC
03-02
ON-BOARD DIAGNOSTIC OUTLINE

[REMOTE FREEWHEEL (RFW)] ..... 03-02-1
./
ON-BOARD DIAGNOSTIC OUTLINE [REMOTE FREEWHEEL (RFW)]
dcf03022710Dt01
The on-board diagnostic function allows for detecting malfunctions in the input/output signals when the engine
switch is at the ON position.
The DLC/DLC-2, which combines the failure detection and detection maintenance connectors, has been
adopted to improve serviceability. By connecting a current diagnostic tool to the DLC/DLC-2, malfunction
diagnosis can be carried out.
Using a current diagnostic tool, DTCs can be retrieved or erased depending on the screen display, thus
improving serviceability.
The on-board diagnostic function of remote freewheel (RFW) is controlled by PCM.
Block Diagram
PCM
OBD SYSTEM
~-------------------------------------------:
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
MEMORY
FUNCTION
c::=::)
I
I
TESTER
COMMUNICATION
FUNCTION
DETECTION
FUNCTION
SIMULATION TEST
FUNCTION
I(
DLC/
)' DLC-2 (CAN)
I
I
I
I
I
I
I
I
I
I
I
I
CURRENT
DIAGNOSTIC
TOOL
'TI
:--------- --------------------1][--------;'
INPUT DEVICE
I[
RFW CONTROL SYSTEM
->
OUTPUT DEVICE
DCF302ZTB001
DTC Table (Related to the RFW)

DTC stored in
memory
Malfunction location
DTC
P1812
RFW Lock solenoid valve circuit failure
P1813
P1814
RFW Lock solenoid valve open circuit

RFW Lock solenoid valve circuit/short to battery
P1815
RFW Lock solenoid valve circuit/short to ground
P1878
RFW Free solenoid valve circuit failure
P1879
P1880
RFW Free solenoid valve open circuit

RFW Free solenoid valve circuit/short to battery
P1885
RFW Free solenoid valve circuit/short to ground
X
X
X
X
X
X
X
X
Simulation Item Table (Related to the RFW)

Operation
Item
4WDMODE_L
Output part
4x4 indicator light
HUBLOCK
HUBLOCK_L
RFW lock solenoid valve

RFW free solenoid valve
Off/On
Off/On
RFW indicator light
Off/On
NTFLAMP
Test condition
Off/On
Engine switch at ON
03-02-1
ON-BOARD DIAGNOSTIC
03-02
ON-BOARD DIAGNOSTIC

[4x4 control module] .............. 03-02-1
ON-BOARD DIAGNOSTIC OUTLINE [4x4 control module]
,I.
\- .
'
id0302a11 001 00
Special Features
When a 4x4 control system malfunction is detected, the 4x4 indicator light and 4L indicator light are flashed to
notify the occurrence of the malfunction.
Memory Function
The memory function records signal systems which have been determined to be abnormal by the malfunction
detection function, and the recorded malfunction information is not cleared even when the engine switch is
turned off (LOCK position) or the malfunction is repaired.
Refer to the Workshop Manual for the DTC clearing procedure.
Malfunction Indication Function
The malfunction indication function flashes the 4x4 indicator light and 4L indicator light as a DTC based on the
signal determined to be a malfunction by the malfunction detection function.
DTCTable
DTC No.
4x4 control module malfunction
2
3
4
5
6
7
Motor component (shift motor) malfunction

Clutch coil malfunction
Speed sensor malfunction
Solenoid valve malfunction .
4x4 switch malfunction
Motor component (position sensor) malfunction
DTC stored in
memory
x
x
x
x
x
x
x
'-.~
03-02-2
FRONT AXLE
03-11
FRONT AXLE
FRONT AXLE OUTLINE ............. 03-11-1
FRONT AXLE
CROSS-SECTIONAL VIEW .......... 03-11-1
FRONT AXLE OUTLINE
dcf0311 04000101
Taper roller bearings, which have a large load capacity, are used as wheel bearings, thus preload adjustment
is necessary.
FRONT AXLE CROSS-SECTIONAL VIEW
dcf0311 04000102
Hi-Rider
4x2
4x4
ABS
WHEEL-SPEED
SENSOR
TAPER
ROLLER
BEARING
(SEPARATETYPE)
TAPER
ROLLER
BEARING
(UNIT-TYPE)
TAPER
ROLLER
BEARING
(UNIT-TYPE)
DCF311ZTB001
03-11-1
REAR AXLE
03-12
REAR AXLE
REAR AXLE OUTLINE . ............. 03-12-1
REAR AXLE
CROSS-SECTIONAL ViEW .......... 03-12-1
REAR AXLE OUTLINE
dcf03120500Ot01
Taper roller bearings are used as wheel bearings.

Bearing end play in the axial direction is adjusted using shims between the rear wheel hub and the axle casing.
REAR AXLE CROSS-SECTIONAL VIEW
WITHOUTABS
dcf03120500Ot02
WITHABS
ABS
WHEEL-SPEED
SENSOR
AXLE CASING
DBG312ZTB001
03-12-1
DRIVE SHAFT
03-13
DRIVE SHAFT
FRONT DRIVE SHAFT OUTLINE ...... 03-13-1
FRONT DRIVE SHAFT

FRONT DRIVE SHAFT OUTLINE
dcf03132550Ot01
The bell joint has been adopted on the wheel side and the double offset joint has been adopted on the
differential side to reduce noise and vibration.
FRONT DRIVE SHAFT CROSS-SECTIONAL VIEW
dcf03132550Ot02
WHEEL SIDE
BELL JOINT
DIFFERENTIAL SIDE
DOUBLE OFFSET JOINT
WHEEL SIDE
BELL JOINT
DIFFERENTIAL SIDE
DOUBLE OFFSET JOINT
RIGHT SIDE
LEFT SIDE
DBG313ZTB001
03-13-1
DIFFERENTIAL
03-14
DIFFERENTIAL
REAR DIFFERENTIAL OUTLINE ...... 03-14-1
REAR DIFFERENTIAL
REAR DIFFERENTIAL OUTLINE
dcf031427100to1
There are two types of differentials available, standard differential and limited slip differential (LSD).
The purpose of the LSD is to provide driving force to both tires by preventing either tire from slipping.
With a standard differential, if a tire starts spinning due to poor traction such as mud or snow, the driving force
is exerted on that tire by the action of the differential. With the LSD, the differential action is automatically
limited and driving force is exerted on both tires.
REAR DIFFERENTIAL CROSS-SECTIONAL VIEW
STANDARD DIFFERENTIAL
dcf031427100l02
LSD
WITH REAR ASS
ASS SENSOR ROTOR

DCF314ZTB001
03-14-1
TRANSFER [5R55S]
03-16
TRANSFER [SRSSS]
TRANSFER CASE
OUTLINE [5R55S] .. ...............
TRANSFER CASE
STRUCTURAL VIEW [5R55S] .......
TRANSFER CASE
POWER FLOW [5R55S] ............
TRANSFER CASE
ELECTRONIC CONTROL SYSTEM
OUTLINE [5R55S] .. ...............
TRANSFER CASE
SYSTEM WIRING DIAGRAM
[5R55S] .........................
03-16-1
03-16-1
03-16-4
03-16-8
03-16-8
TRANSFER CASE OUTLINE [5R55S]
SPEED SENSOR
CONSTRUCTION [5R55S] . ......... . 03-16-9
MOTOR POSITION
DETECTION SWITCH
FUNCTION [5R55S] ................ 03-16-9
MOTOR POSITION
DETECTION SWITCH
[5R55S] . ........................ . 03-16-10
MOTOR CONSTRUCTION [5R55S] ..... 03-16-10
CLUTCH COIL
CONSTRUCTION [5R55S] . ......... . 03-16-11
id0316c1137500
A chain-type transfer drive has been adopted for 4x4 driving to improve noise suppression. In addition, the
drive sprocket, which drives the chain, rotates only during 4x4 driving to improve noise suppression during 4x2
driving .
Shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW is performed by the motor for improved operability.
TRANSFER CASE STRUCTURAL VIEW [5R55S]
TRANSFER CASE
arnffn00000404
03-16-1
'w
Exploded vie
18
3
4
5
=-___=_
r'C~enter transfer case
Center transfer case c_omponent

-'---_
Dowel pin
Bearing
Snap ring
Oil seal
7
8
.
Front transfer
cas=e
Dowel pin
Snap
ring
ca~
Front transfer
03-16-2
~comp~o~nen~t_ __
TRANSFER [SRSSS]
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
Clip
Bolt
Input shaft component
Input shaft
Needle bearing
Bushing
Thrust washer
Planetary gear component
Sun gear
Thrust plate
Snap ring
Ball bearing
Snap ring
Reduction shift fork component
Reduction shift fork
Reduction shift fork facing
Lockup shift fork component
Lockup shift fork
Lockup shift fork facing
Spring
Spacer
Cam
Shift shaft
Rail shift
Return spring
Output shaft and gerotor pump component
Output shaft component
Gerotor pump component
Reduction hub
Pump hose
Hose clamp
Oil strainer
Magnet
Lockup component
Lockup hub
Spring
Lockup collar
Snap ring
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
Drive sprocket
Drive chain
Driven sprocket
Snap ring
Spacer
Lower output shaft
Front output flange component
Front outputflange
Deflector
Oil seal
Washer
Locknut
Rear transfer case component
Rear transfer case
Needle bearing
Sleeve
Seal
Snubber
Bolt
Clutch coil
Nut
Clutch housing
Breather pipe
Speed sensor component
Bracket
Bolt
Spacer
Rear companion flange component
Rear companion flange
Oil plug
Motor component
Bracket
Terminal connector
Clip
Bracket
Clip
Bolt
Bolt
03-16-3
TRANSFER [5R55S]
TRANSFER CASE POWER FLOW [5R55S]
id0316c11 00600
Shifting From 4x2 HIGH to 4x4 HIGH

During 4x2 driving, drive force from the transmission is transmitted from the input shaft to the output shaft
through the reduction hub, and the drive force from the output shaft is transmitted to the rear differential
Shifting between 4x2 and 4x4 is performed using the lockup component operation. During 4x2 driving, drive
force is not transmitted to the chain because the lockup component does not contact the clutch housing,
therefore, the drive force is not transmitted to the front differential.
REAR DIFFERENTIAL
SIDE
~
~
~ TRANSMISSION
~SIDE
LOCKUP
COMPONENT
CLUTCH
HOUSING
CLUTCH
HOUSING
LOCKUP
COMPONENT
arnffn00000336
03-16-4
TRANSFER [SRSSS]
When the 4x4 switch is switched to the 4H position during 4x2 driving, the motor rotates from the 2H to 4H
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates, the lockup shift
fork component slides to the clutch housing side. In conjunction with this operation, the clutch coil is energized
and magnetic force is generated, and the lockup shift fork component is pulled toward the clutch housing. In the
lockup shift fork component operation, the lockup hub contacts the clutch housing first, then the lockup collar
slides to the lockup housing side. At this time, if the lockup hub is not engaged with the clutch housing spline,
the lock up hub is pressed into the lockup collar. If the clutch housing rotates in this condition, such as when the
vehicle is being driven, the lockup hub engages with the clutch housing spline. The lockup shift fork component
is engaged with the drive sprocket and the clutch housing is engaged with the output shaft, therefore, drive
force from the output shaft is transmitted to the lower output shaft via the chain. Due to this, drive force is
transmitted to the front differential.
REAR DIFFERENTIAL ~
SIDE
~
LOCKUP
COMPONENT
~ TRANSMISSION
~SIDE
CHAIN
LOCKUP SHIFT FORK

COMPONENT
LOCKUP
HUB
CLUTCH
HOUSING
LOCKUP
COLLAR
LOCKUP
COMPONENT
LOCKUP
COLLAR
CLUTCH
HOUSING
CLUTCH
HOUSING
LOCKUP
HUB
arnffn00000337
03-16-5
TRANSFER [SRSSS]
Shifting From 4x4 HIGH to 4x2 HIGH
When the 4x4 switch is switched to the 2H position while in 4x4 HIGH, the motor rotates from the 4H to 2H
position. Due to the motor rotation, the cam rotates via the shift shaft. The lockup shift fork component slides
due to the cam rotation and spring force of the return spring, and separates from the clutch housing. At this
time, the clutch coil is not energized.When the lockup shift fork component separates from the clutch housing,
drive force transmission to the lower output side is interrupted, and drive force is transmitted only to the rear
differential.
REAR DIFFERENTIAL
SIDE
~ TRANSMISSION
~SIDE
./L-,
CHAIN
CLUTCH
HOUSING
LOCKUP
COLLAR
CLUTCH
HOUSING
LOCKUP
HUB
arnifn00000338
03-16-6
-,
TRANSFER [5R55S]
Shifting From 4x4 HIGH to 4x4 LOW
When the 4x4 switch is switched to the 4L position while in 4x4 HIGH, the motor rotates from the 4H to 4L
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the spline
which is inside the carrier of the planetary gear component. If the drive force is transmitted to the input shaft in
this condition, the output speed is reduced due to the planetary gear operation, and the rotational torque
increases.This drive force is transmitted to the front and rear differentials.
REAR DIFFERENTIAL
SIDE
~ TRANSMISSION
L-y/ SIDE
INPUT
SHAFT
REDUCTION
SHIFT FORK
COMPONENT
REDUCTION HUB
CAM
arnffn00000339
Shifting From 4x4 LOW to 4x4 HIGH

When the 4x4 switch is switched to the 4H position while in 4x4 LOW, the motor rotates from the 4L to 4H
position. Due to the motor rotation, the cam rotates via the shift shaft. When the cam rotates the reduction shift .
fork component, which is fitted into the cam groove, slides, and the reduction hub engages with the input shaft
spline. Due to this, the drive force from the input shaft is transmitted to the output shaft without being input to
the planetary gear, and then it is transmitted to the front and rear differential with the output speed and
rotational torque remaining unchanged.
REAR DIFFERENTIAL
SIDE
~ TRANSMISSION
L-y/ SIDE
r------------------,
INPUT
SHAFT
REDUCTION
SHIFT FORK
COMPONENT
REDUCTION HUB
CAM
arnffn00000340
03-16-7
TRANSFER [5R55S]
TRANSFER CASE ELECTRONIC CONTROL SYSTEM OUTLINE [5R55S]
id0316c1137600
A 4x4 control module has been adopted which operates the motor according to signals from the speed sensor
and motor position detection switch to control shifting between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW.
TRANSFER CASE SYSTEM WIRING DIAGRAM [5R55S]
B+
4x4
CONTROL
MODULE
id0316c1137700
IG1
TRANSFER CASE
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
DIGITAL TR SENSOR J : i - - - - - {
LOCK SOLENOID
FREE SOLENOID
arnffw00001937
03-16-8
TRANSFER [5R55S]
SPEED SENSOR CONSTRUCTION [5R55S]
id0316c1137000
The speed sensor detects the output shaft rotation speed, and the signal is input to the 4x4 control module.
Signals from the speed sensor are used by the 4x4 control module to perform each control.
SPEED SENSOR
SPEED SENSOR
OUTPUT SHAFT
MOTOR POSITION DETECTION SWITCH FUNCTION [5R55S]
id0316c1137100
The motor position detection switch detects the motor position and outputs control signals to the 4x4 control
module.
The 4x4 control module determines the motor position according to the signals from the motor position
detection switch.
03-16-9
TRANSFER [SRSSS]
MOTOR POSITION DETECTION SWITCH CONSTRUCTION/OPERATION [5R55S]
id0316c1137200
The motor position detection switch is integrated into the motor, and turns on or off according to the motor
position.
The motor position detection switch detects the motor position using a combination of four switches.
Motor Position
Position 1
Position 2
Position 3
Position 4
2H
Off
On
Off
On
On
Off
Off
Off
On
On
Off
On
4H
4L
2H
4L
IZ]:SWITCHON
D: SWITCH OFF
A: POSITION 4
B: POSITION 3
C: POSITION 2
D: POSITION 1
E: GROUND
arnffn00000342
MOTOR CONSTRUCTION [5R55S]
id0316c1137300
The motor switches between 4x2 HIGH, 4x4 HIGH, and 4x4 LOW according to the signals from the 4x4 control
module.
A switch for motor position detection is integrated in the motor.
MOTOR
arnffn00000343
03-16-10
TRANSFER [5R55S]
CLUTCH COIL CONSTRUCTION [5R55S]
id0316c1137400
The clutch coil is integrated in the transfer.

When a 4x4 shift signal is input to the 4x4 control module, electricity flows from the control module to the clutch
coil and magnetic force is generated. Using the magnetic force, the lockup collar is pulled toward the clutch
housing, shifting from 4x2 to 4x4.
CLUTCH COIL
03-16-11
TRANSFER
03-16
TRANSFER
TRANSFER OUTLINE . .............. 03-16-1
TRANSFER
TRANSFER POWER FLOW . ......... . 03-16-2
TRANSFER OUTLINE
dcf031600000t01
The transfer of S1SMX-D manual transmission is a chain-drive part-time transfer in which the shift activates
mechanically.
The speed selection is controlled by a single-lever shift mechanism that provides N, 2H, 4H and 4L.
The purpose of the transfer is for transmission of driving force to either the rear differential only or to the front
and rear differentials simultaneously.
The transfer employs a chain to transfer the driving force to the front differential.
The transfer is a non-synchro type transmission.
The chain is a maintenance-free type, requiring no tension adjustment.
TRANSFER CROSS-SECTIONAL VIEW
dcf031600000t02
LOW GEAR
INPUT GEAR
DRIVE SPROCKET
OUTPUT SHAFT
FROM
TRANSMISSION
FRONT DRIVE
SPROCKET
COUNTER GEAR
TO FRONT
PROPELLER
SHAFT
SHIFT PATTERN
+
CHAIN
DCG316ZTB001
03-16a-1
TRANSFER
TRANSFER POWER FLOW
dcf031600000to3
2H (2-HIGH)
N (NEUTRAL)
4H (4-HIGH)
4L (4-LOW)
DCG316ZTB002
03-16a-2
4-WHEEL DRIVE
03-18
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW)

OUTLINE ................... 03-18-1
CONSTRUCTION ............ 03-18-1
COMPONENTS AND FUNCTIONS ... 03-18-2

SYSTEM DIAGRAM ............ 03-18-3
SYSTEM WIRING DIAGRAM ......... 03-18-4
OPERATION .................. 03-18-4
REMOTE FREEWHEEL (RFW) OUTLINE
dcf031827300l01
The PCM receives signals from the transfer case switch and other switches. It then activates one of two
To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum pump,
such as during acceleration or at high altitude operation, the actuation system includes a one-way check valve.
The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front differential.
The RFW operation is controlled by PCM.
REMOTE FREEWHEEL (RFW) CONSTRUCTION
dcf031827300l02
FRONT DIFFERENTIAL
SLEEVE
DRIVE PINION GEAR

RFW ACTUATOR
DBG314ZTB012
03-18-1
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) COMPONENTS AND FUNCTIONS
dcf031827300t03
Electrical component
Part name
Function
PCM (RFW control)
Transfer neutral switch

Input
4x4 indicator light

RFW switch
RFW main switch
ILock
IFree
Solenoid
Output
RFW indicator light
Detects transfer select lever 2H position

Detects RFW unit "lock"
Creates RFW unit "free"
Switched ON/OFF by electrical signals from PCM

Regulates RFW unit "lock" or "free"
Switched ON when "locked"
Illuminates when RFW unit locked
4x4 indicator light
Sends ON/OFF signals to lock and free solenoids and indicator lights
according to signals from various switches
Detects transfer select lever N position
Switched ON when "free"

Illuminates when 4H or 4L selected
Mechanical component
Part name
Transfer select lever
RFW unit
RFW actuator
One-way check valve
Function
Sets transfer case operation mode (2H, 4H, N, or 4L)

Transmits front propeller shaft rotation to front tires
"Locks" or ''free'' RFW unit
Prevents leakage of vacuum
Relationship of Component and Function

Part name
Function
by driver
Controlled by RFW unit
Controlled by PCM
Controll~d
03-18-2
Transfer
neutral
switch
x
Input
4x4
RFW
indicator
switch
switch
x
Output
RFW
main
switch
Lock
solenoid
Free
solenoid
4x4
indicator
light
RFW
indicator
light
x
x
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) SYSTEM DIAGRAM
4x4
INDICATOR
LIGHT
A: TRANSFER NEUTRAL SWITCH
B: 4x4 INDICATOR SWITCH
4H
[XJ
dcf031827300to4
RFW
INDICATOR
LIGHT
IR.F.WI
LOCK
TO BATTERY
2~",4L
ENGINE
SWITCH
TRANSFER
SELECT
LEVER
FRONT
DIFFERENTIAL
RFW
ACTUATOR
I-.....------.,...---,-J RFW UNIT

RFWSWITCH
ONE-WAY
CHECK VALVE
DBG314ZTB003
03-18-3
4-WHEEL DRIVE
REMOTE FREEWHEEL (RFW) SYSTEM WIRING DIAGRAM
dcf03182730Ot05
MAIN RELAY
ENGINE
SWITCH
RFW FREE
SOLENOID
BATTERY
PCM (RFW CONTROL)
DBG318ZTB001
REMOTE FREEWHEEL (RFW) OPERATION
dcf03182730Ot06
2H (free) to 4H Selection
The remote freewheel (RFW) unit is automatically locked when the select lever is moved from 2H to 4H while
the vehicle is stopped. At this time, the 4x4 indicator light and the RFW indicator light illuminate to inform the
drive that the vehicle is in four-wheel-drive mode and that the RFW unit is locked.
.
Caution
The changeover from 2H (free) to 4H (locked) MUST NOT be made while the vehicle is moving
because it may result in damage to the front differential and RFW components.
If such a shift is made by mistake, a ratching noise may be heard. In this case return the select
lever to 2H and press the RFW main switch.
4H to 2H (free) Selection
The RFW unit will be automatically freed when the RFW main switch is pressed once after the select lever is
moved (while the vehicle is moving or while the vehicle is stopped) from 4H to 2H. At this time, the 4x4 indicator
light and the RFW indicator light go OFF to inform the driver that the vehicle is in 4x2 mode and that the RFW
unit has been freed.
Note
The RFW unit will remain locked only if the RFW main switch is pressed while the vehicle is operating in
4H or 4L.
2H (lock) to 4H, or 4H to 2H (lock) Selection
If the RFW unit is locked, the transfer case can be changed from 2H to 4H or vice versa while the vehicle is
running. At this time, the RFW indicator light remains illuminated to inform the driver that the RFW unit remains
locked.
4H to 4L, or 4L to 4H Selection
As with a conventional 4x4, the transfer case can be shifted from 4H to 4L or vice versa when depressing the
clutch while the vehicle is stopped and the engine is running. At this time, the RFW unit remains locked, and the
4x4 and RFW indicator lights remain illuminated.
03-18-4
4-WHEEL DRIVE
Transmission Oil Temperature Increase Prevention
If the vehicle is driven at high speed with the RFW locked, the temperature of the oil for operating the
transmission, transfer, and front differential increases, resulting in internal part damage. Due to this, the RFW
indicator light flashes (0.3 s intervals) to alert the driver when the following condition is met:
Vehicle is driven at 100 km/h {62 MPH} or more with the RFW locked.
- When the vehicle speed decreases to less than 95 km/h {59 MPH} from the above condition, the RFW
indicator light illuminates again. (Normal indication)
Remote Freewheel Unit: FREE
FRONT DIFFERENTIAL
JOINT SHAFT
SLEEVE
RING GEAR
DRIVE PINION GEAR
RFW ACTUATOR
FRONT PROPELLER SHAFT
DBG314ZTB005
The RFW actuator pulls the sleeve away from the front differential output shaft, allowing the front differential to
rotate freely.
The rotation of the right front tire is absorbed by the front differential, with the result that the ring gear, drive
pinion gear, and front propeller shaft do not turn.
03-18-5
..
4-WHEEL DRIVE
Remote Freewheel Unit: LOCK
FRONT DIFFERENTIAL
JOINT
RFWUNIT
RFW ACTUATOR
DBG314ZTB006
The RFW actuator pushes the sleeve over the output shaft, and the front differential output shaft and joint shaft
are coupled together.
If the sleeve and the output shaft are not aligned when actuated, the RFW actuator applies pressure to the
sleeve unit it can slide into place.
The rotation of the front propeller shaft is then transferred, via the front differential, to the front tires, and fourwheel-drive operation is possible.
03-18-6
4-WHEEL DRIVE
2H (free) to 4H Selection
4x4
INDICATOR
LIGHT
,\111,-
,\\1/,
:00
A: TRANSFER NEUTRAL SWITCH: OFF

B: 4x4 INDICATOR SWITCH: OFF
//
RFW
INDICATOR
LIGHT
JR.F.w1
,\
LOCK
-:....
--...
'.
TO BATTERY
....
~
,
4H
2H
, ,
ENGINE
SWITCH
FRONT
DIFFERENTIAL
TRANSFER ",;\
SELECT
LEVER
RFW
ACTUATOR
ON
RFWSWITCH
Lo---
RF~
MAI~
SWITCH
~
---.- TO VACUUM PUMP
ONE-WAY
CHECK VALVE
DBG314ZTB007
Part name
Condition
2H-F
Transfer
neutral
switch
OFF
Input
4x4
RFW
indicator
switch
switch
ON
OFF
4H-L1
OFF
OFF
OFF
4H-L
OFF
OFF
ON
Output
RFW
main
switch
Lock
solenoid
OFF
RFW
RFW
4x4
actuator
Free
indicator indicator Position
solenoid
light
light
ON
OFF
OFF
Free
ON
OFF
ON
OFF
Lock
ON
OFF
ON
ON
Lock
When the select lever is moved from 2H (2H-F in peM) to 4H, the 4x4 indicator switch (in the transfer case
switch) changes from ON to OFF. As a result, the peM establishes a condition known as 4H-L1' and the lock
solenoid is switched ON, causing the actuator to move toward the lock side. At the same time, the 4x4 indicator
light is illuminated.
When the RFW unit is fully locked, the RFW switch is switched ON, and condition 4H-L is established in the
peM. The RFW indicator light illuminates to notify the driver that the RFW is locked.
03-18-7
4-WHEEL DRIVE
4H to 2H (lock) Selection
4x4
INDICATOR
LIGHT
RFW
INDICATOR
LIGHT
. .)1///

B: 4x4 INDICATOR SWITCH: ON
IR.F.WI
-:....
LOCK
-.........
//
'.
TO BATTERY
ENGINE
SWITCH
FRONT
DIFFERENTIAL
RFW
ACTUATOR
LOCK
ON
---
RFn
MAIN
SWITCH
----.. TO ~ACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB008
Part name
Condition
4H-F
2H-L
Input
Transfer
4x4
RFW
neutral indicator
switch
switch
switch
OFF
OFF
ON
OFF
ON
ON
Output
RFW
main
switch
OFF
RFW
RFW
4x4
actuator
Lock
Free
solenoid solenoid
light
light
. ON
ON
ON
Lock
OFF
ON
OFF
OFF
ON
Lock
When the select lever is moved from 4H (4H-L condition) to 2H, the 4x4 indicator switch (in the transfer case
switch) changes from OFF to ON.
If the RFW main switch is in the OFF position, condition 2H-L is established, the lock solenoid remains ON, and
the RFW actuator is held at the lock position. At this time, the 4x4 indicator light is switched OFF.
03-18-8
4-WHEEL DRIVE
2H (lock) to 2H (free) Selection
4x4
INDICATOR
LIGHT
RFW
INDICATOR
LIGHT
IR.F.WI

LOCK
TO BATTERY
ENGINE
SWITCH
TRANSFER
SELECT
LEVER
FRONT
DIFFERENTIAL
~-,
RFW
ACTUATOR
,, ,
,,
,,
,
ON
RFWUNIT
RFWSWITCH
1(Zz:2'ZZZ~~ ---.- TO VACUUM PUMP

ONE-WAY
CHECK VALVE
DBG314ZTB009
Part name
Condition
2H-L
2H-F1
2H-F
Transfer
neutral
switch
OFF
OFF
OFF
Input
4x4
RFW
indicator
switch
switch
ON
ON
ON
ON
OFF
OFF
Output
RFW
main
switch
OFF
ON
Lock
solenoid
ON
OFF
OFF
RFW
RFW
4x4
actuator
Free
solenoid
light
light
OFF
ON
ON
OFF
OFF
OFF
ON
OFF
OFF
Lock
Free
Free
When the above condition (2H-L) the RFW main switch is pressed once (ON), condition 2H-F1 is established,
the RFW indicator light is switched OFF, and, same time, the free solenoid is switched ON, and the actuator is
pulled to the free side. When the RFW unit becomes fully free, the RFW switch is turned OFF, and 2H-F
condition is established.
03-18-9
4-WHEEL DRIVE
4H to 4L or 4L to 4H Selection
4x4
INDICATOR,
LIGHT
I,\\11,...
R,F,w.1 -:....
,\\1/,
A: TRANSFER NEUTRAL SWITCH: OFF-ON

RFW
INDICATOR
LIGHT
-"";_T
/~\
LOCK
___
'.
TO BATTERY
4H
FRONT
DIFFERENTIAL
ENGINE
SWITCH
ON
RFWSWITCH
---
RF~
MAI~
SWITCH
,J,..
--.. TO VACUUM PUMP
ONE-WAY
CHECK VALVE
DBG314ZTB010
Part name
Condition
4H-L
Transfer
neutral
switch
OFF
ON
Input
4x4
RFW
indicator
switch
switch
OFF
ON
OFF
ON
Output
RFW
main
switch
RFW
4x4
RFW
actuator
Lock
Free
solenoid solenoid
light
light
ON
OFF
ON
ON
Lock
ON
OFF
OFF
ON
Lock
When the select lever is moved from 4H to 4L (both 4H-L in the peM) or vice versa, there is a change to the
neutral condition midway through the changeover thereby momentarily switching ON the transfer neutral switch
(in the transfer case switch), and switching OFF the 4x4 indicator light.
During 4H or 4L operation, the lock solenoid is ON (as a result of 4H-L condition), and the RFW actuator is held
in the lock position. If the RFW main switch is pressed at this time, there is no effect upon the RFW actuator.
03-18-10
4-WHEEL DRIVE
Engine Switch Turned from OFF to ON
4x4
INDICATOR
LIGHT

00
RFW
INDICATOR
LIGHT
IR.F.WI
LOCK
TO BATTERY
ENGINE
SWITCH
TRANSFER
SELECT
LEVER
FRONT
DIFFERENTIAL
RFW
ACTUATOR
PCM
(RFW
CONTROL)'
RFWSWITCH
ONE-WAY
CHECK VALVE
DBG314ZTB011
Part name
Condition
4H-L
2H-L
2H-L
Input
Transfer
4x4
RFW
neutral indicator
switch
switch
switch
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
ON
Output
RFW
main
switch
OFF
RFW
RFW
4x4
actuator
Lock
Free
solenoid solenoid
light
light
ON
OFF
ON
ON
Lock
OFF
OFF
ON
OFF
Free
OFF
ON
OFF
OFF
Free
When the ignition switch is turned from OFF to ON, the switches and solenoid are activated to provide the
same RFW condition as when it was turned off.
03-18-11
4-WHEEL DRIVE [AT (SRSSS)]
03-18
4x4 CONTROL SYSTEM

OUTLINE [AT (SRSSS)] . ............ 03-18-1
4x4 CONTROL SYSTEM
CONSTRUCTION [AT (SRSSS)] ...... 03-18-1
4x4 CONTROL SYSTEM
COMPONENTS AND FUNCTIONS
[AT (SRSSS)] ..................... 03-18-2
4x4 CONTROL SYSTEM

SYSTEM DIAGRAM [AT (SRSSS)] ..... 03-18-3
4x4 CONTROL SYSTEM
[AT (SRSSS)] ..................... . 03-18-4
4x4 CONTROL SYSTEM
OPERATION [AT (SRSSS)] . ......... . 03-18-4
4x4 CONTROL SYSTEM OUTLINE [AT (SRSSS)]
id0318d2164200
A special 4x4 control module has been adopted for the 4x4 control system control, and it operates the transfer
motor according to the signals from the speed sensor, 4x4 switch, and digital TR sensor to perform shifting
between 2H, 4H and 4L.
The 4x4 CM receives signals from the transfer case sensor and other switches. It then activates one of two
To prevent reduced performance of the actuator as a result of a decrease in engine vacuum or vacuum pump,
such as during acceleration or at high altitude operation, the actuation system includes a one-way check valve.
The switching mechanism of the RFW unit is a mechanical dog clutch on the left side of the front differential.
The RFW operation is controlled by 4x4 CM.
4x4 CONTROL SYSTEM CONSTRUCTION [AT (SRSSS)]

FRONT DIFFERENTIAL
JOINT
DRIVE PINION GEAR

RFW ACTUATOR
arnffn00000273
03-18-1

4x4 CONTROL SYSTEM COMPONENTS AND FUNCTIONS [AT (5R55S)]
id0318d2164000
Electrical component
Part name
4x4CM
Digital TR sensor
Input
4x4 switch
Speed sensor
Solenoid
Output
Lock
Free
Motor component (transfer case)

Clutch coil (transfer case)
4x4 indicator light

4L indicator light
Function
Sends ON/OFF signals to lock and free solenoids and indicator lights
according to signals from various switches
Detects selector lever N position
Detects 4x4 switch 2H, 4H or 4L position

Detects output shaft speed
Switched ON/OFF by electrical signals from 4x4 CM
Regulates RFW unit "lock" or "free"
Switched ON when "locked"
Switched ON when "free"
Sets transfer case operation mode (2H, 4H or 4L)
Operates when 4H or 4L selected
Illuminates when 4H or 4L selected
Illuminates when 4L selected
Mechanical component
Part name
RFW unit
RFW actuator
One-way check valve
Motor component (transfer
case)
Clutch coil (transfer case)
Function
Transmits front propeller shaft rotation to front tires
"Locks" or ''free'' RFW unit
Prevents leakage of vacuum
Motor operates to slide each shift fork
Magnetic force occur in clutch coil during operation to pull the lockup component
Relationship of Component and Function

Part name
Function
Controlled by driver
Controlled by 4x4 CM
03-18-2
Input
Digital
TR
sensor
x
4x4
switch
Output
Speed
sensor
Lock
solenoid
Free
solenoid
Motor
compon
ent
Clutch
coil
4x4
4L
indicator indicator
light
light

4x4 CONTROL SYSTEM SYSTEM DIAGRAM [AT (5R55S)]
id0318d2163800
FRONT
DIFFERENTIAL
4x4
INDICATOR
LIGHT
TO BATTERY
[XJ
4L
INDICATOR
LIGHT
RFW
ACTUATOR
DIGITAL TR SENSOR
EXCEPT
N POSITION
TO BATTERY
N POSITION
TRANSMISSION
4x4SWITCH
/4H~
2H
4L
ENGINE
SWITCH
4x4CM
arnffn00000399
03-18-3

4x4 CONTROL SYSTEM SYSTEM WIRING DIAGRAM [AT (5R55S)]
B+
4x4
CONTROL
MODULE
id0318d2163900 .
IG1
TRANSFER CASE
~--~C~--------~
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
4x4 SWITCH
DIGITAL TR SENSOR J 1 - - - - - (
FREE SOLENOID
arnffw00001937
4x4 CONTROL SYSTEM OPERATION [AT (5R55S)]
id0318d2165000
Note
Shifting from 2H to 4H or 4H to 2H can be performed whether the vehicle is stopped or driving.
2H to 4H Selection
When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
4H to 2H Selection
When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
4H to 4L Selection
Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18-4

4L to 4H Selection
Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
Remote Freewheel Unit: FREE
FRONT DIFFERENTIAL
JOINT SHAFT
SLEEVE
RING GEAR
RFW ACTUATOR
arnffn00000029
The RFW actuator pulls the sleeve away from the front differential output shaft, allowing the front differential to
rotate freely.
The rotation of the right front tire is absorbed by the front differential, with the result that the ring gear, drive
pinion gear, and front propeller shaft do not turn.
03-18-5

Remote Freewheel Unit: LOCK
FRONT DIFFERENTIAL
JOINT SHAFT
RFW ACTUATOR
arnffn00000030
The RFW actuator pushes the sleeve over the output shaft, and the front differential output shaft and joint shaft
are coupled together.
If the sleeve and the output shaft are not aligned when actuated, the RFW actuator applies pressure to the
sleeve unit it can slide into place.
The rotation of the front propeller shaft is then transferred, via the front differential, to the front tires, and fourwheel-drive operation is possible.
03-18-6

2H to 4H Selection
4L
INDICATOR
LIGHT
4x4
INDICATOR
LIGHT
TO BATTERY
,\\11,
:00"
FRONT
DIFFERENTIAL
RFW
ACTUATOR
//
DIGITAL TR SENSOR
EXCEPT
N POSITION
TRANSFER
POWER FLOW
TO BATTERY
4x4 SWITCH
/4H~
2H
4L
4x4CM
arnffn00000400
Input
Part name
Condition
2H
4H
Digital
TR
sensor
4x4
switch
Speed
sensor
2H
4H
Output
Motor
Clutch
Lock
Free
compon
coil
solenoid solenoid
ent
OFF
ON
2H
OFF
4H
ON
OFF
ON
RFW
4L
4x4
actuator
indicato indicato Position
r light
r light
OFF
OFF
Free
ON.
OFF
Lock
When the 4x4 switch is switched from 2H to 4H, the clutch coil and motor in the transfer operate, the lockup
shift fork slides to establish the 4H condition and the RFW unit locks automatically. At this time, the 4x4
indicator light illuminates to inform the driver that the vehicle is in four-wheel-drive mode.
03-18-7

4H to 2H Selection
4x4
INDICATOR
LIGHT
4L
INDICATOR
LIGHT
TO BATTERY
FRONT
DIFFERENTIAL
, RFW
ACTUATOR
DIGITAL TR SENSOR
EXCEPT
N POSITION
TRANSFER
POWER FLOW
TO BATTERY @.~0t
TRANSMISSION
4x4 SWITCH
N POSITION
r'--II--'-----I~/ TRANSFER
/4H~
2H
SPEED SENSOR
4L
ENGINE
SWITCH
4x4CM
arnffn0000040 1
Part name
Condition
4H
2H
Input
Digital
TR
sensor
4x4
switch
Speed
sensor
4H
2H
Output
Motor
Lock
Free
Clutch
compon
coil
solenoid solenoid
ent
ON
OFF
4H
ON
2H
OFF
OFF
ON
4x4
indicato
r light
ON
OFF
RFW
4L
actuator
indicato Position
r light
OFF
Lock
OFF
Free
When the 4x4 switch is switched from 4H to 2H, the clutch coil in the transfer stops operation but the motor
operates to slide the lockup shift fork and establish the 2H condition. Also, the RFW unit unlocks automatically.
At this time, the 4x4 indicator light turns off to inform the driver that the vehicle is in 4x2 mode.
I: ..
03-18-8

4H to 4L Selection
4x4
INDICATOR
LIGHT
TO BATTERY
,\\11,
:00"
//
DIGITAL TR SENSOR
4L
INDICATOR
LIGHT
,\11//
FRONT
DIFFERENTIAL
RFW
ACTUATOR
~:
I,
LOCK
,-....
EXCEPT
N POSITION
TO BATTERY
4x4SWITCH
N POSITION
/4H~
2H
SPEED SENSOR
4L
ENGINE
SWITCH
'<Zz22@jF --.. TO VACUUM

PUMP
4x4CM
arnffn00000402
Part name
Input
Digital
TR
sensor
4x4
switch
4H
4H
4L
4L
Condition
Speed
sensor
vehicle
stop
vehicle
stop
Output
Motor
Lock
Free
Clutch
compon
solenoid solenoid
coil
ent
4x4
indicato
r light
RFW
4L
actuator
indicato Position
r light
ON
OFF
4H
ON
ON
OFF
Lock
ON
OFF
4L
ON
ON
ON
Lock
Shifting from 4H to 4L can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4H to 4L, the motor in the transfer operates and the reduction
shift fork slides to establish the 4L condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated and, in addition, the 4L indicator light illuminates.
03-18-9
4-WHEEL DRIVE [AT (5R55S)]

4L to 4H Selection
4x4
INDICATOR
LIGHT
TO BATTERY
4L
INDICATOR
LIGHT
,\\11,
:00\'
FRONT
DIFFERENTIAL
RFW
ACTUATOR
LOCK
//
DIGITAL TR SENSOR
EXCEPT
N POSITION
TRANSFER
POWER FLOW
TO BATTERY
4x4SWITCH
/4H~
4L
4x4CM
arnffn00000403
Input
Part name
Digital
TR
sensor
4x4
switch
Speed
sensor
4L
4L
vehicle
4H
4H
vehicle
Condition
stop
stop
Output
Motor
Clutch
Lock
Free
compon
coil
solenoid solenoid
ent
RFW
4x4
4L
actuator
indicato indicato Position
r light
r light
ON
OFF
4L
ON
ON
ON
Lock
ON
OFF
4H
ON
ON
OFF
Lock
Shifting from 4L to 4H can be performed only when the vehicle is stopped with the selector lever in the N
position. When the 4x4 switch is switched from 4L to 4H, the motor in the transfer operates and the reduction
shift fork slides to establish the 4H condition. At this time, the RFW unit remains locked and the 4x4 indicator
light remains illuminated, but the 4L indicator light turns off.
03-18-10
BRAKES
oUTLI NE . . . . . . . . . . . . . . . . .
04-00
ON-BOARD DIAGNOSTIC
[REAR ANTI LOCK BRAKE
SYSTEM (ABS)] .. . . . . . . .. 04-02A
ON-BOARD DIAGNOSTIC
[4-WHEEL ANTILOCK BRAKE
SYSTEM (4W-ABS)] ....... 04-02B
CONVENTIONAL
BRAKE SYSTEM .......... 04-11
PARKING BRAKE SYSTEM ... 04-12
ANTI LOCK BRAKE SYSTEM
SYSTEM (ABS)] ........... 04-13A
SYSTEM (4W-ABS)] ........ 04-13B
OUTLINE
04-00
BRAKE ABBREVIATIONS . .......... 04-00-1

BRAKE FEATURES ................ 04-00-1
BRAKE SPECIFICATIONS . .......... . 04-00-2
BRAKE ABBREVIATIONS
ABS
CM
HU
IDS
LF
LR
LSPV
PID
PDS
dcf04000000Ot01

Control Module
Hydraulic Unit
Integrated Diagnostic Software
Left Front
Left Rear
Load Sensing Proportioning Valve
Portable Diagnostic Software
RF
RR
Right Front
Right Rear
SW
4W-ABS
Switch
4-Wheel Antilock Brake System
4-wheel 2-d rive
4x2
4x4
4-wheel 4-drive
BRAKE FEATURES
dcf04000000Ot02
Improved safety
Improved braking force
Tandem diaphragm power brake unit adopted

Load sensing proportioning valve (LSPV) has been adopted
Large diameter front disc brakes adopted
Two-piston type front disc brake caliper adopted (Hi-Rider, 4x4)
Wide width lining for the rear brake drum adopted
Vacuum pump adopted
Automatic adjustment mechanism rear brake (drum) has been adopted
Size and weight reduction
4-wheel antilock brake system (4W-ABS) adopted

Rear antilock brake system (ABS) adopted
Integrated construction of the hydraulic unit (HU) and control module (CM) adopted for the ABS
HU/CM (4W-ABS)
04-00-1
OUTLINE
BRAKE SPECIFICATIONS
dcf04000000Ot03
Item
Specification
4x2 (except Hi-Rider)
Brake pedal
Master
cylinder
Front brake
(disc)
Hi-Rider, 4x4
Suspended design
Type
3.68
Pedal lever ratio

Max. stroke
(mm {in})
129 {5.08}
Type
Cylinder bore
(mm {in})
Tandem (with level sensor)

25.4 {1.00}
Type
Cylinder bore
(mm {in})
Ventilated disc
Pad dimensions (area x thickness)

(mm 2 x mm {in 2 x in})
Disc plate dimensions
(outer diameter x thickness)
60.5 {2.38}
42.86 {1.687} x 2
4,950 {7.673} x 10 {0.39}
5,500 {8.525} x 9 {0.35}
256 {10.1} x 24 {0.94}
289 {11.4} x 28 {1.1}
(mm {in})
Type
Wheel cylinder bore
Rear brake
(drum)
Parking brake
Type
Operation system
Brake fluid
Type
23.81 {0.9374}
55 {2.2} x 271 {1 O. 7} x 5.5 {0.22} 55 {2.2} x 296 {11.7} x 5.5 {0.22}
(mm {in})
(mm {in})
270 {10.6}
295 {11.6}
Automatic adjuster
Type
Outer diameter
Rear wheel
braking force Type
control device
04-00-2
(mm {in})
Lining dimensions
(width x length x thickness)
Drum inner diameter
Shoe clearance adjustment
Power brake
unit
Leading-trailing
(mm {in})
Vacuum multiplier
Tandem diaphragm
188.4 {7.417} + 215.2 {8.472}
Load sensing proportioning valve
Mechanical two-rear-wheel control
Stick lever type
SAE J 1703, FMVSS 116 DOT-3
ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK BRAKE SYSTEM (4W-ABS)]
04-02B ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK

BRAKE SYSTEM (4W-ABS)]
ON-BOARD DIAGNOSTIC SYSTEM
OUTLINE [4W-ABS] ............... 04-02B-1
FUNCTION [4W-ABS] . ............. 04-02B-2
PID/DATA MONITOR FUNCTION
[4W-ABS] . ....................... 04-02B-3

ACTIVE COMMAND MODES
FUNCTION [4W-ABS] .............. 04-02B-3
EXTERNAL TESTER COMMUNICATION
FUNCTION [4W-ABS] ............. . 04-02B-4
DLC-2 CONSTRUCTION [4W-ABS] .... 04-02B-5
ON-BOARD DIAGNOSTIC SYSTEM OUTLINE [4W-ABS]
dcf04024375Ot04
The on-board diagnostic system consists of a malfunction detection system that detects abnormalities in inpuV
output signals when the ignition switch is at the ON position, a data monitor function that reads out specified
inpuVoutput signals and a simulation function that allows for override operation of output parts (such as
solenoid valves).
The data link connector 2 (DLC-2), which groups together all the connectors used for malfunction diagnosis
and detecting/repair into a single location, has been adopted, thereby improving serviceability. Diagnosis is
performed by connecting the current diagnostic tool to the DLC-2.
In addition to DTC read-out, the current diagnostic tool is used to clear DTCs using the display screen of the
diagnostic tester, and to access the PID/data monitor and simulation functions, providing enhanced
malfunction diagnosis and improved serviceability.
Block Diagram
ABS
WARNING
LIGHT
ON-BOARD DIAGNOSTIC FUNCTION
,---------------- --------------
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I----~
I
I
- __I
MEMORY
FUNCTION - --I
I
I
1__ -
MALFUNCTION
DETECTION
FUNCTION
IFAIL-SAFE
~FUNcr_
INPUT
DEVICE
MALFUNCTION DISPLAY
~
FUNCTION
vi
_~
SERIAL
COMMUNICATION
PID/DATA
MONITOR
FUNCTION
ACTIVE COMMAND
MODES FUNCTION
DLC-2
HU
INSPECTION
FUNCTION
I
I
I
I
I
I
I
I
I
I
I
I
I
I
CURRENT
DIAGNOSTIC
TOOL
----\7----\7--tt---"
NORMAL CONTROL AREA
-V
OUTPUT
DEVICE
DCF402BTBOOl
04-028-1
ON-BOARD DIAGNOSTIC [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]

ON-BOARD DIAGNOSTIC SYSTEM FUNCTION [4W-ABS]
dcf04024375ot05
Malfunction Detection Function

The malfunction detection function detects malfunctions in the input/output signal system of the ASS HU/CM
when the engine switch is at the ON position.
When the ASS HU/CM are started up, Jhe following malfunction detections are performed.
The ASS warning light illuminate for approx. 3 s when the engine switch is turned to the ON position. At
the same time, the fail-safe relay is operated, and the input/output signals of each part is monitored for
malfunction diagnosis. After starting to drive, the first time the vehicle speed is approx. 12 km/h {7.5 mph}
or more the pump motor is operated and malfunction diagnosis is performed again.
When malfunctions are detected, the corresponding lights are illuminated to alert the driver. Using the external
tester communication function, DTCs can be output through the KLN of the OLC-2. At the same time,
malfunction detection results are sent to the memory and fail-safe functions.
[.. '
Memory Function
The memory function stores OTCs of malfunctions in input/output signal systems. With this function, once a
OIC is stored it is not cleared after the engine switch has been turned off (LOCK position), even if the
malfunctioning signal system has returned to normal.
Since the ASS HU/CM has a built-in non-volatile memory, OTCs are not cleared even if the battery is removed.
Therefore, it is necessary to clear the memory after performing repairs. Refer to the Workshop Manual for the
OTC clearing procedure.
Fail-safe Function
When the malfunction detection function determines a malfunction, each light illuminates to advise the driver.
At this time, the fail-safe function controls the ASS as shown in the fail-safe function table.
Fail-safe Function Malfunction Contents
Fail-safe function
Power supply system
DTC number
B1317
B1318
Warning light illumination status
Control status
ABS warning light
ABS control
IIluminated*1
Control disabled*2
B1342
Illuminated
Control disabled
B1484
Not illuminated
Control enabled
Pump motor, motor relay systems
C1095
C1096
Illuminated
Control disabled
ABS wheel-speed sensor system
C1155
C1165
Illuminated
Control disabled
Illuminated
Control disabled
Illuminated
Control disabled
Illuminated
Control disabled
Illuminated
Control disabled
ABS HUlCM system

Brake switch signal system
C1145
C1175
Fail-safe relay system
Solenoid valve system
C1186
C1194
C1198
C1202
C1206
C1210
C1214
ABS wheel-speed sensor (slip
monitor) system
ABS wheel-speed sensor/ABS
sensor rotor systems
C1222
C1233
C1234
C1235
C1236
Incorrect ABS HU/CM installed
C1414
Illuminated
Control disabled
G sensor system*3
C1730
C1949
IlIumhlated
Control disabled
C1950
If the ignition voltage returns to normal, the light goes out.
*1
*2
: If the ignition voltage returns to normal, control is enabled.
*3 :
Hi-Rider, 4x4
04-028-2
'7

ON-BOARD DIAGNOSTIC SYSTEM PID/DATA MONITOR FUNCTION [4W-ABS]
dcf040243750106
The PID/data monitor function is used for optionally selecting input/output signal monitor items preset in the
ASS HU/CM and reading them out in real-time.
PID/data monitor item
UniUCondition
(Tester display)
InpuUoutput part
ABS_LAMP
ABS_VOLT
ABS warning light
ACCLMTR*
G sensor
On/Off
V
Battery
BOO_ABS
Brake switch
CCNTABS
PMP_MOTOR
RLY_PMP
RLY_VLV
Number of continuous DTCs
G
On/Off
Pump motor
Pump motor relay
On/Off
On/Off
On/Off
Solenoid valve relay

LF inlet solenoid valve
V_LF_INL
V_LF_OTL
On/Off
LF outlet solenoid valve

RF inlet solenoid valve
V_RF_INL
V_RF_OTL
On/Off
On/Off
On/Off
RF outlet solenoid valve

Rear inlet solenoid valve
V_ReaUNL
V_Rear_OTL
On/Off
Rear outlet solenoid valve

ABS wheel-speed sensor (LF)
WSPD_LF
WSPD_LR
On/Off
KPH,MPH
KPH, MPH
ABS wheel-speed sensor (LR)

ABS wheel-speed sensor (RF)
WSPD_RF
WSPD_RR
KPH,MPH
KPH, MPH
ABS wheel-speed sensor (RR)
: Hi-Rider, 4x4
ON-BOARD DIAGNOSTIC SYSTEM ACTIVE COMMAND MODES FUNCTION [4W-ABS]
dcf04024375Ot07
The active command modes function is used for optionally selecting active command modes items of input/
output parts preset in the ASS HU/CM, and to operate them regardless of CM control.
To protect the hydraulic unit interior, operate output related parts for only 10 s or less when using the active
command modes function.
Active Command Modes Table
Command name
Output part name
PM P_MOTOR
V_LF_INL
Pump motor
V_LF_OTL
V_ReaUNL

V_ReacOTL
V_RF_INL
V_RF_OTL
Operation
Operation
condition
On/Off
Engine switch at
ON

04-028-3
ON-BOARD DIAGNOSTIC [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)] .

ON-BOARD DIAGNOSTIC SYSTEM EXTERNAL TESTER COMMUNICATION FUNCTION [4W-ABS]
dcf04024375ot08
The external tester communication function enables communication of diagnostic data (OTC read-outs, input!
output signal read-outs, and operation of input/output parts) between the ABS HU/CM and an external tester.
Connections and Communication Contents
External tester
Current diagnostic tool
On-board diagnostic
(malfunction detection)
function
PID/DATA monitor function
Active command modes
function
Connection
Communication method
Input/output: KLN
Serial communication
Input/output: KLN
Input/output: KLN
Serial communication (two-way communication) allows for multiple data to be sent and received instantly along
the same line.
By connecting the current diagnostic tool to the OLC-2, diagnostic data can be sent and received between the
current diagnostic tool and the ABS HU/CM using the KLN terminals (within the OLC-2).
The ABS HU/CM receives the command signals of the malfunction detection function, PID/data monitor
function, and the active command modes function from the current diagnostic tool, and sends OTCs and data
regarding the operating condition and status of each input/output part to the current diagnostic tool.
DBR402ZTB003
Diagnostic function name

Malfunction detection function
Signal received
OTC verification signal
PIO/data monitor function
Command signal to read selected

monitor item
Active command modes function
Operation command signal for selected

active command modes item
04-028-4
Signal sent
OTC
Monitored data for requested monitor
item
Input/output part name

DLC-2 CONSTRUCTION [4W-ABS]
dcf04024375Ot09
A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been
added .
Shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has
been adopted for this connector. The connector has a 16-pin construction that includes the KLN, GND1, GND2
and B+ terminals.
DLC-2
DBR402ZTB002
Terminal
KLN
GND1
GND2
B+
Function
Serial communication KLN terminal

Body ground terminal
Serial communication ground terminal
Battery power supply terminal
04-028-5
CONVENTIONAL BRAKE SYSTEM
04-11
CONVENTIONAL BRAKE
SYSTEM OUTLINE . ...............
CONVENTIONAL BRAKE
SYSTEM STRUCTURAL ViEW .......
MASTER CYLINDER
CONSTRUCTION . ................
POWER BRAKE UNIT
CONSTRUCTION . ................
VACUUM PUMP CONSTRUCTION ....
04-11-1
04-11-1
04-11-2
04-11-2
04-11-2
LOAD SENSING PROPORTIONING

VALVE (LSPV) CONSTRUCTION ..... 04-11-3
VALVE (LSPV) OPERATION . ....... . 04-11-4
FRONT BRAKE (DISC)
CONSTRUCTION . ................ . 04-11-6
REAR BRAKE (DRUM)
CONSTRUCTION . ................ . 04-11-7
REAR BRAKE (DRUM) OPERATION . . . 04-11-8
CONVENTIONAL BRAKE SYSTEM OUTLINE
dcf041100000t01
A tandem-type master cylinder has been adopted, improving braking force.

A large diameter, tandem diaphragm power brake unit has been adopted, improving braking force.
A large diameter, ventilated disc-type front brake has been adopted, improving braking force.
A two-piston type front disc brake caliper has been adopted, improving braking force. (Hi-Rider, 4x4)
A wide width lining for the rear brake drum has been adopted, improving braking force.
An Automatic adjustment mechanism rear brake (drum) has been adopted, improving serviceability
A vacuum pump has been adopted, improving braking force.
CONVENTIONAL BRAKE SYSTEM STRUCTURAL VIEW
dcf04110000Qt02
LOAD SENSING
PROPORTIONING VALVE (LSPV)
REAR BRAKE (DRUM)
VACUUM PUMP
DCF411ZTB001
04-11-1

MASTER CYLINDER CONSTRUCTION
dcf04114340Ot01
A tandem-type master cylinder with a 25.4 mm

{1.00 in} bore has been adopted, improving
braking force.
DBR411 ZTB002
POWER BRAKE UNIT CONSTRUCTION
dcf041143800to1
A tandem diaphragm type power brake unit has

been adopted for all models, achieving
compatibility between high braking performance
and excellent brake feeling.
DBR411 ZTB003
VACUUM PUMP CONSTRUCTION
dcf041118777to1
A gear-driven vacuum pump has been adopted,

improving braking force.
DBR411ZTB014
04-11-2

LOAD SENSING PROPORTIONING VALVE (LSPV) CONSTRUCTION
dcf041143903t01
This valves is to proportion the braking force to the front and rear wheels as ideally as possible for higher safety
at the time of the brakes being applied, it controls the brake fluid pressure to the rear brakes according to the
load on the rear axle so that the rear end of the vehicle may not spin due to locking of the rear wheels in
advance of the fronts.
This valve also incorporates a bypass passage that prevents pressure reduction so that rear wheels will still
have plenty of braking force to stop the vehicle in the event of a front master cylinder malfunction.
RETAINER
RING VALVE
AXLE CASING
DBR411 ZTBOOB
04-11-3

LOAD SENSING PROPORTIONING VALVE (LSPV) OPERATION
dcf041143903t02
Braking When Vehicle Empty

The hydraulic pressure generated at the rear section of the master cylinder is applied, via input port 1, to the
hydraulic-pressure control section of the LSPV.
The hydraulic pressure generated at the front section of the master cylinder is applied to the front brakes, and
to the bypass section of the LSPV via input port 2. The rear wheel and front wheel hydraulic pressure are
separated by the X-ring of the plunger. Since port 1 hydraulic pressure is normally equal to port 2 hydraulic
pressure, the plunger is pressed against the cylinder base by L.
When port 1 hydraulic pressure is applied to the plunger, the plunger tries to move to the left. But, because
there is also at the same time force applied in the right direction by the lever link (force L), the plunger is held
against the cylinder base. The result is that the hydraulic pressure at the output side is the same as at the input
side when force L is higher than the input pressure.
PRESSURE IN
(REAR)
PORT-1
PRESSURE OUT
PRESSURE IN
(FRONT)
PORT-2
a:
;:)
en
en
a:
0...
I-
;:)
0...
I;:)
~~.
~~~
INPUT PRESSURE
PLUNGER
RING VALVE
DBR411ZTB009
When the input hydraulic pressure increases further and overcomes force L, the plunger is moved slightly
leftward, sealing it against the ring valve. This temporarily separates the input side from the output side. The
output pressure at this time is called the break point. If force L from the lever link changes (i.e. lowering of the
vehicle body), this break point changes accordingly.
PRESSURE IN
(REAR)
PORT-1
PRESSURE OUT
PORT-2
PRESSURE IN
(FRONT)
~t
a:
0...
I;:)
0...
I-
;:)
INPUT PRESSURE
PLUNGER
RING VALVE
DBR411 ZTB01 0
04-11-4

When the input pressure passes the break point, the plunger is moved back against the cylinder base. The
output port is opened, and hydraulic pressure generated at the rear section of the master cylinder is applied to
the rear wheel cylinders.
As the output pressure continues to increase, the plunger is again moved toward the left against the ring valve,
thus separating the input and output side again.
This action is repeated to control the output pressure.
PRESSURE IN
(REAR)
PRESSURE OUT
PRESSURE IN
(FRONT)
UJ
~t
a::
0..
I::J
0..
I-
::J
kP
INPUT PRESSURE
DBR411ZTB011
Braking When Vehicle Loaded

The vehicle height (from the ground) decreases when cargo is loaded into the vehicle. This causes the force of
the spring connected to the axle casing to decrease and the force of the spring on the LSPV to increase force
L, increasing the pressure holding the plunger to the right.
The master cylinder hydraulic pressure (input) needed to cause the plunger to move back to the left also
becomes equally higher as a result.
This causes the break point to be increased and extra barking power is provided in accordance with the weight
of cargo loaded.
PRESSURE IN
(REAR)
PRESSURE OUT
PRESSURE IN
(FRONT)
~
UJ
--------
~t
LOADED
a::
0..
I::J
0..
I-
::J
INPUT PRESSURE
DBR411ZTB012
04-11-5
II
1:./

If Malfunction Of Front Hydraulic System
If there is a malfunction of the front-brake hydraulic system, the hydraulic pressure from input port 2 becomes
zero. The result is that the input pressure presses the plunger to the right, opening the bypass passage.
The output pressure thus equals the input pressure, and there is so pressure reduction.
PRESSURE IN
(REAR)
PRESSURE OUT
PRESSURE IN
(FRONT)
X
PORT-2
w
~1
a:
0..
I:J
0..
I:J
PLUNGER
INPUT PRESSURE
DBR411ZTB013
FRONT BRAKE (DISC) CONSTRUCTION
dcf04113398Ot01
4x2 (Except Hi-Rider)

Large diameter, ventilated disc type front brakes with a 256 mm {10.1 in} diameter and 24 mm {0.94 in}
thickness have been adopted, improving braking force and fade resistance.
,-------------------------------------,
DBR411 ZTB004
Hi-Rider, 4x4
Two-piston type front disc brake caliper has been adopted, improving braking force.
Large diameter, ventilated disc type front brakes with a 289 mm {11.4 in} diameter and 28 mm {1.1 in}
thickness have been adopted, improving braking force and fade resistance.
DBR411ZTB005
04-11-6

REAR BRAKE (DRUM) CONSTRUCTION
dcf04112625ot01
A leading/trailing type rear drum brake, with a 270 mm {10.6 in} (4x2 (except Hi-Rider)) or 295 mm {11.6 in}
(Hi-Rider, 4x4) drum inner diameter and 23.81 mm {0.937 in} wheel cylinder inner diameter, has been
adopted, improving braking force and fade resistance.
Braking stability is ensured by use of 55 mm {2.16 in} width linings.
If has an incremental automatic adjustment mechanism of shoe clearance to improve serviceability.
BACKING PLATE
SHOE HOLD PIN
OPERATING LEVER
BRAKE SHOE
BRAKE DRUM
REAR PARKING
BRAKE CABLE
PAWL LEVER
DBR411 ZTB006
04-11-7

REAR BRAKE (DRUM) OPERATION
dcf041126250t02
Automatic Adjustment Mechanism

This brake is equipped with an auto adjust mechanism, which automatically adjusts shoe clearance when the
brake pedal is depressed.The auto adjust mechanism is composed of an adjust strut and pawl lever.
B
DBR411 ZTB007
When there is large clearance

The end of the adjust strut receives the rotation force against the pawl lever caused by the spring which has pin
A as its fulcrum.When the brake pedal is depressed, the pawl lever moves in the direction of the arrow with pin
A as the fulcrum, because the length of the adjust strut does not change in response to the increase in shoe
space.
The gear rotates because the end B of the pawl lever is engaged with the gear of the adjust strut. Because the
gears and the body are engaged by the bolt and nut, the total length of the adjust strut increases when the gear
rotates in the direction indicated in the figure. When there is a large clearance, the gear rotates one notch each
time the braRe pedal is depressed.
When clearance is proper

When the clearance is proper, clearance is maintained because the shoe does not stroke (the pawl lever does
not tilt) enough at rotate the gear one notch, even when the brake pedal is depressed.
04-11-8
PARKING BRAKE SYSTEM
04-12
PARKING BRAKE SYSTEM OUTLINE .. 04-12-1

STRUCTURAL ViEW ............... 04-12-1
PARKING BRAKE SYSTEM OUTLINE
dcf041200000to1
A stick lever type parking brake has been adopted, improving operability.
PARKING BRAKE SYSTEM STRUCTURAL VIEW
dcf04120000Ot02
WL-3
PARKING BRAKE
SWITCH
PARKING BRAKE
LEVER
FRONT PARKING BRAKE CABLE

WL-C (EXCEPT Hi-Rider)
PARKING BRAKE
LEVER
PARKING BRAKE
SWITCH

WL-C (Hi-Rider),WE-C
PARKING BRAKE
SWITCH
PARKING BRAKE
LEVER
REAR PARKING
BRAKE CABLE
DCF412ZTB001
04-12-1
ANTILOCK BRAKE SYSTEM [4-WHEEL ANTILOCK BRAKE SYSTEM (4W-ABS)]
04-13B ANTI LOCK BRAKE SYSTEM [4-WHEEL ANTILOCK

ABS OUTLINE [4W-ABS] . ...........
ABS STRUCTURAL VIEW [4W-ABS] ..
ABS SYSTEM WIRING DIAGRAM
[4W-ABS] .......................
ABS HUlCM CONSTRUCTION
[4W-ABS] . .......................
ABS HU PART FUNCTION [4W-ABS] ..
ABS HU PART CONSTRUCTION/
OPERATION [4W-ABS] . ............
ABS CM PART FUNCTION [4W-ABS] ..
ABS CONTROL OUTLINE [4W-ABS] .. .
04-13B-1
04-13B-1
04-13B-2
04-13B-2
04-13B-3
04-13B-3
04-13B-5
04-13B-5
ABS CONTROL OPERATION

[4W-ABS] ....................... . 04-13B-6
ABS WHEEL-SPEED SENSOR AND
ABS SENSOR ROTOR FUNCTION
[4W-ABS] ....................... . 04-13B-6
ABS SENSOR ROTOR
[4W-ABS] ....................... . 04-13B-6
G SENSOR FUNCTION [4W-ABS] .... . 04-13B-7
G SENSOR CONSTRUCTION/
OPERATION [4W-ABS] ............ . 04-13B-7
ABS OUTLINE [4W-ABS]
dcf04130000Ot04
The ASS HU/CM, integrating both the hydraulic unit (HU) and control module (CM), has been adopted,
resulting in size and weight reduction.
Select-low controlled-4-wheel anti-lock brake system with 4-sensor and 3-channel has been adopted, and has
the following features.
The integrated ASS Hydraulic UniVControl Module (HU/CM) system is compact, lightweight and highly
reliable.
Combined use of the current diagnostic tool and the ASS HU/CM allows the following functions to improve
serviceability:
4-digit DTC display
PID/DATA monitor function
Active command modes function
ABS STRUCTURAL VIEW [4W-ABS]
dcf04130000Ot05
INSTRUMENT CLUSTER
FRONT ABS WHEEL-SPEED

SENSOR
DCF413BTB001
04-138-1
,

ABS SYSTEM WIRING DIAGRAM [4W-ABS]
dcf04130000Ot06
ABS/SOL20A
------------------------,
Hi-Rider, 4x4
:
I
I
1-----------HniG SENSOR
ABS40A
I
I
:
I
1__ I
________________________ ~I
I
ENGINE SW ENGINE 15A
BRAKE SWITCH
BATTERY
ABSWARNING
LIGHT
~~~---or------------rS
~~N~~~~~~~
BRAKE
LIGHT
ABS HU/CM
Q1----------[]
INSTRUMENT CLUSTER
ABSWHEELSPEED SENSOR
D
DCF413BWB001
ABS HUlCM CONSTRUCTION [4W-ABS]
del 04 1343150[08
A high reliability, reduced size and weight ASS

HU/CM, integrating both the ASS HU and ASS
CM, has been adopted.
DBR413ZTB002
04-138-2

ABS HU PART FUNCTION [4W-ABS]
dcf04134375Ot09
The ABS HU adjusts the fluid pressure to the caliper pistons by controlling (on/off) each solenoid valve and
pump motor according to signals from the ABS CM.
ABS HU PART CONSTRUCTION/OPERATION [4W-ABS]
dcf04134375Ot10
Construction
The integrated ABS HU/CM system controls the ABS. The ABS are an independent front wheel control, rear
axle control, 4-sensor, 3-channel system.
Function of main component Parts
Function
Part name
The solenoid valves control the fluid pressure at individual brake calipers (wheel
cylinders) in accordance with the signal received from the ABS CM.
There are six solenoid valves in total and two solenoid valves in each wheel
(one for retaining pressure and one for reducing pressure) are used. There are
four valves for the front wheel, and the left and right wheels are controlled
separately. There are two valves used to control the rear wheels simultaneously.
Inlet solenoid valve, outlet solenoid valve
Reservoir
The reservoirs temporarily store the hydraulic pressure which flows from the
brake caliper (wheel cylinder) through the outlet solenoid valve during pressure
reduction.
Pump
Pump motor
The pump returns brake fluid from the reservoir to the master cylinder.
Operates the pump according to ABS CM signals.
Hydraulic circuit diagram

MASTER CYLINDER
)(
INLET
SOLENOI
VALVE
CHECK VALVE
OUTLET
SOLENOID
VALVE
BRAKE
CALIPER
RESERVOIR
RESERVOIR
WHEEL
CYLINDER
DBR413ZTB003
04-138-3

Operating
The ASS HU/CM detects wheel-speed and driving condition based on the ASS wheel-speed sensors, and
outputs on/off electronic signals to the inlet solenoid valves and outlet solenoid valves to control the ASS
control.
The ASS HUlCM controls ASS by calculating wheel slip from ASS wheel-speed sensor signals, and adjusting
the brake pressure.
Normal brake
Pressure reduction
Pressure retention
Pressure increase
Solenoid valve (Inlet)

Off (open)
On (close)
On (close)
Off (open)
Pump motor, pump

Stopped
Operating
Stopped
Stopped
Solenoid valve (Outlet)

Off (close)
On (open)
Off (close)
Off (close)
NORMAL BRAKE AND PRESSURE INCREASE

MASTER
CYLINDER "'-r-'-..l....fll
OUTLET SOLENOID
VALVE
RESERVOIR
PRESSURE RETENTION
PRESSURE REDUCTION
l'
ON
(CLOSE;
ON
1 (OPE~
)(
DBR413ZTB004
04-138-4
ANTI LOCK BRAKE SYSTEM [4-WHEEL ANTILOCK BRAKE SYSTEM (4W-ABS)]

ABS CM PART FUNCTION [4W-ABS]
dcf04134375ot11
The ABS eM detects the vehicle wheel speeds based on the signals from the four ABS wheel- speed sensors.
The eM calculates the rotation condition of each wheel from the relation between the detected vehicle wheel
speed and the estimated (based on the detected speed) vehicle speed from there on. It then accordingly
controls brake fluid pressure to each wheel to prevent lock-up.
Function Table
Function name
Contents
ABS control function
Controls brake fluid pressure when braking to maintain directional

stability, ensure steerability and reduce stopping distance.
On-board diagnostic system
Main components of the ABS control system have a self-diagnosis

function. In case a malfunction occurs, warning lights illuminate to alert
the driver, and at the same time a DTC is stored in the ABS HU/CM.
When a malfunction is determined as a result of on-board diagnosis,
system control is suspended or limited to prevent any dangerous
situation while driving.
ABS CONTROL OUTLINE [4W-ABS]
dcf041343750t12
ABS control occurs when wheel slip is determined by the ABS eM (based on the four ABS wheel-speed
sensors). Then, the ABS HU inlet and outlet solenoid valves are operated and brake fluid pressure is controlled
accordingly to prevent wheel lock-up.
Use of ABS control during emergency braking or on slippery road surfaces allows directional stability to be
maintained, steerability ensured and stopping distance to be reduced.
The ABS control system has independent front wheel control and unified control (select low) for the rear
wheels.
Note
Select low control: A control system in which the left and right vehicle wheel speeds are compared and
brake fluid pressure is controlled according to the wheel most likely to lock-up.
Block Diagram
ASS HU/CM
LF ASS WHEEL-SPEED
SENSOR
RF ASS WHEEL-SPEED
SENSOR
LR ASS WHEEL-SPEED
SENSOR
RR ASS WHEEL-SPEED
SENSOR
CM
I
I
CPU
I
I
iI
HU
I
I
I
I
I
I
I
I
LF CALIPER PISTON
SOLENOID
VALVE
RF CALIPER PISTON
iI
PUMP
MOTOR
I
I
I
I
I
I
I
I
LR WHEEL CYLINDER
RR WHEEL CYLINDER
I
DCF413ZTB012
04-138-5
1!II,:,j
IiII

ABS CONTROL OPERATION [4W-ABS]
dcf04134375Ot13
When the ASS CM determines wheel slip conditions based on the signals from the ASS wheel-speed sensors
during braking, the ASS CM operates the ASS HU inlet and outlet solenoid valves, reducing and maintaining
brake fluid pressure in accordance with the wheel slip factors. Then, when the wheel slip condition has passed,
brake fluid pressure is increased and maintained, ensuring braking with a constantly stable brake force.
Operating Condition Transition Diagram
HIGH
SPEED
ESTIMATED VEHICLE SPEED
WHE~~~:~: _______ ~__
TIME
SOLENOID VALVE CONTROL

PRESSURE REDUCTION
PRESSURE MAINTAINED
PRESSURE INCREASE
HIGH
BRAKE FLUID
PRESSURE
TIME
DBR413ZTB012
ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR FUNCTION [4W-ABS]
dcf04134372Ot03
The ASS wheel-speed sensor, which has a magnetic pick-up, transmits the rotation condition of each wheel to
the ASS HU/CM.
ABS WHEEL-SPEED SENSOR AND ABS SENSOR ROTOR CONSTRUCTION/OPERATION [4W-ABS]
dcf04134372Ot04
Construction
The front ASS wheel-speed sensor is installed on the steering knuckle and the front ASS sensor rotor is
integrated with the front wheel hub (4x2 except Hi-Rider) or drive shaft (Hi-Rider, 4x4).
The rear ASS wheel-speed sensor is installed on the hub spindle and the rear ASS sensor rotor is integrated
with the rear axle shaft.
ABS WHEEL-SPEED SENSOR
ABS SENSOR ROTOR

POLE PIECE
DBR413ZTB010
04-138-6

Operation
As the ABS sensor rotor rotates, magnetic flux
formed from the permanent magnet varies and
alternating current is formed with an
electromagnetic conductor. Using this alternating
current, rotation speed is expressed as a varying
proportional cycle and from detection of this cycle
the CM part of the ABS HU/CM can then detect
the wheel rotation speed. While the structures of
the front and rear ABS wheel-speed sensor differ,
the operation is the same.
OUTPUT VOLTAGE WAVEFORM

HIGH SPEED
LOW SPEED
DBR413ZTB011
G SENSOR FUNCTION [4W-ABS]
dcf041343770t01
Note
Because the Hi-Rider vehicle is based on the 4x4 vehicle, the 4x4 vehicle ABS system has been adopted.
Therefore, the G-sensor, which is generally installed to 4x4 vehicles only, is installed to the Hi-Rider.
Because the 4x4 vehicle ABS system has been adopted on the Hi-Rider, the ABS is controlled in the
same way as the 4x4 vehicle.
In the Hi-Rider and 4x4 vehicle, the G sensor detects and calculates the vehicle G force (acceleration and
deceleration G force), and outputs the change in voltage to the ABS HUiCM.
G SENSOR CONSTRUCTION/OPERATION [4W-ABS]
dcf04134377ot02
The G sensor is installed under the RH front seat and detects vehicle movement during a brake lockup event
that is transferred to other wheels through the powertrain, and transmits the signal to the ABS HU/CM.
The drive train of 4x4 vehicles delivers driving force to all four wheels, and due to this interlocking, the speed of
all wheels during braking is the same. When driving on road surfaces with especially low m (friction coefficient),
it is difficult to estimate the vehicle speed based on the wheel speed, and ABS braking becomes unreliable.
(For 4x2 vehicles, the front and rear wheels are independent, so it is possible to accurately estimate the vehicle
speed by measuring the difference between the rotation speeds of the front and rear tires.) A G sensor is
installed to overcome this situation. When braking, the change in G-force is detected, and the road surface m is
judged (low m, high m), enabling a correction of the vehicle speed estimation.
The output characteristics are based on 2.5 V with the vehicle in a stopped or driven with constant speed, and
the subsequent fluctuation is depending on the situation whereby the G force occurs.
OUTPUT VOLTAGE
CHARACTERISTIC
EXTERNAL VIEW
(V)
VEHICLE
FORWARD
2.5
-1.5
+1.5
(G)
DECELERATION
DBR413ZTB006
04-138-7
.,
III
1:4
TRANSMISSION! I RANSAXLE
OUTLINE ................. OS-OO
CLUTCH .................. OS-10
MANUAL TRANSMISSION
[R1SM-D] ................ OS-11 A
MANUAL TRANSMISSION
[S1SM-D, S1SMX-D] ........ OS-11 B
OUTLINE
05-00
TRANSMISSIONfTRANSAXLE
ABBREVIATIONS ................. 05-00-1
FEATURES ....................... 05-00-1
SPECIFICATIONS ............ 05-00-1
TRANSMISSIONfTRANSAXLE ABBREVIATIONS
dcf05000000Dt01
Manual Transmission
MT
1GR
2GR
First Gear
Second Gear
5GR
Fifth Gear
TRANSMISSIONfTRANSAXLE FEATURES
CLUTCH
Reduced noise and
vibration
Improved durability
Improved startability
MT [R15M-D]
Mis-shift prevention
dcf05000000Dt02
Dual-mass flywheel adopted. (S15M-D, S15MX-D)
Clutch cover with wear assurance function adopted.

One-way valve that fits inside a clutch master cylinder adopted.
A double cone synchronizer mechanism has been adopted for 2nd gear.
A double engagement prevention mechanism (interlock mechanism) has been adopted.
A stopper pin-type reverse lock-out mechanism has been adopted.
MT [S15M-D, S15MX-D]
A linked, triple cone synchronizer mechanism has been adopted for 1st and 2nd gears.
A double engagement prevention mechanism (interlock mechanism) has been adopted.
Mis-shift prevention
A cam-type reverse lock-out mechanism has been adopted.
TRANSMISSIONfTRANSAXLE SPECIFICATIONS
dcf050000000t03
Clutch
Item
Specifications
Manual transmission type
R15M-D
Clutch control
Clutch cover
Clutch disc
Clutch pedal
Spring type
Set load
Outer diameter
(N {kgf, Ibf})
(mm {in})
Inner diameter
(mm {in})
Diaphragm
5,290 {539, 1, 189}
10,100 {1 ,030, 2,271}
250 {9.84}
240 {9A5}
160 {6.30}
155 {6.10}
Suspended
Type
Pedal ratio
Full stroke
Clutch master cylinder inner diameter
S15M-D, S15MX-D
Hydraulic
6.0
(mm {in})
(mm {in})
5.2
152 {5.984}
15.87 {0.6248}
05-00-1
OUTLINE
Item
Specifications
R15M-D
S15M-D, S15MX-D
Manual transmission type

Clutch release cylinder inner diameter
(mm {in})
Clutch fluid type
19.05 {0.7500}
I
I
22.23 {0.8752}
SAE J1703, FMVSS 116 00T-3
Manual Transmission [R15M-D]

Item
Specifications
R15M-D
Transmission type
Transmission control
Floor-shift
Shift assist
Gear ratio
Synchromesh
1GR
4.250
2GR
3GR
2.356
1.428
4GR
1.000
5GR
Reverse
0.827
3.656
Grade
Oil
Viscosity
IAll season
IAbove 10C {50F}
Capacity
(approx. quantity)
(L {US qt, Imp qt})
API service GL-4 or GL-5

SAE 75W-90
SAE 80W-90
2.8 {3.0, 2.5}
Manual Transmission [S15M-D, S15MX-D]

Item
Transmission type
Specifications
S15M-D, S15MX-D
Floor-shift
Shift assist
Gear ratio
1GR
Synchromesh
3.905
2GR
2.248
3GR
4GR
1.491
1.000
5GR
0.800
3.391
Mercon Multi-purpose AFT XT-2-QOX
Reverse
Oil
05-00-2
Type
Capacity
(approx. quantity)
(L {US qt, Imp qt})
3.55 {3.75, 3.12}
TRANSMISSION/I RANSAXLE
o UTLI NE . . . . . . . . . . . . . . . . . OS-OO
ON-BOARD
DIAGNOSTIC[SRSSS] ...... OS-02
05-00
AUTOMATIC TRANSMISSION
[SRSSS] .................. OS-13
SHIFT MECHANISM ........ OS-14
OUTLINE
TRANSMISSIONrrRANSAXLE
FEATURES [5R55S] ............... 05-00-1
TRANSMISSIONrrRANSAXLE
SPECIFICATIONS [5R55S] ......... . 05-00-1
TRANSMISSIONrrRANSAXLE FEATURES [5R55S]

Improved marketability
Superior shift quality
id050000100211
Five-speed 5R55S automatic transmission has been adopted.

A water-cooling type and an air-cooling type AT oil cooler has been adopted
Adaptive learn strategy system has been adopted
Engine-transaxle total control system has been adopted
TRANSMISSIONrrRANSAXLE SPECIFICATIONS [5R55S]

Item
Specification
Transmission type
5R55S
Floor-shift
3.22
2.29
1GR
2GR
Gear ratio
id050000100611
3GR
1.55
4GR
1.00
0.71
3.07
5GR
Reverse
ATF
Type
Capacity
(approx. quantity)
Hydraulic
system(Number of
drive/driven gear
plates)
Forward clutch
5/5
Coast clutch
2/2
Direct clutch
5/5
MerconV
(L {US qt, Imp qt})
9.93 {10.49, 8.74}
05-00-3
ON-BOARD DIAGNOSTIC [5R55S]
05-02
ON-BOARD DIAGNOSTIC (OBD)

SYSTEM OUTLINE [5R55S] . ........
ON-BOARD DIAGNOSTIC (OBD)
SYSTEM BLOCK DIAGRAM
[5R55S] . . . . . . . . . . . . . . . . . . . . . . . . .
MALFUNCTION DETECTION
FUNCTION [5R55S] ...............
MEMORY FUNCTION [5R55S] ........
05-02-1
05-02-1
05-02-2
05-02-3
MALFUNCTION INDICATION
FUNCTION [5R55S] ............... . 05-02-3
FAIL-SAFE FUNCTION [5R55S] ...... . 05-02-3
PARAMETER IDENTIFICATION (PID)
DATA MONITORING FUNCTION
[5R55S] . ......................... 05-02-4
SIMULATION FUNCTION [5R55S] ..... 05-02-4
DLC-2 OUTLINE [5R55S] . ........... . 05-02-5
ON-BOARD DIAGNOSTIC (OBD) SYSTEM OUTLINE [5R55S]
id0502c11 001 00
The OBD system has the following functions:

Malfunction detection function: Detects malfunctions of the input/output devices and system components of
the AT.
Fail-safe function: Fixes the output device function and input value of the sensors/switches to ensure
minimum vehicle driveability when a malfunction is detected.
Memory function: Stores the DTC when a malfunction is detected.
PID data monitored function: Monitors the input/output signal and calculated value of the TCM, and sends
the monitoring data to the IDS/PDS.
Simulation function: Allows override operation of simulation items for input/output system parts preset in the
TCM.
ON-BOARD DIAGNOSTIC (OBD) SYSTEM BLOCK DIAGRAM [5R55S]
id0502c1100200
TCM
INSTRUMENT CLUSTER
OBD SYSTEM
--------------------------------------1
1
MALFUNCTION
INDICATION FUNCTION
I-~
OlD OFF
INDICATOR LIGHT
I
H--I
CAN
PCM
1
1
1
1
MEMORY _I
FUNCTION
-I
l_~
SERIAL COMMUNICATION
r---
CAN
MIL
!=
CAN
IIDS/PDS
PID DATA
MONITORING
FUNCTION
MALFUNCTION
DETECTION
FUNCTION
L;"~
FAIL-SAFE
FUNCTION
---V--PCM
CA~
~~
-----
-------- -
TRANSMISSION CONTROL SYSTEM

INPUT
PARTS
r-r--
SIMULATION
FUNCTION
-----
-V
OUTPUT
PARTS
arnffn00000333
05-02-1

MALFUNCTION DETECTION FUNCTION [SRSSS]
id0502c1100300
Malfunction Detection Function

In the malfunction detection function, the TCM detects malfunctions in the automatic transmission while driving.
When vehicle driving conditions correspond with a preset malfunction detection condition, the TCM determines
that the automatic transmission has a malfunction and stores the corresponding DTC.
When a malfunction is detected, stored DTCs can be retrieved using the IDS/PDS connected to the DLC-2.
DTC Table
DTC No.
P0657
P0658
P0705
P0708
P0711
P0712
P0713
P0715
P0717
P0718
P0720
P0721
P0722
P0731
P0732
P0733
P0734
P0735
P0740
P0741
P0742
P0743
P0744
P0745
P0748
P0750
P0753
P0755
P0757
P0758
P0760
P0762
P0763
P0765
P0768
P0775
P0778
P0791
P0794
P0795
P0798
P0960
P0962
P0963
P0964
P0966
P0967
05-02-2
Condition
Solenoid valve power supply circuit open
Solenoid valve power supply circuit voltage low
Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
Turbine shaft speed (TSS) sensor malfunction
Turbine shaft speed (TSS) sensor signal is not input
Turbine shaft speed (TSS) sensor signal noise
Output shaft speed (OSS) sensor malfunction
Output shaft speed (OSS) sensor signal noise
Output shaft speed (OSS) sensor signal is not input
Gear 1 incorrect
Gear 2 incorrect
Gear 3 incorrect
Gear 4 incorrect
Gear 5 incorrect
Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
Pressure control solenoid A malfunction (low pressure)
Pressure control solenoid A circuit malfunction (non-operati0n)
Shift solenoid A circuit malfunction (open or short circuit)
Shift solenoid B circuit malfunction (open or short circuit)
Shift solenoid B malfunction (stuck on)
Shift solenoid C circuit malfunction (open or short circuit)
Shift solenoid C malfunction (stuck on)
Shift solenoid D circuit malfunction (open or short circuit)
Shift solenoid D circuit malfunction (open or short circuit)
Pressure control solenoid B malfunction (low pressure)
Pressure control solenoid B circuit malfunction (non-operation)
Intermediate shaft speed (ISS) sensor malfunction
Intermediate shaft speed (ISS) sensor signal noise
Pressure control solenoid C malfunction (low pressure)
Pressure control solenoid C circuit malfunction (non-operation)
Pressure control solenoid A circuit malfunction (open circuit)
Pressure control solenoid A circuit malfunction (short to ground)
Pressure control solenoid A circuit malfunction (short to power supply)
Pressure control solenoid B circuit malfunction (open circuit)
Pressure control solenoid B circuit malfunction (short to ground)
Pressure control solenoid B circuit malfunction (short to power supply)
ON-BOARD DIAGNOSTIC [SRSSS]

OTC No.
P0968
P0970
P0971
Condition
Pressure control solenoid C circuit malfunction (open circuit)
Pressure control solenoid C circuit malfunction (short to ground)
Pressure control solenoid C circuit malfunction (short to power supply)
P1635
P1700
Tire/axle ratio out of acceptable range

Transmission indeterminate malfunction
P1702
Digital transmission range (TR) sensor circuit intermittent

Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
P1704
P1705
P1711
P1780
P1783
U0100
U0294
Digital transmission range (TR) sensor circuit not indicating P or N position during on-board diagnostic
ATF temperature out of on-board diagnostic range
0/0 OFF switch circuit malfunction (open or short circuit)

ATF overheating
Communication error to PCM
MEMORY FUNCTION [SRSSS]
id0502c11 00400
The memory function stores malfunction information detected in the malfunction detection function. Once
malfunction information is stored, the memory will not be cleared even when the engine switch is turned off
(LOCK position) or the malfunction is repaired.
The stored memory (malfunction information) can be cleared using the IDS/PDS, or by disconnecting the
negative battery cable.
MALFUNCTION INDICATION FUNCTION [SRSSS]
id0502c11 00500
The malfunction indication function illuminates the MIL or flashing the OlD OFF indicator light when the
malfunction detection function determines that there is a malfunction.
FAIL-SAFE FUNCTION [SRSSS]
id0502c11 00600
In the fail-safe function, minimum vehicle driveability is obtained by changing the signals that are determined to
be irregular by the malfunction detection function to the preset values, and limiting TCM control.
05-02-3
,

PARAMETER IDENTIFICATION (PID) DATA MONITORING FUNCTION [SRSSS]
id0502c11 00700
The PID mode allows access to certain data values, analog and digital input and output, calculations and
system state information.
PID/DATA MONITOR AND RECORD function table
Monitor item
BPP
FIRM_ST
Unit!
Condition
on/off
0/1
1/2/3/4/5
1/2/3/4/5
Definition
Brake switch
Firm shaft control (FSC) status requested
GEAR
GEAR_OSC
Calculated gear range in TCM
ISS
ass
ISS sensor
ass sensor
rpm
PCA
Pressure control solenoid A
rpm
pis
PCB
PCC
Pressure control solenoid B
PID used to command gear changes during Simulation Function
TCM terminal
N/A
N/A
N/A
N/A
AM,AS
AD,AG
I,CK
pis
pis
M,CK
Engine speed
Shift solenoid A
rpm
on/off
N/A
B,CK
Shift solenoid B
Shift solenoid C
on/off
on/off
C,CK
F, CK
SSD
Shift solenoid 0
on/off
D,CK
TCC
TCCRAT
TCC control solenoid

Torque converter speed ratio
TFT
TR_D
TR_V
ATF temperature
A,CK
N/A
AY, BH
RPM
SSA
SSB
SSC
TR1
TR2
TR3A
TR4
TSS
VSS
Pressure control solenoid C
ratio
c, OF
Digital TR sensor signal

Digital TR sensor signal voltage
TR1 switch
V
0/1
TR2 switch
TR3 switch
TR4 switch
TSS sensor
Vehicle speed
AX, BU, BY, CA

AX, BU, BY, CA
BY
0/1
0/1
BU
AX
0/1
CA
AH,AP
AD,AG
rpm
mph
SIMULATION FUNCTION [SRSSS]
J, CK
id0502c11 00800
By using the IDS/PDS, simulation items for input/output parts preset in the TCM can be optionally selected and
operated regardless of TCM control conditions.
Simulation item table
PCA
Simulation item
PCB
PCC
SSA

Shift solenoid A
SSB
Shift solenoid B
Unit
pis
pis
pis
on/off
on/off
SSC
SSD
Shift solenoid C
Shift solenoid 0
on/off
on/off
TCC
05-02-4
0/0
TCM terminal
I,CK
J, CK
M,CK
B, CK
C,CK
F, CK
D,CK
A,CK

DLC-2 OUTLINE [5R55S]
id0502c11 00900
A connector (DLC-2) conforming to International Organization for Standardization (ISO) standards has been
adopted .
The shape and terminal arrangement as stipulated by the ISO 15031-3 (SAE J1962) international standard has
been adopted for this connector. The connector has a 16-pin construction that includes the B+, CAN_H,
CAN_L, GND1, GND2 and KLN terminals.
DLC-2
atraan00000380
Terminal
B+
CAN_L
CAN_H
GND1
GND2
KLN
Function
Battery power supply terminal
Serial communication terminal (Lo)
Serial communication terminal (Hi)
Body ground terminal
Serial communication ground terminal
Serial communication terminal (Malfunction diagnosis use)
05-02-5
CLUTCH
05-10
CLUTCH
CLUTCH STRUCTURAL ViEW ........ 05-10-1

CLUTCH MASTER CYLINDER
CONSTRUCTION ................. 05-10-2
CLUTCH RELEASE CYLINDER
construction . .................... 05-10-2
CLUTCH COVER OUTLINE

[S15M-D, S15MX-D] . .............. . 05-10-2
DUAL-MASS FLYWHEEL FUNCTION
[S15M-D, S15MX-D] ............... . 05-10-3
CLUTCH STRUCTURAL VIEW
dcf051 000000102
FLYWHEEL [R15M-D]
DUAL-MASS FLYWHEEL [S15M-D, S15MX-D]
CLUTCH PEDAL
CLUTCH DISC
CLUTCH COVER
RELEASE CYLINDER
DCG510ZTB001
,05-10-1
CLUTCH
CLUTCH MASTER CYLINDER CONSTRUCTION
dcf05100000Dt03
A clutch master cylinder with a built-in one-way valve has been adopted preventing sudden clutch engagement
and ensuring smooth startability.
Vehicles without clutch damper
~----""----'>.--, JOINT BOLT
ONE-WAY
VALVE
PISTON
ONE-WAY
VALVE
SPRING
ONE-WAY VALVE PIN
RETURN SPRING
PRIMARY CUP
DCG510ZT8002
Vehicles with clutch damper

The clutch damper controls hydraulic pulsation
during clutch operation, reducing harsh vibration
transmitted to the clutch pedal and operation
noise.
JOINT BOLT
DCG510ZT8003
CLUTCH RELEASE CYLINDER construction

The clutch release cylinder consists of a return
spring, piston, push rod and a bleeder screw for
bleeding air.
Due to spring pressure maintaining play between
the push rod end and the release fork at zero, an
automatic adjusting, maintenance-free design
has been achieved.
dcf05100000Dt04
BLEEDER SCREW
RETURN SPRING
PISTON
DCG510ZT8004
CLUTCH COVER OUTLINE [S15M-D, S15MX-D]
dcf05100000Dt05
The wear assurance function of the clutch cover maintains the set load of the clutch cover unchanged even as
the clutch disc becomes worn, thereby extending disc life.
05-10-2
CLUTCH
DUAL-MASS FLYWHEEL FUNCTION [S15M-D, S15MX-D]
dcf05100000Ot06
The dual-mass flywheel has separated primary and secondary flywheel, and a torsional damper that is located
inside the flywheel. Due to this structure, the transmission main drive gear shaft rotation can be stabilized,
decreasing noise inside the transmission (gear teeth rattling) created by engine speed fluctuation, and thereby
greatly reducing vehicle booming noise also.
TORSIONAL DAMPER
PRIMARY FLYWHEEL
SECONDARY FLYWHEEL
DCG510ZTB005
05-10-3
MANUAL TRANSMISSION [S1SM-D, S1SMX-D]
05-118 MANUAL TRANSMISSION [S15M-D, S15MX-D]

MANUAL TRANSMISSION OUTLINE
[S15M-D, S15MX-D] ..............
MANUAL TRANSMISSION
CROSS-SECTIONAL VIEW
[S15M-D, S15MX-D] ............
MANUAL TRANSMISSION POWER
FLOW [S15M-D, S15MX-D] ........
SHIFT MECHANISM OUTLINE
[S15M-D, S15MX-D] ..........
TRIPLE CONE SYNCHRONIZER
MECHANISM STRUCTURE
[S15M-D, S15MX-D] ..............
MECHANISM OPERATION
[S15M-D, S15MX-D] ............
05-118-1
DOU8LEconeSYNCHRON~ER
MECHANISM OUTLINE
[S15M-D, S15MX-D] ............ 05-118-7
DOU8LECONESYNCHRON~ER
05-118-2
05-118-3
05-118-4
05-118-5
05-118-5
MECHANISM CONSTRUCTION/
OPERATION [S15M-D, S15MX-D] ..... 05-118-7
SHIFT INTERLOCK MECHANISM
FUNCTION [S15M-D, S15MX-D] ...... 05-118-7
OPERATION [S15M-D, S15MX-D] ..... 05-118-7
REVERSE LOCKOUT MECHANISM
FUNCTION [S15M-D, S15MX-D] ...... 05-118-8
[S15M-D, S15MX-D] ............... 05-118-8
MANUAL TRANSMISSION OUTLINE [S15M-D, S15MX-D]
dcf051100000133
A linked, triple cone synchronizer mechanism has been adopted for 1st and 2nd gears.
A cam-type reverse lockout mechanism has been adopted.
05-118-1

MANUAL TRANSMISSION CROSS-SECTIONAL VIEW [S15M-D, S15MX-D]
dcf0511 00000134
S1SM-D
2ND GEAR
S1SMX-D
r--------------------I
I
COUNTER REVERSE GEAR
REVERSE IDLER GEAR
DCG5118T8001
05-118-2

MANUAL TRANSMISSION POWER FLOW [S15M-D, S15MX-D]
dcf0511 00000135
DCG5118T8002
05-118-3
MANUAL TRANSMISSION [S15M-O, S15MX-O]

SHIFT MECHANISM OUTLINE [S15M-D, S15MX-D]
dcf05110000ot36
To realize assured shift feel, the shift link mechanism has been integrated.
SHIFT LINK UNIT
SEC: A-A
- "'..--=,: =-------------------------------': :. :'~,.---_ ..
_______________ : __________ 3.A __ d>
DCG5118T8003
05-118-4

TRIPLE CONE SYNCHRONIZER MECHANISM STRUCTURE [S1SM-D, S1SMX-D]
dcf051100000t37
Features
A triple cone synchronizer mechanism is used for the 1st and 2nd gears.
The triple cone synchronizer mechanism is a compact device capable of heavy duty meshing.
The synchro mechanism reduces meshing time and improves operation.
The triple cone synchro mechanism includes a synchronizer ring, a double cone, and an inner cone.
Structure
Structural view
DCG5118T8004
TRIPLE CONE SYNCHRONIZER MECHANISM OPERATION [S1SM-D, S1SMX-D]

1. When the hub sleeve moves to the left (in the
direction of the arrow), the synchronizer key
presses against the synchronizer ring.
SYNCHRONIZER
RING
dcf05110000Ot38
CLUTCH HUB SLEEVE
INNER
E5U511 8S501 0
05-118-5

2. As the hub sleeve continues moving to the left,
the key causes friction between the synchronizer
ring, double cone, and inner cone and 2nd gear.
The synchronizer ring turns only the distance that
the key groove gap allows, aligning the teeth of
the hub sleeve and the synchronizer ring. As the
hub sleeve continues moving, the friction
between the cones becomes greater, and the
difference between the rotational speeds of the
synchronizer ring, inner cone, and double cone
(unified with the gear) gradually disappears.
SYNCHRONIZER RING
SYNCHRONIZER KEY
DCG511 BTB005
3. The hub sleeve then moves up onto the

synchronizer key and engages the synchronizer
ring.
SYNCHRONIZER RING
CLUTCH HUB SLEEVE
E5U511BS5012
4. The hub sleeve then engages the synchro spline

of the gear to complete shifting.
SYNCHRO SPLINE
~
DCG511BTB015
05-118-6

DOUBLE cone SYNCHRONIZER MECHANISM OUTLINE [S15M-D, S15MX-D]
dcf05110000ot44
The double cone synchronizer mechanism consists of a synchronizer ring, double cone, and inner cone the
same as a triple cone synchronizer mechanism.
DOUBLE CONE SYNCHRONIZER MECHANISM CONSTRUCTION/OPERATION [S15M-D, S15MX-D]
dcf05110000Ot45
The basic construction of the double cone synchronizer mechanism is the same as a triple cone synchronizer
mechanism except that the inner side of the inner cone is not used as a friction surface.
The basic construction of the double cone synchronizer mechanism is the same as a triple cone synchronizer
mechanism except that friction force is not generated because there is no contact surface between the inner
cone and each gear.
For the double cone synchronizer mechanism operation, refer to the triple cone synchronizer mechanism. (See
05-11 B-5 TRIPLE CONE SYNCHRONIZER MECHANISM OPERATION [S15M-D, S15MX-D].)
SHIFT INTERLOCK MECHANISM FUNCTION [S15M-D, S15MX-D]
dcf05110000Ot39
This provides reliable double-engagement prevention.

SHIFT INTERLOCK MECHANISM OPERATION [S15M-D, S15MX-D]
dcf05110000ot40
Structure
During shifting, the shift rods, except for the one in operation, are locked in the neutral position by the interlock
pins.
Operation
Neutral
Because no shift rod is operated, the interlock
pins are seated in the grooves.
1ST/2ND SHIFT ROD
3RD/4TH SHIFT ROD
""
INTERLOCK PINS
1stl2nd shifting
Movement of the 1stl2nd shift rod forces interlock
pin A out of the 1stl2nd shift rod groove, and locks
the 3rd/4th shift rod. Pin B, forced by pin A,
pushes out pin C to lock the 5th/Reverse shift rod.
5TH/REVERSE SHIFT ROD
1ST/2ND SHIFT ROD

3RD/4TH SHIFT ROD
\...--....J.l..------m ..
~-----

DCG511BTB011
05-118-7

3rd/4th shifting
Movement of the 3rd/4th shift rod forces out pins
A and C, and locks the 1st/2nd and 5th/Reverse
shift rods. Pin B does not affect the other pins or
shift rods during 3rd/4th shifting.
1ST/2ND SHIFT ROD
3RD/4TH SHIFT ROD
t
n-----7~~i--------
c
5th/Reverse shifting
When performing 5th/Reverse shifting, the
interlock pins function the same way as in 1st/2nd
shifting, except the pin movement order is in
reverse, and the 3rd/4th and 1st/2nd shift rods are
locked.
""

DCG511BTB012
1ST/2ND SHIFT ROD

3RD/4TH SHIFT ROD

DCG511 BTB013
REVERSE LOCKOUT MECHANISM FUNCTION [S15M-D, S15MX-D]
dcf051117570to9
The reverse lockout mechanism prevents the driver from accidentally shifting into reverse gear when
downshifting from 5th to 4th gear.
REVERSE LOCKOUT MECHANISM CONSTRUCTION/OPERATION [S15M-D, S15MX-D]
dcf05111757Ot10
A cam-type reverse lockout mechanism is adopted to ensure reliability.

A cam, which is installed to the shift guide plate in the shift control case, restricts the selector movement to
prevent the driver from miss shifting.
When shifting into reverse, by shifting the selector back into the neutral position once and then shifting to the
5th/reverse direction, the selector pushes the cam outward to release the shifting restriction, and shifting into
reverse is made possible.
05-118-8

S15M-D
SHIFTING DIRECTLY FROM
5TH INTO REVERSE
SHIFTING INTO REVERSE AFTER

SHIFTING INTO NEUTRAL
REVERSE
l~J1lllj NEUTRAL
5TH
SELECTOR
SELECTOR
05-118-9

S1SMX-O
SHIFTING DIRECTLY FROM 5TH INTO REVERSE
SHIFTING INTO REVERSE AFTER SHIFTING INTO NEUTRAL

REVERSE
RESTRICTS MOVEMENT
4TH
REVERSE
NEUTRAL
i'
-I--+--___~
NEUTRAL
3RD
5TH
5TH
SELECTOR
SELECTOR
DCG5118T8014
05-118-10
AUTOMATIC TRANSMISSION [5R55S]
05-13
OUTLINE [5R55S] . ................
[5R55S] .........................
CONTROL SYSTEM
WIRING DIAGRAM [5R55S] .........
EC-AT OPERATION CHART
[5R55S] .........................
IDENTIFICATION TAG OUTLINE
[5R55S] .........................
RANGE SELECTION [5R55S] ........
SHIFT PATTERNS [5R55S] ... ........
POWERFLOW OPERATION
[5R55S] .........................
TORQUE CONVERTER OUTLINE
[5R55S] .........................
PLANETARY GEARSETS
CONSTRUCTION [5R55S] ..........
APPLY COMPONENTS
PARKING LOCK
LUBRICATION [5R55S] .............
FLUID PUMP
05-13-1
05-13-2
05-13-3
05-13-4
05-13-5
05-13-6
05-13-7
05-13-8
05-13-16
05-13-17
05-13-18
05-13-25
05-13-26
FLUID FILTER
CONSTRUCTION [5R55S] . ......... . 05-13-28
CONTROL VALVE BODY
OUTLINE [5R55S] ................ . 05-13-29
PRESSURE CONTROL
HYDRAULIC CIRCUITS
CONSTRUCTION [5R55S] . ......... . 05-13-32
SHIFT SOLENOID
HYDRAULIC CIRCUITS
CONSTRUCTION [5R55S] . ......... . 05-13-36
TORQUE CONVERTER/LUBE
HYDRAULIC CIRCUITS
CONSTRUCTION [5R55S] . ......... . 05-13-42
APPLY COMPONENT
HYDRAULIC CIRCUITS
CONSTRUCTION [5R55S] . ......... . 05-13-44
ELECTRONIC CONTROL
SYSTEM OUTLINE [5R55S] ........ . 05-13-55
ELECTRONIC CONTROL
SYSTEM BLOCK DIAGRAM
[5R55S] . ......................... 05-13-55
ELECTRONIC CONTROL
SYSTEM STRUCTURE [5R55S] ..... . 05-13-56
OIL COOLER CONSTRUCTION
[5R55S] . ......................... 05-13-58
05-13-27
AUTOMATIC TRANSMISSION OUTLINE [5R55S]

This transmission has the following features:
Five forward speeds
Electronic shift, pressure and torque
converter clutch controls
Three compound planetary gearsets
- Three bands (overdrive, intermediate, low/
reverse)
- Three multi-plate clutches (coast, direct,
forward)
- Two one-way clutches (Overdrive, low/
reverse)
All hydraulic functions are directed by electronic
solenoids. The solenoids control:
Static engagement feel.
Shift feel.
Shift scheduling.
Modulated torque converter clutch (TCC) applications.
Engine braking utilizing the coast clutch and band.
Manual 1st and 2nd timing.
Reverse inhibit timing.
05-13-1

AUTOMATIC TRANSMISSION CROSS-SECTIONAL VIEW [5R55S]
FLUID
PUMP
TSS SENSOR
ISS SENSOR
id0513c1250400
LOW/REVERSE
ONE-WAY CLUTCH
OSS SENSOR
LOW/REVERSE
BRAKE
OVERDRIVE
BRAKE
OVERDRIVE ONEWAY CLUTCH
INTERMEDIATE
BRAKE
CONTROL VALVE
BODY
arnffn00000345
05-13-2

AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [5R55S]
IG1
B+
id0513c1250900
B+
TCM
AT RELAY
OTHER
MODULE
TCC CONTROL SOLENOID

SHIFT SOLENOID A
SHIFT SOLENOID B
4x4
CONTROL
MODULE
SHIFT SOLENOID C
SHIFT SOLENOID D
IG1
PRESSURE CONTROL SOLENOID A
PRESSURE CONTROL SOLENOID B
J~----I
PRESSURE CONTROL SOLENOID C

MI------I
INSTRUMENT
CLUSTER
OSS SENSOR
ISS SENSOR
TSS SENSOR
arnffn00000405
05-13-3
AUTOMATIC TRANSMISSION [SRSSS]

EC-AT OPERATION CHART [5R55S]
id0513c1251 000
Solenoid Operation Chart

Selector position
Gear
Shift
Shift
position solenoid A solenoid 8
-
Reverse
1GR
2GR
Normal
3GR
4GR
5GR
1GR
0/0 OFF
2GR
3GR
4GR
3GR
2GR
1GR
On
On
On
On
On
On
Off
Off
On
On
On
Off
On
On
On
Pressure
Pressure
control
control
solenoid A solenoid 8
High/Low
Low
Low
Low/High
Low
High/Low
High
High/Low
Low/High
High
High
Low/High
High
Low/High
High
High/Low
High
High/Low
Low/High
High
High
Low/High
Low/High
High
Low
High
High
Low
High
Low
Shift
Shift
solenoid C solenoid D
On
On
On
On
On
On
On
On
On
On
On
Off
Off
Off
Off
Off
Off
Off
Off
On
Off
Off
On
Off
On
Off
Off
Off
On
Off
Off
Off
Off
Off
Off
On
Off
Off
Off
Off
On
Off
On
Off
Off
Pressure
control
solenoid C
Low
High
Low
Low
Low
Low
High
High
Low
Low
Low
High
High/Low
High/Low
High/Low
Band and Clutch Application Chart A

Selector position
Normal
0
0/0 OFF
Gear
position
Overdrive
band
05-13-4
Low/reverse
band
Forward
clutch
-
Direct clutch .Coast clutch
Ac
1GR
2GR
3GR
Reverse
-
4GR
5GR
1GR
2GR
3GR
4GR
Ac
Ac
Ac
2GR
Ac
1GR
Ac
Ac
3GR
A : Applied
Ac : Applied to carry coast torque.
- : N/A
Intermediate
band

Band and Clutch Application Chart B
Selector position
R
N
Normal
D
OlD OFF
3
2
1
Gear
position
-
Reverse
-
1GR
2GR
3GR
4GR
5GR
1GR
2GR
3GR
4GR
3GR
2GR
1GR
Direct one-way clutch

Coast
Drive
Low/reverse one-way clutch

Drive
Coast
Engine braking
NE
NE
No
NE
H
OR
H
H
OR
H
OR
H
H
H
OR
H
NE
OR
NE
NE
OR
NE
OR
NE
NE
NE
OR
NE
H
H
OR
OR
OR
H
H
OR
OR
OR
H
H
NE
NE
OR
OR
OR
NE
NE
OR
OR
OR
NE
NE
No
No
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
H : Hold
NE: No effect
OR: Overrunning
- : N/A
IDENTIFICATION TAG OUTLINE [SRSSS]

All vehicles are equipped with a vehicle
certification label, located on the driver side door
lock post. Refer to the code in the space marked
TR. For model, service ID level or build date
information, refer to the transmission service ID
tag located on the transmission case.
id0513c1323600
TRANSMISSION
PART NUMBER
BAR CODE 1 ITEM

DESCRIPTION
6M3P 7000 AB
1lllllllllllmlll~llmlllllllllllllllll
BL2
404
1111111111111111111111111111111111111111111111111111111111111111
A6G12
ASSEMBLY PLANT
LINE SHIFT
020204
TRANSMISSION
PLANT MODEL CODE
PART 1
TRANSMISSION
PLANT MODEL
CODE PART 2
BAR CODE 2
040508
TRANSMISSION BUILD
DATE (DD MM YY)
TRANSMISSION
SERIAL NUMBER
arnffn00000347
05-13-5

RANGE SELECTION [SRSSS]
id0513c1323700
The transmission has 7 range positions: P, R, N,

D, 3, 2 and 1.
SELECTOR
LEVER
arnffn00000349
Park (P Position)
In the P position:
There is no power flow through the transmission.
The parking pawl locks the output shaft to the case.
The engine may be started.
The ignition key may be removed.
Reverse (R Position)
In the R position:
- The vehicle may be operated in a rearward direction, at a reduced gear ratio.
Neutral (N Position)
In the N position:
There is no power flow through the transmission.
- The output shaft is not held and is free to turn.
- The engine may be started.
Drive-Overdrive Enabled (0 range)
D range (overdrive enabled) is the normal position for most forward driving.
The D range provides:
Automatic shifts 1-5 and 5-1.
Apply and release of the torque converter clutch.
Maximum fuel economy during normal operation.
Engine braking in 5GR
Drive-Overdrive Canceled (0 range, 010 OFF mode)
The D range provides:
Automatic shifts 1-4 and 4-1.
Apply and release of the torque converter clutch.
Maximum fuel economy during normal operation.
Engine braking in 4GR
Manual 3 (3 range)
The 3 range provides:
3GR start and hold.
Torque converter clutch apply and release.
Improved traction on slippery roads.
Engine braking.
Manual 2 (2 range)
If this position is selected at normal road speeds, the transmission will downshift into the next lower gear and
continue downshifting until the vehicle reaches 2GR.
The 2 range provides:
2GR start and hold.
Torque converter clutch apply and release.
Improved traction on slippery roads.
Engine braking.
Manual 1 (1 range)
If this position is selected at normal road speeds, the transmission will downshift into the next lower gear and
continue downshifting until the vehicle reaches 1GR.
This position provides:
- 1GR operation only.
- Engine braking for descending steep grades.
05-13~6

SHIFT PATTERNS [SRSSS]
id0513c1323800
Upshifts
Transmission upshifting is controlled by the TCM. The TCM receives inputs from various engine or vehicle
sensors and driver demands to control shift scheduling, shift feel and torque converter clutch (TCC) operation.
The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel.
Even if the battery is disconnected or a new battery installed, transmission operating parameters are kept. The
TCM must relearn these parameters.
Downshifts
Under certain conditions the transmission will downshift automatically to a lower gear range (without moving
the range selector lever).
There are 3 categories of automatic downshifts: coastdown, torque demand and forced or kickdown shifts.
Coastdown
The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio.
If applied, the transmission will disengage the TCC to provide added acceleration.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor.
A forced downshift into a lower gear is possible below calibrated speeds.
Specifications for downshift speeds are subject to variations due to tire size and engine and transmission
calibration requirements.
05-13-7
1

POWERFLOW OPERATION [5R55S]
id0513c1320600
P or N Position
Apply component operation
Overdrive one-way clutch holding
Output shaft stationary with the parking pawl holding the parking gear (transmission shifter in P position)
Planetary gearset operation
Overdrive gearset indirect
Forward/Reverse gearset driving member:
- None
Forward/Reverse gearset driven member:
- None
Forward/Reverse gearset held member:
- None
Forward/Reverse gearset member also rotating:
- None
P OR N POSITION
OVERDRIVE ONE-WAY
CLUTCH HOLDING
R Position
Overdrive one-way clutch holding (drive)
Direct clutch applied
Low/reverse band applied
- Forward/reverse sun gear
- Forward planetary carrier component and reverse ring gear
- Reverse planetary carrier component .
- Forward ring gear
05-13-8

R POSITION
OVERDRIVE ONE-WAY CLUTCH
HOLDING (DRIVE ONLY)
l.:OW/REVERSE
BAND APPLIED
arnfin00000388
ORange 1GR
Forward clutch applied
Low/reverse one-way clutch holding (drive)
- Forward ring gear
Reverse planetary carrier component
Forward/reverse sun gear
ORANGE 1GR
LOW/REVERSE ONE-WAY
CLUTCH (DRIVE ONLY)
arnffn00000389
05-13-9
-,

D Range 2GR
Overdrive band applied
Overdrive gearset in overdrive
- Forward ring gear
- Reverse planetary carrier component
D RANGE 2GR
OVERDRIVE BAND
APPLIED
LOW/REVERSE ONE-WAY CLUTCH
arnifn00000390
D Range 3GR
Intermediate band applied
- Forward ring gear
05-13-10

ORANGE 3GR
INTERMEDIATE BAND
APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
FORWARD CLUTCH
APPLIED
D Range 4GR
Forward ring gear
Forward planetary carrier component and reverse ring gear
None
ORANGE 4GR
DIRECT CLUTCH
APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
FORWARD CLUTCH
APPLIED
05-13-11

D Range 5GR
Forward ring gear
- None
D RANGE 5GR
DIRECT CLUTCH
APPLIED
OVERDRIVE BAND
APPLIED
FORWARD CLUTCH
APPLIED
arnffn00000393
D Range 4GR, OlD OFF Mode (Manual 4GR)

Coast clutch applied
- Forward ring gear
- None
05-13-12

ORANGE 4GR, %
OFF MODE (MANUAL 4GR)
DIRECT CLUTCH
APPLIED
COAST CLUTCH
APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
FORWARD CLUTCH
APPLIED
3 Range (Manual 3GR)

Overdrive one-way clutch, holding (drive)
Intermediate band applied
Forward ring gear
3 RANGE (MANUAL 3GR)
INTERMEDIATE
BAND APPLIED
COAST CLUTCH
APPLIED
FORWARD CLUTCH
APPLIED
OVERDRIVE ONE-WAY
CLUTCH HOLDING
(DRIVE ONLY)
arnffn00000395
05-13-13
,

- Forward ring gear
2 RANGE (MANUAL 2GR)
FORWARD CLUTCH
APPLIED
OVERDRIVE BAND
APPLIED
LOW/REVERSE BAND
APPLIED
LOW/REVERSE ONE-WAY
CLUTCH HOLDING (DRIVE
ONLY)
arnffn00000396
05-13-14

Forward ring gear
1 RANGE (MANUAL 1 GR)
FORWARD CLUTCH
APPLIED
COAST CLUTCH
APPLIED
OVERDRIVE ONE-WAY
ONLY)
LOW/REVERSE BAND
APPLIED
LOW/REVERSE ONE-WAY
ONLY)
05-13-15

TORQUE CONVERTER OUTLINE [5R55S]
id0513c1321000
The torque converter of the 5R55S transmission is a four-element component. It contains an impeller, a turbine
and a reactor, plus TCC (torque converter clutch) for increased fuel economy.
The impeller and cover assembly drives the impeller blades and fluid pump. It contains hydraulic fluid and
provides a mating surface for the TCC damper assembly.
The turbine is driven by fluid from the impeller and transmits power to the turbine shaft and planetary gearsets.
The reactor redirects fluid flow returned from the turbine to the impeller so that it rotates in the same direction
as the impeller. This action assists in torque multiplication.
The reactor has a one-way clutch to hold it stationary during torque multiplication (at lower vehicle speeds) and
allow it to rotate (at higher vehicle speeds).
TCC has the following features:
A piston with damper assembly that connects to the turbine and transmission input shaft
A friction paper surface on the piston (or on a ring connected to the piston) that makes contact with the
torque converter cover when TCC is applied
Fluid that flows through the torque converter and pushes the TCC piston away from the torque converter
cover during TCC release
Fluid that flows through the torque converter and pushes the TCC piston into contact with the torque
converter cover during TCC apply
TCC operates in three stages:
Full release
- Controlled modulation
Full apply
The TCM controls TCC operation, using the TCC control solenoid.
TCC control solenoid operation provides the modulation of hydraulic pressure to change the position of the
control valves. The control valves change the pressure and direction of fluid flow in the torque converter.
TCC may be applied in 2nd gear, 3rd gear, 4th gear and 5th gear.
FULL Tee RELEASE
TURBINE
REACTOR
FROM
CONVERTER
CONTROLVALVE
IMPELLER
TCC
FULL Tee APPLY
FROM
CONVERTER
CONTROL VALVE
TO
CONVERTER
CONTROL
VALVE AND
LUBE
arnffn00000346
05-13-16

PLANETARY GEARSETS CONSTRUCTION [SRSSS]
id0513c1321100
The 5R55S transmission has three planetary gearsets to provide operation in reverse and in five forward
speeds.
The overdrive planetary gearset has the following parts:
- Overdrive sun gear
- Overdrive planetary carrier component
- Overdrive ring gear
The input shaft rotates the overdrive planetary carrier component as a driving member. The input shaft may
also drive the overdrive ring gear directly with a 1.00 to 1 ratio.
When the transmission case holds the overdrive sun gear stationary, the overdrive planetary carrier drives the
overdrive ring gear with an overdrive ring gear with an overdrive ratio of either 0.71 to 1.
The forward and reverse planetary gearsets have the following parts:
Forward planetary carrier component
Forward ring gear
Output ring gear
The forward/reverse sun gear is a driving member in reverse. The forward ring gear is a driving member in each
forward gear.
The forward/reverse sun gear and forward ring gear are driving members for a 1.00 to 1 ratio in 4GR and 5GR.
The forward planetary carrier component and output ring gear are both connected to the output shaft and are
driven members in reverse and in all forward speeds.
The transmission case holds the reverse planetary carrier component stationary in 1GR and 2GR.
The reverse planetary carrier component is a member that rotates at a different speed that the driving and
driven members in 3GR.
The reverse planetary carrier component rotates at the same speed as the forward/reverse sun gear and
forward ring gear as part of the 1.00 to 1 ratio in 4GR and 5GR.
OUTPUT SHAFT
OUTPUT RING GEAR

Ii'
~
o
FORWARD
PLANETARY
_~
~~
~~
FORWARD
'~ING GEAR
~
REVERSE PLANETARY
CARRIER
SUN GEAR AND INPUT

____- - - - . SHELL
____________
----
_----
'~'
-~-
~ ____
~,
____ -
CARRIER
-----
~,
-~----
" " OVERDRIVE

SUN GEAR
____ -
OVERDRIVE RING
GEAR AND CENTER
SHAFT
OVERDRIVE
PLANETARY
CARRIER
INPUT SHAFT
arnffn00000348
05-13-17

APPLY COMPONENTS CONSTRUCTION [5R55S]
id0513c1321200
Clutch/Band Operation
The apply components of the 5R55S transmission work together to provide a flow of power.
The coast clutch is applied to provide coast braking in manual 1GR, manual 3GR and manual 4GR. Coast
braking occurs without the use of the coast clutch in manual 2GR and in 5GR.
Position/Range
Gear position
Reverse
1GR
Overdrive band
2GR
4GR
Intermediate band
Low/reverse band
3GR
5GR
Manual
4GR
Manual
3GR
Manual
2GR
Manual
1GR
A
A
FRS
A
RP
OS
FRS
Drive
OR
OR
OR
Coast
OR
OR
OR
OR
OR
OR
OR
OR
OR
OR
Drive
OR
OR
OR
OR
OR
Coast
OR
OR
OR
OR
OR
OR
OR
OR
OR
Forward clutch
A : Applied
H : Holding
OR: Overrunning
OS: Overdrive sun gear
RP: Reverse planetary carrier component
FRS:Forward/reverse sun gear
FR: Forward ring gear
05-13-18
Planetary
component
OS
A
A
Direct clutch
Low/
reverse
one-way
clutch
Coast clutch
Overdrive
one-way
clutch
D
(O/D
OFF)
FR
OS
RP

Overdrive Band
The overdrive band connects the overdrive sun gear to the transmission case.
The overdrive band is applied in 2GR and 5GR, as well as in manual 2GR.
During 2GR and 5GR operation, hydraulic pressure is applied to the overdrive servo.
This pressure causes the piston to move and apply force to the band.
This action causes the overdrive band to hold the overdrive drum.
This causes the overdrive sun gear to be held stationary through the adapter plate and the overdrive drum.
~~
SERVO COVER, SEALS

AND RETAINING RING
SERVO PISTON AND

RETURN SPRING
OVERDRIVE
BAND
~
~
.'
~-~
OVERDRIVE SUN
GEAR AND
ADAPTER
APPLYSTRUT~~
COAST CLUTCH
DRUM
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
05-13-19

Overdrive One-Way Clutch
The overdrive one-way clutch connects the input shaft to the center shaft during drive operation.
The overdrive one-way clutch transmits torque in Reverse, 1GR, 3GR and 4GR, as well as in manual 3GR.
The direct one-way clutch is a sprag-type one-way clutch that is pressed into the center shaft.
The overdrive one-way clutch is driven by the ring gear of the overdrive planetary carrier.
The overdrive one-way clutch holds and drives the outer splines of the center shaft in 1GR, 3GR, 4GR and
Reverse gears.
The overdrive one-way clutch overruns during all coast operations and at all times in 2GR and 5GR.
OVERDRIVE ONE-WAY CLUTCH SPRAG
ASSEMBLY AND OUTER RACE (PART OF
OVERDRIVE RING GEAR/CENTER
OVERDRIVE ONE-WAY CLUTCH INNER RACE

(PART OF OVERDRIVE PLANETARY CARRIER)
arnffn00000351
Coast Clutch
The coast clutch connects the overdrive planetary carrier component to the overdrive sun gear.
The coast clutch is applied in manual 1GR, manual 3GR, manual 4GR (0 range OlD OFF mode) and Reverse
positions.
The coast clutch is a multi-disc clutch made up of steel and friction plates.
The coast clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
the hydraulic pressure.
The coast clutch is housed in the overdrive drum.
When applied, the coast clutch locks the overdrive sun gear to the overdrive planetary carrier, thus
preventing the one-way clutch from overrunning when the vehicle is coasting.
This allows the use of engine compression to help slow the vehicle and provide engine braking.
OVERDRIVE
PLANETARY
CARRIER
PRESSURE
PLATES
OVERDRIVE SUN
GEARAND
ADAPTER ~
~~~
STEEL
PLATES
~ ~
PISTON AND
SEALS
COAST
CLUTCH
DRU~
....
--%~
(\f0'~~ ~
~~
~
f\.\)X:\J
~-
~~~~~~~'NG
FRICTION PLATES
RETURN SPRINGS,
RETAINER AND
RETAINING RING
arnfin00000352
05-13-20
'

Intermediate Band
The intermediate band connects the forward/reverse sun gear to the transmission case.
The intermediate band is applied in 3GR, as well as in manual 3GR.
During 3GR operation, hydraulic pressure is applied to the intermediate servo.
This pressure causes the servo to move and apply force to the intermediate band.
This action causes the direct clutch drum to be held.
The intermediate band holds the intermediate brake and direct clutch drum to the case in 3GR.
This causes the input shell and forward sun gear to be held stationary.
SERVO COVER,
SEALS AND
RETAINING RING
.~
INTERMEDIATE
W~
BAND
FORWARD/REVERSE SUN
GEAR AND INPUT SHELL
SERVO PISTON
AND SPRING
APPLY STRUT
~-
DIRECT CLUTCH
DRUM
ANCHOR STRUT,
ADJUSTING SCREW
AND NUT
05-13-21

Direct Clutch
The direct clutch connects the center shaft to the forward/reverse sun gear.
The direct clutch is applied in Reverse, 4GR and 5GR, as well as in manual4GR (0 range % OFF mode).
The direct clutch is a multi-disc clutch made up of steel and friction plates.
The direct clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
It is housed in the direct clutch drum.
During 4GR, 5GR and Reverse gear application, the direct clutch is applied transferring torque from the
forward clutch cylinder to the direct clutch drum.
This action causes the forward sun gear to drive the pinions of the low/reverse planetary carrier.
FORWARD/REVERSE SUN
GEAR AND INPUT SHELL
FORWARD CLUTCH
CYLINDER
PRESSURE
PLATES
FRICTION
RETURN SPRINGS,
PLATES~
6Jf;Jf(J ~
/
ETAINERAND
RETAINING RING
DIRECT CLUTCH
DRUM
CENTER SHAFT
rrn
(r
~
~~
~~.l~
\J
ny--'\\J
~
~ETAINING
~\
RING
(SELECT FIT)
STEEL
PLATES
PISTON AND
SEALS
arnffn00000354
Forward Clutch
The forward clutch connects the center shaft to the forward ring gear.
The forward clutch is applied in all forward gears.
The forward clutch is a multi-disc clutch made up of steel and friction plates.
The forward clutch is applied with hydraulic pressure and disengaged by return springs and the exhaust of
When applied, the forward clutch provides a direct mechanical coupling between the center shaft and the
forward ring gear and hub.
arnffn00000355
05-13-22

Low/Reverse Band
The low/reverse band connects the reverse planetary carrier to the transmission case.
The low/reverse band is applied in Reverse, as well as in manual 1GR and manual 2GR.
During 2GR operation, 1GR operation and Reverse, hydraulic pressure is applied to the low/reverse servo.
This pressure causes the servo to move and apply force to the low/reverse band.
This action causes the low/reverse brake drum to be held.
This action causes the low/reverse planetary assembly to be held stationary.
LOW/REVERSE
BAND
\~
-----v ,/
/i
/',
~~ JI
BAND
ACTUATING
LEVER AND
SHAFT
LOW/REVERSE
DRUM
SERVO PISTON - - - - 1
ASSEMBLY
arnffn00000356
05-13-23

Low/Reverse One-Way Clutch
The low/reverse one-way clutch connects the reverse planetary carrier to the transmission case during drive
operation.
The low/reverse one-way clutch transmits torque in 1GR and 2GR, as well as in manual 1GR and manual 2GR.
The low/reverse one-way clutch is a sprag-type one-way clutch.
The low/reverse one-way clutch holds the low/reverse drum and low/reverse planetary assembly to the
case in 1GR and 2GR.
In all other gears the low/reverse one-way clutch overruns.
REVERSE PLANETARY
CARRIERAND
RETAINING RING
05-13-24
LOW/REVERSE ONE-WAY CLUTCH

ASSEMBLY AND OUTER RACE (PART
OF LOW/REVERSE DRUM)
LOW/REvERSE ONE-WAY CLUTCH INNER

RACE (PART OF TRANSMISSION CASE)
arnffn00000357

PARKING LOCK CONSTRUCTION [5R55S]
id0513c1321300
The parking gear is connected to the output shaft. The parking gear has lugs on its outer surface to allow the
operation of the parking lock.
The parking lock prevents the vehicle wheels from rotating by allowing the transmission case to hold the output
shaft stationary through the parking gear. When the parking pawl engages the parking gear, it holds the gear
stationary.
When the manual control lever is rotated to the P position, the parking lock works as follows:
The inner manual control valve detent lever (connected to the manual control shaft) rotates, pushing a
spring-loaded actuator rod.
The actuator rod pivots the parking pawl into alignment between the lugs of the parking gear.
The parking pawl (connected to the transmission case) holds the parking gear.
PARKING PAWL, SHAFT

AND SPRING
ACTUATOR ROD
.'
'~~"
MANUAL SHAFT
'h.Q.
""'-
DETENT SPRING
INNER MANUAL
VALVE DETENT
LEVER
DIGITAL TR
SENSOR
J"
!~
MANUAL SHAFT
LEVER
arnffn00000358
05-13-25

LUBRICATION [SRSSS]
id0513c1321500
The 5R55S transmission provides lubrication for rotating mechanical components through three hydraulic
circuits to the front, center and rear areas. Fluid in the torque converter hydraulic circuit provides fluid to
lubricate the impeller hub bushing.
Fluid in this circuit also flows from the transmission case, through a tube, to a cooler located at the front of the
vehicle. Fluid from the cooler returns through another tube into the transmission and then through the three
lube circuits.
When the temperature of fluid that exits the torque converter contains less heat, the action of a thermostatically
controlled valve in the main control causes the cooler to be bypassed. Fluid flows directly from the torque
converter into the lube circuits.
As transmission fluid temperature increases, the thermostatically controlled valve allows directs the flow of fluid
exiting the torque converter to pass through the cooler before it enters the lube circuits.
FRONT LUBE
arnffn00000359
05-13-26

FLUID PUMP CONSTRUCTION [5R55S]
id0513c1323500
The 5R55S transmission has a gear type pump that supplies fluid under pressure to the hydraulic system.
The fluid pump provides the fluid pressure necessary to charge the torque converter, main control assembly,
transmission cooling system, lubrication system and apply devices.
The torque converter impeller hub rotates the drive gear of the pump. The drive gear has an O-ring on its
impeller hub contact surface.
The fluid pump has the following parts:
Pump cover
Adapter plate
Pump assembly, with drive and driven gears and an integral stator support
STATOR SUPPORT
SEAL
FLUID PUMP BODY
WITH GEARS
IMPELLER HUB
SEAL
FLUID PUMP COVER,

ADAPTER PLATE AND
GASKET
TORQUE CONVERTER
FLUID PUMP INNER

GEAR O-RING SEAL
FLUID PUMP
CONTROL VALVE
AND SEAL
FLUID PUMP BODY

OUTER SEAL
05-13-27

FLUID FILTER CONSTRUCTION [5R55S]
id0513c1321600
Fluid in a sump area formed by the fluid pan flows from a filter, through passages in the valve body and
transmission case, to the suction port of the fluid pump.
The transmission fluid filter and its accompanying seals are part of the fluid path from the sump (pan) to the
fluid pump.
- The transmission fluid filter has a bypass section which allows fluid vented at the main regulator valve to be
recirculated to the fluid pump, without passing through the transmission fluid filter.
A magnet attached to the inside of the fluid pan collects unwanted magnetic material.
TRANSMISSION
CASE
FROM MAIN
REGULATOR
VALVE
FLUID PUMP
SUCTION
FLUID
FILTER
FLUID PAN AND

GASKET
~
DRAIN PLUG
FLUID LEVEL
INDICATOR PLUG
arnfln00000361
05-13-28

CONTROL VALVE BODY OUTLINE [SR5SS]
id0513c1636600
The control valve body component and related components are part of the pressure side of the hydraulic
system.
The control valve body component consists of the solenoids, the valve body assembly and the separator plate.
These components combine to convert electrical signals into hydraulic actions.
All valves in the control valve body component are anodized aluminum and cannot be sanded, filed or
dressed in any other way. If there is any damage to the valves that prevents or restricts their movement,
install a new control valve body component.
TRANSMISSION CASE
SEPARATOR PLATE WITH

BONDED GASKET
CONTROL
VALVE BODY
COMPONENT
\
,
~
.
~-
~-\
,
\b
SOLENOID BODY
COMPONENT AND
O-RING SEALS
, .0
LOW/REVERSE SERVO
CONTROL VALVE
\)
LOW/REVERSE
SERVO ASSEMBLY
~~
\
arnffn00000362
05-13-29

Control Valve Body Component Exploded View
b5r5za00000083
Retainer clip
2
3
Retainer plug
Thermo valve component
30
31
Reverse modulator valve

Reverse modulator valve spring
32
Retainer clip
Fluid cooler bypass valve

Fluid cooler bypass spring
33
34
Retainer plug
Reverse engagement valve
5
6
7
8
9
10
Retainer clip
35
Reverse engagement valve spring
Retainer plug
Converter clutch control valve spring
Converter clutch control valve
36
37
Retainer clip
Retainer plug
38
VFS1 modulator valve
Plate
Coast clutch control spring
VFS1 modulator valve spring

Retainer clip
11
12
Coast clutch control valve
39
40
41
13
Retainer clip
42
Booster valve
14
15
16
Retainer plug
Converter clutch back pressure valve
43
44
Booster valve
Inner spring
Converter clutch back pressure spring
45
Outer spring
17
Retainer clip
46
Retainer spring
18
Retainer plug
47
Main regulator valve
19

48
Retainer clip
Retainer plug
20
21
Retainer clip
Sleeve
49
50
Converter limit spring
22
Retainer plug
51
Converter limit valve
23
Intermediate servo release valve
52
Plate
24
Intermediate servo release valve spring
53
25
26
Plate
High clutch control spring
54
55
Solenoid regulator valve spring

Solenoid regulator valve
Manual valve
27
High clutch control Valve
56
Retainer clip
28
Retainer plug
57
Retainer plug
29
Retainer clip
58
Rear servo control valve spring
05-13-30

59
60
61
62
63
64
65
66
67
68
69
Rear servo control valve

Retainer clip
Retainer plug
RS ISA select valve spring
RS ISA select valve
Retainer clip
Retainer plug
Forward engagement control valve spring
Forward engagement control valve
Plate
Overdrive servo control spring
70
71
72
73
74
75
76
77
78
79
80
Overdrive servo control valve

Clip retainer
Converter clutch modulator control sleeve
Converter clutch modulator control valve
Converter clutch modulator valve
Converter clutch modulator control spring
Separator plate
Lubrication check ball
Shuttle valve ball
Lower control valve body
Bolt
05-13-31

PRESSURE CONTROL HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321800
Line Pressure Hydraulic Circuit

Fluid under pressure from the pump flows to several hydraulic controls in the valve body, including the main
regulator valve. The main regulator valve varies line pressure as part of controlling shift feel and efficient apply
component operation.
The TCM controls the. position of the main regulator valve with the pressure control solenoid A and B.
When pressure control solenoid A and B pressures are lower, the main regulator valve position provides lower
line pressure. As the fluid pressures from pressure control solenoid A and B increase, the main regulator valve
provides higher line pressure.
When the transmission shifter is in the R position, fluid under pressure from the manual valve to the apply
components also affects the position of the main regulator valve. This results in a pressure boost.
LINE PRESSURE CIRCUITS
(SHOWN IN P POSITION)
INTERMEDIATE
CONTROL VALVE
REVERSE PRESSURE
MODULATOR VALVE
FROM PCB
FROM
REVERSE - - - - ,
CIRCUIT
------ FROM PC A
MAIN
I!:rI=FTr~~~~
REGULATOR
VALVE
r-------------~--~------~
CONVERTER
CLUTCH LIMIT
VALVE
OVERDRIVE SERVO
CONTROL VALVE
TORQUE
CONVERTER
...............
SOLENOID FEED
LIMIT VALVE
LUBE
CIRCUITS
--'
PRND321
- - - - _I
Il ~~Ir
~t'-F=ILT,-=E.R
I
I
L-_ _
SUMP
arnffn00000363
05-13-32

Pressure Control Solenoid A Hydraulic Circuit
In the 5R55S transmission, pressure control solenoid A affects the operation of the main regulator valve and
the VFS1 modulator control valve .
VFS1 pressure indirectly affects the feel of the forward clutch engagement. VFS1 pressure is directly applied to
the intermediate servo. It is also directly applied to the low/reverse servo in manual 1GR and manual 2GR.
CIRCUITS (SHOWN IN 3GR)
LOW/REVERSE
SERVO
INTERMEDIATE
BAND SERVO
Dp
DIRECT FORWARD
CLUTCH CLUTCH
--1
1
1
VFS1 MODULATOR
CONTROL VALVE
.I :
1
1
,- - - - --- -- --- - - --- - - - - - ~- -
:
:,
1
1
,1-------- 4--
I
I
- - - - --
---,
I :,
____ I
11
:,
,
MAIN
REGULATOR
VALVE
11
VFS2
11
__I
OVERDRIVE SERVO
CONTROL VALVE
FORWARD
INTERMEDIATE
ENGAGEMENT SERVO SELECT
CONTROL VALVE
VALVE
REVERSE
SERVO
CONTROL
VALVE
~--------------------------------
LINE - - - - -....- - - - - - - - - - - - - '
MANUAL
VALVE
PRND321
arnffn00000364
05-13-33

Pressure Control B Solenoid B Hydraulic Circuit
In the 5R55S transmission, pressure control solenoid 8 affects the operation of the main regulator valve, the
VFS2 modulator control valve, the forward engagement control valve and the reverse engagement control
valve.
VFS2 pressure indirectly affects the feel of the forward clutch engagement, as well as the direct clutch
engagement in reverse. VFS2 pressure is directly applied to the overdrive servo or the coast clutch.
CIRCUITS (SHOWN IN 2GR)
COAST
CLUTCH
OVERDRIVE BAND
SERVO
COAST CLUTCH
CONTROL VALVE
DIRECT
CLUTCH
VFS2 MODULATOR
CONTROL VALVE
FORWARD
CLUTCH
REVERSE
ENGAGEMENT
CONTROL
VALVE
I-I
I
I
I
I
I
I
I
I
MAIN
______ ...
L...-_-('[I,I
----------
OVERDRIVE SERVO
CONTROL VALVE
1!:rI=:::I/::::ilIr-I:ff~~~ REGULATOR
I
I
I
I
I
I
I
I
I
I
VALVE
..
FORWARD
ENGAGEMENT
CONTROL VALVE
LINE - - - - - - - - -...............- - - - - - -...
MANUAL
VALVE
PRND321
arnifn00000365
05-13-34

Pressure Control Solenoid C Hydraulic Circuit
In the 5R55S transmission, pressure control solenoid C solenoid affects the operation of the reverse pressure
modulator valve and the reverse engagement control valve.
Pressure control solenoid C pressure indirectly affects the feel of direct clutch engagement in reverse. Pressure
control solenoid C pressure is directly applied to the direct clutch in 4GR and 5GR.
CIRCUITS (SHOWN IN R POSITION)
DIRECT FORWARD
CLUTCH CLUTCH
##~
: DIRECT
REVERSE
REVERSE
CLUTCH
PRESSURE ENGAGEMENT
:CONTROL
MODULATOR
CONTROL
: VALVE
VALVE
VALVE
...
...~
r-----+----+-
I
I
I
PRND321
LlNE--........................~~................~~....................................................~
arnffn00000366
05-13-35

SHIFT SOLENOID HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1321900
Solenoid Feed Hydraulic Circuit

In the 5R55S transmission, fluid under line pressure moves to the solenoid feed limit valve. The solenoid feed
limit valve provides fluid under a steady regulated pressure to the shift solenoids and TCC control solenoid.
The TCM operates the shift solenoids with on/off control. When the TCM turns off each solenoid, fluid flow is
blocked. When the TCM turns on each solenoid, full fluid flow occurs.
The TCM operates the TCC control solenoid with varying Pulse-Width Modulation (PWM) control. This results
in variable fluid flow and pressure from the TCC control solenoid to the hydraulic valve it controls.
SOLENOID FEED CIRCUITS
(SHOWN IN 1 GR)
CONVERTER
CLUTCH LIMIT
VALVE
SOLENOID
FEED LIMIT
VALVE
LINE - - - - - - - - - - - - - -.....
OFF
ON
OFF
OFF
ON
arnffn00000367
05-13-36

Shift Solenoid A Hydraulic Circuit
In the 5R55S transmission, shift solenoid A affects the operation of the direct clutch. When shift solenoid A is
on in forward speeds, the direct clutch is released. When shift solenoid A is turned off, the direct clutch is
applied. shift solenoid A is also related to the operation of the intermediate band.
When the transmission shifter is moved to the R position under conditions that may cause transmission
damage, the TCM turns off shift solenoid A to inhibit reverse operation. This affects various hydraulic control
valves in order to keep the direct clutch released.
SHIFT SOLENOID A CIRCUITS
(SHOWN IN 4GR)
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
DIRECT CLUTCH
CONTROL VALVE
FROM RE VERSE
.:.u:-==== PRESSURE MODULATOR

VALVE
SS1
- FROM VFS1 MODULATOR

CONTROL VALVE
INTERMEDIATE
SERVO SELECT
VALVE
, - - - - FROM SOLENOID
FEED LIMIT VALVE
OFF
arnffn00000368
05-13-37

Shift Solenoid 8 Hydraulic Circuit
In the 5R55S transmission, shift solenoid B affects the operation of the intermediate band. When shift solenoid
B is on, the intermediate band is applied. When shift solenoid B is turned off, the intermediate band is released.
shift solenoid B is also related to the operation of the low/reverse band in manual 1st gear and manual 2nd
gear.
The TeM does not use shift solenoid B to inhibit reverse operation in 5R55S transmission.
SHIFT SOLENOID B CIRCUITS
(SHOWN IN 3GR)
LOW/REVERSE
SERVO
INTERMEDIATE
BAND SERVO
SMALL AREA
LARGE AREA
INTERMEDIATE
CONTROL VALVE
FROM VFS1 MODULATOR
CONTROL VALVE
SS4
SS2
INTERMEDIATE
SERVO SELECT
VALVE
REVERSE
SERVO
CONTROL
VALVE
,....-_ _ _ _ _ FROM SOLENOID FEED

LIMIT VALVE
ON
arnffn00000369
05-13-38

Shift Solenoid C Hydraulic Circuit
In the 5R55S transmission, shift solenoid C affects the operation of the overdrive band. When shift solenoid C
is on, the overdrive band is applied. When shift solenoid C is turned off, the overdrive band is released.
SHIFT SOLENOID C CIRCUITS
(SHOWN IN 2GR)
OVERDRIVE BAND
SERVO
Re
:OSR
1
1
1
1
1-------------------------------1
1
1
1
1
1
.----1-----<;"--;1 SS3
1
1
1
1____ 1
L___ FROM VFS2 MODULATOR

CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
FROM SOLENOID
, . . . . - - - - - - - - - FEED LIMIT VALVE
ON
05-13-39

Shift Solenoid 0 Hydraulic Circuit
In the 5R55S transmission, shift solenoid D affects the operation of the coast clutch. When shift solenoid D is
on, the coast clutch is released. When shift solenoid D is turned off, the coast clutch is applied.
SHIFT SOLENOID D CIRCUITS
(SHOWN IN MANUAL 3GR)
COAST CLUTCH
,~
1
1
1
1
1
1--------------1
1
1
: COAST CLUTCH
CONTROL
:
1
VALVE
1
1
1
1
L __
SS3rr=l'--
------1
1___
FROM VFS2 MODULATOR

CONTROL VALVE
OVERDRIVE SERVO
CONTROL VALVE
r------------
FROM SOLENOID
FEED LIMIT VALVE
OFF
arnffn00000371
05-13-40

Torque Converter Clutch (TCC) Control Solenoid Hydraulic Circuit
In the 5R558 transmission, the Tee control solenoid affects the operation of the torque converter clutch in
forward speeds.
Tee pressure affects the positions of the converter pressure modulator valve and the converter control valve.
TCC CONTROL SOLENOID CIRCUITS
(SHOWN WITH TCC APPLY)
....
\
j
CON...r:VE:::1R~TdE~R~W~Ir-TH911====~ THERMOSTAT BYPASS VALVE

TORQUE CONVERTER
CLUTCH
I
I
I
I
I
I
I
I
(HOT POSITION)
CONVERTER CONTROL
VALVE
-EXHAUST
CONVERTER
PRESSURE
MODULATOR VALVE
FROM CONVERTER
CLUTCH LIMIT VALVE
MANUAL
VALVE
PRND321
FROM SOLENOID
, - = = = = = = = - - - FEED LIMIT VALVE
arnffn00000372
05-13-41

TORQUE CONVERTER/LUBE HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c1322000
In the 5R55S transmission, fluid for torque converter operation flows as follows during TCC release:
From the LINE circuit, through the converter clutch limit valve, through the converter control valve, to the
torque converter
From the torque converter, through the converter control valve, into the lube circuits
The thermostat bypass valve allows fluid from the torque converter to bypass the fluid cooler and enter into the
lube circuits when fluid temperature is cold.
TORQUE CONVERTER/LUBE CIRCUITS
(SHOWN WITH TCC RELEASE)
"~- {---------,
"
JI
..--------.,"
"
CONVERTER WITH
TORQUE CONVERTER
CLUTCH NOT APPLIED
::
"
::THERMOSTAT BYPASS VALVE
::
(COLD POSITION)
::
"
CONVERTER CONTROL
VALVE
"
rr===i====*=,======11 b
"
""
"
====.
r-
L_="
rlr
" ,"
I>- II t4 i==T
II
II ___
, ______ LL_
......
:;::;
""
-::=:
:: ------rr--.--------------- :;::;
FROM MAIN
REGULATOR VALVE
"
"
REAR LUBRICATION
rF==;;;~::::~~~~=i
*B
CENTER LUBRICATION
FRONT LUBRICATION
ffi
(5 ~
86
TO SUMP
II:
"
"
"
"
"
REAR/LUBE
"
"
SHUTTLE BALL
"
"
"
"
"
"
"
"
"
"
CONVERTER BUSHING
:S~L!::::::==.
~:ri-----?ft:~~~~~~TR~=.:!,
8~ (MAJORITY OF FLOW
ICOOLERI BYPASSES COOLER)
~.- -
EXHAUST
>- ............ ..
t ........
.- tt
~l ~ [RJI
"B-
LINE
CONVERTER CLUTCH
LIMIT VALVE
SOLENOID FEED
LIMIT VALVE
LINE
arnffn00000373
05-13-42

When TCC is applied, fluid for torque converter operation flows as follows:
From the LINE circuit, through the converter clutch limit valve, through the converter control valve, into the
lube circuits
From the LINE circuit, through the converter pressure modulator valve, through the converter control valve,
to the torque converter
TORQUE CONVERTER/LUBE CIRCUITS
(SHOWN WITH TCC APPLY)
CONVERTER WITH-I
TORQUE CONVERTER I
CLUTCH
I
THERMOSTAT BYPASS VALVE
(HOT POSITION)
I
I
I
I
CONVERTER CONTROL
VALVE
I
I
IL _ _
1===
,I"
,I"
"
",I
--1'-
ji====== =~==FROM MAIN

REGULATOR VALVE
REAR LUBRICATION
W=====~~~~~~~==*REA~LUBE
* B a SHUTTLE BALL
CENTER LUBRICATION
FRONT LUBRICATION
ffi
-'
"
. t
t .
CONVERTER CLUTCH
LIMIT VALVE
"
"
"
SOLENOID FEED
LIMIT VALVE
ffi
01O::J
() 0
(MAJORITY OF FLOW
COOLER BYPASSES COOLER)
LINE
CONVERTER PRESSURE
MODULATOR VALVE
FROMTCC
"" SOLENOID
CONVERTER BUSHING
-"Iq--------~ LUBRICATION
0""L-.:....J~-----------I
A_Jol ------------.
8,
TO SUMP
"
"
"
"
"
"
"
"
"
"
"
"
"
""
- - - EXHAUST
...... -.
LINE
arnffn00000374
05-13-43

APPLY COMPONENT HYDRAULIC CIRCUITS CONSTRUCTION [5R55S]
id0513c13221 00
P and N Positions (Park and Neutral)

With the transmission in the P or N position, fluid under pressure is present at the following components:
Overdrive servo-release
- Intermediate servo-release
LOW/REVERSE
SERVO
P POSITION
COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
INTERMEDIATE
SERVO SELECT
VALVE
~n--'"'"T"'r'tH
VFS1
MODULATOR
CONTROL
VALVE
SS1
REVERSE
PRESSURE
MODULATOR
VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
INTERMEDIATE
CONTROL VALVE
CT"T.I--I------,
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000375
05-13-44

R Position (Reverse)
With the transmission in the R position, fluid under pressure is present at the following components:
Intermediate servo-release
Direct clutch
Low/reverse servo-apply
LOW/REVERSE
SERVO
R POSITION
COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
~=:t==~ MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000376
05-13-45

D Range, 1GR
With the transmission in the D range, fluid under pressure is present at the following components in 1GR:
Forward clutch
LOW/REVERSE
SERVO
D RANGE 1GR
COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
--=.Jr..............,..,
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
~=::J:::==: MODULATOR
VFS2
.:r
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000377
05-13-46

D Range, 2GR
Overdrive servo-apply
Forward clutch
LOW/REVERSE
SERVO
D RANGE 2GR
COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
[I5=+==:
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000378
05-13-47

Drange,3GR
Intermediate servo-apply
Forward clutch
LOW/REVERSE
SERVO
D RANGE 3GR
COAST
CLUTCH
OVERDRIVE BAND
SERVO
~~
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
~~p
~ ~~
~~I
COAST CLUTCH
CONTROL VALVE
Jj SMALL AREA
-:;=;r-
,;::::
LARGE AREA
DIRECT CLUTCH
COf:i!"RO,!:.YALVE
;=t-
==
REVERSE
SERVO AREA
CONTROL
VALVE
~
/--
4r1
LJ
INTERMEDiATE
SERVO SELECT
VALVE
INTERMEDIATE
CONTROL VALVE
t;n';I--t--~
'-- -:r: '1'

,!:!
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VFS1
MODULATOR
CONTROL
VALVE
VFS2
MODULATOR
CONTROL
VALVE
lJf
'ftJ
~
/--
REVERSE
PRESSURE
MODULATOR
VALVE
~I
[]
-:;::;-
:::;
--f=-
jj
~t
REVERsE
SERVO
CONTROL
VALVE
LINE
PRND321
MANUAL
VALVE
=;
I--i
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000379
05-13-48
.......

D range, 4GR
Forward clutch
Direct clutch
LOW/REVERSE
SERVO
D RANGE4GR
COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
~~~~
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
q-I,I--I---. MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000380
05-13-49

Drange,5GR
Forward clutch
Direct clutch
LOW/REVERSE
SERVO
D RANGE 5GR
COAST
CLUTCH
OVERDRIVE BAND
SERVO
~~~
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
I ,
~ ~~
~a ~In
COAST CLUTCH
CONTROL VALVE
RJ
SMALL AREAY
-ij=jr-
L~
DIRECT CLUTCH
CONTROL VALVE
~r'-'
I=-
r-
~
I---"
1]
INTERrviEisiATE
SERVO SELECT
VALVE
L-
I
R
!...d
~
la---"
VFS1
MODULATOR
I~~
CONTROL
VALVE
INTERMEDIATE
CONTROL VALVE
-
~t':...1n=:::t=~
_~
_
[i
L---
OVERDRIVE
SERVO
CONTROL
VALVE
VFS2
MODULATOR
CONTROL
VALVE
r-
==9
II
F'i
REVERSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
~V.E
REVERSE
PRESSURE
MODULATOR
VALVE
tr
IFi
--
-;C;-
ra
-~
loJ
L -_ _~_ _ _ _ _ _ _ _ _ _~_ _r-~kd
--B
~----~-+----------~--~
A1
r=i
REVERsE
SERVO
CONTROL
VALVE
LARGEAREA~
n
II!=II
MANUAL
VALVE
LINE
PRND321
II
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000381
05-13-50

D range OlD OFF Mode, 4GR (Manual 4GR)
With the transmission in the 0 range (OlD OFF mode), fluid under pressure is present at the following
components in manual 4GR:
Forward clutch
Direct clutch
Coast clutch
LOW/REVERSE
SERVO
D RANGE MANUAL 4GR (OlD OFF)

COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
g:g=:::t:==:
VFS2
MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000382
05-13-51

With the transmission in the 3 range, fluid under pressure is present at the following components in manual
3GR:
Intermediate servo-apply
Forward clutch
Coast clutch
LOW/REVERSE
SERVO
3 RANGE MANUAL 3GR

COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
REVERSE
SERVO AREA
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
VFS1
1....kr-'ld::::tlrt1ll MODULATOR
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
VFS2
IJI.!--+----, MODULATOR
CONTROL
VALVE
OVERDRIVE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000383
05-13-52

2GR:
Forward clutch
LOW/REVERSE
SERVO
2 RANGE MANUAL 2GR

COAST
CLUTCH
OVERDRIVE BAND
SERVO
INTERMEDIATE
BAND SERVO
DIRECT FORWARD
CLUTCH CLUTCH
COAST CLUTCH
CONTROL VALVE
DIRECT CLUTCH
CONTROL VALVE
212
REVERSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
VALVE
INTERMEDIATE
SERVO SELECT
VALVE
----=-1-.-.......,..,
VFS1
MODULATOR
CONTROL
VALVE
REVERSE
PRESSURE
MODULATOR
VALVE
INTERMEDIATE
CONTROL VALVE
aE:=:t===:
VFS2
MODULATOR
CONTROL
VALVE
OV
D
E
SERVO
CONTROL
VALVE
REVERSE
SERVO
CONTROL
VALVE
MANUAL
VALVE
LINE
PRND321
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000384
05-13-53

1 Range (Manual 1 GR)
1GR:
Forward clutch
Coast clutch
LOW/REVERSE
SERVO
1 RANGE MANUAL 1GR

COAST
CLUTCH
OVERDRIVE BAND
SERVO
DIRECT FORWARD
CLUTCH CLUTCH
'----<M
;----'r'--'
11 ~
~SMALLAREA
11
r--
REaRSE
SERVO AREA
CONTROL
VALVE
REVERSE
ENGAGEMENT
CONTROL
en
IF9
"-'
..-1:::,--
INTERMEDIATE
SERVO SELECT
VALVE
Ip
1=
'--
~
I'\.
IS-d-:::j
VFS1
MODULATOR
CONTROL
VALVE
INTERMEDIATE
CONTROL VALVE
-
~=:I==~
,==
VFS2
MODULATOR
CONTROL
VALVE
LARGE AREAI----'
DIRECT CLUTCH
CONTROL VALVE
~
:--
L...........<~
~ F~
~~ ~~ll1
COAST CLUTCH
CONTROL VALVE
-U-
~~,
INTERMEDIATE
BAND SERVO
~VE
REVERSE
PRESSURE
MODULATOR
VALVE
-c~
r-
F=9
III
OVERDRIVE
SERVO
CONTROL
VALVE
REVERsE
SERVO
CONTROL
VALVE
[~r====~~rll
LINE
111111
PRND321
MANUAL
VALVE
IF"'
~
FORWARD
ENGAGEMENT
CONTROL VALVE
arnffn00000385
05-13-54

ELECTRONIC CONTROL SYSTEM OUTLINE [SRSSS]
id0513c1221600
The TCM and its input/output network control the following transmission operations:
- Shift timing
- Line pressure (shift feel)
- Torque converter clutch
The transmission control strategy combined with the engine control provides optimum powertrain operation
under all conditions.
When determining the best operating strategy for transmission operation, the TCM uses input information from
the PCM via the CAN bus. In addition, the TCM receives input signals from certain transmission-related
sensors and switches.
The TCM also uses these signals when determining transmission operating strategy.
Using all of these input signals, the TCM can determine when the time and conditions are right for a shift or
when to apply or release the torque converter clutch.
It will also determine the pressure needed to optimize shift feel.
To accomplish this the PCM uses 3 pressure controls, 1 torque converter clutch and 4 shift solenoids to control
transmission operation.
ELECTRONIC CONTROL SYSTEM BLOCK DIAGRAM [SRSSS]

INPUT
id0513c1218800
OUTPUT
TURBINE SHAFT SPEED (TSS) SENSOR
INTERMEDIATE SHAFT SPEED (ISS)

SENSOR
OUTPUT SHAFT SPEED (OSS) SENSOR
TRANSMISSION FLUID TEMPERATURE

(TFT) SENSOR
SHIFT SOLENOID A
DIGITAL TRANSMISSION RANGE (TR)

SENSOR
SHIFT SOLENOID B
TCM
OlD OFF SWITCH
PCM
(APP) SENSOR
(ECT) SENSOR
SHIFT SOLENOID C
SHIFT SOLENOID D
TORQUE CONVERTER CLUTCH (TCC)

CONTROL SOLENOID

SENSOR
OlD OFF INDICATOR LIGHT

SENSOR
BRAKE SWITCH
MALFUNCTION INDICATOR LAMP (MIL)
arnffn00000386
05-13-55

ELECTRONIC CONTROL SYSTEM STRUCTURE [5R55S]
id0513c1221900
TCM
The operation of the transmission is controlled by the TCM.
Many input sensors provide information to the TCM. The TCM then controls the actuators which determine
transmission operation.
Air
Conditioning (AlC) Clutch

An electromagnetic clutch is energized when the clutch cycling pressure switch closes.
The switch is located on the suction accumulator/drier.
The closing of the switch completes the circuit to the clutch and draws it into engagement with the compressor
driveshaft.
When the AlC is engaged, operating pressures are adjusted to compensate for additional load on the engine.
Brake Switch
The brake switch tells the PCM when the brakes are applied.
The PCM sends this message to TCM via CAN bus.
The torque converter clutch disengages when the brakes are applied.
The brake switch closes when the brakes are applied and opens when they are released.
Engine Coolant Temperature (ECT) Sensor
The ECT sensor detects temperature of engine coolant and supplies the information to the PCM.
.
The ECT sensor is used to control torque converter clutch (TCC) operation.
Crankshaft Position (CKP) Sensor
The CKP sensor detects pulse wheel rotational signals as crank angle signals.
The PCM uses engine speed signal in the transmission strategy, wide-open throttle (WOT) shift control, torque
converter clutch control and operating pressures.
Mass Air Flow (MAF) Sensor
The MAF sensor measures the mass of air flowing into the engine.
The MAF sensor output signal is used by the PCM to calculate injector pulse width.
For transmission strategies, the MAF sensor is used to regulate electronic pressure control, shift and torque
converter clutch scheduling.
010 OFF Switch

The % OFF switch is a momentary contact switch that allows the driver to cancel operation of 5GR.
The % OFF switch is located on the left side of the selector lever.
When the driver initially presses the % OFF switch a signal is sent to the TCM.
The TCM uses the shift solenoids to disengage/disable 5GR operation and activate the coast clutch. At the
same time, the TCM illuminates the % OFF Indicator Light to notify the driver that 5GR is canceled.
When the % OFF switch is pressed again, 5GR operation is enabled, the coast clutch is released and the 0/
o OFF indicator light is turned off.
Whenever the ignition is cycled (vehicle shut off, then started again), the % OFF switch is turned off and 5GR
will be enabled, even if the % OFF switch had been on when the ignition was shut off.
010 OFF Indicator Light
The OlD OFF indicator light is located in the instrument panel and is labeled %
conjunction with the % OFF switch.
OFF. It is illuminated in
Accelerator Pedal Position (APP) Sensor

The APP sensor is mounted on the accelerator pedal. The APP sensor detects the position of the accelerator
pedal and inputs this information as a voltage to the PCM.
The TCM uses the APP sensor information to aid in determining shift scheduling, presser control and torque
converter control.
Digital Transmission Range (TR) Sensor
The digital TR sensor is located on the outside of the transmission at the mariuallever.
The digital TR sensor completes the start circuit in PARK, NEUTRAL and the back-up lamp circuit in
REVERSE.
The digital TR sensor also opens and closes a set of 4 switches that are monitored by the TCM to determine
the position of the manual lever (P, R, N, 0, 3, 2, 1).
05-13-56

Turbine Shaft Speed (TSS) Sensor
The TSS sensor is a magnetic pickup that sends the TCM torque converter turbine speed information.
The TSS sensor is mounted externally on the case.
The TCM uses TSS information to help determine appropriate operating pressures and TCC operation.
Output Shaft Speed (OSS) Sensor
The OSS sensor is a magnetic pickup, located at the park gear trigger wheel assembly, that sends a signal to
the TCM to indicate transmission output shaft speed.
The OSS sensor is mounted externally on the case.
The OSS is used for torque converter clutch control, shift scheduling and to determine pressure control.
Intermediate Shaft Speed (ISS) Sensor
The ISS sensor is a magnetic pickup that sends planetary sun gear speed information to the TCM.
It is mounted externally on the center of the case.
The TCM uses the intermediate shaft speed sensor information to aid in determining pressure requirements.
Pressure Control Solenoid A, Band C
The pressure control solenoids are a variable-force style (VFS) solenoid. The VFS-type solenoid is an electrohydraulic actuator combining a solenoid and a regulating valve.
The line pressure tap is used to verify output pressure from pressure control solenoid A or B by turning either
one off while verifying the output from the other solenoid.
The second pressure tap is used to verify the output from the pressure control solenoid C.
There are 3 pressure control solenoids located in the solenoid body assembly used to control line pressure,
band and clutch application pressure within the transmission.
The TCM varies the current to the pressure control solenoid.
The TCM has an adaptive learn strategy to electronically control the transmission which will automatically
adjust the shift feel. When the battery has been disconnected or a new battery installed, certain transmission
operating parameters may be lost. The TCM must relearn these parameters.
During this learning process you may experience slightly firm shifts, delayed or early shifts. This operation is
considered normal and will not affect the function of the transmission. Normal operation will return once these
parameters are stored by the TCM.
Torque Converter Clutch (TCC) Control Solenoid
The TCC control solenoid is a pulse width modulating type solenoid which is used to control the apply and
release of the TCC.
Shift Solenoid A, B, C and D
Four ON/OFF shift solenoids allow the TCM to control shift scheduling.
- The solenoids are 3-way, normally open style.
- The shift solenoids shift solenoid A, B, C and D provide gear selection of 1GR through 5GR and REVERSE
gears by directing pressure control pressures to the appropriate elements.
Coast braking and manual gears are also controlled by the shift solenoids.
Transmission Fluid Temperature (TFT) Sensor
The TFT sensor is a thermistor-type sensor that varies a reference voltage signal. The resistance in the TFT
varies with temperature.
The TCM monitors the voltage signal across the TFT and uses this information to determine the transmission
fluid temperature.
The TFT is located on the solenoid body.
The TCM uses the TFT signal to help determine shift scheduling, torque converter clutch operation and
pressure control requirements.
It sends a voltage signal to the TCM. The voltage signal varies with transmission fluid temperature. The TCM
uses this signal to determine whether a cold start shift schedule is necessary. The shift schedule is
compensated when the transmission fluid temperature is cold. The TCM also inhibits TCC operation at low
transmission fluid temperatures and uses it to determine PC solenoid operations.
05-13-57
1

OIL COOLER CONSTRUCTION [5R55S]
id0513c1221500
A water-coaling type AT oil cooler has been adopted and is installed in the radiator. The oil cooler cools the
heated ATF in the AT.
An air-cooling type AT oil cooler has also adopted.
FRONT
RADIATOR
(IN TANK OIL COOLER)
OIL COOLER
.IIf
FRONT
AUTOMATIC
TRANSMISSION
arnffn00000398
05-13-58
AUTOMATIC TRANSMISSION SHIFT MECHANISM
05-14
SHIFT MECHANISM OUTLINE . ...... 05-14-1
SHIFT MECHANISM
STRUCTURAL ViEW ............... 05-14-1
AUTOMATIC TRANSMISSION SHIFT MECHANISM OUTLINE
id051400219700
The cable type shift mechanism has been adopted.

The floor-shift type selector lever has been adopted.
AUTOMATIC TRANSMISSION SHIFT MECHANISM STRUCTURAL VIEW
id051400219800
,-j--_ _
:['~~~~:--"'f"..c:--"/"
SELECTOR
LEVER
DIGITAL TR
SENSOR
SELECTOR CABLE
arnffn00000334
05-14-1
STEERING
OUTLINE ................. 06-00
06-00
POWER STEERING ......... 06-14
OUTLINE
STEERING ABBREVIATION ........ 06-00-1

STEERING FEATURES ........... 06-00-1
STEERING SPECIFICATIONS ........ 06-00-1
STEERING ABBREVIATION
IATF
dcf060000000t01
IAutomatic Transmission Fluid
STEERING FEATURES
Improved handling stability
Improved safety
dcf06000000Ot02
Engine sp~ed sensing power steering adopted

Steering shaft with a tilt mechanism adopted (Some models)
Collapsible steering shaft adopted
STEERING SPECIFICATIONS
dcf06000000Ot03
Item
Steering wheel
Steering column and

shaft
Steering gear and
linkage
Outer diameter
(mm {in})
(turns)
Lock-to-Iock
Shaft type
(mm {in})
(mm {in})
Joint type
Amount of tilt
Ball nut
Type
Power assist type
Power steering
system
Engine speed sensing

Type
Power steering fluid
Specification
380 {15.0} [with air bag],
390 {15.4} [without air bag]
3.7
Collapsible
Rubber coupling
30 {1.2}
Fluid capacity*1 (approx quantity)

(L {US qt, Imp qt})
ATF M-1I1 or equivalent (e.g. DexronII)
1.1 {1.2, 1.0}
*1 : When fluid reservoir is at maximum volume.
06-00-1
-,
POWER STEERING
06-14
POWER STEERING
POWER STEERING OUTLINE ........ 06-14-1

POWER STEERING STRUCTURAL
VIEW . .......................... 06-14-2
POWER STEERING OUTLINE

CONSTRUCTION .................. 06-14-3
POWER STEERING OIL PUMP
CONSTRUCTION .................. 06-14-4
STEERING SHAFT CONSTRUCTION . . . 06-14-5
dcf06140000Ot01
With the adoption of an engine speed sensing power steering mechanism, handling stability has been
improved.
With the adoption of a steering column with a tilt mechanism, operability has been improved. (some models)
With the adoption of a steering shaft with an energy absorbing mechanism, safety has been improved.
06-14-1
,
POWER STEERING
POWER STEERING STRUCTURAL VIEW
dcf06140000Dt02
STEERING WHEEL
RESERVE TANK
STEERING COLUMN AND SHAFT
POWER STEERING
OIL PUMP
DBR614ZTB801
06-14-2
POWER STEERING
STEERING GEAR AND LINKAGE CONSTRUCTION
dcf061432960t01
A ball nut type steering gear has been adopted.

The hydraulic pressure from the oil pump is transmitted to the cylinder part by the control valve according to the
operation of the steering wheel.
The ball nut rotation resistance is reduced in proportion to the amount of the hydraulic pressure transmitted to
the cylinder part.
CONTROL VALVE
CYLINDER PART
PITMAN ARM
BALL NUT
SECTOR SHAFT
DBR614ZTB002
06-14-3
POWER STEERING
POWER STEERING OIL PUMP CONSTRUCTION
dcf061432650t01
The oil pump is driven through the crankshaft (timing gear), idle gear, and vacuum pump gear. As a result, a
lowering of performance due to belt slippage or breakage has been eliminated.
A flow control valve which adjusts the amount of oil sent to the steering gear has been designed in the oil pump
to control hydraulic pressure fluctuation according to engine speed.
FLOW CONTROL VALVE
A
CAM RING
GEAR
ROTOR SHAFT
ROTOR
VANE
A'
DISCHARGE PORT
LOCATION PIN
CAM RING
ROTOR SHAFT
SUCTION
VANE
SUCTION PORT
ROTOR
DISCHARGE
SECTION A-A'
DBR614ZTB003
06-14-4
POWER STEERING
STEERING SHAFT CONSTRUCTION
dcf06143201Ot01
Tilt steering has been optionally equipped to adjust the position of the steering wheel to suit the driver's
particular body shape and driving posture.
The tilt system is adjustable by 30mm {1.2 in} in the up/down direction.
A collapsible steering shaft has been adopted to minimize driver injury in the event of a frontal collision.
DBR614ZTB004
06-14-5
HEATER, VENTILATION &

AIR CONDITIONING (HVAC)
OUTLINE . ................ 07-00
BASIC SYSTEM . ........... 07-11
07
SECTION
CONTROL SYSTEM . ....... . 07-40
OUTLINE
07-00
HVAC ABBREVIATION . ............. 07-00-1

HVAC FEATURES . ................. 07-00-1
HVAC SPECIFICATIONS . ........... . 07-00-1
HVAC ABBREVIATION
dcf070000000to1
AlC
Air Conditioning
B+
DEF

Defroster
HI
LOW
High
Low
M
MAX
OFF
Motor
Maximum
Switch Off
ON
REC
Switch On
Recirculate
HVAC FEATURES
Improved air conditioning
performance
dcf070000000t02
Sub-cooling system to multi-flow condenser adopted
HVAC SPECIFICATIONS
dcf070000000to3
Airflow volume
(during air conditioner Blower motor
operation)
Electricity
consumption (during
air conditioner
operation)
Refrigerant
450
(W)
(g {oz})
48
475 {16.8}
AlC compressor
180 {180, 6.08}
07-00-1
OUTLINE
Specification
Multiflow (sub-cooling type)
Item
Type
Condenser
Radiated heat
Receiver/drier capacity
Desiccant
Expansion valve
Type
Evaporator
Type
10.46 {8,996}
220 {220, 7.44}
(kW {kcal/h})
(ml {cc, fl oz})
Synthetic zeolite
Internal pressure equalizar
Single-tank drawn cup
Dual-pressure type
Type
Operating pressure
Refrigerant pressure
switch
1 L------1
0.176-0.216
ON - -
(MPa {kgf/cm 2 , psi})
:1:
,.20, 25.<C6-31.2B,
OFF ----me
I
I
:f
l:
0.02 {0.20, 2.B4}

or Jess
Fusible plug
07-00-2
Melting point
2.94-3.34
<;".D-34.0i"-483'
:'
l:
0.39-0.79
{3.9B-B.05,57-114}
102-107 {216-224}
BASIC SYSTEM
07-11
BASIC SYSTEM
BASIC SYSTEM LOCATION INDEX .. 07-11-1

BLOWER UNIT
CONSTRUCTION/OPERATION .... 07-11-2
COOLING UNIT
CONSTRUCTION/OPERATION ... 07-11-3
AlC COMPRESSOR
CONSTRUCTION .................. 07-11-4
CONDENSER CONSTRUCTION ...... 07-11-5
REFRIGERANT LINE
CONSTRUCTION ............ 07-11-5
BASIC SYSTEM LOCATION INDEX
dcf07110000Ot01
R.H.D.
(WE-C, WL-3, WL-C)
HEATER UNIT
BLOWER UNIT
CONDENSER
07-11-1
BASIC SYSTEM
Without Ale
HEATER HOSE
'!
BLOWER UNIT
arnffn00000021
07-11-1a
BASIC SYSTEM
BLOWER UNIT CONSTRUCTION/OPERATION
dcf071161133to1
The blower unit consists of a blower motor, resistor, blower harness, blower case.
Construction
1'R::fI1t---i-_---,BLOWER CASE
BLOWER
MOTOR
DBG711 ZTB016
Operation
The blower unit blows recirculated air into the
passenger compartment.
RECIRCULATED AIR
DBG711ZTB004
07-11-2
BASIC SYSTEM
HEATER UNIT CONSTRUCTION
id0711 008061 00
The heater unit consists of a heater core, airflow mode main link, air mix link etc .
The heater unit regulates the airflow mode and the o,utlet airflow temperature.
(
AIRFLOW MODE
MAIN LINK
arnffn00000023
07-11-2a
BASIC SYSTEM
COOLING UNIT CONSTRUCTION/OPERATION
dcf07116152ot01
The cooling unit consists of an evaporator, expansion valve, high pressure pipe, cooler case.
The cooling unit cools and dehumidifies the airflow from the blower unit.
The thermistor is built into the cooling unit and controls the Ale compressor.
COOLER CASE (1)
THERMISTOR
COOLER CASE (2)

DBG711 ZTB005
Evaporator
The evaporator vaporizes the refrigerant flowing
inside it. The latent heat of the vaporized
refrigerant cools the air passing through the
evaporator. At the same time, moisture in the air
condensates. In this way, dehumidified air is
supplied to the passenger compartment.
The evaporator is a single tank drawn cup type.
Because refrigerant flows through several
separate tubes, flow path resistance is kept low
and the surface area for heat exchange is
increased, improving air conditioning efficiency.
EVAPORATOR
COOLING UNIT
EVAPORATOR
REFRIGERANT FLOW
DBG711ZTB006
07-11-3
BASIC SYSTEM
Expansion valve
The expansion valve causes a sudden decrease
in the pressure of the liquid refrigerant. This
atomizes the refrigerant, making it easier for the
evaporator to vaporize it. The expansion valve
also regulates the flow volume of the refrigerant
sent to the evaporator.
An internal pressure equalizer expansion valve is
used. It regulates the flow volume of the
refrigerant supplied to the evaporator so that the
heat absorption process of the evaporator is
utilized efficiently.
EVAPORATOR
EXPANSION VALVE
--lI-+++H*C"/'c~
EXPANSION VALVE
COLD, LOWPRESSURE,
AND VAPOROUS
REFRIGERANT
II
HOT, HIGHPRESSURE,
AND LIQUID
REFRIGERANT
II
FROM
RECEIVER/DRIER
DBG711ZTB007
AlC COMPRESSOR CONSTRUCTION
dcf07116145ot01
The A/C compressor compresses the low-pressure gaseous refrigerant vaporized from the evaporator into a
high-pressure gas so that the condenser can liquidize it more easily. A swash-plate of the NC compressor is
used to reduce weight and vibration and to improve driving performance when the A/C compressor is
operating.
The NC compressor is belt-driven via the engine crankshaft pulley.
Five double-acting pistons positioned axially around the compressor shaft are actuated by a swash plate that is
pressed onto the compressor shaft. The swash plate changes the rotating action of the. shaft to reciprocating
movement of the five pistons. This driving force is applied to the midpoint of each of the double-ended pistons.
DUBLE-ACTING PISTON
SUCTION
COMPRESSOR SHAFT
DISCHARGE
SUCTION
DISCHARGE
-DISCHARGE
-SUCTION
DISCHARGE
SUCTION
---- ..
I
---~
SWASH PLATE
DBG711 ZTB008
07-11-4
BASIC SYSTEM
CONDENSER CONSTRUCTION
The receiver/drier, main condenser, and subcondenser are integrated into the sub-cooling
system multi-flow condenser.
The sub-cooling system multi-flow condenser
sends refrigerant cooled in the main condenser to
the receiver/drier and re-cools it in the subcondenser for a more efficient cooling process.
dcf07116148ot01
RECEIVER/DRIER
CONDENSER
DBG711ZTB009
REFRIGERANT LINE CONSTRUCTION
dcf071161460t01
Cooler pipes and cooler hoses are refrigerant passages.

Refrigerant flows inside of each pipe and hose in the form of high-pressure gas from the A/C compressor to
condenser, in the form of high-pressure liquid from the condenser to the expansion valve, and in the from of
low-pressure gaseous from the expansion valve to the A/C compressor.
The diameter of each pipe is different according to the state of the refrigerant.
LOW PRESSURE
GASEOUS
REFRIGERANT
HIGH-PRESSURE LIQUID
REFRIGERANT
Piping Connection
To prevent O-rings from falling off while piping
work is being performed, stay-on O-rings are
used at the piping connections.
DBG711 ZTB022
DBG711 ZTB015
07-11-5
CONTROL SYSTEM
07-40
CONTROL SYSTEM
CONTROL SYSTEM OUTLINE ........

CONTROL SYSTEM LOCATION
INDEX . .........................
CONTROL SYSTEM WIRING
DIAGRAM .................... ...
BLOWER MOTOR CONSTRUCTION . ..
RESISTOR CONSTRUCTION . ........
07-40-1
07-40-1
07-40-2
07-40-2
07-40-3
MAGNETIC CLUTCH
CONSTRUCTION . ................
REFRIGERANT PRESSURE SWITCH
CONSTRUCTION . ................
CLIMATE CONTROL UNIT
CONSTRUCTION . ................
MANUAL AIR CONDITIONER
CONTROL SYSTEM . ..............
. 07-40-3
. 07-40-4
. 07-40-4
. 07-40-4
CONTROL SYSTEM OUTLINE
IImproved operability
dcf074000000l01
Climate control unit with enlarged operation dial and switch adopted
CONTROL SYSTEM LOCATION INDEX
dcf07400000Qt02
REFRIGERANT PRESSURE
SWITCH
THERMOSWITCH
BLOWER MOTOR
07-40-1
CONTROL SYSTEM
CONTROL SYSTEM WIRING DIAGRAM
defO?400000Ot03
IG2 B+
IG2
IG2
IG2 B+
BLOWER
RELAY
NC RELAY
BLOWER
MOTOR
MAGNETIC
CLUTCH
THERMISTOR
FAN SWITCH
AlC SWITCH
AlC AMPLIFIER
DBG?40ZTB800
BLOWER MOTOR CONSTRUCTION
dcfO? 4061020101
The blower motor rotates the blower fan to blow

air into the passenger compartment.
The blower fan is a sirocco-type fan.
To prevent a blower motor from burning by
overheating, the blower air always blows inside of
the blower motor from the air duct when the
blower motor is operated.
DBG?40ZTB009
07-40-2
CONTROL SYSTEM
RESISTOR CONSTRUCTION
delO? 4061 015t01
The resistor controls the voltage applied to blower

motor, corresponding to fan switch operation. The
resistor controls the rotation speed (airflow
volume) in 4 stage.
RESISTOR
IG2
BLOWER
MOTOR
1 2
OFF
FAN SWITCH
DBG?40ZTB010
MAGNETIC CLUTCH CONSTRUCTION
delO?406101 Otol
A magnetic clutch drives the compressor shaft.

When voltage is applied to the stator, the magnetic force locks the pressure plate and the pulley together as
one unit. As a result the compressor shaft then turns with the pulley.
When voltage is removed from the stator, the pressure plate returns from the pulley by the rubber spring force.
As a result the the compressor shaft does not turn.
ro
SPRING~
RUBBER
AlC COMPRESSOR
PULLEY
SNAP RING
COMPRESSOR SHAFT
SNAP RING
PRESSURE PLATE
DBG?40ZTBOll
07-40-3
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH CONSTRUCTION
dcf074061503to1
The refrigerant pressure switch is fitted to the cooler pipe and senses the refrigerant pressure.
A dual-pressure refrigerant pressure switch is used to respond to both abnormally high and abnormally low
pressures.
When pressure is abnormal, the refrigerant pressure switch turns off and cuts the voltage sent from the
magnetic clutch, thereby stopping the AlC compressor.
IG2
0.176-0.216
{1.79-2.20,2S.46-31.28}
2.94-3.34
{30.0-34.0, 427-483}
----r -
OFF-mm~
ON
B+
AlC
- 1
L----..1
+.
.
.
if
!,,!
0.02 {0.20, 2.84}

or less
RELAY
):
0.39-0.79
{3.98-8.0S, S7-114}
MPa {kgf/cm2, psi}
DBG740ZTB002
CLIMATE CONTROL UNIT CONSTRUCTION
dcf074061190101
Each switches and dials have been enlarged to improve ease of operation.
AIRFLOW MODE
SELECTOR DIAL
TEMPERATURE
CONTROL DIAL
CLIMATE CONTROL
UNIT
REC/FRESH LEVER
DBG740ZTB012
MANUAL AIR CONDITIONER CONTROL SYSTEM
dcf074000005101
Block Diagram
The fan switch and thermistor sends an AlC signal to the PCM via the AlC amplifer.
-.FAN SWITCH
-.-
{~
AMPLIFIER
PCM
AlCCUT
CONTROL
AlC RELAY
REFRIGERANT
PRESSURE
SWITCH
AlC COMPRESSOR
THERMISTOR
DBG740ZTB019
07-40-4
CONTROL SYSTEM
AlC Compressor Control
The A/C signal from the thermistor and A/C amplifer controls the magnetic clutch via the PCM, AlC relay and
refrigerant pressure switch.
Q AlC
SIGNAL ~~AlC
SIGNAL r-::-l
--. L-.J--'
lL --.
THERMISTOR
AlC
AMPLIFIER
--.OPERATE
AlC RELAY
REFRIGERANT
PRESSURE
SWITCH
AlC COMPRESSOR
DBG740ZTB020
07-40-5
RESTRAINTS
OUTLINE ................. 08-00
ON-BOARD DIAGNOSTIC . ... 08-02
08-00
AIR BAG SYSTEM .......... 08-10

SEAT BELT ................ 08-11
OUTLINE
RESTRAINTS ABBREViATIONS ...... 08-00-1
RESTRAINTS FEATURES . .......... . 08-00-1
RESTRAINTS ABBREVIATIONS
DLC
Data Link Connector
DTC
ELR
Diagnostic Trouble Code

Emergency Locking Retractor
GND
PID
SAS
Ground
Sophisticated Air Bag Sensor
RESTRAINTS FEATURES
Improved safety
dcf080000000t01
dcf08000000Ot02
A
A
A
A
driver-side air bag module has been adopted.

passenger-side air bag module has been adopted.
side air bag module has been adopted.
pre-tensioner seat belt has been adopted.
08-00-1
".
ON-BOARD DIAGNOSTIC
08-02
ON-BOARD DIAGNOSTIC

OUTLINE .................... 08-02-1

[AIR BAG SySTEM] ................ 08-02-1
ON-BOARD DIAGNOSTIC FUNCTION OUTLINE
dcf080200000t01
The air bag system has an on-board diagnostic function to facilitate the system diagnosis.
The on-board diagnostic function consists of the following functions: a malfunction detection function, which
detects overall malfunctions in the air bag system-related parts; a memory function, which stores detected
DTCs; a display function, which indicates system malfunctions by DTC display; a PID/data monitoring function,
which reads out specific input/output signals.
"
Using the current diagnostic tool, DTCs can be read out and deleted, and the PID/data monitoring function can
be activated.
The system has a fail-safe function to prevent the accidental activation of the air bags in case of an air bag
system malfunction.
ON-BOARD DIAGNOSTIC FUNCTION [AIR BAG SYSTEM]
dcf08020000Dt02
Self-Malfunction Diagnostic Function

The self-diagnostic function determines that there is a malfunction, outputs a signal, as a DTC, to the DLC-2,
and at the same time, flashes the air bag system warning light to advise the driver of a malfunction.
The air bag system warning light illuminates or flashes to indicate a single DTC according to the present
malfunction. (If there is more than one present malfunction, only one DTC will be displayed according to the
preset priority ranking.)
The air bag system warning light will flash the DTC pattern for five cycles, and then will remain illuminated until
the engine switch is turned to the LOCK position.
The self-diagnostic function consists of a present malfunction diagnostic and a past malfunction diagnostic.
DTC table
DTC
Air bag system warning light
Current
diagnostic
tool
display
""
Flashing pattern
81231
13
81317
81318
12
81342
81869
81870
Priority
ranking
~
Air bag system warning light is illuminated all
the time.
the time
ULJ
the time.
the time.
Air bag system warning light is illuminated
does not illuminate.
the time.
81879
33
SAS control module activation (deployment)

control freeze
The SAS control module power supply voltage
increases (16.1 V or more)
The SAS control module power supply voltage
decreases (less than 9 V)
SAS control module
SAS control module (DTC 12 detection circuit

malfu nction)
Air bag system warning light system circuit open
81877
81878
10
Air bag system warning light system circuit short

to ground
Air bag system warning light system circuit short
to power supply
Driver-side pre-tensioner seat belt circuit
resistance high
Driver-side pre-tensioner seat belt circuit short to
power supply
Driver-side pre-tensioner seat belt circuit short to
ground
08-02-1
ON-BOARD DIAGNOSTIC
DTC
Current
diagnostic
tool
display
Flashing pattern
81881
81882
34
81883
81885
33
81886
34
19
81913
81916
19
81925
21
81932
19
81933
21
81934
19
81935
21
10
Driver-side pre-tensioner seat belt circuit

resistance low
Passenger-side pre-tensioner seat belt circuit

resistance low
JLJlJlJlJlJlflJ
Driver-side air bag module circuit short to body

ground
JULJ
Passenger-side air bag module circuit short to

body ground
JLJlJlJlJlJlflJ
Driver-side air bag module circuit short to power

supply
JULJ
Passenger-side air bag module system circuit

short to power supply
JLJlJlJlJlJlflJ
Driver-side air bag module circuit resistance high
JULJ
Passenger-side air bag module circuit resistance

high
JLJlJlJlJlJlflJ
Driver-side air bag module circuit resistance low
JULJ
Passenger-side air bag module circuit resistance

low
JlflJLJl11JLJ
1--
21
81992
81993
22
12
23
JULJlJ1LJ
11
81994
81995
81996
81997
81998
81999
08-02-2

resistance high
short to ground
1--
Priority
ranking
Driver-side side air ba~ module circuit short to

power supply
Driver-side side air bag module circuit short to
ground
Driver-side side air bag module circuit resistance
high
Driver-side side air bag module circuit resistance
low
Passenger-side side air bag module circuit short
to power supply
Passenger-side side air bag module circuit short
to body ground
Passenger-side side air bag module circuit
resistance high
Passenger-side side air bag module circuit
resistance low
ON-BOARD DIAGNOSTIC
OTC
Current
diagnostic
tool
display
82228
82230
82232
82234
82229
Priority
ranking
Flashing pattern
19
Driver-side air bag module assembly incorrect
Passenger-side air bag module assembly

incorrect
82444
Driver-side side air bag sensor system (internal

circuit disabled)
82445
Passenger-side side air bag sensor system

(internal circuit disabled)
82867
Poor connection of any SAS control module

connectors
U2017
Driver-side side air bag sensor (communication

error)
U2018
Passenger-side side air bag sensor

(communication error)
82231
82233
82235
1---=---------1
21
PID/Data Monitoring Function

By using the PID/data monitoring function, the monitored item of the input/output signal, as set on the SAS
control module, can be freely selected and read out in real-time .
An current diagnostic tool is used to read out PID/data monitor information.
PIO name (definition)
CONT_RCM
(Number of continuous DTC)
CRSH_ST_D1
(Driver-side air bag sensor
communication state)
CRSH_ST_D2
ci rcu it state)
CRSH_ST_P1
(Passenger-side air bag
sensor communication state)
CRSH_ST_P2
sensor circuit state)
D_PTENSFLT
(Driver-side pre-tensioner seat
belt circuit state)
DA8AGR
(Driver-side air bag module
resistance)
DR_PTENS
belt resistance)
Unit/condition
Condition/specification
DTC is detected: 1-255
DTC is not detected: 0
terminal
OK!
FAULT
Sensor normal: OK
Sensor communication error: FAULT
2Z,2AA
OK!
FAULT
Sensor normal: OK
Sensor internal circuit error: FAULT
2Z,2AA
OK!
FAULT
Sensor normal: OK
28,2C
OK!
FAULT
Sensor normal: OK
28,2C
Air bag module circuit resistance low: SQ_LOWRES

Related wiring harness circuit open: OPEN
Related wiring harness short to power supply: SHRT_8+
Related wiring harness short to ground: SHRT_GND
Related wiring harness normal: Normal
2P,2S
SQ_LOWRES
OPEN
SHRT_8+
SHRT_GND
Normal
ohm
Under any condition: 1.5-3.7 ohm
1S,1V
ohm
2P,2S
08-02-3
ON-BOARD DIAGNOSTIC
DS_AB
(Driver-side side air bag
module resistance)
DS_AB_ST
module circuit state)
DS1_STAT
circuit state)
DSB_P_ST
(On demand driver-side pretensioner seat belt circuit
state)
IG_V_2
(System IG1 voltage value)
OD_CRST_D1
(On demand driver-side side
air bag sensor communication
state)
OD_CRST_D2
air bag sensor circuit state)
OD_CRST_P1
(On demand passenger-side
side air bag sensor
OD_CRST_P2
side air bag sensor circuit
state)
OD_DAB1_ST
(On demand driver-side air
bag module circuit state)
OD_DSAB_ST
air bag circuit state)
OD_PAB1_ST
air bag module circuit state)
I,
OD_PSAB_ST
state)
P_PTENSFLT
(Passenger-side pre-tensioner
seat belt circuit state)
Unit/condition
ohm
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal
V
terminal
2M, 20
Related wiring harness short to power supply: SHRT_B+

Related wiring harness short to ground: SHRT GND
Related wiring harness short to power supply: SHRT B+
engine switch to ON position: B+
2M,20
1S,1V
2P,2S
1W
OK!
FAULT
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2B,2C
OK!
FAULT
Sensor normal: OK
2B,2C
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES

Nnrm",(
n.

21,2L

2G,2J
SHRT~B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal
1S,1V
2M,20

lIirinn h",rnA"'''' nnrm",('
1M,1P
Normal
PABAGR
module resistance)
ohm
1M,1P
PS_AB
(Passenger-side side air bag
module resistance)
ohm
21,2L
08-02-4
.\
ON-BOARD DIAGNOSTIC
PS_AB_ST
PS_PTENS
seat belt resistance)
PS1_STAT
PSB_P_ST
pre-tensioner seat belt circuit
state)
Unit/condition
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
ohm
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal


terminal
21,2L
2G,2J
1M,1P
2G,2J
08-02-5
i:.
AIR BAG SYSTEM
08-10
AIR BAG SYSTEM
AIR BAG SYSTEM OUTLINE .........

AIR BAG SYSTEM STRUCTURAL
VIEW . ..........................
AIR BAG SYSTEM
WIRING DIAGRAM ................
SAS CONTROL MODULE
FUNCTION .. ....................
SAS CONTROL MODULE
CONSTRUCTION/OPERATION ......
DRIVER-SIDE AIR BAG MODULE
FUNCTION . .....................

CONSTRUCTION/OPERATION . ..... . 08-10-5
PASSENGER-SIDE AIR BAG MODULE
FUNCTION . ..................... . 08-10-5
SIDE AIR BAG MODULE FUNCTION ... 08-10-5
SIDE AIR BAG MODULE
PRE-TENSIONER SEAT BELT
FUNCTION . ..................... . 08-10-6
CONSTRUCTION/OPERATION ....... 08-10-7
08-10-1
08-10-2
08-10-2
08-10-3
08-10-3
08-10-4
AIR BAG SYSTEM OUTLINE
dcf081000000to1
The air bag system is a device that supplements the passenger restraint function of the seat belts. The air bag
system will not have the designed effect if the seat belts are not worn properly.
The air bag system is composed of the following parts:
Item
Outline
Recognizes actually equipped air bag module or pretensioner seat belt based on module configuration.
Detects degree of impact, converts to an electrical signal, and
sends the signal to the SAS control module. For operation,
refer to SAS control module, Air Bag Module and Pretensioner Seat Belt Deployment Operation. (See 08-10-3
SAS CONTROL MODULE CONSTRUCTION/OPERATION)
Driver-side air bag module

Passenger-side air bag module
Adopted to improve safety in frontal collisions.
Side air bag module

Pre-tensioner seat belt
Chest-protection type side air bag module has been adopted.
SAS control module
Side air bag sensor
Piston-type pre-tensioner seat belt has been adopted.
08-10-1
AIR BAG SYSTEM

AIR BAG SYSTEM STRUCTURAL VIEW
dcf081000000t02
AIR BAG SYSTEM WARNING LIGHT
CLOCK SPRING
,,~
PASSENGER-SIDE
AIR BAG MODULE
DRIVER-SIDE AIR BAG

MODULE
~
SIDE AIR BAG MODULE
SIDE AIR BAG SENSOR
~
DCF810ZTB001
AIR BAG SYSTEM WIRING DIAGRAM
POOR CONNECTION
DETECTOR BAR
dcf081 000000103
CLOCK SPRING
AIR BAG
SYSTEM
WARNING
.;1---+--+---[
LIGHT
)-----{
~---1:::;:::;:~Afi\~:::;- DRIVER-SIDE
AIR BAG
1------1 ~--t:=~~:!.C::=---l MODULE
SAS
CONTROL
MODULE
r------1,!:l..C:=--1
DRIVER-SIDE PRETENSIONER SEAT

BELT
r----f,l:=:::.J
AIR BAG MODULE
PRE-TENSIONER SEAT
BELT
TWISTED PAIR
DRIVER-SIDE
SIDE AIR BAG
SENSOR
,_ ................. ...
PASSENGER-SIDE A
SIDE AIR BAG
SENSOR
B
DRIVER-SIDE SIDE
r--~:::::::..J
PASSENGER-SIDE SIDE
AIR BAG MODULE
1--------
I ................. _
TWISTED PAIR
POOR CONNECTION
DETECTOR BAR
i,.
DCF810ZWB001
08-10-2
.. "
AIR BAG SYSTEM

SAS CONTROL MODULE FUNCTION
dcf08105703Ot01
Outline
Sensing function
Safing and the crush sensors are built into the SAS control module.
If the degree of impact detected by the safing and the crush sensors exceeds the set value during a collision,
the SAS control module sends an operation (deployment) signal to the air bag module and the pre-tensioner
seat belt.
Backup power supply function
The backup power supply function enables the condenser to discharge and supply power to assure air bag
system operation/deployment properly for a specified time even if the power supply to the SAS control module
is cut due to a collision.
SAS CONTROL MODULE CONSTRUCTION/OPERATION
dcf08105703Ot02
Air Bag System

1. The impact of a frontal or frontal offset collision to the vehicle is transmitted to the SAS control module.
2. The safing sensor inside the SAS control module detects the collision and activates. In !addition, the crash
sensor determines the impact and converts it to an electronic signal and outputs it to the output control circuit.
SAS CONTROL MODULE
SAFING
SENSOR
AIR BAG MODULE (DRIVER

OR PASSENGER-SIDE AIR
BAG MODULE)
OUTPUT
CONTROL
CIRCUIT
I~

(DRIVER OR PASSENGERSIDE)
DCF810ZTB002
3. The output control circuit calculates the electronic signals from the crash sensor and the valve is compared with
the preset valve. If the output signal received from the crash sensors exceeds the preset value, an ignition
circuit is completed and an operation (deployment) signal is sent to both the driver and passenger-side air bag
modules.
08-10-3
AIR BAG SYSTEM

4. In conjunction with both the driver and passenger-side air bag module deployment, an ignition circuit for the
pre-tensioner seat belt is completed and an operation (deployment) signal is sent to the pre-tensioner seat belt.
SAS CONTROL MODULE
,..
I 0
IL I;>_
SAFING
~ SENSOR
OUTPUT
CONTROL
CIRCUIT
-~~,..
CRASH
SENSOR
--
1-
- - - I~
-
_ _
_ __ I
~,
AIR BAG MODULE (DRIVER

OR PASSENGER-SIDE AIR
BAG MODULE)
I 0
IL I;>_

(DRIVER OR PASSENGERSIDE)
V'
DCF810ZTB003
Side air bag system

1. During a lateral collision to the vehicle, the crash sensors in the side air bag sensor and SAS control module
detect the collision.
2. The degree of impact detected by the crash sensor in the side air bag sensor is converted to an electrical signal
and sent to the SAS control module through the signal amplification circuit.
3. Simultaneously, the SAS control module crash sensor converts the degree of impact detected to an electrical
signal.
4. The SAS control module processes the calculations for the two electrical signals at the output control circuit
and compares the value to a preset value.
5. The output control circuit determines the degree of impact to the vehicle by the value from the crash sensors,
completes a side air bag module ignition circuit, and sends the deployment signal to the air bag modules.
SIDE AIR BAG SENSOR
SAS CONTROL MODULE
ICRASH I
SENSOR
'-r-
SIGNAL
AMPLIFICATION
CIRCUIT
CRASH
SENSOR
119
L _
-_ -_ -_I ~
SIDE AIR BAG MODULE
~~
OUTPUT CONTROL-CIRCUIT
V'
DCF810ZTB004
DRIVER-SIDE AIR BAG MODULE FUNCTION
dcf081 05701 ot01
Outline
During a frontal or front offset collision, an operation signal from the SAS control module is received and the
front air bag operates (deploys), softening the impact to the head and face areas of the driver.
08-10-4
AIR BAG SYSTEM

DRIVER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION
dcf081 05701 ot02
Installed in the center of the steering wheel.

The inflator operates in the following order.
Inflator Operation
1. When an operation (deployment) signal is received from the SAS control module, the igniter built into the
inflator generates heat and ignites the ignition agent.
2. The ignition of the ignition agent causes the combustion of a gas generating agent which forms nitrogen gas.
3. The nitrogen gas is cooled at the filter and the filtrate is injected into the air bag.
IGNITION OF
GAS
INFLATION
GENERATION AGENT
AGENT
GAS
GENERATION
AGENT
GAS GENERATING
AGENT COMBUSTION
IGNITOR
NITROGEN
GAS
FILTER
FILTER
DCF810ZTB005
PASSENGER-SIDE AIR BAG MODULE FUNCTION
dcf08105705ot01
Outline
During a frontal or front offset collision, an operation signal from the SAS control module is received and the air
bag operates (deploys), softening the impact to the head and face areas of the front passenger.
PASSENGER-SIDE AIR BAG MODULE CONSTRUCTION/OPERATION
dcf08105705ot02
Installed in the dashboard.

The inflator operation is the same as the driver's side air bag. (See 08-10-5 DRIVER-SIDE AIR BAG MODULE
CONSTRUCTION/OPERATION.)
SIDE AIR BAG MODULE FUNCTION
dcf081 000147101
During a collision to the side of the vehicle, the air bag operates (deploys) after receiving an operation signal
from the SAS unit, defusing impact to the chest area of the driver and front passenger.
08-10-5
AIR BAG SYSTEM

SIDE AIR BAG MODULE CONSTRUCTION/OPERATION
dcf081000147to3
Construction
Side air bag modules are installed on the outboard sides of the seat backs.
The side air bag module is composed of an inflator, module cover and air bag.
When an air bag deploys, the side air bag module cover is spread apart by the generation of argon gas from
the inflator, inflating the air bag.
MODULE
COVER
AIR BAG
DCF810ZTB006
Operation
Air bag module deployment operation
Refer to the SAS control module, Air Bag Module and Pre-tensioner Seat Belt Deployment Operation. (See 0810-3 SAS CONTROL MODULE CONSTRUCTION/OPERATION.)
Inflator operation
1. The igniter built into the inflator begins to build up heat when the operation (deployment) signal is sent from the
SAS control module. The inflation agent is ignited by the build up of heat in the igniter.
2. The argon gas expands due to the heat of the ignited inflation agent.
3. The expanding argon gas breaks the discharge barrier, is cooled and filtered by the filter, and then injected into
the air bag.
INFLATION AGENT
m~~-1----===1(====!1====='--J~ +~ V~
\
IGNITOR
COMBUSTION OF
INFLATION AGENT
ARGON GAS
c:::::>
ARGON GAS EXPANSION

\\
~~~IR
~+~ t )'====i1ijr~
~ ~~OAIR
-
DISCHARGE BARRIER
BAG
EPU810ZT3006
PRETENSIONER SEAT BELT FUNCTION
dcf08105763ot01
When a vehicle is involved in a frontal or frontal offset collision and the seat belts are buckled, the pre-tensioner
seat belt system receives an operation signal from the SAS control module, retracting and tightening the belt
webbing instantly on the driver and passenger restraints.
08-10-6
AIR BAG SYSTEM

PRE-TENSIONER SEAT BELT CONSTRUCTION/OPERATION
dcf08105763Ot02
Construction
SPRING SEAT
SPINDLE
BASE
PISTON
CAP NUT
GAS GENERATOR
CYLINDER
EPU810ZT3011
08-10-7
AIR BAG SYSTEM

Operation
Normal (Seat Belt Pretensioners Not Operating)
Normally, the clutch roller installed to the outer circumference of the spindle sits in the recess of the gear and
does not interfere with the spindle .
The gear does not rotate when the belt is pulled or retracted because the spindle and gear are not engaged.
lr-+---GEAR
SPINDLE
CLUTCH ROLLER
EPU810ZT3012
Seat Belt Pretensioners Operating

1. When an operation signal is received from the SAS control module, the gas generator produces gas. Due to the
pressure from the gas, the piston in the cylinder is pressed up.
2. The gear rotates while the piston moves up.
3. Based on the gear rotation, the clutch roller in the gear presses against the spindle. Due to this, the gear and
spindle are engaged.
4. The belt is retracted in conjunction with the gear rotation.
GEAR
SPINDLE
GEAR
CLUTCH ROLLER
GAS
GENERATOR
EPU810ZT3013
08-10-8
SEAT BELT
08-11
SEAT BELT
SEAT BELT OUTLINE ............... 08-11-1

SEAT BELT STRUCTURAL ViEW ..... 08-11-1
LOAD LIMITER RETRACTOR

SEAT BELT OUTLINE
dcf08115700Dt01
Features
Improved safety
Three-point seat belt with the following functions for driver and passeger seat adopted
- ELR (Emergency Locking Retractor: emergency locking mechanism)
- Pre-tensioner seat belt (vehicle with pre-tensioner seat belt) (See 08-10-7
PRE-TENSIONER SEAT BELT CONSTRUCTION/OPERATION.)
- Load limiter, which adjusts restraint force of the seat belt to reduce the possibility of injury
to passengers caused by excess seat belt pressure after pre-tensioner operation. (vehicle
with pre-tensioner seat belt)
Three-point seat belt with the following functions for rear seat passengers adopted (Double
cab)
-ELR
SEAT BELT STRUCTURAL VIEW
dcf081157000t02
BENCH SEAT
DCF811ZTB001
LOAD LIMITER RETRACTOR CONSTRUCTION/OPERATION
1. Initial state
CPJ811ZNB004
08-11-1
SEAT BELT
2. ELR operation
When the force of impact is transfered to the belt,
the retractor changes to the ELR condition,
locking the belt and securing the passenger's
body.
THE VEHICLE IS
INVOLVED IN AN IMPACT
DCF811ZTB002
3. Load limiter operation

After locking, if the force of impact transferred to
the belt is strong enough to cause injury to the
chest of the occupant, an adequate amount of
belt is released to absorb the load applied to the
chest.
CPJ811ZNB006
08-11-2
BODY & ACCESSORIES

OUTLINE .................
BODY PANELS ............
GLASSIWINDOWS/
MIRRORS ...............
SEATS ...................
SECURITY AND LOCKS .....
EXTERIOR TRIM. . . . . . . . . . .
09-00
09-10
09-12
09-13
09-14
09-16
INTERIOR TRIM ............ 09-17

LIGHTING SYSTEMS ........ 09-18
WIPERIWASHER SYSTEM ... 09-19
ENTERTAINMENT .......... 09-20
POWER SYSTEMS .......... 09-21
INSTRUMENTATION/DRIVER
INFO..................... 09-22
BODY AND ACCESSORIES

ABBREVIATIONS . ................ 09-00-1

FEATURES . ..................... . 09-00-1
09-00
OUTLINE
BODY AND ACCESSORIES ABBREVIATIONS

4W-ABS
ABS
ACC
ALC
CM
GND
HI
HU
IG
INT
LCD
LED
LH
LO
M
OFF
ON
PCM
RFW
RH
SW
TNS
dcf09000000Dt01

Accessories
Auto Level Control
Control Module
Ground
High
Hydraulic Unit
Ignition
Intermittent
Liquid Crystal Display
Light Emitting Diode
Left Hand
Low
Motor
Switch Off
Switch On
Remote Free Wheel
Right Hand
Switch
Tail Number Side Lights
BODY AND ACCESSORIES FEATURES

Power window system adopted

Power door lock system adopted
Keyless entry system adopted
Improved security
Immobilizer system adopted

Theft-deterrent system adopted
Improved convenience
A center panel unit, composed of the installed audio unit and the audio switches built into
the center panel, has been adopted
09-00-1
BODY PANELS
09-10
BODY PANELS
BODY PANEL OUTLINE ............. 09-10-1
BODY PANEL OUTLINE
BODY PANEL STRUCTURAL VIEW .... 09-10-1
dcf091 0561 00t01
Front and Rear Bumper has been changed.

BODY PANEL STRUCTURAL VIEW
dcf091 0561 OOt02
REAR BUMPER
FRONT BUMPER
DBG910ZTB001
09-10-1
I
GLASSIWINDOWS/MIRRORS
09-12
REAR WINDOW DEFROSTER

OUTLINE ....................
STRUCTURAL ViEW ..............
REAR WINDOW DEFROSTER SYSTEM
WIRING DIAGRAM ..........
OPERATION ...................
POWER WINDOW SYSTEM OUTLINE ..
POWER WINDOW SYSTEM
STRUCTURAL ViEW .............
09-12-1
09-12-1
09-12-1
09-12-2
09-12-2
09-12-2
POWER WINDOW SYSTEM

WIRING DIAGRAM .......... 09-12-3
POWER WINDOW SYSTEM
OPERATION ................ 09-12-3
POWER OUTER MIRROR OUTLINE .... 09-12-3
POWER OUTER MIRROR
STRUCTURAL ViEW ............ 09-12-4
POWER OUTER MIRROR SYSTEM
WIRING DIAGRAM ............... 09-12-4
POWER OUTER MIRROR
OPERATION .................. 09-12-5
REAR WINDOW DEFROSTER OUTLINE
dcf09126300Ot01
Rear window defroster system has been adopted.

REAR WINDOW DEFROSTER STRUCTURAL VIEW
dcf09126300Ot02
REAR DEFROSTER SWITCH
FILAMENT
DBR912ZT2001
REAR WINDOW DEFROSTER SYSTEM WIRING DIAGRAM
dcf091263000t03
REAR WINDOW
DEFROSTER RELAY
REAR WINDOW
DEFROSTER SWITCH
FILAMENT
DBG912ZTB451
09-12-1
REAR WINDOW DEFROSTER SYSTEM OPERATION
dcf09126300Ot04
When the rear window defroster switch is pressed, the rear window defroster turns on.
Fogging is cleared from the rear window and outer mirror glass by heating of the filament.
If the rear window defroster switch is pressed again with the rear window defroster on, defrosting will stop.
Defroster operation also stops if the engine switch is turned to LOCK while the system is operating
POWER WINDOW SYSTEM OUTLINE
dcf09125800Ot07
The following functions have been adopted for all windows.

- Manual open/close function
- Auto-open function
A power-cut function that permits disabling the operation of all window switches from the driver's seat has been
adopted.
POWER WINDOW SYSTEM STRUCTURAL VIEW
dcf09125800Ot02
POWER WINDOW
MAIN SWITCH
POWER WINDOW
SUBSWITCH
(PASSENGER'S SIDE)
DBR912ZT2002
09-12-2
POWER WINDOW SYSTEM WIRING DIAGRAM
MANUAL
CLOSE
dcf091258000t03
MANUAL AUTO
OPEN
POWER-CU
SWITCH
CLOSE/
CLOSE/
CLOSE/
OPEN
OPEN
OPEN
PfWl------f---H-,
eM
Passenger's side
Rear right
Rear left
DCF912ZT2001
POWER WINDOW SYSTEM OPERATION
dcf091258000t06
Manual Open/Close
The window opens/closes according to the down (push) or up (pull) operation of the power window main
switches and the power window subswitches_
Auto-Open
The window automatically moves to a fully-opened position when the power window main switches is operated
to fully open positions, either down (push)_
POWER OUTER MIRROR OUTLINE
IImproved convenience
dcf09126910Dt01
I Power outer mirror (mirror glass adjusting function) adopted
09-12-3
POWER OUTER MIRROR STRUCTURAL VIEW
dcf091269100t02
POWER OUTER
MIRROR SWITCH
DBR912ZT2004
POWER OUTER MIRROR SYSTEM WIRING DIAGRAM
dcf09126910Ot03
----------------------------
ACC
RETRACT/RETURN
MOTOR (LH)
.........
POWER OUTER
MIRROR (RH)
POWER OUTER
MIRROR (LH)
RIGHT........ LEFT
.....
-"W
UP
...
RETURN RETRACT
RIGHT..... "'LEFT M
r-
UP
RETRACT/RETURN
MOTOR (RH)
...
r-
RETURN RETRACT
.....
DOWN
DOWN
r--
DOVr
LEr
:I
j 0\ 0\
I
boo
~I
e)1
UP
L~ ~GHT
SIDE
RIGHT
DOWN; I
SIDE
~HT
L'EF:P
SIDE ( ) SIDE
RETl!JRN
I
~I
UP
RIGlfT
bI
1
~I
RETURN;(~
RETRACT
RETRACT
I
I
I
I
LEFt
I
I
I
I
I
I
I
I
I
I
POWER OUTER MIRROR SWITCH
---------------------------WITH RETURN/RETRACT
?iT
DBR912ZT2005
09-12-4
POWER OUTER MIRROR OPERATION
dcf09126910Qt04
Mirror Glass Adjustment

The left/right selection switch establishes left or right side outer mirror circuit and current is supplied in either
one of the four directions according to the position of the mirror glass adjustment switch. Due to this, the motor
rotates either up or down, left or right.
LEFT SIDE OUTER MIRROR IS
MOVED UPWARD
UP/DOWN
ADJUSTMENT
/MOTOR
ACC
.........
POWER OUTER
MIRROR (LH)
-'M"UP
;--
r-
LE~I:
-I-
RIGHT DO N
~~
-'M"M
~
LEFT
l~HT
DOWN~ I ~up
~HT
LEFT
SIDE ( ) SIDE
RIGH)
I J,0 I
LEFT
.....
7} 'r
E5U912ZS5007
09-12-5
SEATS
09-13
SEATS
SEATS OUTLINE . .................. 09-13-1

SEATS SPECIFICATION . ............ 09-13-1
SEATS STRUCTURAL ViEW .......... 09-13-2
SEATS OUTLINE
dcf091357000l01
FEATURES
Two types of have been adopted for the driver and passenger seats.
- Separate type
- Bench type
SEATS SPECIFICATION
Body type
Stretch cab
dcf091357000l02
Item
Seat
Function
Recliner
Slide
Side air bag module (See 08-10-5 SIDE AIR BAG MODULE FUNCTION.)
Regular cab
Seat
Double cab
Front seat
Rear seat
Recliner
Slide
Armrest
Recliner
Slide
Side air bag module (See 08-10-5 SIDE AIR BAG MODULE FUNCTION.)
Armrest
09-13-1
SEATS
SEATS STRUCTURAL VIEW
dcf091357000t03
STRETCH CAB
(WITH REAR ACCESS SYSTEM)
REGULAR CAB
DOUBLE CAB
REAR SEAT
FRONT SEAT
DCF913ZTB003
09-13-2
SECURITY AND LOCKS
09-14
SECURITY AND LOCKS
SECURITY AND LOCKS OUTLINE . ...

KEYLESS ENTRY SYSTEM
OUTLINE ... .....................
STRUCTURAL VIEW . .............
OPERATION .....................
09-14-1
09-14-1
09-14-1
09-14-2
09-14-2
THEF~DETERRENTSYSTEM
OUTLINE .. ...................... 09-14-2

THEFT-DETERRENT SYSTEM
STRUCTURAL ViEW .............. 09-14-3
SYSTEM WIRING DIAGRAM ........ 09-14-3
INPUT/OUTPUT DIAGRAM .......... 09-14-4
CONDITION ...................... 09-14-4
PHASE .......................... 09-14-5
IMMOBILIZER SYSTEM OUTLINE . ... . 09-14-7
IMMOBILIZER SYSTEM STRUCTURAL
ViEW ............................ 09-14-8
IMMOBILIZER SYSTEM
WIRING DIAGRAM ................. 09-14-8
IMMOBILIZER SYSTEM SYSTEM
COMPONENT . ................... . 09-14-9
IMMOBILIZER SYSTEM OPERATION ... 09-14-10
[IMMOBILIZER SYSTEM] .......... . 09-14-11
SECURITY AND LOCKS OUTLINE

Improved security
dcf091400001t01
Power door lock system adopted

Keyless entry system adopted
Theft-deterrent system adopted
Immobilizer system adopted
KEYLESS ENTRY SYSTEM OUTLINE
dcf09146600Dt01
The doors also can be locked/unlocked by operating the key or transmitter.

The answer-back function has been adopted where the hazard warning lights flash and a buzzer sounds to
confirm that the doors are locked/unlocked.
A rolling code type transmitter has been adopted to prevent theft by radiowave interception.
To prevent improper operation while the vehicle is moving, the doors cannot be locked/unlocked by operating
the transmitter if the ignition key is not in the LOCK position.
KEYLESS ENTRY SYSTEM STRUCTURAL VIEW
REAR DOOR
FRONT DOOR
LOCK ACTUATOR
LOCK ACTUATOR
dcf09146600Dt02
FRONT DOOR
LOCK ACTUATOR
FLASHER CONTROL
MODULE
DOOR LOCK
CONTROL MODULE
TRANSMITIER
KEYLESS CONTROL
MODULE
DFC914ZWZ001
09-14-1
SECURITY AND LOCKS

KEYLESS ENTRY SYSTEM WIRING DIAGRAM
8+
IG1
KEYLESS
CONTROL
MODULE
dcf09146600ot03
8+
DOOR LOCK
CONTROL MODULE
DOOR
SWITCH
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
DBR914ZWB002
KEYLESS ENTRY SYSTEM OPERATION
dcf091466000t04
When the transmitter LOCK/UNLOCK button is pushed, all doors lock/unlock.

In response to transmitter operation (lock/unlock), the hazard warning lights flash to enable visual verification of
operation.
- When the transmitter LOCK button is pushed, the hazard warning lights flash once.
- When the transmitter UNLOCK button is pushed, the hazard warning lights flash twice.
When any door is not opened within 30 s after the transmitter UNLOCK button is pressed, the UNLOCK signal
is cancelled and the doors are locked.
THEFT-DETERRENT SYSTEM OUTLINE
dcf09145000ot01
The theft-deterrent system includes sound and light alarms that activate when the bonnet or a door is opened
by means other than the key. The turn lights flash and the theft-deterrent horn sounds. When the key is inserted
into the door key cylinder and turned to unlock, the warnings stop.
09-14-2
SECURITY AND LOCKS

THEFT-DETERRENT SYSTEM STRUCTURAL VIEW
THEFT-DETERRENT
CONTROL MODULE
FRONT DOOR
LATCH AND LOCK
ACTUATOR
dcf09145000Ot02
REAR DOOR
LATCH AND LOCK
ACTUATOR
FRONT DOOR
LATCH AND LOCK
ACTUATOR
BONNET SWITCH
DBR914ZTB006
THEFT-DETERRENT SYSTEM SYSTEM WIRING DIAGRAM
dcf09145000Ot03
B+ INSTRUMENT B+
CLUSTER
B+
DOOR AJAR
WARNING
LIGHT
FLASHER
UNIT
KEY REMINDER
SWITCH
SECURITY
LIGHT
HAZARD WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
KEYLESS
CONTROL
MODULE
DRIVER'S DOOR
LOCK-LINK
SWITCH
DOOR LOCK
CONTROL
r-~---'----~---;
MODULE
l.
DOOR KEY
CYLINDER
SWITCH
BONNET
SWITCH
B+
THEFTDETERRENT
HORN
DFC914ZTB111
09-14-3
SECURITY AND LOCKS

THEFT-DETERRENT SYSTEM INPUT/OUTPUT DIAGRAM
dcf091450000to4
INPUT
OUTPUT
KEY REMINDER
SWITCH
...
ENGINE SWITCH
DOOR SWITCH
..
BONNET
SWITCH
SECURITY
LIGHT
..
THEFT-DETERRENT
CONTROL MODULE
TURN LIGHT
DOOR KEY
CYLINDER SWITCH
(DRIVER'S SIDE)
DOOR LOCK-LINK
SWITCH
THEFT-DETERRENT
HORN
...
DOOR KEY
CYLINDER SWITCH
(PASSENGER'S SIDE)
.....
DBR914ZWB003
THEFT-DETERRENT SYSTEM CONDITION

System phase
Prearming
2
Arming
Alarm 1
Alarm 2
*1
Off
Off
Off
Off
Off
Off
Off
Off
On or
Unlock
(at least
one is on or
lock)
Off
Off
On
(at least
one is on)
Off/Lock
Off
Off
Off
Off
Off
Off
Initial
Timer period
Key reminder
switch
On
(at least
one is on)
Off
Bonnet switch
Door lock-link
switch
Driver's and
passenger's door
key cylinder
switch
OUTPUT
Prearming
Dead
Engine switch
Door switch
INPUT
dcf091450000t05
Theft-deterrent
horn
Turn light
Off
Off
Off
Off
Security light
Off
Off
Off
Off
*1: Theft-deterrent horn timer period is 25 s. Turn light timer period is 4.5 min.
09-14-4
Off
On or Off
(at least
one is on)
Off
On or Off
On or Off
On or Off
On or Off
Off/Lock
Off/Lock
Off
Off
Off
Off
SECURITY AND LOCKS

THEFT-DETERRENT SYSTEM PHASE
dcf09145000Dt06
Dead
The condition before the key is removed from the steering lock. (The key is at either ON position, ACC position,
or LOCK position.)
The security light is not lit at this time.
Initial
The condition after the key is removed from the steering lock (with all doors and the bonnet closed).
ZBR8120W004
Prearming 1
The key is removed from the steering lock and a door or a bonnet is open.
ZBR8120W005
Prearming 2
The key is removed from the steering lock and a door is opened or not locked, and the bonnet is opened.
ZBR8120W006
09-14-5
SECURITY AND LOCKS

Arming 1
The doors are locked with the key after all doors and the bonnet are closed.
The turn lights have been flashed for 2 s shifting to "Arming 1" phase from "Prearming 2" phase.
The security light is flashes at an interval of 3 s. The alarm system is fully set.
SECOND
DBR914ZWB004
Alarm 1
A door or the bonnet is opened without using the key, or the ignition circuit is short-circuited. The theft-deterrent
horn sounds intermittently for 25 s and the turn lights flash intermittently for 4.5 min.
The theft-deterrent horn sounds intermittently for 25 s and turn lights flash intermittently for 4.5 min again when
a door or the bonnet is opened or closed without using the key from the period of 25 s until 4.5 min.
ZBRB120WOOB
Alarm 2
The condition (after 4.5 min have passed from the time "Alarm 1" phase was activated) in which the warning
system is deactivated.
When the door or the bonnet is opened again, the condition returns to "Alarm 1" phase.
ZBRB120W009
09-14-6
SECURITY AND LOCKS

Alarm Stop Phase (Initial)
The warning system is cancelled and the condition returns to "Initial" phase when either front door is unlocked
with the key.
ZBR8120W010
IMMOBILIZER SYSTEM OUTLINE
dcf09146700Ot01
The immobilizer system prevents the engine from starting even if the engine switch is short-circuited. As a
result, it keeps the vehicle from being stolen.
The system is composed of a special key, the security light, the coil, the immobilizer unit, and PCM. The engine
can be started using the key, which has an ID number registered in its transponder and which uses an
algorithmic verification method.
The code word is input to the immobilizer unit and PCM. The vehicle dose not start if the code word is not newly
input when parts are replaced.
The procedure for registering the ID number and the procedure for inputting the code word are different
according to the parts being replaced and the number of the registered keys.
09-14-7
SECURITY AND LOCKS

IMMOBILIZER SYSTEM STRUCTURAL VIEW
dcf091467000to2
KEY
SECURITY LIGHT
PCM
DBR914ZWB005
IMMOBILIZER SYSTEM WIRING DIAGRAM
dcf091467000to3
B+
SECURITY
LIGHT
IG1
IG1
B+
1
STARTER
RELAY
COIL
PCM
DBR914ZTB007
09-14-8
SECURITY AND LOCKS

IMMOBILIZER SYSTEM SYSTEM COMPONENT
dcf091467000t04
Key
The transponder in the key has a registered 10
number.
TRANSPONDER
DBR914ZTB008
Coil
The coil is located in the steering lock.
The coil has an antenna function and sends the
10 number to the immobilizer unit.
COIL
STEERING
LOCK
DBR914ZTB009
Immobilizer Unit
The immobilizer unit compares the 10 number and the algorithmic verification method of the key with those of
the immobilizer unit.
When the 10 number and the algorithmic verification method are correct, the immobilizer unit sends the code
word to the peM
When there is a malfunction in the immobilizer system, the immobilizer unit flashes the security light.
09-14-9
SECURITY AND LOCKS

IMMOBILIZER SYSTEM OPERATION
dcf091467000to5
This is a conceptual flow chart for understanding how the immobilizer system operates. It shows how the
system decides whether or not to start the vehicle when the engine switch is turned to ON position.
Insert the key into the key cylinder. (Key reminder switch ON)
Coil reads the ID number of the key and sends it to the immobilizer unit.
Immobilizer unit compares the ID number of the key with .that of the immobilizer unit.
ID number agreement
liD number disagreement
Starter relay ON
Turn ignition switch to ON position.
Immobilizer unit sends unlock

signal and code word to the
PCM.
PCM compares the code word of

the immobilizer unit with that of
the PCM.
Immobilizer unit sends lock

signal to the PCM.
Engine can not be start
Security light start flashing
Code word disagreement

Code word agreement
Security light illuminates
for 1 - 2 seconds.
Engine will start
Engine can not be start
Security light start flashing
I
DBR914ZTC001
09-14-10
SECURITY AND LOCKS

ON-BOARD DIAGNOSTIC SYSTEM [IMMOBILIZER SYSTEM]
dcf091467000t06
Outline
If the immobilizer system has a malfunction, the on-board diagnostic system displays the diagnostic trouble
code number by flashing the security light when the engine switch is at ON position.
DTCTable
DTC
Output pattern
Description
01
02
Jl1l
03
10 number is not input into immobilizer unit after engine switch is

turned to ON position or cranking engine.
11
JlJLJ
Coil or wiring harness between immobilizer unit and coil is open

circuit.
21
Code word/lO number stored in immobilizer unit EEPROM cannot

be read.
24
Open or short circuit in wiring harness between immobilizer unit

and PCM.
30
mrLJ
PCM is defective. (Malfunction of communication line inside PCM)
10 number unregistered in immobilizer unit is input after engine

switch is turned to ON position or cranking engine.
10 number format error (voltage range, frequency)
09-14-11
EXTERIOR TRIM
09-16
EXTERIOR TRIM
EXTERIOR TRIM OUTLINE . ......... 09-16-1
EXTERIOR TRIM STRUCTURAL

VIEW . .......................... . 09-16-1
EXTERIOR TRIM OUTLINE
dcf091600000t01
Front and rear flaps have been adopted.

Over fender has been adopted.
Rope hook has been adopted.
EXTERIOR TRIM STRUCTURAL VIEW
dcf09160000Dt02
ROPE HOOK
REAR FLAP
DCG916ZTBOOO
09-16-1
INTERIOR TRIM
09-17
INTERIOR TRIM
INTERIOR TRIM OUTLINE ........... 09-17-1
INTERIOR TRIM STRUCTURAL VIEW .. 09-17-1
INTERIOR TRIM OUTLINE
dcf091755000to1
Glove compatment upper have been added.

Various storage spaces have been added.
INTERIOR TRIM STRUCTURAL VIEW
dcf09175500Ot02
GLOVE COMPARTMENT UPPER
CUP HOLDER
CUP HOLDER
(EXCEPT REGULAR CAB)
DOOR POCKET
DCG917ZTBOOO
09-17-1
LIGHTING SYSTEMS
09-18
LIGHTING SYSTEMS
LIGHTING SYSTEM OUTLINE ........ 09-18-1

LIGHTING SYSTEMS
SPECiFiCATION .................. 09-18-1
LIGHTING SYSTEM STRUCTURAL
VIEW . .......................... 09-18-2
FRONT COMBINATION LIGHT

CONSTRUCTION . ................ . 09-18-3
REAR COMBINATION LIGHT
STRUCTURAL VIEW . ............. . 09-18-4
LIGHTING SYSTEM OUTLINE
dcf09180000Ot01
Headlight with built-in front turn and parking light has been adopted.
A projector type has been adopted to the headlight (low-beam).
Stepped reflectors have been adopted to the rear combination lights.
LIGHTING SYSTEMS SPECIFICATION
Item
Headlight bulb
dcf09180000Ot03
IHigh-beam
ILow-beam
Front turn light bulb

Parking light bulb
Front fog light bulb
Exterior light bulb capacity
Front side turn light bulb

Brake/taillight bulb
Rear turn light bulb
Back-up light bulb
License plate light bulb
High-mount brake light bulb
Map light bulb
Interior light bulb capacity
Interior light bulb

Glove compartment light bulb
IG key illumination bulb
Console illumination bulb
Specifications (W) x number
60 x 2
55 x 2
21 x 2
5x2
55 x 2
5x2
21/5 x 2
21 x 2
21 x 2
5x2
5x4
5x2
8x1
1.7 x 1
1.4 x 1
1.4 x 1
09-18-1
LIGHTING SYSTEMS
LIGHTING SYSTEM STRUCTURAL VIEW
dcf09180000Dt02
DCG918ZTBOOO
1
2
3
Front combination light

Front side turn light
License plate light
09-18-2
Rear combination light

High-mount brake light
LIGHTING SYSTEMS
DCG918ZTB001
2
3
Glove compartment light

Console illumination
Interior light (regular cab)

Interior light (except regular cab)
IG key illumination
FRONT COMBINATION LIGHT CONSTRUCTION
dcf091851060to1
Projector type headlights (low-beam) have been adopted, and these have been incorporated, along with the
front turn light and the parking light, into a single unit to improve size reduction.
FRONT TURN
LIGHT BULB
HEADLIGHT
BULB
SEC.A-A
SEC.B-B
09-18-3
LIGHTING SYSTEMS
REAR COMBINATION LIGHT STRUCTURAL VIEW
dcf09185115Ot03
TYPE A
BRAKE
rrAILLIGHT BULB
i.
TURN LIGHT
BULB
BACK-UP
LIGHT BULB
TYPEB
~
'III'
I
BACK-UP LIGHT
BRAKE rrAILLIGHT
TURN LIGHT
SEC.A-A
II"
,I
DCG918ZTB003
09-18-4
ENTERTAINMENT
09-20
ENTERTAINMENT
AUDIO SYSTEM OUTLINE . ..........

AUDIO SYSTEM STRUCTURAL
VIEW . ..........................
AUDIO SYSTEM BLOCK DIAGRAM ...
AUDIO SYSTEM SPECIFICATIONS . ...
CENTER PANEL UNIT OUTLINE . .....
CENTER PANEL UNIT
CONSTRUCTION .................
09-20-1
09-20-1
09-20-2
09-20-2
09-20-3
09-20-3
AUTO LEVEL CONTROL (ALC)

FUNCTION . ..................... . 09-20-5
OPERATION . .................... . 09-20-5
OUTLINE . ...................... . 09-20-6
FUNCTION . ..................... . 09-20-6
AUDIO UNIT STRUCTURAL VIEW . ... . 09-20-9
AUDIO UNIT CONSTRUCTION . ...... . 09-20-9
AUDIO SYSTEM OUTLINE
dcf092000001t01
Type A
A center panel unit, composed of the installed audio unit and the audio switches built into the center panel, has
been adopted.
Module availability depends on vehicle grade.
The auto level control (ALC) function has been adopted.
Type B
AM/FM radio with the CD player has been adopted.
AUDIO SYSTEM STRUCTURAL VIEW
dcf092000001t02
TWEETER RH
ANTENNA FEEDER
DCF920ZTBA02
09-20-1
ENTERTAINMENT
AUDIO SYSTEM BLOCK DIAGRAM
dcf092000001t03
TYPE A
ROOF
ANTENNA
CENTER PANEL
UNIT
AUDIO
UNIT
/
~ ---1-'::::=L==':'~
.1
I'
I'.1
I'
---4
-----n
.1
TNS SIGNAL
VEHICLE
SPEED
SIGNAL
TWEETER
(RH)
FRONT SPEAKER
(RH)
FRONT SPEAKER
(LH)
BASE UNIT
TWEETER
(LH)
REAR SPEAKER
(RH)
I~-----... .
.....L.___
'*~~~E I i I
___
REAR SPEAKER
(LH)
'I
II
L.---.:.==~
TYPES
ROOF
ANTENNA
TWEETER
(RH)
FRONT SPEAKER
(RH)
FRONT SPEAKER
(LH)
AUDIO UNIT
TWEETER
(LH)
REAR SPEAKER
(RH)
REAR SPEAKER
(LH)
DCF920ZTBA03
09-20-2
ENTERTAINMENT
AUDIO SYSTEM SPECIFICATIONS
id092000100400
Audio Unit
Specification
Type A
Item
Without RDS
With RDS
12
(V)
Rated voltage
LW
(kHz)
153-279
MW
(kHz)
531-1602
FM
Audio amplifier maximum output
power
Output impedance
(MHz)
AM
Frequency band
I
l
Type 8
522-16291
530-1620
87.5-108
531-1629
35x4
(W)
(ohm)
Speaker
Item
Front speaker
(W)
(ohm)
(mm)
Maximum input
Impedance
Size
160
I
I
Specification
Rear speaker
Double cab
I Freestyle cab
1
I
Tweeter
30
25
4
100
160
CENTER PANEL UNIT OUTLINE
dcf092066900to1
The center panel unit is composed of the installed audio unit and the audio switches built into the center panel.
CENTER PANEL UNIT CONSTRUCTION
dcf09206690Ot02
Structural View
BASE UNIT
CENTER PANEL
AUDIO UNIT
COVER
LOWER MODULE
DCF920ZTBA01
09-20-3
ENTERTAINMENT
Terminal Layout and Signal
Audio unit
Terminal
Signal
1A
1B
1C
Front speaker LH (-)
10
Front speaker RH (+)
1E
TNS (+)
Front speaker RH (-)
1F
1G
Illumination (-)
1H
Antenna control
11
1J
1K
1L
UART-1
1M
1N
10
1P
10
1R
1S
1T
1U
1V
1W
1X
Terminal
2A
2B
2C
2D
2E
2F
1m
2G
In!
20 2MI2KI21 12GI2EI2C 2A
2P 2NI2LI2J 12HI2FI2D 2B
.........
""
"'7
UART-2
ACC
Rear speaker LH (+)
Rear speaker LH (-)
Rear speaker RH (+)
Power ground
Rear speaker RH (-)
Signal
Power ground
System mute
Input signal RH (+)
Input signal RH (-)
Input signal LH (+)
Input signal LH (-)
Signal ground
2H
21
TEXT DATA
2J
TNS (+)
BUS (-)
2K
2L
2M
2N
09-20-4
Front speaker LH (+)

B+ (Power back up)
TEXTCLK
BUS (+)
AUX control
-
20
ACC
2P
+B
i'
ENTERTAINMENT
Button and switch Location
~
I
I
I
@)
(jJ)
,I
,I
1/
C: 1
II
@
(j])
1
1
1
19
DCF920ZTBS03
1
2
3
4
5
6
7
8
9
10
CLOCK button
LOAD button
FM 1 button
FM 2 button
AM button
CD button
MEDIA button
EJECT button
Preset button 1
Preset button 2
11
12
13
14
15
16
17
18
19
Preset button 3
Preset button 4
Preset button 5
Preset button 6
DISP/AUTO-M button
SEEKlAPCITRACK switch
Traffic information button
AUDIO CONTITUNEITEXT button
POWERNOLUME button
AUTO LEVEL CONTROL (ALC) FUNCTION
dcf09206690Qt03
Adjusts the audio volume so that the sound is balanced against wind and road noise while driving.
AUTO LEVEL CONTROL (ALC) OPERATION
dcf09206690Qt04
The audio unit changes the volume automatically based on the vehicle speed signal sent from the instrument
cluster.
HIGHER VEHICLE SPEED
AUDIO UNIT (BASE UNIT)
SPEAKE R
ALC
CIRCUIT
r-
POWER
AMPLIFIER
~ HIGHER VOLUME
LOWER VEHICLE SPEED

AUDIO UNIT (BASE UNIT)
SPEAKE R
ALC
,-CIRCUIT
POWER
AMPLIFIER
- - -......~ NORMAL VOLUME
DCF920ZTBA04
09-20-5
ENTERTAINMENT
The ALC function is divided into four modes that can be used effectively to match the driving conditions.
Mode
Condition
RLC OFF
ALC function cancelled
RLC LEUELl
Outside road noise low
RLC LEUEL2
Outside road noise slightly high
RLC LEUEL3
Outside road noise high
ON-BOARD DIAGNOSTIC SYSTEM OUTLINE
dcf09206690Dt05
The on-board diagnostic system has a self-diagnostic function and diagnostic assist function to help
technicians locate malfunctions.
ON-BOARD DIAGNOSTIC SYSTEM FUNCTION
dcf09206690Dt06
Self-diagnostic Function
Malfunction detection function
The malfunction detection section detects malfunctions occurring in the system.
Memory function
The memory function detects a malfunction, changes it to a DTC, and stores it in the memory. The memory can
store a maximum of three DTCs. If another malfunction is detected when three DTCs are already stored, the
memory function clears the oldest DTC and stores the new one.
Once a DTC is stored, it can only be cleared by the designated procedure; not by turning the ignition switch to
the LOCK position or disconnecting the negative battery cable. The procedure is mentioned in the Service
Section.
Display function
When the self-diagnostic function is activated, the information display displays the DTC stored in the memory.
The DTC consists of the following codes and numbers:
- Supplier code (indicates manufacturer)
- Part number (indicates malfunctioning part)
- Error code (indicates malfunction description)
Refer to the Service Section for the display method.
Supplier code
1
2
Supplier name
SANYO Automedia
Panasonic
Clarion
Pioneer
Parts number
SUPPLIER CODE
Parts name
03
05
CD player
CD changer (external)
06
07
CD changer (upper module)

MD player (lower module)
09
10
MP3 applicable CD player
21
Center panel
22
MP3 applicable CD changer
Base unit
01
Malfunction description
Internal mechanism error
02
Servo mechanism error
07
08
Disc reading error
Error code
09-20-6
Blank media
\
.-.-.-,........2
1
.--'.'-' '-'
ERROR CODE
\
07:Er011
PART NUMBER
DCF920ZTBA09
ENTERTAINMENT
Error code
09
10
17
18
19
20
21
22
DTC
03: Er01
03: Er02
03: Er07
03: Er10
05: Er01
05: Er07
05: Er10
06: Er01
06: Er02
06: Er07
06: Er10
07: Er01
07: Er02
07: Er07
07: Er08
07: Er10
09: Er20
09: Er21
09: Er22
10: Er01
10: Er02
10: Er07
10: Er09
10: Er10
21: Er17
21: Er18
21: Er19
22: Er01
22: Er02
22: Er07
22: Er09
22: Er10
no Er.r
Malfunction description
Unplayable files or tracks
BUS line (communication line) error
Incorrect combination
Incorrect combination
Communication line
Insufficient power supply
Amplifier related circuit
Tuner error
Screen display
Output signal
CHECK CD
CHECK CD
-
CHECK CD
CHECK CD
CHECK CD
-
CHECKMD
CHECKMD
-
CHECK CD
CHECK CD
CHECK CD
CHECK CD
CD player system
CD player system
CD player system
CD player communication circuit system
CD changer system
CD changer system
CD changer communication circuit system
CD changer system
CD changer system
CD changer system
CD changer communication circuit system
MD player system
MD player system
MD player system
MD system
MD player communication circuit system
Power supply circuit to base unit
Base unit (peripheral circuit for power amplifier)
Base unit (peripheral circuit for tuner)
MP3 applicable CD player system
MP3 applicable CD data
MP3 applicable CD player communication circuit system
Center panel system
Center panel system
Center panel system
CD system
CD system
CD system
MP3 applicable CD data
MP3 applicable CD changer system
No DTCs stored
Diagnostic Assist Function

The diagnostic assist function displays the operating condition of the following functions (components) and
forces them to operate in order to examine whether they are malfunctioning or not.
For the start procedure of each mode, refer to the Service Section.
09-20-7
ENTERTAINMENT
Information display
The diagnostic assist function illuminates all
characters in the information display to check for
truncated or faint characters.
,-, '_1_ ,-1 ,-1 I
STCI:lI(J)@(i)@@@134
6.11"IRIPTIAUTOIMIRDMIAFIPTY'ITAITPII
,-; ,-; _,-;
,-; MD
IN
"
___, _,
CD IN
c
1
..... .....
DCF902ZWBS04
Speaker
The diagnostic assist function outputs sound to the speakers in the following order to determine the operating
condition of the speakers and wiring harnesses between the base unit and each speaker.
1. Front speaker and tweeter (LH)
2. Front speaker and tweeter (RH)
3. Rear speaker*1 (LH)
4. Rear speaker*1 (RH)
*1 : Mayor may not be equipped, depending on the vehicle.
Radio
The diagnostic assist function displays the radio
reception condition in 10 levels (0-9) to assist in
determining the condition of the antenna, antenna
feeders, and base unit (tuner).
S-METER
?
I
""""-'"'
0-9
E5U920ZS5008
Antenna control condition

The diagnostic assist function displays the output
state of the antenna amplifier power supply to
determine the condition of the antenna amplifier,
base unit, and wiring harness between the base
unit and antenna amplifier.
ANTENNA AMPLIFIER POWER SUPPLY IS OUTPUT
I=INT-ON
ANTENNA AMPLIFIER POWER SUPPLY IS NOT OUTPUT
I=INT-OFF
E5U920ZS5202
09-20-8
ENTERTAINMENT
AUDIO UNIT STRUCTURAL VIEW
dcf092066900to7
CBF920ZW4001
AUDIO UNIT CONSTRUCTION

Terminal Layout and Signals
AM/FM radio with CD player
dcf092066900to8
Terminal
Signal
1A
Input RH (+)
1B
Signal ground
1C
Input LH (+)
10
Combi cont
1E
101M 1K 11
1G1E 1C 1A
~~
~jJ j2J!iJq Gl GCl

1~ ~i ~J fHfF ~o
1P
1B
1F
Aux cont
1G
Bus ground
1H
Bus line
11
ACC
1J
Power ground
1K
B+ (power back up)
1L
System mute (input)
1M
TNS (+)
1N
Illumination (-)
10
1P
2A
ACC
2B
2C
2K
2M
2A
2E 2C
/~FlI~ 11
1'-------1
~=
2N
2L 2J 2H 2F 20
"
3C
31
3A
~
Q.Q~
3J
3H 3F
3D
'3B
'2B
B+ (power back up)
2D
2E
TNS (+)
2F
2H
2J
2K
Front speaker LH (+)
2L
Front speaker LH (-)
2M
Front speaker RH (+)
2N
Front speaker RH (-)
3A
Rear speaker LH (+)
3B
Rear speaker LH (-)
3C
3D
3F
Rear speaker RH (+)
3H
Rear speaker RH (-)
31
3J
4A
Ground (power)
09-20-9
POWER SYSTEMS
09-21
POWER SYSTEMS
POWER SYSTEMS STRUCTURA

VIEW ........................ 09-21-1
POWER SYSTEMS STRUCTURAL VIEW
dcf092167730t02
DCF921ZTBOOl
09-21-1
INSTRUMENTATION/DRIVER INFO.
09-22
INSTRUMENT CLUSTER OUTLINE ....

INSTRUMENT CLUSTER
SPECiFiCATIONS .................
INSTRUMENT CLUSTER
STRUCTURAL ViEW ..............
INSTRUMENT CLUSTER
SYSTEM WIRING DIAGRAM . .......
INPUT/OUTPUT CHECK MODE
OUTLINE . .......................
INPUT/OUTPUT CHECK MODE
OPERATION .....................
LIGHTS-ON REMINDER WARNING
ALARM OUTLINE . ................
ALARM CONSTRUCTION/
OPERATION .....................
KEY REMINDER WARNING ALARM
OUTLINE . .......................
09-22-1
09-22-1
09-22-2
09-22-3
09-22-5
09-22-5
09-22-6
09-22-6
09-22-7
KEY REMINDER WARNING

ALARM CONSTRUCTION/
OPERATION . .................... . 09-22-7
SPEEDOMETER CONTROL
OUTLINE ........................ 09-22-7

SPEEDOMETER CONTROL
TACHOMETER CONTROL OUTLINE .. . 09-22-8
TACHOMETER CONTROL
FUEL GAUGE CONTROL OUTLINE . .. . 09-22-8
FUEL GAUGE CONTROL
WATER TEMPERATURE GAUGE
CONTROL OUTLINE . ............. . 09-22-9
CONTROL CONSTRUCTION/
OPERATION . .................... . 09-22-9
HORN CONSTRUCTION ............ . 09-22-9
INSTRUMENT CLUSTER OUTLINE
dcf09225543Ot01
LEDs have been adopted for warning and indicator lights installed on the instrument cluster.
A flat-type horn has been adopted.
INSTRUMENT CLUSTER SPECIFICATIONS
Instrument Cluster
dcf092255430t02
Specification
Item
Meter type
Speedometer
Indication range
Input signal source
Rated voltage
(km/h)
Stepping motor type

0-180
(V)
Speedometer sensor
DC12
Meter type
Indication range
Tachometer
Red zone
(rpm)
(rpm)
Input signal source

Rated voltage
Meter type
Fuel gauge
Input signal source

Rated voltage
(V)
Odometer/
Tripmeter
Warning
alarms
DC12
Stepping motor type
(Medium range stabilized type)
Water temperature sender unit (WL-3)
ECT sensor (WL-C, WE-C)
Input signal source

Rated voltage
PCM
DC12
Stepping motor type (Reset-to-zero type)
Fuel gauge sender unit
(V)
Meter type
Water
temperature
gauge
Stepping motor type

0-5,000
4,500-5,000 (WL-3, WL-C)
4,250-5,000(WE-C)
(V)
Display
DC12
LCD
Odometer: 6 digits, Tripmeter: 4 digits
Indication digits
Rated voltage
Sound frequency
(V)
DC12
(Hz)
2,000-2,200
Output sound pressure level
(dB)
67.5
Clock
Item
Clock accuracy (Reference value)'
(s/day)
Specification
-1.5-1.5
: If the clock accuracy varies largely from the reference value, battery deterioration or an audio unit (base unit)
malfunction may have occurred.
09-22-1
INSTRUMENT CLUSTER STRUCTURAL VIEW
id092200101200
Meter And Gauge

TACHOMETER
SPEEDOMETER
ODOMETEMRIPMETER
TRIPMETER SWITCH
FUEL GAUGE
arnffn00000036
Warning And Indicator Light
arnffn00000420
09-22-2
No.
Warning and indicator light

RFW indicator light
Input signal source

RFW control module
4x4 indicator light
RFW main switch
3
4
Turn indicator light

High-beam indicator light
Flasher control module

Headlight (HI)
Fuel-level warning light
ABS warning light
Brake system warning light
Generator warning light
10
Security light
11
Oil pressure warning light
12
Door ajar warning light

Sedimentor warning light
MIL
13
14
15
16
17
18
19
20
ABS HU/CM (with 4-W ABS)

ABS control module (with rear ABS)
Parking brake switch
Brake fluid level sensor
ABS HU/CM (with 4-W ABS)
ABS control module (with rear ABS)
SAS control module
Note
4x4
4x4
With ASS
With air bag system
Generator
Immobilizer unit
Theft deterrent control module
Oil pressure,switch
Door switches
Sediment switch
PCM
PCM
Front fog indicator light

Rear fog indicator light
Front fog light relay

Rear fog light relay
Seat belt warning light

Selector indicator light
OlD OFF indicator light
Buckle switch
TCM
TCM
WE-C, WL-3, WL-C, WLT-1, WLT-2
WE-C, WL-3, WL-C, WLT-1, WLT-2

With front fog light
AT
AT
09-22-2a
INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM
id092200101300
TACHOMETER
~E~GAUGE~PEEDOMETER
rr.=;i;l
~
~I-----;
~ ~ ~~
I
;: : :
~__________~~'~-41~-;
I'--_-H-'"\.,.l'-I+_ _
i.--
r-~~i.--
--{~}---V----i
'2i3
MICROCOMPUTER
~'l-------I
PCM
Iv
WATER TEMPERATURE SENDER UNIT

OR ECT SENSOR
~1
r- fo,J------+----,
~
~}---------i
riTi'i'\l
~}-----------------------'
r
KEY REMINDER SWITCH
~
~~--{----{~r---E-N-G-IN-E-K-E-Y-~IL~L-U-M-IN-~-J-IO-N--~~
r-~-~~r---------,
'2s:l-----I
~}----------------------~~
'2Fl---"\.,
IPANEL LIGHT
ICONTROL SWITCH I
TRIPMETER SWITCH
SPEEDOMETER SENSOR
VEHICLE SPEED
SIGNAL OUTPUT
ODOMETERITRIPMETER
*~
r--
b.
~
~r_--~-H-~~r----------r;-~-,
'-'
-VI;K J
I~ST;UMENT
CLUSTER
ILLUMINATION
FUEL-LEVEL
I ~WAR~G LIGHT
I ~
~
DOOR SWITCH
(DRIVER-SIDE)
DOOR SWITCH
/
(PASSENG~R-SIDE)
I.e-
DOOR AJAR
WARNI~G LIGHT
LIGHT
SWITCH
~+
~. ~OOR S~'TCH (L~ ~1l--+!--l<I---O<&-'1,,->,\fv-----tt-=DOOR SWITCH (RR)
,j;'
}-J
l6
TNSRELAY
oo'~-------q+-t-t-----rm'"
c::.::rt-o-..-o--J1
~~~~~~r---r--ir.
SECURJ6,Y LIGHT
!;.+
~,}---+------(,...,,~tr------tt--"
klMMOBILIZER UNIT
THEFT-DETERRENT
CONTROL MODULE
. - - - ....................... -
:
:
~"O-Vt-r-{(~HE)}A'-'DLIGHT
GENERATOR L :rgl--t1rt<J----4>---~~.Wv-----i
'r,GENERATOR
.............. - - - - .. - - ...... - - - --I
WARNING LIGHT
l~_________________
HEADLIGHT
RELAY
-------,0;---------.
p ~ --- --;~~f!~~~~~Ij
SEDIME~WITCH
:
.~,
'
'SEDIMENTOR:
, h
' 1G
<ai}--_ _ _ _-+-__
FOG
wr;-c, Wl.-S, Wl.-C.
---1_l+~
. . o_ilf_T-N-S- '~
.tn;{,
I F~ FOG
!.Jr FRONT LIGHT RELAY
REAR
INDICATOR LIGHT 8+
WLT-1, WLT-2
(;\
~ ,--_...,-_~IDI.'tr-----'-'T
FOG
I ~
LIGHT
,..,
~
~----~r-~ky~--------_1--------~~~
r-"
~
IJJ
.....
1.Jr
HIGH-BEAM
IN_D_IC_~_JtI<t5.'0:9JRWiL,-IG--HT--+____{~iI_----------'
r--__
TURN INDICATOR
I'-"
TURN INDICATOR
TURN
TURN ~HT (RH)
REAR
FOG
LIGHT
R~ FOG
LIGHT RELAY
~_L_IG_H_T~(L~~H~)\fv-_--I_-;~'~____________~-f---~~8~+--1
~_L_IG_H_T_(...,R,Q(~H~)\fv----I--;~. ~
_----
.........
....,.
-------.........
.Jr
L~HT (LH)
FLASHER
~g~1~~L
arnffn00000062
09-22-3
r---.-___a
---
RFW CONTROL II--___(~}---;R~F-W-IN-D-I-C_ij<

IDIATqrOWR\r-L_IG_H_T_.
MODULE
R
"-"
RFW MA.!!i.WITCH
4X4 INDICATOR LIGHT
r----+I--~
...
~~1_ _ _--(~~-~---IDI~Mr--_.
rv
,j,.
'0'
-WLT-1, WLT-2
-WL-C, WE-C
-WL-3 (WITH
4W-ABS)
I--"'-_(~J-t---';"'----t------------...J-Wi--r--------+-:_+
ABS HU/CM (WITH

4W-ABS) or ABS
CONTROL MODULE
(WITH REAR ABS)
"
:h
l_t' _____________ j
ABSWARNING
LI~T
---------------.
'
:I. ,b.
:
______________ ...
I . ______ _
WITHOUTABS
(WL-C, WE-C, WLT-1, WLT-2)
---,!<,7------i-;,
-----------~---------~
WITHOUT 4W-ABS (WL-3)

BRAKE FLUID
LEVEL SENSOR
r---{/r=/r--~_+:-----------{-~}_~--'~--~IDIMr--_.
-WLT-1':WLT-2 :- -::------- ~
'BRAKESYSTEM
-WL-C, WE-C :
:
WARNING LIGHT
-WL-3 (WITH
:
:
4W-ABS)
::
r-_--;~~~__'~-J_ ___1~r---~
,j,. ~R~NG
~
BRAKE SWITCH
r----;~~~-----_{~~~---~~~M---_+
"J,.. BUCKLE SWITCH
SEAT BELT
WARNING LIGHT
i'--'
WITH AIR
BAG SYSTEM
1-----------------
!ISASCONTROLI~:~--_(~r---t-------~----~
p ,- -, ~
:1.:
!IMODULE
:- - - - - - - - - - - - - - - - J!!
WITHOUT AIR!. !
BAG SYSTEM ,___ J
OIL PRESS~ SWITCH
~
AIR
BAG~YSTEM
WARNING LIGHT
r-
OIL PRESSURE
WARNINX LIGHT
~r----------~'O'~----~
i--------l------t'1l
PCM
-.;.;.. ,---------------.:':"-----------'1A: GLOW INDIC~OR LIGHT
V/
WE-C, WL-3, WL-C,

WLT-1, WLT-2
J---l"" :________________"::: __________ J
L...-_ _ _ _
arnffn00000063
09-22-4
INSTRUMENT CLUSTER SYSTEM WIRING DIAGRAM[5R55S]
TACHOMETER
WATER TEMPER~ GAUGE

FUEL GAUGE
FUEL GAUGE~DER UNIT
J,.
I~
~PEEDOMETER
"/
~~~~
I-- ODOMETERfTRIPMETER
,.
- !---o~~
id0922001013z3
I-- TRIPMETER SWITCH
g
~
I~'
If
VEHICLE SPEED
SIGNAL OUTPUT
MICROCOMPUTER
IPANEL LIGHT
CONTROL SWITCH I
n.
IV
.----
r bro
I'-"
I'-'
1I
I;':;;
.."
r-!
I--
ENGINE KEY,lkLUMINATION
i=
KEY REMINDER SWITCH
I'-'
~
I'-'
~
OR ECT SENSOR
1~1
"2J
L-s
PCM
~
kA
TCM
I~ST;UMENT
CLUSTER
ILLUMINATION
FUEL-LEVEL
DOOR SWITCH
(DRIVER-SIDE)
DOOR SWITCH
/
(PASSENG R-SIDE)
~[~ '0"' ~
It WARN~G
LIGHT
DOOR AJAR
WARNI~G LiGHT
kH
~
LIGHT
SWITCH
~+
"-"
,l;"
, DOOR SWITCH (LR)

.",.
.",.
DOOR SWITCH (RR)
I IMMOBILIZER UNIT
THEFT-DETERRENT
CONTROL MODULE
I GENERATOR
SEDIME~WITCH
,J,.
L.........J
J
B+
H~LlGHT (HIFW
0-
kl...
~ p~
'P1G
iADLIGHT ( L ; \
to.
,J;"' >-0...,.0
SEDIMENTOR
WARNING LIGHT
FRONT FOG
I.h-
"-"
~j:r
CV
-----
I.h-
'fcl
1M
P
TURN INDICATOR
LIGHT (RAil
"-"
;a,
'-"
TURN INDICATOR
LIGHT (LJciI
TURN L~HT (LH)
~
p
TURN
-,
j.:
;a,
I FRONT FOG
FRONT LIGHT RELAY
FOG
LIGHT
'-"
HIGH-BEAM
INDICAT,RR LIGHT
11
INDICATO~..IGHT ~
I .-:-::-01"
TNS
-3
"-"
REAR FOG
HEADLIGHT
RELAY
,J;"' )-()..,2""""'
GENERATOR
WARNING LIGHT
INDICATO~IGHT
09-22-4a
A-
J-+
SECURJJ,Y LIGHT
~
p
~RE~Y
,j,.
.."
~HT (RH)
"'"
REAR
FOG
LIGHT
J ~J J
REAR FOG
LIGHT RELAY
FLASHER
CONTROL
MODULE
arnffn00000293
-.------
--
4L INDICATOR LIGHT
~--~1F~--~----~~~~--~
\;,,;...
'U'
TCM
4X4 INDICATOR LIGHT
~----~1D'~--~-----4~~~--~
~
'U'
ASS HU/CM (WITH
4W-ASS) or ASS
t--....--{'2l~_-----1~--...J.t.~--~
CONTROL MODULE
~
~
(WITH REAR ABS)
~ .
,
~
ABSWARNING
LI~T
---------------.
'
: m-
1- ______________ ...
WITHOUTABS
(WL-C, WE-C, WLT-1, WLT-2)
BRAKE FLUID
LEVEL SENSOR
r---~~~----~----~1P~~--~--~~~~--~
'=--'
BRAKESYSTEM
WARNING LIGHT
\;,,;...
r----+v~~---4------~~.r---~
,.J,.. PARKING
BRAKE SWITCH
r----+v~~----------~1a.~~------~~~~--~
,.J,.. BUCKLE SWITCH
SEAT BELT
WARNING LIGHT
OlD OFF
"-"
OlD OFF INDICATOR LIGHT

TCM
WITH AIR
BAG SYSTEM
1-----------------
ilsASCONTROL~:~--;~r_--~------~r_--~
il MODULE
: ,- -,
i
i
:________________ J
WITHOUT AIRi" i
BAG SYSTEM ,___ J
OIL PRESS~ SWITCH
~
*-
~ . AIR BAGq,YSTEM
WARNING LIGHT
OIL PRESSURE
WARNINQ LIGHT
~r---------~~~~--~
r---------LI__~~r_--~----~~~IL~----_i
~
PCM
'--______
1_
"-"
GLOW INDIC,IlTOR LIGHT
r----~A,r_--~------~r~Wr--~
p
'U'
"-"
--
SELECTOR INDICATOR LIGHT

arnffn00000294
09-22-4b
INPUT/OUTPUT CHECK MODE OUTLINE
dcf092255430t05
The microcomputer built into instrument cluster detects the quality of input signals and individual parts.
Input/output check mode has both input circuit inspection and individual part inspection functions.
INPUT/OUTPUT CHECK MODE OPERATION
I.
dcf09225543Ot06
Operation procedure
Refer to Workshop Manual.
Input circuit check
When the parts listed in the chart are operated and a signal is output to the instrument cluster, the built-in
microcomputer determines the operability of the input circuit based on that signal.
Check
code
04
08
10
11
22
24
31
Parts sending input signal

Door switch
TNS relay
Engine speed signal
ECT sensor
Water temperature sender unit
Key reminder switch
DOOR
SWITCH
TNS
RELAY
SPEEDOMETER
SENSOR
PCM
INSTRUMENT
CLUSTER
MICROCOMPUTER
FUEL GAUGE
SENDER UNIT
I~
~
ECT SENSOR OR
WATER
TEMPERATURE
SENDER UNIT
II
KEY REMINDER
SWITCH
LCD
~
DCF922ZTB005
09-22-5
Individual circuit check
By operating the parts listed in the chart, the built-in microcomputer determines the operability of the individual
parts.
Check
code
12
13
14
16
18
23
25
26
Parts sending input signal

Speedometer
Tachometer
Buzzer
Fuel-level warning light
Engine key illumination output
Fuel gauge
Water temperature gauge
LCD, warning and indicator light
SP(;TERG)
TACHOMETER
BUZZER
WATER
TEMPERATURE
GAUGE
LCD,
WARNING AND
INDICATOR LIGHT
ENGINE KEY
ILLUMINATION
c~
MICROCOMPUTER
INSTRUMENT CLUSTER
DCF922ZTB006
LIGHTS-ON REMINDER WARNING ALARM OUTLINE
dcf09225543Ot07
Warns the driver that the headlights or TNS are on when the driver-side door is opened.
LIGHTS-ON REMINDER WARNING ALARM CONSTRUCTION/OPERATION
dcf092255430t08
System Wiring Diagram

B+
B+
TO LIGHT
SWITCH
INSTRUMENT
CLUSTER
MICROCOMPUTER
BUZZER
DOOR SWITCH
(DRIVER-SIDE)
DCF922ZTB007
Operation
The buzzer in the instrument cluster sounds continuously when all the following three conditions are met:
The engine switch is in the LOCK or ACC position.
- The headlight switch is in the TNS or headlight position.
- The driver-side door is open (driver-side door switch is on).
09-22-6
KEY REMINDER WARNING ALARM OUTLINE
dcf09225543Ot11
Warns the driver that the key is in the steering lock when the driver-side door is opened.
,r
KEY REMINDER WARNING ALARM CONSTRUCTION/OPERATION
dcf09225543Ot1
~\ .
B+KEY REMINDER
IG1
B+
~TCH
INSTRUMENT CLUSTER
BUZZER
DOOR SWITCH
(DRIVER-SIDE)
DCF922ZTB008
Operation
The buzzer in the instrument cluster sounds when all the following three conditions are met:
The engine switch is in the LOCK or ACC position.
- The key is in the steering lock (key reminder switch is on).
- The driver-side door is open (driver-side door switch is on).
SPEEDOMETER CONTROL OUTLINE
dcf09225543Ot15
The vehicle speed signal is output from the speedometer sensor to the microcomputer in the instrument cluster.
SPEEDOMETER CONTROL CONSTRUCTION/OPERATION
dcf09225543Ot16
System Wiring DiagramIG1
B+
SPEEDOMETER
INSTRUMENT
CLUSTER
Operation
The vehicle speed signal sent from the speedometer sensor is input to the microcomputer in the instrument
cluster. The microcomputer calculates the current vehicle speed based on the vehicle speed signal, and sends
an output signal to the speedometer.
09-22-7
TACHOMETER CONTROL OUTLINE
dcf09225543ot17
The engine speed signal is output from the PCM to the microcomputer in the instrument cluster.
TACHOMETER CONTROL CONSTRUCTION/OPERATION
,
dcf092255430t 18

IG1
B+
TACHOMETER
INSTRUMENT
CLUSTER
DCF922ZTB010
Operation
The engine speed signal sent from the PCM is input to the microcomputer in the instrument cluster. The
microcomputer calculates the current engine speed based on the engine speed signal, and sends an output
signal to the tachometer.
FUEL GAUGE CONTROL OUTLINE
dcf092255430t 19
The fuel level signal is output from the fuel gauge sender unit to the microcomputer in the instrument cluster.
Fuel gauge variation caused by fluctuating fuel level when cornering or driving on a slope, is reduced by
microcomputer control.
FUEL GAUGE CONTROL CONSTRUCTION/OPERATION
dcf09225543ot20

IG1
INSTRUMENT
CLUSTER
B+
FUEL GAUGE
Operation
A resistance according to fuel level is sent from the fuel gauge sender unit to the microcomputer. The
microcomputer calculates the average resistance within a specified time, and sends the output signal to the fuel
gauge based on the calculated value.
09-22-8
WATER TEMPERATURE GAUGE CONTROL OUTLINE
dcf09225543Ot21
The engine coolant temperature signal is output from the water temperature sender unit or ECT sensor to the
microcomputer in the instrument cluster.
WATER TEMPERATURE GAUGE CONTROL CONSTRUCTION/OPERATION
dcf09225543Ot22

IG1 B+

INSTRUMENT
CLUSTER
WATER TEMPERATURE
SENDER UNIT OR ECT SENSOR
DCF922ZTB012
Operation
The engine coolant temperature signal sent from the water temperature sender unit or ECT sensor is input to
the microcomputer in the instrument cluster. The microcomputer calculates the current engine coolant
temperature based on the engine coolant temperature signal, and sends an output signal to the water
temperature gauge.
HORN CONSTRUCTION
dcf09226679Ot01
A flat-type horn has been adopted.
DCF922ZTB013
09-22-9
ALPHABETICAL INDEX
A
AlC COMPRESSOR CONSTRUCTION ......... 07-11-4
AlC CUT-OFF CONTROL
BLOCK DIAGRAM [WL-3] ................. 01-40A-14
AlC CUT-OFF CONTROL
CONDITION [WL-3] ...................... 01-40A-14
AlC CUT-OFF CONTROL OUTLINE [WL-3] .... 01-40A-14
AlC CUT-OFF CONTROL
BLOCK DIAGRAM [WL-C, WE-C] ........... 01-40B-18
AlC CUT-OFF CONTROL
OPERATION [WL-C, WE-C] ............... 01-40B-18
AlC CUT-OFF CONTROL
OUTLINE [WL-C, WE-C] .................. 01-40B-18
ABS CM PART CONSTRUCTION/
OPERATION [REAR ABS] ................. 04-13A-6
ABS CM PART FUNCTION [4W-ABS] ......... 04-13B-5
ABS CM PART FUNCTION [REAR ABS] ....... 04-13A-5
ABS CONTROL OPERATION [REAR ABS] ..... 04-13A-8
ABS CONTROL OPERATION [4W-ABS] ....... 04-13B-6
ABS CONTROL OUTLINE [4W-ABS] .......... 04-13B-5
ABS CONTROL OUTLINE [REAR ABS] ........ 04-13A-7
OPERATION [4W-ABS] .................... 04-13B-3
ABS HU PART FUNCTION [4W-ABS] .......... 04-13B-3
ABS HU PART FUNCTION [REAR ABS] ....... 04-13A-2
ABS HU/CM CONSTRUCTION [4W-ABS] ...... 04-13B-2
ABS OUTLINE [4W-ABS] ................... 04-13B-1
ABS OUTLINE [REAR ABS] ................. 04-13A-1
ABS SPEED SENSOR AND ABS
SENSOR ROTOR CONSTRUCTION/
ABS SPEED SENSOR FUNCTION
[REAR ABS] ............................ 04-13A-8
ABS STRUCTURAL VIEW [4W-ABS] .......... 04-13B-1
ABS STRUCTURAL VIEW [REAR ABS] ........ 04-13A-1
[4W-ABS] .............................. 04-13B-2
[REAR ABS] ............................ 04-13A-2
ABS SENSOR ROTOR FUNCTION
[4W-ABS] ........................ , ...... 04-13B-6
ABS SENSOR ROTOR
CONSTRUCTION/OPERATION [4W-ABS] ..... 04-13B-6
CONSTRUCTION [WL-C, WE-C] ............ 01-13B-6
DESCRIPTION [WL-3] .................... 01-13A-5
(APP) SENSOR CONSTRUCTION/
OPERETION [WL-3] ..................... 01-40A-18
(APP) SENSOR DESCRIPTION
[WL-C, WE-C] .......................... 01-40B-23
(APP) SENSOR FUNCTION [WL-3] ......... 01-40A-18

(APP) SENSOR FUNCTION
[WL-C, WE-C] .......................... 01-40B-23
AIM OF DEVELOPMENT ..................... 00-00-1
AIR BAG SYSTEM OUTLINE. ................. 08-10-1
AIR BAG SYSTEM STRUCTURAL VIEW ........ 08-10-2
AIR BAG SYSTEM WIRING DIAGRAM .......... 08-10-2
AIR CHARGING SYSTEM DIAGRAM
[WL-C, WE-C] ........................... 01-13B-4
AIR CHARGING SYSTEM OPERATION
[WL-C, WE-C] ........................... 01-13B-4
AIR CHARGING SYSTEM OUTLINE
[WL-C, WE-C] ........................... 01-13B-4
AIR CLEANER CONSTRUCTION [WL-3] ....... 01-13A-3
AIR CLEANER CONSTRUCTION
[WL-C, WE-C] ........................... 01-13B-3
AUDIO SYSTEM BLOCK DIAGRAM ............ 09-20-2
AUDIO SYSTEM OUTLINE ................... 09-20-1
AUDIO SYSTEM SPECIFICATIONS ............ 09-20-2
AUDIO SYSTEM STRUCTURAL VIEW .......... 09-20-1
AUDIO UNIT CONSTRUCTION ................ 09-20-9
AUDIO UNIT STRUCTURAL VIEW ............. 09-20-9
AUTO LEVEL CONTROL (ALC) FUNCTION ...... 09-20-5
OPERATION ............................. 09-20-5
AUTO TENSIONER CONSTRUCTION
[WL-C, WE-C] ........................... 01-10B-8
B
BASIC SYSTEM LOCATION INDEX ............ 07-11-1
BLOWER MOTOR CONSTRUCTION ........... 07-40-2
BLOWER UNIT CONSTRUCTION/OPERATION .. 07-11-2
BODY AND ACCESSORIES ABBREVIATIONS ... 09-00-1
BODY AND ACCESSORIES FEATURES ........ 09-00-1
BODY PANEL OUTLINE ..................... 09-10-1
BODY PANEL STRUCTURAL VIEW ............ 09-10-1
BOOST PRESSURE CONTROL
OUTLINE [WL-C, WE-C] .................. 01-40B-12
BOOST SENSOR CONSTRUCTION/
OPERATION [WL-3] ..................... 01-40A-17
BOOST SENSOR CONSTRUCTION/
BOOST SENSOR FUNCTION [WL-3] ......... 01-40A-17
BOOST SENSOR FUNCTION [WL-C, WE-C] ... 01-40B-22
BRAKE ABBREVIATIONS .................... 04-00-1
BRAKE FEATURES ......................... 04-00-1
BRAKE SPECIFICATIONS ................... 04-00-2
11m
CAMSHAFT CONSTRUCTION [WL-3] ......... 01-10A-9

CAMSHAFT CONSTRUCTION [WL-C, WE-C] ... 01-10B-8
[WL-C, WE-C] .......................... 01-40B-26
AI-1
ALPHABETICAL INDEX
FUNCTION [WL-C, WE-C] .................01-40B-25
CENTER PANEL UNIT OUTLINE .............. 09-20-3
CENTER PANEL UNIT CONSTRUCTION ........ 09-20-3
CHARGE AIR COOLER
CONSTRUCTION [WL-3] ................... 01-13A-4
CHARGE AIR COOLER
CONSTRUCTION [WL-C, WE-C] ............. 01-13B-6
CHARGING SYSTEM OUTLINE
[WL-3, WL-C, WE-C] ....................... 01-17-1
CHARGING SYSTEM STRUCTURAL
VIEW [WL-3, WL-C, WE-C] .................. 01-17-1
CHECK VALVE (TWO-WAY)
CONSTRUCTION/OPERATION [WL-3] ........ 01-16A-7
FUNCTION [WL-3] ........................ 01-16A-7
CHECK VALVE FUNCTION [WL-C, WE-C] ..... 01-14B-13
CLIMATE CONTROL UNIT CONSTRUCTION .... 07-40-4
CLUTCH COVER OUTLINE
[S15M-D, S15MX-D] ........................ 05-10-2
CONSTRUCTION .......................... 05-10-2
SWITCH CONSTRUCTION/
OPERETION [WL-3] ... , .................. 01-40A-24
SWITCH FUNCTION [WL-3] ...............01-40A-24
SWITCH DESCRIPTION [WL-C, WE-C] ...... 01-40B-28
SWITCH FUNCTION [WL-C, WE-C] ......... 01-40B-27
CLUTCH RELEASE CYLINDER construction ..... 05-10-2
CLUTCH STRUCTURAL VIEW ................ 05-10-1
COMMON RAIL CONSTRUCTION
[WL-C, WE-C] ..........................01-14B-10
COMMON RAIL FUNCTION [WL-C, WE-C] ..... 01-14B-10
COMMON RAIL INJECTION
SYSTEM FUNCTION [WL-C, WE-C] .......... 01-14B-4
COMMUNICATION FUNCTION [WL-3] ......... 01-02A-4
CONDENSER CONSTRUCTION ............... 07-11-5
CONNECTING ROD, CONNECTING ROD
BEARING CONSTRUCTION [WL-3] .......... 01-10A-7
CONNECTING ROD, CONNECTING ROD
. BEARING CONSTRUCTION [WL-C, WE-C] .... 01-10B-5
CONTROL SLEEVE (CS) SENSOR
CONSTRACTION/OPERATION [WL-3] ....... 01-40A-21
FUNCTION [WL-3] .......................01-40A-20
CONTROL SYSTEM LOCATION INDEX ......... 07-40-1
CONTROL SYSTEM OUTLINE ................ 07-40-1
CONTROL SYSTEM WIRING DIAGRAM ....... . 07-40:-2
CONVENTIONAL BRAKE SYSTEM OUTLINE .... 04-11-1
CONVENTIONAL BRAKE
SYSTEM STRUCTURAL ViEW ............... 04-11-1
COOLING FAN CONSTRUCTION
[WL-C, WE-C] ............................01-12B-4
COOLING FAN CONSTRUCTION [WL-3] ....... 01-12A-4
COOLING SYSTEM
FLOW DIAGRAM [WL-C, WE-C] ............. 01-12B-2
COOLING SYSTEM OUTLINE [WL-3] .......... 01-12A-1
COOLING SYSTEM OUTLINE [WL-C, WE-C] ....01-12B-1
COOLING SYSTEM STRUCTURAL
VIEW [WL-C, WE-C] .......................01-12B-1
COOLING SYSTEM FLOW DIAGRAM JWL-3] .... 01-12A-2
AI-2
COOLING SYSTEM
STRUCTURAL VIEW [WL-3] ............... 01-12A-1
COOLING UNIT
CONSTRUCTION/OPERATION ............. , 07-11-3
SENSOR FUNCTION [WL-3] .............. 01-40A-22
SENSOR CONSTRUCTION/
OPERATION [WL-3] ..................... 01-40A-23
. SENSOR CONSTRUCTION/
SENSOR FUNCTION [WL-C, WE-C] ........ 01-40B-26
CRANKSHAFT PULLEY
CRANKSHAFT PULLEY, DRIVE BELT
CONSTRUCTION [WL-3] .................. 01-10A-5
CRANKSHAFT, MAIN BEARING
CRANKSHAFT, MAIN BEARING, THRUST
BEARING CONSTRUCTION [WL-3] ......... 01-10A-4
CYLINDER BLOCK CONSTRUCTION [WL-3] ... 01-10A-3
CYLINDER BLOCK
CYLINDER HEAD CONSTRUCTION [WL-3] .... 01-10A-2
CYLINDER HEAD CONSTRUCTION
[WL-C, WE-C] ........................... 01-10B-2
CYLINDER HEAD COVER
CYLINDER HEAD COVER,
CYLINDER HEAD COVER GASKET
D
DIAGNOSTIC SYSTEM
WIRING DIAGRAM [WL-3] ................. 01-02A-2
DIAGNOSTIC SYSTEM
WIRING DIAGRAM [WL-C, WE-C] ........... 01-02B-2
DLC-2 CONSTRUCTION [4W-ABS] ........... 04-028-5
DOUBLE CONE SYNCHRONIZER
MECHANISM CONSTRUCTION/
OPERATION [S15M-D, S15MX-D] ........... 05-11B~7
MECHANISM OPERATION [R15M-D] ........ 05-11A-4
DOUBLE cone SYNCHRONIZER
MECHANISM OUTLINE
[S15M-D, S15MX-D] ...................... 05-11B-7
MECHANISM STRUCTURE [R15M-D] ....... 05-11A-3
DRIVE BELT CONSTRUCTION [WL-C, WE-C] .. 01-10B-5
DRIVELINE/AXLE ABBREVIATIONS .......... , 03-00-1
DRIVELINE/AXLE FEATURES ............... , 03-00-1
DRIVELINE/AXLE SPECIFICATIONS .......... 03-00-2
CONSTRUCTION/OPERATION ............. , 08-10-5
DRIVER-SIDE AIR BAG MODULE FUNCTION ... 08-10-4
CONDITIONS [WL-3] ..................... 01-02A-6
ALPHABETICAL INDEX
CONDITIONS [WL-C, WE-C] ............... 01-02B-9
DTC TABLE [WL-3] ........................ 01-02A-4
DTC TEST MODE [WL-C, WE-C] ............. 01-02B-6
DUAL-MASS FLYWHEEL FUNCTION
[S15M-D, S15MX-D] ....................... 05-10-3
E
EGR CONTROL BLOCK DIAGRAM [WL-3] .... 01-40A-13
EGR CONTROL BLOCK
DIAGRAM [WL-C, WE-C] ................. 01-40B-17
EGR CONTROL OPERATION [WL-3] ......... 01-40A-13
EGR CONTROL OPERATION [WL-C, WE-C] ... 01-40B-17
EGR CONTROL OUTLINE [WL-3] ., ......... 01-40A-13
EGR CONTROL OUTLINE [WL-C, WE-C] ..... 01-40B-17
DESCRIPTION [WL-3] .................... 01-16A-5
DESCRIPTION [WL-C, WE-C] .............. 01-16B-5
FUNCTION [WL-3] ....................... 01-16A-5
FUNCTION [WL-C, WE-C] ................. 01-16B-5
EGR COOLER DESCRIPTION [WL-3] ......... 01-16A-6
EGR COOLER DESCRIPTION [WL-C, WE-C] ... 01-16B-6
EGR COOLER FUNCTION [WL-3] ............ 01-16A-5
EGR COOLER FUNCTION [WL-C, WE-C] ...... 01-16B-5
EGR SORENOID VALVE (VACUUM, VENT)
DESCRIPTION [WL-3] .................... 01-16A-5
EGR SORENOID VALVE (VACUUM, VENT)
FUNCTION [WL-3] ....................... 01-16A-5
EGR SORENOID VALVE
DESCRIPTION [WL-C, WE-C] .............. 01-16B-5
EGR SORENOID VALVE
EGR SYSTEM DIAGRAM [WL-3] ............. 01-16A-4
EGR SYSTEM DIAGRAM [WL-C, WE-C] ....... 01-16B-4
EGR SYSTEM FUNCTION [WL-3] ............ 01-16A-4
EGR SYSTEM FUNCTION [WL-C, WE-C] ...... 01-16B-4
EGR SYSTEM OPERATION [WL-3] ........... 01-16A-4
EGR SYSTEM OPERATION [WL-3] ........... 01-16A-5
EGR SYSTEM OPERATION [WL-C, WE-C] ..... 01-16B-4
EGR SYSTEM OPERATION [WL-C, WE-C] ..... 01-16B-5
EGR SYSTEM OUTLINE [WL-3] .............. 01-16A-4
EGR SYSTEM OUTLINE [WL-C, WE-C] ........ 01-16B-4
FUNCTION [WL-3] ...................... 01-40A-23
FUNCTION [WL-C, WE-C] ................ 01-40B-27
ELECTRONIC GOVERNOR
ELECTRONIC GOVERNOR
FUNCTION [WL-3] ....................... 01-14A-6
ELECTRONIC GOVERNOR
OPERATION [WL-3] ...................... 01-14A-7
EMISSION SYSTEM DIAGRAM [WL-3] ........ 01-16A-3
EMISSION SYSTEM DIAGRAM [WL-C, WE-C] .. 01-16B-3
EMISSION SYSTEM OUTLINE [WL-3] ......... 01-16A-1
EMISSION SYSTEM OUTLINE [WL-C, WE-C] ... 01-16B-1
VIEW [WL-3] ............................ 01-16A-2
VIEW [WL-C, WE-C] ...................... 01-16B-2
Ii
ENGINE ABBREVIATIONS ................... 01-00-1

BLOCK DIAGRAM [WL-3] .................. 01-40A-7
BLOCK DIAGRAM [WL-C, WE-C] ............ 01-40B-9
DIAGRAM [WL-3] ......................... 01-40A-4
DIAGRAM [WL-C, WE-C] ................... 01-40B-4
OUTLINE [WL-3] ......................... 01-40A-2
OUTLINE [WL-C, WE-C] ................... 01-40B-2
RELATION CHART [WL-3] ................. 01-40A-8
RELATION CHART [WL-C, WE-C] .......... 01-40B-10
STRUCTURAL VIEW [WL-3] ................ 01-40A-3
STRUCTURAL VIEW [WL-C, WE-C] .......... 01-40B-3
(ECT) SENSOR CONSTRUCTIONI
OPERATION [WL-3] ................ " ... 01-40A-22
(ECT) SENSOR CONSTRUCTIONI
(ECT) SENSOR FUNCTION [WL-3] ......... 01-40A-22
(ECT) SENSOR FUNCTION [WL-C, WE-C] ... 01-40B-25
ENGINE FEATURES [WL-3, WL-C, WE-C] ....... 01-00-2
ENGINE MOUNT STRUCTURAL VIEW
[WL-3] ................................. 01-10A-10
ENGINE MOUNT STRUCTURAL
VIEW [WL-C, WE-C] ...................... 01-10B-9
ENGINE SPECIFICATION [WL-3] .............. 01-00-3
ENGINE SPECIFICATION [WL-C, WE-C] ........ 01-00-5
ENGINE STRUCTURAL VIEW [WL-3] .... " .... 01-10A-1
ENGINE STRUCTURAL VIEW [WL-C, WE-C] .... 01-10B-1
EVAPORATIVE CHAMBER
CONSTRUCTION/OPERATIN [WL-3] ......... 01-16A-7
EVAPORATIVE CHAMBER
FUNCTION [WL-3] ........................ 01-16A-7
EXHAUST SYSTEM OUTLINE [WL-3] .......... 01-15A-1
EXHAUST SYSTEM OUTLINE [WL-C, WE-C] ... 01-15B-1
VIEW [WL-3] ............................ 01-15A-1
VIEW [WL-C, WE-C] ...................... 01-15B-1
EXTERIOR TRIM OUTLINE ................... 09-16-1
EXTERIOR TRIM STRUCTURAL VIEW ......... 09-16-1
Ii
FilII
FAIL-SAFE FUNCTION [WL-3] ............... 01-02A-4

FAILURE DETECTION FUNCTION [WL-3] ...... 01-02A-4
FAILURE INDICATION FUNCTION [WL-3] ...... 01-02A-4
FRONT AXLE OUTLINE ..................... 03-11-1
FRONT AXLE CROSS-SECTIONAL VIEW ....... 03-11-1
AI-3
ALPHABETICAL INDEX
FRONT BRAKE (DISC) CONSTRUCTION ....... 04-11-6
CONSTRUCTION .......................... 09-18-3
FRONT DRIVE SHAFT
CROSS-SECTIONAL VI EW .................. 03-13-1
FRONT DRIVE SHAFT OUTLINE .............. 03-13-1
FRONT LOWER ARM AND TIE ROD
CONSTRUCTION [4x2 (EXCEPT Hi-Rider)] ..... 02-13-3
FRONT SUSPENSION DESCRIPTION .......... 02-13-3
FRONT SUSPENSION OUTLINE .............. 02-13-1
FRONT SUSPENSION STRUCTURAL ViEW ..... 02-13-1
FRONT WHEEL ALIGNMENT DESCRIPTION .... 02-11-1
FUEL CUT SOLENOID VALVE
FUNCTION [WL-3] ........................01-14A-8
OPERATION [WL-3] ....................... 01-14A-8
OPERATION [WL-3] ....................... 01-14A-4
OPERATION [WL-C, WE-C] ................. 01-14B-5
FUEL FILTER FUNCTION [WL-3] ............. 01-14A-4
FUEL FILTER FUNCTION [WL-C, WE-C] ....... 01-14B-4
FUEL GAUGE CONTROL OUTLINE ............ 09-22-8
FUEL GAUGE CONTROL
CONSTRUCTION/OPERATION .............. 09-22-8
BLOCK DIAGRAM [WL-C, WE-C] .......... .Q1~40B-13
CONTROL BLOCK DIAGRAM [WL-3] ........ 01-40A-10
OPERATION [WL-C, WE-C] ................01-40B-13
CONTROL OUTLINE [WL-3] ...............01-40A-10
OUTLINE [WL-C, WE-C] .................. 01-40B-12
CONTROL OPERATION [WL-3] ............ 01-40A-11
FUEL INJECTION PUMP
FUEL INJECTION PUMP FUNCTION [WL-3] .... 01-14A-4
FUEL INJECTION PUMP OPERATION [WL-3] ... 01-14A-5
CONTROL OPERATION [WL-3] ............ 01-40A-12
OPERATION [WL-C, WE-C] ................ 01-40B-14
CONTROL OUTLINE [WL-3] ...............01-40A-12
OUTLINE [WL-C, WE-C] .................. 01-40B-13
BLOCK DIAGRAM [WL-3] .................01-40A-12
FUEL INJECTOR CONSTRUCTION
[WL-C, WE-C] ...........................01-14B-10
FUEL INJECTOR FUNCTION [WL-C, WE-C] ... 01-14B-10
FUEL INJECTOR OPERATION [WL-C, WE-C] .. 01-14B-12
FUEL METERING VALVE
[WL-C, WE-C] ...........................01-14B-9
FUEL METERING VALVE
FUNCTION [WL-C, WE-C] ..................01-14B-9
AI-4

OUTLINE [WL-C, WE-C] .................. 01-40B-16
[WL-C, WE-C] ......................... 01-40B-25
FUEL PUMP SPEED SENSOR
CONSTRUCTION [WL-3] ................. 01-40A-20
FUNCTION [WL-3] ...................... 01-40A-19
OPERATION [WL-3] ..................... 01-40A-20
FUEL SYSTEM DIAGRAM [WL-3] ............ 01-14A-3
FUEL SYSTEM DIAGRAM [WL-C, WE-C] ...... 01-14B-3
FUEL SYSTEM OUTLINE [WL-3] ............. 01-14A-1
FUEL SYSTEM OUTLINE [WL-C, WE-C] ....... 01-14B-1
FUEL SYSTEM STRUCTUAL VIEW [WL-3] ..... 01-14A-2
FUEL SYSTEM STRUCTURAL VIEW
[WL-C, WE-C] ........................... 01-14B-2
FUEL TANK CONSTRUCTION [WL-C, WE-C] ... 01-14B-4
FUEL TANK CONSTRUCTION [WL-3] ......... 01-14A-4
.
[WL-C, WE-C] ......................... 01-40B-24
CONSTRUCTION/OPERATION [WL-3] ...... 01-40A-19
FUNCTION [WL-3] ...................... 01-40A-19
G
G SENSOR CONSTRUCTION/
OPERATION [4W-ABS] ................... 04-13B-7
G SENSOR FUNCTION [4W-ABS] ............ 04-13B-7
GENERATOR CONSTRUCTION
[WL-3, WL-C, WE-C] .................... " 01-17-2
GLOW CONTROL BLOCK DIAGRAM [WL-3] ... 01-40A-9
GLOW CONTROL
BLOCK DIAGRAM [WL-C, WE-C] .......... 01-40B-11
GLOW CONTROL OPERATION
[WL-C, WE-C] ......................... 01-40B-12
GLOW CONTROL OPERATION [WL-3] ........ 01-40A-9
GLOW CONTROL OUTLINE [WL-3]. .......... 01-40A-9
GLOW CONTROL OUTLINE [WL-C, WE-C] ... 01-40B-11
GLOW PLUG CONSTRUCTION [WL-3] ........ 01-13A-7
GLOW PLUG CONSTRUCTION [WL-C, WE-C] .. 01-13B-7
GLOW PLUG FUNCTION [WL-3] ............. 01-13A-6
GLOW PLUG FUNCTION [WL-C, WE-C] ....... 01-13B-6
GLOW PLUG OUTLINE [WL-3] " ............ 01-13A-6
GLOW PLUG RELAY OPERATION [WL-3] ..... 01-13A-7
GLOW PLUG RELAY OPERATION
[WL-C, WE-C] .......................... 01-13B-7
GLOW SYSTEM CONSTRUCTION
[WL-C, WE-C] .......................... 01-13B-6
GLOW SYSTEM OPERATION [WL-3] ......... 01-13A-5
GLOW SYSTEM OPERATION [WL-C, WE-C] ... 01-13B-6
GLOW SYSTEM OUTLINE [WL-3] ............ 01-13A-5
GLOW SYSTEM OUTLINE [WL-C, WE-C] ...... 01-13B-6
ALPHABETICAL INDEX
H
HORN CONSTRUCTION ....................
HVAC ABBREVIATION ......................
HVAC FEATURES ..........................
HVAC SPECIFICATIONS ....................
09-22-9
07-00-1
07-00-1
07-00-1
I
IDLE SPEED CONTROL BLOCK
DIAGRAM [WL-C, WE-C] ................. 01-40B-11
IDLE SPEED CONTROL
IDLE SPEED CONTROL OUTLINE
[WL-C, WE-C] .......................... 01-40B-10
IDLE SWITCH CONSTRUCTION/
OPERETION [WL-3] ..................... 01-40A-19
IDLE SWITCH DESCRIPTION
[WL-C, WE-C] .......................... 01-40B-24
IDLE SWITCH FUNCTION [WL-3] ............ 01-40A-19
IDLE SWITCH FUNCTION [WL-C, WE-C] ..... 01-40B-23
IMMOBILIZER SYSTEM BLOCK
DIAGRAM [WL-C, WE-C] ................. 01-40B-19
IMMOBILIZER SYSTEM
IMMOBILIZER SYSTEM OPERATION ......... 09-14-10
IMMOBILIZER SYSTEM
OUTLINE [WL-C, WE-C] .................. 01-40B-19
IMMOBILIZER SYSTEM OUTLINE ............. 09-14-7
IMMOBILIZER SYSTEM STRUCTURAL VIEW ... 09-14-8
IMMOBILIZER SYSTEM SYSTEM
COMPONENT. : .......................... 09-14-9
IMMOBILIZER SYSTEM WIRING DIAGRAM ..... 09-14-8
INJECTION NOZZLE
CONSTRUCTION/OPERATION [WL-3] ....... 01-14A-9
INJECTION NOZZLE FUNCTION [WL-3] ....... 01-14A-9
INJECTION PUMP EPROM
FUNCTION [WL-3] ....................... 01-14A-9
INPUT/OUTPUT CHECK MODE OPERATION .... 09-22-5
INPUT/OUTPUT CHECK MODE OUTLINE ...... 09-22-5
INSTRUMENT CLUSTER OUTLINE ............ 09-22-1
INSTRUMENT CLUSTER SPECIFICATIONS ..... 09-22-1
INSTRUMENT CLUSTER
STRUCTURAL VIEW ...................... 09-22-2
INSTRUMENT CLUSTER
SYSTEM WIRING DIAGRAM ................ 09-22-3
INTAKE AIR SYSTEM DIAGRAM [WL-3] ....... 01-13A-3
INTAKE AIR SYSTEM DIAGRAM
[WL-C, WE-C] ........................... 01-13B-3
ROUTING DIAGRAM [WL-3] ................ 01-13A-2
ROUTING DIAGRAM [WL-C, WE-C]. ......... 01-13B-2
INTAKE AIR SYSTEM OUTLINE [WL-3] ........ 01-13A-1
INTAKE AIR SYSTEM OUTLINE
[WL-C, WE-C] ........................... 01-13B-1
VIEW [WL-3] ............................ 01-13A-1
VIEW [WL-C, WE-C] ...................... 01-13B-2

SENSOR NO.1 FUNCTION [WL-3] ......... 01-40A-16
SENSOR NO.1 FUNCTION [WL-C, WE-C] .... 01-40B-21
INTAKE AIR TEMPERATURE (lAT)
OPERATION [WL-3] ..................... 01-40A-16
SENSOR NO.2 FUNCTION [WL-3] .......... 01-40A-15
SENSOR NO.2 FUNCTION [WL-C, WE-C] .... 01-40B-21
INTAKE SHUTIER SOLENOID VALVE
DESCRIPTION [WL-C, WE-C] ............... 01-16B-6
INTAKE SHUTIER VALVE
DESCRIPTION [WL-C, WE-C] ............... 01-16B-6
INTERIOR TRIM OUTLINE ................... 09-17-1
INTERIOR TRIM STRUCTURAL VIEW .......... 09-17-1
K
KEY REMINDER WARNING ALARM OUTLINE ... 09-22-7
KEY REMINDER WARNING
ALARM CONSTRUCTION/OPERATION ........ 09-22-7
KEYLESS ENTRY SYSTEM OPERATION ....... 09-14-2
KEYLESS ENTRY SYSTEM OUTLINE .......... 09-14-1
STRUCTURAL VIEW ....................... 09-14-1
WIRING DIAGRAM ........................ 09-14-2
KOEO/KOER SELF-TEST [WL-3] ............. 01-02A-8
KOEO/KOER SELF-TEST [WL-C, WE-C] ...... 01-02B-16
L
LIGHTING SYSTEM OUTLINE ................ 09-18-1
LIGHTING SYSTEM STRUCTURAL VIEW ....... 09-18-2
LIGHTING SYSTEMS SPECIFICATION ......... 09-18-1
ALARM CONSTRUCTION/OPERATION ........ 09-22-6
ALARM OUTLINE ......................... 09-22-6
LOAD LIMITER RETRACTOR
VALVE (LSPV) CONSTRUCTION ............. 04-11-3
VALVE (LSPV) OPERATION ................. 04-11-4
LUBRICATION SYSTEM
FLOW DIAGRAM [WL-3] ................... 01-11A-2
LUBRICATION SYSTEM
FLOW DIAGRAM [WL-C, WE-C] ............. 01-11B-3
LUBRICATION SYSTEM OUTLINE [WL-3] ...... 01-11A-1
LUBRICATION SYSTEM OUTLINE
[WL-C, WE-C] ........................... 01-11B-1
VIEW [WL-3] ............................ 01-11A-1
VIEW [WL-C, WE-C] ...................... 01-11B-2
AI-5
II
'
ALPHABETICAL INDEX
M
MAGNETIC CLUTCH CONSTRUCTION ......... 07-40-3
MANUAL AIR CONDITIONER
CONTROL SYSTEM ....................... 07-40-4
[R15M-D] ...............................05-11A-1
[S15M-D, S15MX-D] ....................... 05-11B-1
MANUAL TRANSMISSION POWER
FLOW [S15M-D, S15MX-D] .................05-11B-3
MANUAL TRANSMISSION
[S15M-D, S15MX-D] ....................... 05-11 B-2
MANUAL TRANSMISSION
CROSS-SECTIONAL VIEW [R15M-D] ......... 05-11 A-1
MANUAL TRANSMISSION
POWER FLOW [R15M-D] ..................05-11A-2
[WL-C, WE-C] ..........................01-40B-20
MASS AI R FLOW (MAF) SENSOR
FUNCTION [WL-3] ....................... 01-40A-14
FUNCTION [WL-C, WE-C] .................01-40B-20
MASTER CYLINDER CONSTRUCTION ......... 04-11-2
MEMORY FUNCTION [WL-3] ................01-02A-4
MMINTAKE AIR TEMPERATURE (IAT)
OPERATION [WL-3] ...................... 01-40A-17
OPERATION [WL-C, WE-C] ................01-40B-15
MULTIPLE FUEL INJECTION
CONTROL OUTLINE [WL-C, WE-C] ......... 01-40B-15
II
NEUTRAL SWITCH CONSTRUCTION/

NEUTRAL SWITCH FUNCTION
[WL-C, WE-C] ........................... 01-40B-28
NEUTRAL SWITCH FUNCTION [WL-3] ........ 01-40A-24
NEUTRAL SWITCH OPERATION [WL-3] ...... 01-40A-24
II
NEW STAN DARDS ........................ 00-0()-'14
II

CONSTRUCTION [WL-C, WE-C] ............. 01-11B-4
OIL FILTER CONSTRUCTION [WL-3] .......... 01-11A-2
OIL FILTER CONSTRUCTION [WL-C, WE-C] .... 01-11 B-3
OIL JET VALVE CONSTRUCTION/
OPERATION [WL-C, WE-C] .................01-11B-6
OIL JET VALVE
OIL PAN CONSTRUCTION [WL-3] ............ 01-11A-3
AI-6
OIL PAN CONSTRUCTION [WL-C, WE-C] ..... 01-11B-4

OIL PUMP CONSTRUCTION [WL-3] .......... 01-11A-4
OIL PUMP CONSTRUCTION [WL-C, WE-C] .... 01-11 B-5
OIL STRAINER CONSTRUCTION
[WL-C, WE-C] ........................... 01-118-5
OIL STRAINER CONSTRUCTION [WL-3] ...... 01-11A-4
[AI R BAG SYSTEM] . . . . . . . . . . . . . . . . . . . . . . . 08-02-1
[WL-C, WE-C] .......................... 01-02B-1
ON-BOARD DIAGNOSTIC OUTLINE [WL-3] .... 01-02A-1
[REMOTE FREEWHEEL (RFW)] ............. 03-02-1
OUTLINE ............................... 08-02-1
ON-BOARD DIAGNOSTIC SYSTEM ACTIVE
COMMAND MODES FUNCTION [4W-ABS] ... 04-02B-3
EXTERNAL TESTER COMMUNICATION
FUNCTION [4W-ABS] ..................... 04-02B-4
FUNCTION [4W-ABS] ..................... 04-02B-2
FUNCTION [REAR ABS] ................. , 04-02A-1
OUTLINE [4W-ABS] ...................... 04-02B-1
OUTLINE [REAR ABS] .................... 04-02A-1
PID/DATA MONITOR FUNCTION [4W-ABS] ... 04-02B-3
[IMMOBILIZER SYSTEM] .................. 09-14-11
FUNCTION ... " ....................... " 09-20-6
ON-BOARD DIAGNOSTIC SYSTEM OUTLINE. " 09-20-6
OVERFLOW VALVE CONSTRUCTION [WL-3] .. 01-14A-6
OVERFLOW VALVE FUNCTION [WL-3] ....... 01-14A-6
OXIDATION CATALYTIC
CONVERTER FUNCTION [WL-3] ........... 01-16A-6
OPERATION [WL-3] ...................... 01-16A-6
II
PARKING BRAKE SYSTEM OUTLlNE. ......... 04-12-1

STRUCTURAL VIEW .................... " 04-12-1
CONSTRUCTION/OPERATION ............ " 08-10-5
FUNCTION ............................ " 08-10-5
PCM CONSTRUCTION [WL-3] .............. 01-40A-14
PCM CONSTRUCTION [WL-C, WE-C] ........ 01-40B-19
PCM FUNCTION [WL-3] ................... 01-40A-14
PCM FUNCTION [WL-C, WE-C] ............. 01-40B-19
..,
ALPHABETICAL INDEX
PID/DATA MONITOR AND RECORD
[WL-C, WE-C] .......................... 01-02B-15
PID/DATA MONITOR AND RECORD [WL-3] .... 01-02A-7
PISTON CONSTRUCTION [WL-C, WE-C] ...... 01-10B-4
PISTON, PISTON RING, PISTON PIN
POWER BRAKE UNIT CONSTRUCTION ........ 04-11-2
POWER OUTER MIRROR OUTLINE ........... 09-12-3
POWER OUTER MIRROR SYSTEM
WIRING DIAGRAM ........................ 09-12-4
POWER OUTER MIRROR OPERATION ........ 09-12-5
POWER OUTER MIRROR
STRUCTURAL VIEW ...................... 09-12-4
CONSTRUCTION ......................... 06-14-4
POWER STEERING OUTLINE ................ 06-14-1
POWER STEERING STRUCTURAL VIEW ....... 06-14-2
POWER SYSTEMS STRUCTURA VIEW ........ 09-21-1
POWER WINDOW SYSTEM OUTLINE ......... 09-12-2
POWER WINDOW SYSTEM OPERATION ....... 09-12-3
POWER WINDOW SYSTEM
STRUCTURAL VIEW ...................... 09-12-2
POWER WINDOW SYSTEM
WIRING DIAGRAM ........................ 09-12-3
PRE-TENSIONER SEAT BELT FUNCTION ...... 08-10-6
R
REAR AXLE OUTLINE ...................... 03-12-1
REAR AXLE CROSS-SECTIONAL VIEW ........ 03-12-1
REAR BRAKE (DRUM) CONSTRUCTION ....... 04-11-7
REAR BRAKE (DRUM) OPERATION ........... 04-11-8
STRUCTURAL VIEW ...................... 09-18-4
REAR DIFFERENTIAL
CROSS-SECTIONAL VIEW ................. 03-14-1
REAR DIFFERENTIAL OUTLINE .............. 03-14-1
REAR SUSPENSION OUTLINE ............... 02-14-1
REAR SUSPENSION STRUCTURAL ViEW ...... 02-14-1
OPERATION ............................. 09-12-2
WIRING DIAGRAM ........................ 09-12-1
REAR WINDOW DEFROSTER OUTLINE ....... 09-12-1
STRUCTURAL VIEW ...................... 09-12-1
REFRIGERANT LINE CONSTRUCTION ........ 07-11-5
CONSTRUCTION ......................... 07-40-4
COMPONENTS AND FUNCTIONS ........... 03-18-2
CONSTRUCTION ......................... 03-18-1
REMOTE FREEWHEEL (RFW) OPERATION .... 03-18-4
SYSTEM DIAGRAM ....................... 03-18-3
REMOTE FREEWHEEL (RFW) OUTLINE ........ 03-18-1

RESISTOR CONSTRUCTION ................. 07-40-3
RESONANCE CHAMBER OUTLINE [WL-3] ..... 01-13A-7
RESTRAINTS ABBREVIATIONS ............... 08-00-1
RESTRAINTS FEATURES .................... 08-00-1
CONSTRUCTION/OPERATION [R15M-D] ..... 05-11A-6
[S15M-D, S15MX-D] ...................... 05-11B-8
FUNCTION [R15M-D] ..................... 05-11A-6
FUNCTION [S15M-D, S15MX-D] ............. 05-11B-8
ROLLOVER VALVE
ROLLOVER VALVE
[WL-C, WE-C] ........................... 01-16B-7
ROLLOVER VALVE FUNCTION [WL-3] ........ 01-16A-6
ROLLOVER VALVE FUNCTION [WL-C, WE-C] .. 01-16B-7
SAS CONTROL MODULE

SAS CONTROL MODULE FUNCTION .......... 08-10-3
SEAT BELT OUTLINE ....................... 08-11-1
SEAT BELT STRUCTURAL ViEW .............. 08-11-1
SEATS OUTLINE ........................... 09-13-1
SEATS SPECIFICATION ..................... 09-13-1
SEATS STRUCTURAL VIEW ................. 09-13-2
SECURITY AND LOCKS OUTLINE ............. 09-14-1
FUNCTION [R15M-D] ..................... 05-11A-5
FUNCTION [S15M-D, S15MX-D] ............. 05-11B-7
OPERATION [R15M-D] .................... 05-11A-5
OPERATION [S15M-D, S15MX-D] ........... 05-11B-7
SHIFT MECHANISM OUTLINE
[S15M-D, S15MX-D] ...................... 05-11 B-4
SHIFT MECHANISM STRUCTURE [R15M-D] .... 05-11A-3
SIDE AIR BAG MODULE FUNCTION ........... 08-10-5
SIDE AIR BAG MODULE
SIMULATION TEST [WL-3] .................. 01-02A-8
SIMULATION TEST [WL-C, WE-C] ........... 01-02B-16
SPEEDOMETER CONTROL
SPEEDOMETER CONTROL OUTLINE .......... 09-22-7
STARTER CONSTRUCTION
[WL-3, WL-C, WE-C] ....................... 01-19-1
STARTING SYSTEM OUTLINE
[WL-3, WL-C, WE-C] ....................... 01-19-1
STARTING SYSTEM STRUCTURAL
VIEW [WL-3, WL-C, WE-C] .................. 01-19-1
STEERING ABBREVIATION .................. 06-00-1
STEERING FEATURES ...................... 06-00-1
CONSTRUCTION ......................... 06-14-3
STEERING SHAFT CONSTRUCTION .......... 06-14-5
STEERING SPECIFICATIONS ................ 06-00-1
AI-7
III
IiiII
ALPHABETICAL INDEX
SUPPLY PUMP CONSTRUCTION/
SUPPLY PUMP FUNCTION [WL-C, WE-C] ...... 01-14B-5
SUSPENSION ABBREVIATIONS .............. 02-00-1
SUSPENSION FEATURES ................... 02-00-1
SUSPENSION SPECIFICATIONS .............. 02-00-2
TURBOCHARGER FUNCTION [WL-C, WE-C] .. 01-13B-5
UNITS .................................. 00-00-13
~===T==~III~I====V==~
TACHOMETER CONTROL OUTLINE ........... 09-22-8
TACHOMETER CONTROL
THEFT-DETERRENT SYSTEM CONDITION ..... 09-14-4
INPUT/OUTPUT DIAGRAM .................. 09-14-4
THEFT-DETERRENT SYSTEM OUTLINE ........ 09-14-2
THEFT-DETERRENT SYSTEM PHASE ......... 09-14-5
STRUCTURAL VIEW ....................... 09-14-3
SYSTEM WIRING DIAGRAM ................. 09-14-3
THERMOSTAT CONSTRUCTION/
OPERATION [WL-3] ....................... 01-12A-3
THERMOSTAT CONSTRUCTION/
OPERATION [WL-C, WE-C] .................01-12B-3
TIMER CONTROL VALVE (TCV)
FUNCTION [WL-3] ........................01-14A-8
TIMER POSITION SENSOR
CONSTRUCTION/OPERETION [WL-3] ...... 01-40A-22
FUNCTION [WL-3] .......................01-40A-21
TIMING GEAR CONSTRUCTION [WL-3] ....... 01-10A-8
TIMING GEAR CONSTRUCTION
[WL-C, WE-C] ...........................01-10B-6
TRANSFER OUTLINE ....................... 03-16-1
TRANSFER POWER FLOW .................. 03-16-2
TRANSFER CROSS-SECTIONAL VIEW ......... 03-16-1
TRANSMISSIONITRANSAXLE
ABBREVIATIONS ......................... 05-00-1
TRANSMISSIONITRANSAXLE FEATURES ...... 05-00-1
SPECIFICATIONS ......................... 05-00-1
MECHANISM OPERATION
[S15M-D, S15MX-D] ....................... 05-11B-5
MECHANISM STRUCTURE
[S15M-D, S15MX-D] ....................... 05-118-5
TURBOCHARGER CONSTRUCTION [WL-3] .... 01-13A-3
TURBOCHARGER CONSTRUCTION/
TURBOCHARGER DESCRIPTION [WL-3] ......01-13A-4
TURBOCHARGER FUNCTION [WL-3] ......... 01-13A-3
AI-8
VACUUM CHAMBER FUNCTION

[WL-C, WE-C] .......................... 01-13B-7
VACUUM CHECK VALVE
VACUUM CHECK VALVE FUNCTION
[WL-C, WE-C] ........................... 01-13B-7
VACUUM PUMP CONSTRUCTION ............ 04-11-2
VIEW [WL-3] ............................ 01-10A-7
VIEW [WL-C, WE-C] ...................... 01-10B-6
VALVE, ROCKER ARM
VALVE, ROCKER ARM
VARIABLE BOOST CONTROL (VBC)
SOLENOID VALVE CONSTRUCTION
[WL-C, WE-C] ........................... 01-13B-3
SOLENOID VALVE FUNCTION
[WL-C, WE-C] ........................... 01-13B-3
(VIN) CODE ............................ 00-00-12
VEHICLE IDENTIFICATION NUMBERS (VIN) ... 00-00-12
WASHER TANK SPECIFICATION ............. 09-19-4

WATER PUMP CONSTRUCTION/
OPERATION [WL-3] ...................... 01-12A-3
WATER PUMP CONSTRUCTION/
CONTROL CONSTRUCTION/
OPERATION ............................. 09-22-9
CONTROL OUTLINE ...................... 09-22-9
WHEEL AND TIRES OUTLINE ................ 02-12-1
WHEEL AND TIRES STRUCTURAL VIEW ...... 02-12-1
WIPER SYSTEM OPERATION ................ 09-19-2
WIPER SYSTEM OUTLINE .................. 09-19-1
WIPER SYSTEM WIRING DIAGRAM ........... 09-19-2
WIPERIWASHER SYSTEM OUTLINE .......... 09-19-1
WIPERIWASHER SYSTEM
STRUCTURAL VIEW ...................... 09-19-1
SERVICE
PROCEDURES
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-trained technicians in mind. This manual
may be useful to non-Ford 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 expected to at least 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 Motor
Company 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 Motor Company 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 replacement parts or
with parts which match the quality of genuine Ford replacement
parts. Persons using replacement parts of lesser quality than that
of genuine Ford replacement parts must satisfy themselves
thoroughly that neither personal safety nor safety of the vehicle
will be jeopardized.
Ford Motor Company 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 servicerelated training, use of improper tools, use of replacement parts
of lesser quality than that of genuine Ford replacement parts, or
not being aware of any revision of this manual.
VEHICLE IDENTIFICATION NUMBERS (VIN)

MNA
MNA
MNA
MNA
BS******
DS******
LS******
US******
i.
RELATED MATERIALS
RANGER Training Manual .......................
RANGER Overhaul Manual ......................
RANGER Body Measurement Chart Manual ........
RANGER Wiring Diagrams.......................
F340-10-0SL
F198-20-0SL
F34D-20-0SL
F198-30-0SL
PJ Ranger
Overhaul Manual
(Part No. OHM380)
WARNING
may be useful to.non-Ford trained technicians, but a technician
procedures.
problems includes but is noflimited to insufficient servicerelated training, use of improper tools, use of replacement parts
not being aware ofany revl.sion of this manual.
,
CONTENTS
Title
GENERAL INFORMATION
RANGER
Overhaul
Manual
ENGINE
MANUAL TRANSMISSION
FOREWORD
This Manual explains the disassembly,

inspection, repair, and reassembly
procedures for the above-indicated engines
and manual transmissions. 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 DECEMBER 2005. 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.
Ford Motor Company
ENGINE
DRIVE LINE/AXLE
TRANSMISSIONI
TRANSAXLE
2005 Ford Sales & Sarvice (Thailand) Co., Ltd.
PRINTED IN THAILAND, DECEMBER 2005
F198-20-05L
GENERAL INFORMATION
SECTION
GENERAL INFORMATION . .. 00-00
00-00
GENERAL INFORMATION
HOW TO USE THIS MANUAL. ..... 00-00-2

UNITS .............. 00-00-5
FUNDAMENTAL PROCEDURES ... 00-00-5
)!
00 m
ELECTRICAL SYSTEM ........ 00-00-9

NEW STANDARDS ....... 00-00-10
ABBREVIATIONS .............. 00-00-12
00-00-1
GENERAL INFORMATION
DCFOOOOOOOOOW01
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (Le., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.
t .
SHOWS PROCEDURE ORDER

FORSE VICE
SHOWS TIGHTENING
_ -.. TORQUE
SPECIFICATIONS
Connect the gauge set from under
the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-00-2
GENERAL INFORMATION
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 removal/installation procedures that 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 requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps 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 additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
ITEM (S)
Procedure
...
"R
III t II t'
emova ns a a Ion
Portion
"U
INDICATES ANY RELEVANT

REFERENCES WHICH NEED
TO BE FOLLOWED DURING
INSTALLATION
LOWER TRAILING LINK UPPER TRAILING LINK REMOVALIINSTALLATION

1.Jack up the rear 01 the vehicle and support it with saletystands.
2. Remove the undercover. (See 01-104 Undercover Removal
3. Remove in the order indicated In the table.
4. Install in the reverse order 01 removal.
'~I~-~~~~;i~~- ~-~~; - - - - , - '-- 5. Inspect the rear wheel alignment and a~djust
it il necessary.
Installation" Portion

FOR SERVICE
INSTALL THE PARTS BY
PERFORMING STEPS
1---3 IN REVERSE ORDER
SHOWS SPECIAL
SERVICE TOOL (SST)
=~ lil~OR SERVICE OPERATION
~Ilm
iii
Q-----
SHOWSTIGHTENI~~'~'~1
43-56 {4.3-S.8.32-41)
TORQUE
SPECIFICATIONS
SHOWS APPLICATION
POINTS OF GREASE, ETC.
I.~
SHOWS NON-REUSEABLE PARTS
SHOWS DETAILS
94-116 (9.5-11.9, 59-86}
SHOWS TIGHTENING
TORQUE UNITS
CD iii
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
Nm{kgfrn,ftlbf)
1
~
3
Split pin
Nut
Qwertralln In al Oint
(See 02-14-5 Lower Trailing Link 8all Joint Removal Note)
7
8
9
SoUtoin
Nut
Upper trailing link ball joint
(See 02-14-5 Upper Trailing Link Ball Joint Removal Note)
Bo[t
LowertraiUn link
Dust boot (lower trailing link)
10
11
12
Nut
Upper trailing link
Dust boot (upper trailing link)
LowerTrailing Link Ball JOint, Upper Trailing Link

Ball Joint Removal Note
Remove the ball joint using the SSTs.
UPPER TRAILING LINK
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
BHEOOOOW104
00-00-3
GENERAL INFORMATION
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol
"
Meaning
Kind
Apply oil
New appropriate
engine oil or gear
oil
II
Apply brake fluid
New appropriate
brake fluid
II
Apply automatic
transaxle/
transmission fluid
New appropriate
automatic
transaxle/
transmission fluid
Apply grease
Appropriate
grease
Apply sealant
Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part
O-ring, gasket,
etc.
Use SST or
equivalent
Appropriate tools
-~
~A
II
~I
e
iii
ED
Advisory Messages
You will 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 or parts 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 indicate 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.
00-00-4
GENERAL INFORMATION
UNITS
DCFOOOOOOOOOW02
Electric current
A (ampere)
Nm (Newton meter)
Electric power
Electric resistance
W (watt)
Electric voltage
Length
Negative pressure
Positive pressure
ohm
V (volt)
in (inch)
kPa (kilo pascal)

L (liter)
mm (millimeter)
US qt (U.S. quart)
Volume

ml (milliliter)
kPa (kilo pascal)
cu in (cubic inch)
fl oz (fluid ounce)
centimeter)

Number of
revolutions
Torque
rpm (revolutions per minute)
Weight
g (gram)
oz (ounce)

from these values.
Rounding Off
an upper limit and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}
270-310 kPa {2.7-3.2 kgf/cm 2 , 39-45 psi}
FUNDAMENTAL PROCEDURES
Preparation of Tools and Measuring Equipment
Be sure that all necessary tools and measuring
equipment are available before starting any work.
DCFOOOOOOOOOW03
CHU0014W003
00-00-5
GENERAL INFORMATION
Special Service Tools
Use special service tools or equivalent when they
are required.
WGIWXX0024E
Disassembly
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.
WGIWXX0027E
Inspection During Removal, Disassembly

When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
t':
,~
WGIWXX0028E
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.
WGIWXX0029E
00-00-6
GENERAL INFORMATION
i'
Cleaning of Parts
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.
C5UOOOOW001
Reassembly
Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, the following parts should be replaced
with new ones:
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
WGIWXX0031E
Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
Use suitable gauges and testers when making
adjustments.
CHU0014W005
00-00-7
GENERAL INFORMATION
Rubber Parts and Tubing
Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
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.
WGIWXX0035E
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the written torque must be
recalculated due to the extra length that the SST
or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
Torque Unit
Nm
kgfm
kgfcm
ftlbf
inlbf
~------------------------~f
1mB
~=======1fp
Formula
Nm x [U (L+A)]
kgfm x [U (L+A)]
kgfcm x [U (L+A)]
ftlbf x [U (L+A)]
inlbf x [U (L+A)]
WGIWXX0036E
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
PROTECTIVE PLATES
CHU0014W010
00-00-8
GENERAL INFORMATION
ELECTRICAL SYSTEM
Connectors
Disconnecting connectors
. , . When disconnecting connector, grasp the
connectors, not the wires.
DCFOOOOOOOOOW04
GOOD
NO GOOD
Connectors can be disconnected by pressing or

pulling the lock lever as shown.
WGIWXX0042E
Locking connector
.
.
When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection
. .
When a tester is used to inspect for continuity or
measuring voltage, insert the tester probe from
the wiring harness side.
GOOD
NO GOOD
00-00-9
GENERAL INFORMATION
Inspect the terminals of waterproof connectors from the connector side since they cannot be accessed from the
wiring harness side.
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
r-------------------------~~----------_.
GOOD
NO GOOD
CHUOOOOW012
NEW STANDARDS
DCFOOOOOOOOOW05

New Standard
Abbreviation
AP
ACL
AlC
BARO
B+
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Barometric Pressure
Brake Switch
Charge Air Cooler
CAC
Closed Loop System
CLS
CTP
CPP
CIS
CS sensor Control Sleeve Sensor
DLC
Data Link Connector
DTM
DTC
DI
DLI
Electronic Ignition
EI
ECT
Engine Modification
EM
EVAP
EGR
FC
Fan Control
FF
Flexible Fuel
4GR
Fourth Gear
Fuel Pump Relay
FSO
solenoid
GEN
Generator
GND
Ground
H02S
Idle Air control
lAC
IDM Relay
00-00-10
Previous Standard
Abbreviation
Remark
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Battery Voltage
Vb
Stoplight
Switch
Crank Angle Sensor
Intercooler
Feedback System
Fully Closed
Idle Switch
Clutch Position
CSP sensor Control Sleeve Position Sensor
Diagnosis Connector
Test Mode
Service Code(s)
Spark Ignition
Direct Ignition
Water Thermo
Engine Modification
Engine RPM Signal
Fan Control
Flexible Fuel
Overdrive
FCV
#6
#6
#1
#2
#3
Fuel Cut Valve
#6
Alternator
Ground/Earth
Oxygen Sensor
Idle Speed Control
Spill Valve Relay
With heater
#6
t)
GENERAL INFORMATION
New Standard
Abbreviation
Name

Injection Pump
InputfTurbine Speed Sensor
IAT
Knock Sensor
KS
MIL
MAP
MFL
On-Board Diagnostic
OBD
OL
Open Loop
Output Speed Sensor
OC
02S
Oxygen Sensor
PNP
PCM Control Relay
PSP
PCM
PAIR
.,
AIR
SAPV
SFI
Pump Speed Sensor
NE Sensor

Reed Valve
12 Shift Solenoid Valve
3rd Gear
Catalytic Converter
Throttle Body
Throttle Sensor
Lockup Position
EC-AT Control Unit
ATF Thermosensor
Inhibitor Position
Turbocharger
IC Regulator
Air flow Sensor
Catalytic Converter
Fully Open
Shift Solenoid A
Shift Solenoid B
Shift Solenoid C
3GR
Third Gear
TWC
Throttle Body
TB
TP sensor Throttle Position Sensor
TCV
Timer Control Valve
TCC
TCM
Module
Temperature Sensor
TR
TC
Turbocharger
VSS
Voltage Regulator
VR
WUTWC
Converter
WOT
Wide Open Throttle
FIP
ECU
TCV
Remark
Name
Fuel Injection Pump

Pulse Generator
Intake Air Thermo
Knock Sensor
Intake Air Pressure
Airflow Sensor
Diagnosis/SelfDiagnosis
Open Loop
Catalytic Converter
Oxygen Sensor
Park/Neutral Range
Main Relay
Engine Control Unit
Previous Standard
Abbreviation
#6
#6
#4
Pulsed
injection
#6
Injection
with air
pump
#6
<,
#5
#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).
#4 : Device that controls engine and powertrain
#5 : Directly connected to exhaust manifold
#6 : Part name of diesel engine
00-00-11
II
GENERAL INFORMATION
ABBREVIATIONS
I:
ATDC
BTDC
Aft er Top Dead Center

EX
HLA
IN
Ex haust
Hydraulic Lash Adjuster
Intake
SST
I:
TDC
VRS
I,i:
VSS
4x2
4x4
!,
'I:
I'
Ii
i!
Ii
1::
':
i
!
'i
!,
!
00-00-12
To p Dead Center
Vi bration Reducing Stiffener
Ve hicle Speed Sensor
4-wheel 2-d rive
4-wheel 4-drive
DCFOOOOOOOOOW06
~!
ENGINE
MECHANICAL [WL-3] ....... 01-10A

MECHANICAL
[WL-C, WE-C] . . . . . . . . . . . . 01-108
TECHNICAL DATA [WL-3] . . . 01-50A
01
SECTION
TECHNICAL DATA
[WL-C, WE-C] ............. 01-508
SERVICE TOOLS [WL-3] ..... 01-60A
SERVICE TOOLS
[WL-C, WE-C] ............. 01-608
01-10A MECHANICAL [WL-3]

ENGINE MOUNTING [WL-3] ........ 01-10A-2,
ENGINE DISMOUNTING [WL-3] .... 01-10A-3
TIMING BELT DISASSEMBLY [WL-3] .. 01-10A-4
CYLINDER HEAD
DISASSEMBLY(I) [WL-3] ...... 01-10A-6
CYLINDER HEAD DISASSEMBLY (II)
[WL-3] ............ 01-10A-8
CYLINDER BLOCK DISASSEMBLY (I)
[WL-3] .................. 01-10A-9
CYLINDER BLOCK DISASSEMBLY (II)
[WL-3] ............. " ...... 01-10A-10
CYLINDER BLOCK DISASSEMBLY (III)
[WL-3] ................ 01-10A-15
CYLINDER HEAD INSPECTION/REPAIR
, . [WL-3] ......... 01-10A-16
VALVE INSPECTION [WL-3] ...... 01-10A-17

VALVE GUIDE INSPECTION [WL-3] . 01-10A-18
VALVE GUIDE REPLACEMENT [WL-3]. 01-10A-19
VALVE SEAT
INSPECTION/REPAIR [WL-3] ... 01-10A-19
VALVE SPRING INSPECTION [WL-3] . 01-10A-20
CAMSHAFT INSPECTION [WL-3] ... 01-10A-21
CAMSHAFT OIL CLEARANCE
INSPECTION [WL-3] ......... 01-10A-21
CAMSHAFT END PLAY
INSPECTION [WL-3] ......... '. 01-10A-22
CYLINDER BLOCK
INSPECTION/REPAIR [WL-3] .. , . 01-10A-22
OIL JET VALVE, NOZZLE
INSPECTION [WL-3] .......... 01-10A-23
PISTON INSPECTION [WL-3] ...... 01-10A-23
PISTON CLEARANCE
INSPECTION/REPAIR [WL-3] .... 01-10A-23
PISTON RING CLEARANCE
INSPECTION [WL-3] ....... 01-10A-23
PISTON PIN CLEARANCE
INSPECTION [WL-3] ........ 01-10A-24
CRANKSHAFT INSPECTION [WL-3] .. 01-10A-25

CRANKSHAFT OIL CLEARANCE
INSPECTION/REPAIR [WL-3] ... 01-10A-26
CRANKSHAFT END PLAY
INSPECTION/REPAIR [WL-3] ...... 01-1 OA-26
CONNECTING ROD INSPECTION
[WL-3] ....................... 01-1 OA-26
CONNECTING ROD OIL CLEARANCE
INSPECTION/REPAIR [WL-3] ...... 01-1 OA-27
CONNECTING ROD SIDE CLEARANCE
INSPECTION [WL-3] ....... 01-10A-27
PISTON AND CONNECTING ROD
INSPECTION [WL-3] ......... 01-10A-28
BOLT INSPECTION [WL-3] ..... 01-10A-28
TENSIONER SPRING INSPECTION
[WL-3] ..................... 01-1 OA-28
VALVE CLEARANCE INSPECTION
[WL-3] ................. 01-1 OA-29
VALVE CLEARANCE. ADJUSTMENT
[WL-3] ........... 01-1 OA-29
INJECTION TIMING ADJUSTMENT
[WL-3] ................... 01-1 OA-30
GEAR CLEARANCE INSPECTION
[WL-3] ...................... 01-10A-32
PLUNGER SPRING INSPECTION,
[WL-3] ................. 01-1 OA-32
CYLINDER BLOCK ASSEMBLY (I)
[WL-3] ........ ';.... 01-1 OA-33
CYLINDER BLOCK ASSEMBLY (II)
[WL-3] .................... 01-1 OA-36
CYLINDER BLOCK ASSEMBLY (III)
[WL-3] .................. 01-1 OA-42
CYLINDER HEAD ASSEMBLY (I)
[WL-3] ................... 01-1 OA-44
CYLINDER HEAD ASSEMBLY (II)
[WL-3] ............... 01-1 OA-46
TIMING BELT ASSEMBLY [WL-3] .. " . 01-10A-51
01-10A-1
IiII
MECHANICAL [WL-3]
ENGINE MOUNTING [WL-3]
1. Install the engine hanger (JE48 10 561 C) or SST
(303-050 (49 UN30 3050)) to the cylinder head
using the bolt (99794 0820 or M8X1.25, ST,
length 20mm {O.79 in}) as shown in the figure.
DCF011002000W01
JE48 10561 C
or SST (303-050 (49 UN30 3050))
Tightening torque
18.S-25.5 Nm {1.90-2.S0 kgfm, 13.8-18.8
ft Ibf}
BOLT
DBG110AEBR01
2. If the SST (303-050 (49 UN30 3050)) is used, use

the SST (49 L017 5AO) when suspending the
engine.
~W~~~~-M8x1.25
BOLT
DBG110AEBR84
3. Install the SST (arms) to the holes as shown in

the figure, and hand tighten the SST (bolts).
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
DBG110AEB003
01-10A-2
MECHANICAL [WL-3]
5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed.
6. Align the SSTs (plate and arms) so that they are
parallel by adjusting the SSTs (bolts and nuts).
7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly.
8. Mount the engine on the SST (engine stand).
II
ENGINE
Warning
The self-locking brake system for the
engine stand may not operate if the
engine is held in an unbalanced position.
DBG110AEB105
This could lead to sudden, rapid
movement of the engine and mounting
stand handle and cause serious injury. Never hold the engine in an unbalanced position, and
always grasp the rotating handle firmly when turning the engine.
9. Remove the engine hanger (JE48 10561 C) or
SST (303-050 (49 UN30 3050)).
10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4-41.2 Nm {3.00-4.20 kgfm, 21.7-30.3
ft.lbf}
DBG110AEB004
ENGINE DISMOUNTING [WL-3]

1. Dismount in the reverse order of mounting.
DCF011002000W02
01-10A-3
TIMING BELT DlSASSE
MECHANICAL [WL-3]
1. Disassembl'
MBLY [WL-3]
er shown in the f'Igure.
_ ____~~e~~In~t~he~or~der~
DCF011002000W03
---=---L.W
.. :a~t"er pump
Vacuum pump
Cylinder
head cover
T
.
Imlng belt cover
pUlley:np;J;la+,:;te---..:....:...~-
01-10A-4
(se:I~~=r1' tensioner sprin
DBG110AEBR05
Ten'
D'.Isassembly
OA-5
Te'
Note
)sloner,g Tensioner S .
Timing b e l t '
__
pnng
ote.)
~ls~as~s~em~~bl~~N~L_...
I
-5 Timing
Belt D'
-L.:..(S:::.:e::e~O~1-~1~OA~2im
_ ____
MECHANICAL [WL-3]
Tensioner, Tensioner Spring Disassembly Note

1. Turn the crankshaft clockwise and align the timing
marks as shown in the figure.
--TIMING MARK
CAMSHAFT
PULLEY
~.
TENSIONER
SPRING
TENSIONER
+---- FUEL INJECTION
PUMP
PULLEY
DBG110AEBR11
Timing Belt Disassembly Note

1. Mark the timing belt rotation on the belt for proper
reinstallation.
'\.
Caution
The following will damage the timing belt
and shorten its life; forcefully twisting it,
turning it inside out, or getting oil or
grease on it.
After removing the timing belt, do not
move the crankshaft and/or camshaft
pulley from this position because it can
cause the valve and piston to contact and
damage them .
~~~
~ROTATION
~I ~
ARROW
30 mm {1.2 in } MIN.
NG
DBG110AEBR10
01-10A-5
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY(I) [WL-3]
DCF011002000W04
1. Disassemble in the order shown in the figure.

LOWER CAP IS MACHINED TOGETHER WITH
CYLINDER HEAD AND CANNOT BE REMOVED
10
11
iii
DBG110AEBR08
2
3
4
Camshaft pulley
(See 01-10A-7 Camshaft Pulley Disassembly
Note.)
Seal plate
Camshaft cap
(See 01-10A-7 Camshaft Cap Disassembly Note.)
Camshaft
(See 01-10A-7 Camshaft Disassembly Note.)
01-10A-6
5
6
7
8
9
10
11
Rocker arm
ECT sensor
Water outlet pipe
Blind cover
Cylinder head
(See 01-1 OA-7 Cylinder Head Disassembly Note.)
Cylinder head gasket
MECHANICAL [WL-3]
Camshaft Pulley Disassembly Note
Caution
Do not move the camshaft from this position because it can cause the valve and piston to contact
each other and damage them.
..
mI
1. Hold the camshaft by using a wrench on the cast

hexagon.
DBG110AEB015
Camshaft Cap Disassembly Note

Caution
Removing the camshaft cap under load can break the camshaft. When removing the camshaft cap,
loosen the locknut and the adjust screw to prevent the camshaft from pressing down the rocker
arm.
Note
Mark the camshaft cap so that they can be reinstalled in the position from which they were removed.
1. Loosen the camshaft cap bolts in three or four

steps in the order shown in the figure.
ENGINE
FRONT
DBG110AEB025
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01-1 OA-21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-3].)
Cylinder Head Disassembly Note
1. Remove bolts A.
2. Loosen the cylinder head bolts in two or three
DBG110AEB016
01-10A-7
MECHANICAL [WL-3]
CYLINDER HEAD DISASSEMBLY (II) [WL-3]
DCF011002000W05
DBG110AEBR24
3
4
Pivot
Valve keeper
(See 01-10A-8 Valve Keeper Disassembly Note.)
Upper valve spring seat
Valve spring
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
5
6
7
Lower valve spring seat

Valve
Valve seal
(See 01-10A-9 Valve Seal Disassembly Note.)
~.
I.
I , :
I'
DBG110AEB026
01-10A-8
MECHANICAL [WL-3]
Valve Seal Disassembly Note
1. Remove the valve seal using the SST.
VALVE GUIDE
DBG110AEB104
CYLINDER BLOCK DISASSEMBLY (I) [WL-3]
DCF011002000W06
DBG110AEB033
Oil drain plug
Oil pan
(See 01-10A-10 Oil Pan Disassembly Note.)
-3
IOil strainer
01-10A-9
MECHANICAL [WL-3]
Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
DBG110AEB035
CYLINDER BLOCK DISASSEMBLY (II) [WL-3]
DCF011002000W07

17
DBG110AEBR40
Crankshaft pulley
(See 01-10A-11 Crankshaft Pulley Disassembly
Note.)
Fuel injection pump pulley
(See 01-10A-11 Fuel Injection Pump Pulley
Disassembly Note.)
Timing gear cover
(See 01-10A-12 Timing Gear Cover Disassembly
Note.)
01-1 OA-1 0
4
5
Oil pump
Fuel injection pump gear
(See 01-10A-12 Fuel Injection Pump Gear
Disassembly Note.)
Timing gear
Fuel injection pump
MECHANICAL [WL-3]
8
9
10
11
Timing gear case

(See 01-10A-14 Timing Gear Case Disassembly
Note.)
Flywheel
(See 01-10A-14 Flywheel Disassembly Note.)
End plate
Rear cover
(See 01-10A-14 Rear Cover Disassembly Note.)
12
13
14
15
16
17
Oil pump cover

Driven gear
Plug
Plunger spring
Control plunger
Oil pump body
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
Caution
The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling.
DBG110AEB042
PLATE
DBG110AWB021
Fuel Injection Pump Pulley Disassembly Note

1. Remove the fuel injection pump pulley using the
SST.
DBG110AEB043
01-10A-11
MECHANICAL [WL-3]
Timing Gear Cover Disassembly Note
1. Remove the timing gear cover using a separator
tool.
DBG110AEB044
2. Remove the oil seal using a screwdriver protected

with a rag.
Fuel Injection Pump Gear Disassembly Note

1. Set the No.1 cylinder to TOC of compression.
2. Rotate the flywheel ring gear from TOC to
approximately 30 BTOC (about 13 teeth on the
gear).
BTDC30
DBG110AEB046
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel
injection pump gear are aligned.
Note
If the chip cut gear is hard to find, move the
fuel injection pump gear on notch back and
forth, then check the chip cut gear.
GEAR CASE (V GROOVE)
FUEL INJECTION
PUMP GEAR
FUEL INJECTION
PUMP GEAR
(HELICAL GEAR)
CHIP CUT GEAR
ABOUT3.0mm
{O.12 in}
DBG110AEBRR8
01-10A-12
MECHANICAL [WL-3]
4. Fix the scissors gear to the fuel injection pump gear using a lock bolt (M8x1.25; length under the bolt head is
approximately 14 mm {O.55 in}).
Warning
When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a lock bolt (M8x1.25; length under the bolt head is approximately 14 mm
{O.55 in}). Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
Caution
When removing the fuel injection pump gear, be sure to secure the scissors gear to the fuel
injection pump gear using a look bolt (M8x1.25; length under the bolt head is approximately 14
mm {O.55 in}) to prevent the scissors gear form rotating with the spring force. Otherwise, the
scissors gear will not align with the fuel injection pump gear, and the fuel injection pump gear with
the scissors gear will not engage with the idler gear.
'
Note
The fuel injection pump gear with a scissors
gear has a lock bolt hole.
DBG110AEBR97
5. Hold the crankshaft using the SST and loosen the

gear nut.
01-10A-13
MECHANICAL [WL-3]
6. Remove the fuel injection pump gear using the
SST.
.
DBG110AEBR48
Timing Gear Case Disassembly Note

1. Remove the timing gear case using the separator
tool.
Flywheel Disassembly Note

1. Remove the flywheel using the SST.
Rear Cover Disassembly Note

with a rag.
RAG
DBG110AEB052
01-10A-14
MECHANICAL [WL-3]
CYLINDER BLOCK DISASSEMBLY (III) [WL-3]
DCF011002000W08
3
13
DBG110AEBR67
2
3
4
5
6
Connecting rod cap

(See 01-10A-15 Connecting Rod Cap Disassembly
Note.)
Lower connecting rod bearing
Piston, connecting rod
(See 01-10A-15 Piston, Connecting Rod
Disassembly Note.)
Upper connecting rod bearing
Piston ring
Piston pin clip
Piston pin
(See 01-10A-16 Piston Pin Disassembly Note.)
9
10
11
12
13
14
15
Piston
Connecting rod
Main bearing cap
(See 01-10A-16 Main Bearing yap Disassembly
Note.)
Lower main bearing, lower thrust bearing
Crankshaft
(See 01-10A-16 Crankshaft Disassembly Note.)
Upper main bearing, upper thrust bearing
Oil jet valve, nozzle
cylinder block
Connecting Rod Cap Disassembly Note

1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-1 OA-27
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3].)
Piston, Connecting Rod Disassembly Note
1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01-1 OA-27
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3].)
2. Inspect the oscillation torque. (See 01-1 OA-28 PISTON' AND CONNECTING ROD INSPECTION [WL-3].)
01-10A-15
MECHANICAL [WL-3]
Piston Pin Disassembly Note
1. Remove the piston pin using the SST.
"
II
DBG110AEB06S
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01-1 OA-26 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-3].)
2. Loosen the main bearing cap bolts in two or three
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01-1 OA-26 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-3].)
CYLINDER HEAD INSPECTION/REPAIR [WL-3]
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure.
Y
DCF011 01 01 OOWOl
Maximum cylinder head distortion

X distortion: 0.02 mm {O.OOOS in}
Y distortion: 0.05 mm {0.0020 in}
DBG110AEB11E
01-10A-16
MECHANICAL [WL-3]
4. Measure the receded or projected amount of
combustion chamber insert from the cylinder
head surface.
If it exceeds the maximum specification,
replace the cylinder head.
Maximum combustion chamber recession
0.02 mm {0.0008 in}
Maximum combustion chamber projection
0.005 mm {0.0002 in}
COMBUSTION CHAMBER
INSERT
DBG110AEB074
5. Inspect the combustion chamber insert crack.

If it exceeds the limit specification, replace the
cylinder head.
Combustion chamber crack
Limit: 10mm {0.39 in}
DBG110AEB075
6. Measure the manifold contact surface distortion

as shown in the figure.
If the distortion exceeds the maximum
specification, grind the surface or replace the
cylinder head.
Maximum manifold contact surface distortion
0.05 mm {0.0020 in}
Maximum manifold contact surface grinding
0.15 mm {0.0059 in}
DBG110AEB076
VALVE INSPECTION [WL-3]
1. Measure the valve head margin thickness of each

valve.
If it exceeds the standard specification,
replace the valve:
Standard valve margin thickness
IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
2. Measure the length of each valve. Replace the

valve if necessary.
If it is less than the minimum specification,
replace the valve.
DCF011012111W01
-I r-
r-----L.1
THICKNESS
LENGTH
B3E0110ER68
Standard valve length

IN: 111.6-112.1 mm {4.394-4.413 in}
EX: 111.5-112.0 mm {4.390-4.409 in}
Minimum valve length
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
01-10A-17
MECHANICAL [WL-3]
3. Measure the stem diameter of each valve in the X
and Y directions at the three points (A, B, and C)
shown in the figure.
replace the valve.
Standard valve stem diameter

IN: 6.970-6.985 mm {0.2745-0.2749 in}
EX: 6.965-6.980 mm {0.2743-0.2748 in}
Minimum valve stem diameter
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
DBG110AEB106
VALVE GUIDE INSPECTION [WL-3]
DCF011 01 0280W01
1. Measure the inner diameter of each valve guide in

the X and Y directions at the three pOints (A, B,
and C) shown in the figure.
If it is not within the specification, replace the
valve guide.
Standard valve guide inner diameter

7.025-7.045 mm {0.2766-0.2773 in}
c
DBG110AEB108
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
valve guide.
Standard valve guide height

14.0-14.5 mm {0.552-0.570 in}
@-'----L.......JI
DBG110AEB077
01-10A-18
MECHANICAL [WL-3]
VALVE GUIDE REPLACEMENT [WL-3]
DCF011 01 0280W02
Valve Guide Removal

1. Remove the valve guide from the combustion
chamber side using the SST.
GUIDE
DBG110AEB107
Valve Guide Installation

1. Assemble the SSTs so that depth L is as
specified.
Depth L
14.0-14.5 mm {0.552-0.570 in}
DBG110AEB110
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 is
within the specification.
, Standard valve guide height
14.0-14.5 mm {0.552-0.570 in}
VALVE GUIDE
B3E0110E072
VALVE SEAT INSPECTION/REPAIR [WL-3]
DCF011 01 01 02W01
1. Measure the seat contact width.

If it is not within the specification, resurface
the valve seat using the 45 valve seat cutter.
Standard valve seat contact width
IN: 1.6-2.2 mm {0.063-0.086 in}
EX: 1.7-2.3 mm {0.067-0.090 in}
SEAT CONTACT
WIDTH
.\
DBG110AEB109
01-10A-19
MECHANICAL [WL-3]
2. Verify that the valve seating position is at the
center of the valve face.
If the seating position is too high, correct the
valve seat using a 60 cutter, and then a 45
cutter.
If the seating position is too low, correct the
valve seat using a 37 (IN) or 30 (EX) cutter,
and a 45 cutter.
Valve seat angle

IN: 45
EX: 45
IN
EX
DBG110AEBR75
3. Measure the receded amount from the cylinder

head surface.
replace the cylinder head.
Standard valve recession

IN: 0.61-1.09 mm {0.025-0.042 in}
EX: 0.71-1.19 mm {0.028-0.046 in}
Maximum valve recession
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
VALVE SPRING INSPECTION [WL-3]
1. Apply a pressing force to the pressure spring and
check the spring height.
valve spring.
DBG110AEB112
DCF011012125W01
Valve spring installation pressing force

238-269 N {25-27 kgf, 54-60 Ibf}
Valve spring installation height
35.5 mm {1.40 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-ofsquare.

replace the valve spring.
Maximum valve spring out-of-square

2.0 (1.70mm {0.067 in})
DBG110AEB079
01-10A-20
MECHANICAL [WL-3]
CAMSHAFT INSPECTION [WL-3]
DCF011012420W01
1. Set the No.1 and No.5 journals on V-blocks.

Measure the camshaft runout.
replace the camshaft.
Maximum camshaft runout

0.03 mm {0.0012 in}
DBG110AEB114
2. Measure the cam lobe height at the two points as

Standard cam lobe height

IN: 42.400-42.500 mm {1.6692-1.6732 in}
EX: 42.395-42.495 mm {1.6691-1.6730 in}
Minimum cam lobe height
IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
.. ..
D o=r
t t
DBG110AEB080
3. Measure the journal diameters in the X and Y

directions at the two pOints (A and 8) as shown in
the figure.
Standard cam journal diameter

No.1, No.5: 25.940-25.965 mm {1.02131.0222 in}
No.2-No.4: 25.910-25.935 mm {1.02011.0210 in}
DBG110AEB081
Minimum cam journal diameter

No.1, No.5: 25.890 mm {1.0193 in}
No.2-No.4: 25.860 mm {1.0181 in}
CAMSHAFT OIL CLEARANCE INSPECTION [WL-3]
1.
2.
3.
4.
Position a plastigage on top of the journals in the axial direction.

Install the camshaft cap. (See 01-1 OA-49 Camshaft Cap Assembly Note.)
Remove the camshaft cap. (See 01-10A-7 Camshaft Cap Disassembly Note.)
Measure the oil clearance.
If it exceeds the maximum specification, replace the camshaft.
DCF011012420W02
r-----------------------------------~
Standard camshaft clearance

No.1, 5: 0.035-0.081 mm {0.0014-0.0031
in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043
in}
Maximum camshaft clearance
No.1, 5: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
DBG110AEB082
01-10A-21
MECHANICAL [WL-3]
CAMSHAFT END PLAY INSPECTION [WL-3]
1. Install the camshaft cap. (See 01-10A-49 Camshaft Cap Assembly Note.)
2. Measure the camshaft end play.
If it exceeds the maximum specification, replace the cylinder head or camshaft.
DCF011012420W03
~------------------------------------.
Standard camshaft end play

0.030-0.160 mm {0.0012-0.0062 in}
Maximum camshaft end play
0.20 mm {0.0079 in}
3. Remove the camshaft cap. (See 01-1 OA-7
Camshaft Cap Disassembly Note.)
DBG110AEB083
CYLINDER BLOCK INSPECTION/REPAIR [WL-3]

1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the
figure.
If the distortion exceeds the maximum
specification, replace the cylinder head.
DCF011 01 0300W01
Maximum cylinder block distortion

X direction: 0.02 mm {0.0008 in}
Y direction: 0.05 mm {0.0020 in}
DBG110AEB115
2. Measure the cylinder bore using the cylinder

gauge. Measurement positions are in the X and Y
directions at 83 mm {3.27 in} below the top
surface of the cylinder.
If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the
cylinder and install the oversized pistons so
that the specified piston-to-cylinder clearance
is obtained.
Note
Base the boring diameter on the diameter of
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size
Standard: 93.000-93.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
Cylinder bore wear limit
0.15 mm {0.0059 in}
01-10A-22
ADA2224ER91
MECHANICAL [WL-3]
OIL JET VALVE, NOZZLE INSPECTION [WL-3]
DCF011 01 0730W01
1. Apply compressed air to oil jet valve A and verify

"a that air passes through oil jet valve B.
'.
oil jet.
Oil jet air pressure

137.6-196.4 kPa {1.5-2.0 kgf/cm 2 , 20-28
psi}
2. Check the oil jet nozzle for clogs. Replace the
nozzle if necessary.
DBGll0AEB085
PISTON INSPECTION [WL-3]
DCF011011010W01
1. Measure the outer diameter of each piston at right

angle (90) to the piston pin, 17 mm {0.67 in}
from the lower end of the piston.
piston.
Piston diameter
Standard: 92.951-92.977 mm {3.65953.6605 in}
0.25 {0.0098} oversize: 93.186-93.212 mm
{3.6688-3.6697 in}
0.50 {0.02} oversize: 93.436-93.462 mm
{3.6786-3.6795 in}
_
17mm
{O.67 in}
PISTON CLEARANCE INSPECTION/REPAIR [WL-3]
DBG110AEBR74
DCF011011010W02
1. Measure the piston-to-cylinder clearance.

If it exceeds the maximum specification, replace the piston or rebore the cylinders to fit the oversized
piston.
, Standard piston clearance

0.055-0.073 mm {0.0022-0.0028 in}
Maximum piston clearance
0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.
PISTON RING CLEARANCE INSPECTION [WL-3]

1. Measure the piston ring-to-ring land clearance
.
around the entire circumference.
replace the piston and piston ring.
DCF011011010W03
Standard piston ring clearance

Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
Maximum piston ring clearance
0.15 mm {0.0059 in}
DBGll0AEB116
2. Insert the piston ring into the cylinder by hand and

use the piston to push it to the bottom of the ring travel:
01-10A-23
MECHANICAL [WL-3]
3. Measure each piston ring end gap with a feeler
gauge.
replace the piston ring.
Standard piston ring end gap
Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.32-0.47 mm {0.0126-0.0185 in}
Oil: 0.22-0.37 mm {0.0087-0.0145 in}
PISTON
RING
Maximum piston ring end gap

1.0 mm {0.039 in}
DBG110AEB087
PISTON PIN CLEARANCE INSPECTION [WL-3]
DCF011011010W04
1. Measure each piston pin bore diameter in the X

and Y directions at the four points (A, B, C, and D)
Standard piston pin bore diameter
31.997-32.007 mm {1.2598-1.2601 in}
~
v
DBG110AEB088
2. Measure each connecting rod small end inner

diameter in the X and Y directions as shown in the
figure.
Standard connecting rod small end inner

diameter
32.012-32.033 mm {1.2604-1.2611 in}
DBG110AEB117
3. Measure each piston pin diameter in the X and Y

directions at the four pOints (A, B, C and D) as
Standard piston pin diameter
31.994-32.000 mm {1.25961-1.25984 in}
x
J
--v
t
4. Calculate the piston pin-to-piston pin bore

clearance.
piston or the piston pin.
Standard piston pin-to-piston pin bore
clearance
-0.003-0.013 mm {-0.00011-0.00051 in}
5. Calculate the connecting rod small end-to-piston pin clearance.

If it is not within the specification, replace the connecting rod or the piston pin.
Standard connecting rod small end-to-piston pin clearance
0.012-0.039 mm {0.00048-0.00153 in}
01-10A-24
DBG110AEB118
MECHANICAL [WL-3]
CRANKSHAFT INSPECTION [WL-3]
DCF011011301W01
1. Measure the crankshaft runout.

replace the crankshaft.
Maximum crankshaft run out

0.05 mm {0.0020 in}
DBG110AEB089
2. Measure the main journal or crank pin diameter in

the X and Y directions at the two points (A and 8)
If it is not within the specification or if it
exceeds the maximum off-round, grind the
main journal or crank pin with an undersized
bearing.
Main journal diameter

Standard
No.1, 2, 4, 5: 66.937-66.955 mm {2.63542.6360 in}
No.3: 66.920-66.938 mm {2.6347-2.6353
in}
0.25 {0.01} undersize
No.1, 2, 4, 5: 66.687-66.705 mm {2.6255~2.6261 in}
No.3: 66.670--':66.688 mm {2.6248-2.6255 in}
No.1, 2, 4, 5: 66.437-66.455 mm {2.6157-2.6163 in}
No.3: 66.420-66.438 mm {2.6150-2.6156 in}
No.1, 2, 4, 5: 66.187-66.205 mm {2.6058-2.6064 in}
No.3: 66.170-66.188 mm {2.6052-2.6058 in}
x
1+---+----1 y
DBG110AEB090
Main journal wear limit

0.05 mm {0.0020 in}
Main journal out-of-round
0.03 mm {0.0012 in}
Crank pin diameter
Standard: 54.940-54.955 mm {2.1630-2.1635 in}
0.25 {0.01} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
0.50 {0.02} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.03} undersize: 54.190-54.205 mm {2.1335-2.134 in}
Crank pin wear limit
0.05 mm {0.0020 in}
Crank pin out-of-round
0.03 mm {0.0012 in}
\I
01-10A-25
MECHANICAL [WL-3]
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-3]
1.
2.
3.
4.
DCF011011301W02

Install the main bearing cap. (See 01-10A-34 Main Bearing Cap Assembly Note.)
Remove the main bearing cap. (See 01-1 OA-16 Main Bearing Cap Disassembly Note.)
Measure the main journal oil clearance.
If the clearance exceeds the maximum specification, replace the main bearing or grind the main journal and
install the undersize bearings so that the specified oil clearance is obtained.
Standard main journal clearance
No.1, 2, 4, 5: 0.027-0.046 mm {0.0011-0.0018 in}
No.3: 0.044-0.063 mm {0.0018-0.0025 in}
Maximum main journal clearance
0.08 mm {0.0031 in}
Main bearing thickness
Standard: 2.006-2.021 mm {0.0790-0.0795 in}
0.25 {0.01} undersize: 2.124-2.134 mm {0.0837-0.0840 in}
0.50 {0.02} undersize: 2.249-2.259 mm {0.0886-0.0889 in}
0.75 {0.03} undersize: 2.374-2.384 mm {0.0935-0.0938 in}
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-3]
DCF011011301W03
1. Install the main bearing cap. (See 01-1 OA-34 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play.
,----------------------,
If the end play exceeds the maximum
specification, replace the thrust bearing or
grind the crankshaft and install an oversized
bearing so that the specified end play is
obtained.
Standard crankshaft end play
0.040-0.282 mm {0.0016-0.0111 in}
Maximum crankshaft end play
0.3 mm {0.012 in}
DBG110AEB120
Thrust bearing thickness

Standard: 2.454-2.506 mm {0.0967-0.0986 in}
0.35 {0.014} oversize: 2.629-2.681 mm {0.1 036-0.1 055 in}
3. Remove the main bearing cap. (See 01-10A-16 Main Bearing Cap Disassembly Note.)
CONNECTING ROD INSPECTION [WL-3]
1. Measure each connecting rod for bending and
distortion.
replace the connecting rod.
DCF011011211W01
Maximum connecting rod bending

0.075 mm {0.0030 in} /50 mm {2.0 in}
Maximum connecting rod distortion
0.18 mm {0.0071 in} /50 mm {2.0 in}
Connecting rod center-to-center distance
151.96-152.04 mm {5.9827-5.9858 in}
01-10A-26
DBG110AEB119
~'
''''i1
MECHANICAL [WL-3]
2. Measure the length of the connecting rod bolt.
replace the connecting rod and connecting
rod cap.
Standard connecting rod bolt length

67.5-68.5 mm {2.66-2.69 in}
Maximum connecting rod bolt length
69 mm {2.7 in}
DBG110AEB092
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-3]

1.
2.
3.
4.

Install the connecting rod cap. (See 01-10A-35 Piston, Connecting Rod Assembly Note.)
Remove the connecting rod cap.
Measure the crankpin oil clearance.
If the clearance exceeds the maximum,
replace the connecting rod bearing or grind
the crankpin and use undersized bearings so
that the specified clearance is obtained.
DCF011011211W02
Standard connecting rod oil clearance

0.025-0.052 mm {0.0010-0.0020 in}
Maximum connecting rod oil clearance
0.08 mm {0.0031 in}
)')1
Connecting rod bearing thickness

Standard: 1.507-1.516 mm {0.0594-0.0596
in}
0.25 {0.01} undersize: 1.624-1.634 mm {0.0640-0.0643 in}
0.50 {0.02} undersize: 1.749-1.759 mm {0.0689-0.0692 in}
0.75 {0.03} undersize: 1.874-1.884 mm {0.0738-0.0741 in}
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-3]
1. Install the connecting rod cap. (See 01-10A-35 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance.
replace the connecting rod and connecting
rod cap.
DBG110AEB121
DCF011011211W03
Standard connecting rod side clearance

0.110-0.262 mm {0.0044-0.0103 in}
Maximum connecting rod side clearance
0.35 mm {0.014 in}
3. Remove the connecting rod cap.
DBG110AEB122
01-10A-27
MECHANICAL [WL-3]
PISTON AND CONNECTING ROD INSPECTION [WL-3]
DCF011011010W05
1. Check the oscillation torque as shown in the

figure. If the large end does not drop by its own
weight, replace the piston or the piston pin.
DBG110AEB093
BOLT INSPECTION [WL-3]
DCF011010135W01
1. Measure the length of each bolt.

replace the bolt.
Cylinder head bolt length

Bolt head mark W
Standard length: 101.2-101.8 mm
4.007 in}
Maximum length: 102.5 mm {4.035
Bolt head mark N
Standard length: 113.2-113.8 mm
4.480 in}
Maximum length: 114.5 mm {4.508
~
{3.985in}
I.
((
J);));))))))))))))
LENGTH
.1
{4.457DBG110AEB097
in}
Main bearing cap bolt length

Standard length: 84.7-85.3 mm {3.34-3.35 in}
Maximum length: 86.0 mm {3.39 in}
TENSIONER SPRING INSPECTION [WL-3]
DCF011012711W01
1. Measure the free length of the tensioner spring.

replace the tensioner spring.
Standard tensioner spring length

63.0 mm {2.48 in}
FREE LENGTH
DBG110AEB098
01-10A-28
MECHANICAL [WL-3]
VALVE CLEARANCE INSPECTION [WL-3]
DCF011012111W02
1. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinder is at TOG of
compression.
2. Measure valve clearances A with the No.1
A
A
A
cylinder at TOG of compression, and those of B
with the No.4 cylinder at TOG of compression.
If it is not within the specification, adjust and
recheck the valve clearance.
ENGINE
FRONT
B
DBGll0AEB099
Valve clearance (engine cold)

IN: 0.05-0.15 mm {0.0020-0.0059 in}
EX: 0.15-0.25 mm {0.0060-0.0098 in}
FEELER GAUGE
LOCKNUT
3. Turn the crankshaft one full turn and measure the

remaining valve clearances. Adjust if necessary.
DBG110AEB100
;1
VALVE CLEARANCE ADJUSTMENT [WL-3]
DCF011012111W03
Caution
Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker
arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw,
rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly
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 cylinders is at
TOG of the compression.
CAM LOBE
LOCKNUT
CLAW -t--;::;.:;:t:j,.......,
DBG110AWB002
01-10A-29
MECHANICAL [WL-3]
3. Adjust the valve clearances A with the No.1
cylinder at TOG of compression, and those of B
with the No.4 cylinder at TOG of compression.
ENGINE
FRONT
B
DBGll0AWBOOl
Valve clearance
IN: 0.05 - 0.15 mm {0.0020 - 0.0059 in}
[Engine cold]
0.15 mm {0.0059 in}
[Engine hot (reference)]
EX: 0.15 -0.25 mm {O.OOSO - 0.0098 in}
[Engine cold]
0.25 mm {0.0098 in}
[Engine hot (reference)]
Tightening torque (locknut)
1S-20 Nm {1.7-2.0 kgfm, 12-14 ftlbf}
DBGll0AWB003
4. Turn the crankshaft one full turn and adjust the remaining valve clearances.
INJECTION TIMING ADJUSTMENT [WL-3]
DCF011002000W09
Caution
Excessive tension on the timing belt may cause damage to the timing belt and camshaft. If the bolt
and nuts of the fuel injection pump are temporarily loosened, re-tension the timing belt.
1. Loosen the bolts and nuts of the fuel injection
pump and bracket.
DBGll0AEBR76
2. Rotate the crankshaft clockwise and align the

crankshaft pulley TOG mark (yellow mark) with
the indicator pin.
3. Remove the hydraulic head plug of the fuel
injection pump.
01-10A-30
INDICATOR PIN
TDC (YELLOW MARK)
MECHANICAL [WL-3]
-4. Insert the SST into the hydraulic head plug hole
and install it so that the dial gauge indicates
approx. 2 mm {O.OS in}.
5. Rotate the crankshaft counterclockwise and find

the place where the dial gauge needle does not
move near approx. 30 BTDC .. (SST installation
bolt hole of crankshaft pulley and indicator pin
align at approx. 30 BTDC)
6. Set the dial gauge to 0 mm {O in}.
7. Rotate the crankshaft clockwise and read the dial

gauge when the 10 ATDC mark (white mark) of
the crankshaft pulley and the indicator pin align.
8. Adjust the dia1auge within the specification.
Fuel injection pump plunger adjustment value
0.95-1.05 mm {0.03S-0.041 in}
9. Tighten the fuel injection pump in the order shown

in the figure.
10. Remove the SST and install the hydraulic head
plug through a new gasket.
11. Re-tension the timing belt.
DBGll0AEBR77
01-10A-31
MECHANICAL [WL-3]
GEAR CLEARANCE INSPECTION [WL-3]
1. Measure the following clearance.
If it exceeds the maximum specification, replace the gear and/or pump body.
DCF011019220W01
r-----------------------------------~
Standard oil pump tip clearance

0.10-0.19 mm {0.0040-0.0074 in}
Maximum oil pump tip clearance
0.20 mm {0.0079 in}
DBG110AEB101
Standard oil pump side clearance

0.04-0.09 mm {0.0016-0.0035 in}
Maximum oil pump side clearance
0.15 mm {0.0059 in}
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-3]

1. Measure the free length of plunger spring .
replace the plunger spring.
DCF011014116W01
Standard plunger spring length

43.8 mm {1.72 in}
DBG110AEB103
01-10A-32
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (I) [WL-3]
DCF011 002000W1 0
1. Assemble in the order indicated in the table.
12-18 Nm {123-183 kgfcm, 107-159 inlbf}

26.5-31.5
{2.8-3.2, 2D-23} + 82.5-97.5
+ 90-105
Nm {kgf.m, ftlbf}
DBG110AEBR68
1
2
3
4
5
6
7
Cylinder block
Crankshaft
Main bearing cap
(See 01-10A-34 Main Bearing Cap Assembly
Note.)
10
11
Connecting rod
. .
(See 01-1 OA-34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
Piston
(See 01-10A-34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
14
15
12
13
Piston pin
(See 01-10A-34 Piston, Connecting Rod, Piston
Pin Assembly Note.)
Piston pin clip
Piston ring
(See 01-10A-35 Piston Ring Assembly Note.)
(See 01-10A-35 Piston, Connecting Rod Assembly
Note.)
Connecting rod cap
01-10A-33
MECHANICAL [WL-3]
Main Bearing Cap Assembly Note
1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
2., Tighten. the b~lts in two or three steps in the order
8
4
1
shown In the figure.
Tightening procedure
(1) 14.5-34.5 Nm {1.5-3.5 kgfm, 11-25
ftlbf}
(2) 74.0-82.0 Nm {7.6-8.3 kgfm, 55-60
ft.lbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5-34.5 Nm {1.5-3.5 kgfm, 11-25
ftlbf}
(5) 42.5-45.5 Nm {4.4-4.6 kgfm, 32-33
ftlbf}
DBG110AEB071
3. Put a paint mark on each bolt head.

4. Using the marks as a reference, tighten the bolts
by turning each 90-105 as in Step 2.
PAINT MARK
DBG110AEBR72
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
FMARK
as shown. If the pin cannot be installed easily,
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01-10A-34
MECHANICAL [WL-3]
piston Ring Assembly Note

1. Install the oil ring.
2. Install the second ring with tapered face side upward.
3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
==(
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap nuts in two or
three steps.
FMARK
Tightening torque
26.5-31.5 Nm {2.8-3.2 kgf.m, 20-23 ft.lbf}
3. Put a paint mark on each nut.
DBG110AEBR95
4. Using the marks as a reference, tighten the nuts

by turning each 82.5-97.5
PAINT MARK
DBG110AEBR73
01-10A-35
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (II) [WL-3]
DCF011002000W11
~~~~~~==~------------------It
lS.6-25.5 {1.9-2.6, 14-1S}
7.S-10.S Nm
{Sl-110 kgfcm,
70-95 inlbf}
iii
J~A
7.S-9.S Nm {S0-99 kgfcm,

70-S6 inlbf}
7.S-10.S Nm {SO-ll a kgf.cm,

70-95 inlbf}
Nm {kgfm, ftlbf}
DBG110AEBR41
2
3
4
5
6
7
10
Oil pump body

Control plunger
Plunger spring
Plug
Driven gear
Oil pump cover
(See 01-10A-37 Oil Pump Cover Assembly Note.)
Rear cover, end plate
(See 01-10A-37 Rear Cover, End Plate Assembly
Note.)
End plate
(See 01-10A-37 Rear Cover, End Plate Assembly
Note.)
Flywheel
(See 01-10A-38 Flywheel Assembly Note.)
Timing gear case
(See 01-1 OA-38 Timing Gear Case Assembly
Note.)
01-10A-36
11
12
13
14
15
16
17
Fuel injection pump

Timing gear
(See 01-10A-38 Timing Gear, Fuel Injection Pump
Gear Assembly Note.)
Fuel injection pump gear
(See 01-10A-38 Timing Gear, Fuel Injection Pump
Gear Assembly Note.)
Oil pump
Timing gear cover
(See 01-10A-40 Timing Gear Cover Assembly
Note.)
(See 01-10A-41 Fuel Injection Pump Pulley
Assembly Note.)
Crankshaft pulley
(See 01-10A-41 Crankshaft Pulley Assembly
Note.)
-Oil Pump Cover Assembly Note
MECHANICAL [WL-3]
1. Tighten the bolts in two or three steps in the order

Rear Cover, End Plate Assembly Note

1. Apply soapy water along the perimeter of the new oil seal.
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 correctly,
measure the distance between the end of the rear
cover and the face of the oil seal.
Rear oil seal press-in amount
0-0.5 mm {O-O.01 in}
f...Q:-O.5 mm {O-O.01 in}
t~ REAR OIL SEAL
DBGll0BEB059
5.
~pply fSilicone sealant to the rear cover as shown

In
the igure.
Thickness
~2.0-3.0
mm {O.079-0.118 in}
DBGll0AEBR55
6. Apply silicone sealant to the rear cover as shown

in the figure.
Thickness
~2.0-3.0
mm {O.079-0.118 in}
7. Install the end plate.
DBGll0AEBR94
01-10A-37
MECHANICAL [WL-3]
Flywheel Assembly Note
1. Hold the crankshaft using the SST.
2. Tighten the bolts in the order shown in the figure.
DBGll0AEB056
Timing Gear Case Assembly Note

1. Install the new O-ring.
.
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the 0ring.
Thickness
4>2.0-3.0 mm {0.079-0.118 in}

Timing Gear, Fuel Injection Pump Gear Assembly Note

1. Put a paint mark on the chip cut gear of the fuel
injection pump gear.
.-----------------~
r------------------~
PAINT MARK
CHIP CUT
GEAR
DBGll0AEB9R3
01-10A-38
MECHANICAL [WL-3]
2. Put a paint mark on the 11 th and 12th teeth of the
helical gear counting clockwise from the chip cut
gear.
CHIP CUT GEAR

FUEL
INJECTION
PUMP GEAR
VIEWA
PAINT MARK
3. Verify that the 11 th and 12th teeth of fuel injection

pump gear (helical gear) and the teeth of the
scissors gear are aligned, then put a paint mark
on the scissors gear.
DBG110AEBR83
SCISSORS GEAR
HELICAL GEAR
~I
~~11
~~12TEETH
TEETH
PAINT MARK

approximately 30 BTOC (13 teeth on the gear).
DBG110AEBR82
BTDC30
I
DBG110AEBR59
6. Align the timing marks. For the fuel injection pump gear, align the timing mark as shown in the figure (View A).
Note
The helical gears except for the fuel injection pump gear have a punch mark as the timing mark. The
timing mark of each gear can be aligned easily if the paint mark is made on the punch mark.
TIMING MARK (WHITE PAINT)
FUEL INJECTION
PUMP GEAR
DBG110AEBR60
01-10A-39
MECHANICAL [WL-3]
7. Remove the lock bolt.
DBG110AEBR97
8. Tighten the bolts using the SST.
Timing Gear Cover Assembly Note

3. Tap the oil seal in evenly using the SST and a
,
hammer.
measure the distance between the end of the
timing gear cover and the face of the oil seal.
Front oil seal press-in amount

0-0.4 mm {0-0.01 in}
Fuel injection pump oil seal press-in amount
0-0.4 mm {0-0.01 in}
DBG110BEBR12
5. Apply silicone sealant to the timing gear cover as

Thickness
~2.0-3.0
mm {0.079-0.118 in}
o
DBG110AEBR63
01-10A-40
MECHANICAL [WL-3]
Fuel Injection Pump Pulley Assembly Note

1. Install the fuel injection pump pulley using the
SST.
DBG110AEB065
Crankshaft Pulley Assembly Note

Caution
The CKP sensor plate is a very important
part for engine operation control; any
deformation of the plate may disable the
operation control.
'When disassembling/assembling the
crankshaft pulley, be very careful not to
deform the plate by interference with
other parts or improper handling.
PLATE
DBG110AWB021
1. Install the crankshaft pulley using the SST.
I
DBG110AEB066
01-10A-41
MECHANICAL [WL-3]
CYLINDER BLOCK ASSEMBLY (III) [WL-3]
DCF011002000W12
...----_18.6-25.5 {1.9-2.6, 14-18}
7.8-10.8 Nm
{80-110 kgf.cm,
70-95 inlbf}
Nm {kgfm, ftlbf}
DBG110AEBR90
Oil pipe
(See 01-10A-43 Oil Pipe Assembly Note.)
Oil strainer
01-10A-42
3
4
Oil pan
(See 01-10A-43 Oil Pan Assembly Note.)
Oil drain plug
MECHANICAL [WL-3]
Oil Pipe Assembly Note
DBGll0AEBR89
..
Oil Pan Assembly Note

1. Apply silicone sealant to the oil pan as shown in
the figure.
Thickness
~2.0-3.0
mm {O.08-0.118 in}
A
o
DBGll0AEBR87
2. Tighten the oil pan bolts A as shown in the figure.
Caution
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.
3. Tighten the remaining oil pan bolts in several
passes.
!o'
ly@=E
~
OLD SEALANT
CHUOlllW004
01-10A-43
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (I) [WL-3]
DCF011002000W13
Nm {kgf.m, ftlbf}
DBG110AEBR27
2
3
4
Valve seal
(See 01-10A-44 Valve Seal Assembly Note.)
Valve
Valve spring
6
7

Valve keeper
(See 01-10A-45 Valve Keeper Assembly Note.)
Pivot
Valve Seal Assembly Note

1. Assemble the SSTs so that depth L is as
specified.
Depth L
15.6 mm {O.614 in}
2. Press the valve seal onto the valve guide by hand.
DPE110ZE1R26
01-10A-44
MECHANICAL [WL-3]
3. Tap the SST using a plastic hammer until its lower
end touches the cylinder head.
.
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
01-10A-45
MECHANICAL [WL-3]
CYLINDER HEAD ASSEMBLY (II) [WL-3]
DCF011002000W14

11.27-14.21 Nm {115-144 kgfcm,
100-125 in.lbf}r-_ _ _ _ _...J
15.7-23.5 {1.7-2.3, 12-17}
5
6.5-9.0 Nm {67-91 kgfcm,
58-79inlbf}
11
17.6-19.6 {1.8-1.9, 13-14}
+ 90_105
+ 90_105
1m
10
11
Nm {kgfm, ttlbf}
DBG110AEBR09
2
3
4
5

(See 01-10A-47 Cylinder Head Gasket Assembly
Note.)
Cylinder head
(See 01-10A-48 Cylinder Head Assembly Note.)
Blind cover
(See 01-10A-48 Blind Cover Assembly Note.)
Water outlet pipe
ECTsensor
(See 01-10A-48 Water Temperature Sender Unit
Assembly Note.)
01-10A-46
7
8
9
10
11
Rocker arm
(See 01-10A-49 Rocker Arm Assembly Note.)
Camshaft
Camshaft cap
(See 01-10A-49 Camshaft Cap Assembly Note.)
Seal plate
(See 01-10A-50 Seal Plate Assembly Note.)
Camshaft pulley
(See 01-10A-50 Camshaft Pulley Assembly Note.)
MECHANICAL [WL-3]
cylinder Head Gasket Assembly Note

1. Measure the piston topping of all the cylinders .
.:
'.. .
~ TOPPING
CYLINDER
BLOCK
PISTON
DPE110ZE1R02
2. Choose the gasket according to each measured

piston topping.
Cylinder head gasket select table
Piston topping (mm {in})

identification mark
0.205-0.325 {0.081-0.127}
0.265-0.385 {0.105-0.151}
0.325-0.445 {0.128-0.175}
IDENTIFICATION MARK
POSITION
DPE11 OZE1 R01
L - - -_ _ _. . . . L . . - - _ - - - '
3. Apply silicone sealant to the cylinder block as

Thic,kness
~2.0-3.0
mm {O.079-0.118 in}
15.0 mm
{0.53 in}
40.5 mm
{1.59 in}
48.5 mm
{1.91 in}
ENGINE
FRONT
9.0mm
{0.35 in}
DBG110AEBR17
01-10A-47
MECHANICAL [WL-3]
Cylinder Head Assembly Note
1. Before installing the cylinder head bolts, inspect their length. (See 01-10A-28 BOLT INSPECTION [WL-3].)
2. Apply clean engine oil to the threads and the seat face of each bolt and install them.
3. Tighten the cylinder head bolts in the order
indicated in the figure in several passes.
Tightening torque
29 Nm {3.0 kgfm, 2.1 ftlbf}
4. Retighten the bolts in the order shown in the
figure until all the bolts are tightened to 29 Nm
{3.0 kgfm, 2.1 ft.lbf}.
DBG110AEB018

6. Using the marks as a reference, tighten the
cylinder head bolts by turning each 90-105 in
the order indicated in Step 3.
7. Further tighten each bolt by turning another 90105 in the order indicated in Step 3.
8. Tighten the bolts A.
PAINT MARK
--
Tightening torque
17.6-19.6 Nm {1.8-1.9I<:gfm, 13-14 ft.lbf}
DBG110AEB019
Blind Cover Assembly Note

1. Apply silicone sealant to the blind cover as shown
in the figure.
Thickness
~1.5-2.5
mm {0.059-0.098 in}
DBG110AEBR23
Water Temperature Sender Unit Assembly Note

1. Apply silicone sealant to the thread of the water
temperature sender unit as shown in the figure.
DBG110AEB022
01-10A-48
MECHANICAL [WL-3]
Rocker Arm Assembly Note

1. If new rocker arm is used, set dimension A as
follows.
"
"
3:
"
"c,
Dimension A
0.0-4.0 mm {0.0-0.15 in}
DBG110AEB030
Camshaft Cap Assembly Note

1. Apply silicone sealant to the front camshaft cap
mounting surfaces as indicated in the figure.
Avoid getting sealant onto the camshaft journal,
camshaft oil seal surface, and camshaft thrust
surface.
ENGINE
FRONT
DBG110AEB031
2. Tighten the camshaft cap bolts gradually in three

or four steps in the order shown in the figure.
Caution
Because there is little camshaft thrust
clearance, the camshaft must be held
horizontally while it is installed.
Otherwise, excessive force will be
applied to the thrust area, causing burrs
on the thrust receiving area of the
cylinder head journal. To avoid this, the
following procedure must be observed.
ENGINE
FRONT
DBG110AEB032
3. Apply soapy water along the perimeter of the new

oil seal.
5. Tap the oil seal lightly into the cylinder head
using the SST and a hammer.
cylinder head and the face of the oil seal.
0.5-1.0 mm {0.02-0.03 in}
Camshaft oil seal press-in amount

0.5-1.0 mm {0.02-0.03 in}
HAMMER
Ii
OIL SEAL
DPE110ZE1R41
01-10A-49
MECHANICAL [WL-3]
Seal Plate Assembly Note
1. Tighten the seal plate bolts in the order indicated
in the figure.
DBG110AEB020
Camshaft Pulley Assembly Note

1. Install the camshaft pulley on the camshaft with
the knock pin fitted into the hole at the timing
mark.
Timing mark
TIMING MARK
KNOCK PIN
WL
DBG110AEBR85
2. Hold the camshaft using a wrench on the cast hexagon and tighten the pully lock bolt.
Caution
Do not move the camshaft from this
position because it can cause the valve
and piston to contact each other and
damage them.
DBG110AEB021
01-10A-50
MECHANICAL [WL-3]
TIMING BELT ASSEMBLY [WL-3]
DCF011002000W15
4.9-8.8 Nm {50-90 kgfcm, 44-78 inlbf} - - - -_ _~
7.8-10.8 Nm {80-110 kgf.cm,

70-95 inlbf}
18.6-25.5 {1.9-2.6, 14-18}
Nm {kgfm, ftlbf}
DBG110AEBR07
Timing belt
(See 01-10A-52 Timing Belt, Tensioner, Tensioner
Spring Assembly Note.)
Tensioner, tensioner spring
(See 01-1 OA-52 Timing Belt, Tensioner, Tensioner
Spring Assembly Note.)
Pulley plate
4
5
6
7
Timing belt cover

(See 01-10A-52 Timing Belt Cover Assembly
Note.)
<'
Cylinder head cover
(See 01-10A-52 Cylinder Head Cover Assembly
Note.)
Vacuum pump
Water pump
t
01-10A-S1
MECHANICAL [WL-3]
Timing Belt, Tensioner, Tensioner Spring Assembly Note
Caution
Overtensioning of the timing belt can cause breakage of the belt and the camshaft.
1. Align the timing marks as shown in the figure.
TENSIONER
2. Verify that the fuel injection pump attaching bolts
LOCK BOLT
CAMSHAFT
and nuts are tightened to the specified torque.
PULLEY
This must be done to prevent overtensioning of
the timing belt after it has been installed.
3. Install the timing belt.
TENSIONER
4. Install the tensioner, tensioner spring, and the
SPRING
lock bolt.
5. Tighten the tensioner lock bolt.
TENSIONER
6. Turn the crankshaft clockwise twice, and align the
- / - - - - FUEL INJECTION PUMP
timing marks. If they are not aligned, remove the
PULLEY
timing belt and repeat from Step 1.
DBG110AEBR11
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.
Timing Belt Cover Assembly Note

1. Tighten the timing belt cover bolts in the order
.
DBG110AEB012
Cylinder Head Cover Assembly Note

1. Before installing the cylinder head cover, inspect the valve clearance. (See 01-1 OA-29 VALVE CLEARANCE
INSPECTION [WL-3].)
2. Apply silicone sealant to the cylinder head as
shown.
DBG110AEB013
3. Tighten cylinder head cover bolts A and B.
Tightening torque
1.5-2.9 Nm {16-29 kgfcm, 14-25 inlbf}
CD
4. Tighten the cylinder head cover bolts in the order

Tightening torque
4.9-8.8 Nm {50-89 kgfcm, 44-77 in.lbf}
A
ENGINE
FRONT
(j)
DBG110AEBR14
:i
,~
01-10A-S2
01-108
,.,
,
I
.
ENGINE MOUNTING [WL-C, WE-C] .. 01-10B-2

ENGINE DISMOUNTING
[WL-C, WE-C] . . . . . . . . . . . . . 01-10B-3
TIMING BELT DISASSEMBLY
[WL-C, WE-C] . . . . . . . . . . . 01-10B-4
CYLINDER HEAD DISASSEMBLY(I)
[WL-C, WE-C] ........... 01-10B-6
CYLINDER HEAD DISASSEMBLY (II)
[WL-C, WE-C] . . . . . . . . . . . . 01-10B-8
CYLINDER BLOCK DISASSEMBLY (I)
[WL-C, WE-C] . . . . . . . . . 01-10B-9
CYLINDER BLOCK DISASSEMBLY (II)
[WL-C, WE-C] .............. 01-10B-10
CYLINDER BLOCK DISASSEMBLY (III)
[WL-C, WE-C] ........ 01-10B-15
CYLINDER HEAD INSPECTION/REPAIR
[WL-C, WE-C] ............. 01-10B-16
VALVE INSPECTION [WL-C, WE-C] ... 01-10B-17
VALVE GUIDE INSPECTION
[WL-C, WE-C] ........ 01-10B-18
VALVE GUIDE REPLACEMENT
[WL-C, WE-C] . . . . . . . . .. 01-10B-18
VALVE SEAT INSPECTION/REPAIR
[WL-C, WE-C] ............. 01-10B-19
VALVE SPRING INSPECTION
[WL-C, WE-C] ............ 01-10B-20
CAMSHAFT INSPECTION
[WL-C, WE-C] .............. 01-10B-20
CAMSHAFT OIL CLEARANCE
INSPECTION [WL-C, WE-C] .... 01-10B-21
CAMSHAFT END PLAY INSPECTION
[WL-C,WE-C] .......... 01-10B-21
CYLINDER BLOCK
INSPECTION/REPAIR [WL-C, WE-C] 01-10B-22
DUAL-MASS FLYWHEEL
INSPECTION [WL-C, WE-C] .... 01-10B-22
OIL JET VALVE, NOZZLE
INSPECTION [WL-C, WE-C] ...... 01-10B-25
PISTON INSPECTION
[WL-C, WE-C] . . . . . . . . . . . . .. . 01-10B-25
PISTON CLEARANCE
INSPECTION/REPAIR
[WL-C, WE-C] . . . . . . . . . . 01-10B-25
>
PISTON RING CLEARANCE

INSPECTION [WL-C, WE-C] ...... 01-10B-26
PISTON PIN CLEARANCE
INSPECTION [WL-C, WE-C] ..... 01-10B-26
CRANKSHAFT INSPECTION
[WL-C, WE-C] .......... 01-1 OB-27
CRANKSHAFT OIL CLEARANCE
INSPECTION/REPAIR
[WL-C, WE-C] ............. 01-1 OB-28
CRANKSHAFT END PLAY
INSPECTION/REPAIR
[WL-C, WE-C] ........... 01-1 OB-28
CONNECTING ROD
INSPECTION [WL-C, WE-C] ........ 01-10B-29
CONNECTING ROD OIL CLEARANCE
INSPECTION/REPAIR
[WL-C, WE-C] ........... 01-1 OB-29
CONNECTING ROD SIDE CLEARANCE
INSPECTION [WL-C, WE-C] ....... 01-10B-29
PISTON AND CONNECTING
ROD INSPECTION [WL-C, WE-C] 01-10B-30
BALANCE SHAFT INSPECTION
[WL-C, WE-C] ........... 01-1 OB-30
BOLT INSPECTION [WL-C, WE-C] .. 01-10B-31
[WL-C, WE-C] ........... 01-1 OB-31
VALVE CLEARANCE ADJUSTMENT
[WL-C, WE-C] ............... 01-1 OB-32
GEAR CLEARANCE INSPECTION
[WL-C, WE-C] ............ 01-10B-33
PLUNGER SPRING INSPECTION
[WL-C, WE-C] ............ 01-1 OB-33
CYLINDER BLOCK ASSEMBLY (I)
[WL-C, WE-C] ................ 01-1 OB-34
CYLINDER BLOCK ASSEMBLY (II)
[WL-C, WE-C] ........... 01-10B-37
CYLINDER BLOCK ASSEMBLY (III)
[WL-C, WE-C] ............. 01-10B-43
CYLINDER HEAD ASSEMBLY (I)
[WL-C, WE-C] .............. 01-10B-45
CYLINDER HEAD ASSEMBLY (II)
~
[WL-C, WE-C] .............. 01-10B-47
TIMING BELT ASSEMBLY
[WL-C, WE-C] .............. 01-10B-51
t
01-108-1

ENGINE MOUNTING [WL-C, WE-C]
1. Install the SST to the cylinder head using the bolt
(99784 1020 or M1 OX1.2S, ST, length 20mm
{0.79 in}) as shown in the figure.
DCF011002000W16
Tightening torque
43.1-60.S Nm {4.40-6.10 kgf.m, 31.S-44.S
ft.lbf}
2. Suspend the engine using the SST.
DBG110BWB89
3. Install the SST (arms) to the holes as shown in

the figure, and hand tighten the SST (bolts).
DBG110AEB002
4. Assemble the SSTs (bolts, nuts and plate) to the

specified positions.
DBG110AEB003
01-108-2

5. Adjust the SST (bolts) so that 20 mm {0.79 in} or
more of thread is exposed.
6. Align the SSTs (plate and arms) so that they are
parallel by adjusting the SSTs (bolts and nuts).
7. Tighten the SSTs (bolts and nuts) to affix the SST
firmly.
DBG110AEB105
8. Mount the engine on the SST (engine stand).
Warning
The self-locking brake system for the
engine stand may not operate if 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 hold the engine in an unbalanced
position, and always grasp the rotating
handle firmly when turning the engine.
DBG110AEB004
9. Remove the SST (303-050 (49 UN30 3050)).

10. Drain the engine oil into a container.
11. Install the drain plug using new washer.
Tightening torque
29.4-41.2 Nm {3.0-4.2 kgfm, 22-30 ft.lbf}
ENGINE DISMOUNTING [WL-C, WE-C]
DCF011002000W17
1. Dismount in the reverse order of mounting.
01-108-3

TIMING BELT DISASSEMBLY [WL-C, WE-C]
DCF011002000W18
DBG110BEB014
2
3
4
Water pump
Vacuum pump
Timing belt cover
Tensioner
(See 01-10B-5 Tensioner Disassembly Note.)
01-108-4
6
7
8
Idler
Timing belt
(See 01-10B-5 Timing Belt Disassembly Note.)
Injector
Cylinder head cover

Tensioner Disassembly Note
marks as shown in the figure.
INTAKE
CAMSHAFT
PULLEY
EXHAUST
CAMSHAFT
PULLEY
DBG110BWB98
2. Turn the auto tensioner counterclockwise using

an Allen wrench. (Rotate the auto tensioner with a
force of 39 Nm {4.0 kgfm, 28.8 ft.lbf} or less.)
3. Insert a fixing pin of approx. 6 mm {O.24 in}
diameter into hole A to secure the auto tensioner.
4. Remove the bolts in the order of Band C, then
remove the auto tensioner.
Note
If the rod projects suddenly while removing
the auto tensioner, the air flows into the
pressure chamber and the rod could move
slightly. If this occurs, bleed the air from the
pressure chamber using the following
procedure.
39 Nm {4.0 kgfm, 28.8 ftlbf}

MAX.
DBG110BEB033
5. Assemble the auto tensioner to the engine.

'" 6. Turn the auto tensioner with a force of 39 Nm
{4.0 kgfm, 28.8 ftlbf} or less using an Allen
wrench, then turn it back slowly. Repeat this
procedure several times.
7. Verify that the rod has resistance when it is in the
most proJected position. If there is no resistance,
repeat the above procedure.
..... t
39 Nm
{4.0 kgfm,
28.8 ftlbf} MAX.
REPEAT
SEVERAL
TIMES
ALLEN
WRENCH
DBG110BWB999
Timing Belt Disassembly Note

Caution
The following will damage the timing belt and shorten its life; forcefully twisting it, turning it inside
out, or getting oil or grease on it.
After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this
position because it can cause the valve and piston to contact and damage them.
reinstallation.
~~OTATION
~I ~
ARROW
30 mm {1.2 in } MIN.
~
NG
DBG110BWB003
01-108-5
," ..
!
CYLINDER HEAD DISASSEMBLY(I) [WL-C, WE-C]
DCF011002000W19
Ii)
DBG110BEB062
2
3
4
Camshaft pulley
(See 01-108-7 Camshaft Pulley Disassembly
Note.)
Seal plate
Camshaft cap upper
(See 01-108-7 Camshaft Cap Upper Disassembly
Note.)
Camshaft
01-108-6
5
6
7
8
Camshaft cap Lower

ECT sensor
Cylinder head
(See 01-108-7 Cylinder Head Disassembly Note.)
-camshaft Pulley Disassembly Note
1. Hold the camshaft using a wrench on the cast hexagon.

caution
damage them.
CAMSHAFT PULLEY
DBG110BEB082
Camshaft Cap Upper Disassembly Note

DBG110BEB083
Camshaft Disassembly Note

1. Before removing the camshaft, inspect the camshaft oil clearance. (See 01-1 OB-21 CAMSHAFT OIL
CLEARANCE INSPECTION [WL-C, WE-C].)
Cylinder Head Disassembly Note
1. Remove bolts A.
DBG110BEB084
t.'.
"
--
01-108-7

CYLINDER HEAD DISASSEMBLY (II) [WL-C, WE-C]
DCF011002000W20
DBG110BEB016
2
3
4
5
Rocker arm
Pivot
Valve cap
Valve keeper
(See 01-1 OB-8 Valve Keeper Disassembly Note.)
Valve Keeper Disassembly Note

1. Remove the valve keeper using the SST.
01-108-8
6
7
8
9
10
Valve spring
Valve
,
Valve seal
(See 01-108-9 Valve Seal Disassembly Note.)
Water outlet pipe
Valve Seal Disassembly Note

1. Remove the valve seal using the SST.
VALVE GUIDE
DBG110BEB085
CYLINDER BLOCK DISASSEMBLY (I) [WL-C, WE-C]
DCF011002000W21
iii
DBG110BEB075
Oil drain plug

Oil pan
(See 01-108-10 Oil Pan Disassembly Note.)
3
4
IOil strainer
Oil pipe
01-108-9

Oil Pan Disassembly Note
1. Remove the oil pan using a separator tool.
DBG110BEB086
CYLINDER BLOCK DISASSEMBLY (II) [WL-C, WE-C]
DCF011002000W22
mJ
3
DBG110BEB019
01-108-10
2
3
4
5
6
7
8
Crankshaft pulley
(See 01-108-11 Crankshaft Pulley Disassembly
Note.)
Seal plate
Supply pump pulley
(See 01-108-11 Supply Pump Pulley Disassembly
Note.)
Timing gear cover
(See 01-108-11 Timing Gear Cover Disassembly
Note.)
Oil pump
Supply pump gear
(See 01-108-12 Supply Pump Gear Disassembly
Note.)
Timing gear
Supply pump
9
10
11
12
13
14
15
16
17
18
19
Timing gear case

(See 01-108-14 Timing Gear Case Disassembly
Note.)
Dual-mass flywheel
(See 01-108-14 Dual-mass flywheel Disassembly
Note.)
End plate
Rear cover
(See 01-108-14 Rear Cover Disassembly Note.)
Seal plate
Oil pump cover
Driven gear
Plug
Plunger spring
Control plunger
Oil pump body
Crankshaft Pulley Disassembly Note

1. Remove the crankshaft pulley using the SST.
,
DBG110BEB064
Supply Pump Pulley Disassembly Note

1. Remove the supply pump pulley using the SST.
DBG110BEB055
Timing Gear Cover Disassembly Note

1. Remove the timing gear cover using a separator
tool.
SEPARATOR TOOL
DBG110BEB087
01-108-11

with a rag,
Supply Pump Gear Disassembly Note

approximately 30 BTOC (about 13 teeth on the
gear).
BTDC30
DBG110BEB089
3. Verify that the end-gap (V groove) of the timing

gear case and the chip cut gear of the fuel
injection pump gear are aligned.
Note
If the chip cut gear is hard to find, move the
supply pump gear on notch back and forth,
then check the chip cut gear.
SUPPLY
PUMP GEAR
SUPPLY
PUMP GEAR
(HELICAL GEAR)
CHIP CUT GEAR
ABOUT3.0mm
{O.12 in}
DBG110BEB90
01-108-12
4. Fix the scissors gear to the supply pump gear using a lock bolt (M6x1.0; length under the bolt head is
approximately 16 mm {O.63 in}).
Warning
When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a lock bolt (M6x1.0; length under the bolt head is approximately 16 mm {O.63 in}).
Otherwise, the scissors gear will rotate with the spring force, causing personal injury.
caution
When removing the supply pump gear, be sure to secure the scissors gear to the supply pump
gear using a look bolt (M6x1.0; length under the bolt head is approximately 16 mm {O.63 in}) to
prevent the scissors gear form rotating with the spring force. Otherwise, the scissors gear will not
align with the supply pump gear, and the supply pump gear with the scissors gear will not engage
with the idler gear.
Note
The supply pump gear with a scissors
gear has a lock bolt hole.
DBG110BEB091
5. Hold the crankshaft using the SST and loosen the

gear nut.
6. Remove the supply pump gear using the SST and

bolt (M6X1.0, Length 30mm {1.18 in}).
01-108-13

-----------------------------------------~~--~------~--------------------------- ~~
Timing Gear Case Disassembly Note
1. Remove the timing gear case using the separator
tool.
,------------:-----------..,
:ti'
DBG110BEB094
Dual-mass flywheel Disassembly Note

1. Remove the Dual-mass flywheel using the SST.
:.'
DBG110BEB034
Rear Cover Disassembly Note

with a rag.
RAG
DBG110BEB095
01-108-14
~,

CYLINDER BLOCK DISASSEMBLY (III) [WL-C, WE-C]
DCF011002000W23
16
13
~
I
11
DBG110BEB021
1
2
Balance shaft
Connecting rod cap
(See 01-10B-16 Connecting Rod Cap Disassembly
Note)
9
10
Piston
Connecting rod
11
Main bearing cap

(See 01-10B-16 Main Bearing Cap Disassembly
Note)
12
13

(See 01-10B-16 Piston, Connecting Rod
Disassembly Note)
Piston ring
14

Piston pin clip

Piston pin
(See 01-10B-16 Piston Pin Disassembly Note)
15
16
Crankshaft
(See 01-10A-16 Crankshaft Disassembly Note)
Cylinder block
01-108-15

Connecting Rod Cap Disassembly Note
1. Before removing the connecting rod cap, inspect the connecting rod side clearance. (See 01-1 OB-29
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C].)
Piston, Connecting Rod Disassembly Note
1. Before removing the piston and connecting rod, inspect the connecting rod oil clearance. (See 01-1 OB-29
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
2. Inspect the oscillation torque. (See 01-1 OB-30 PISTON AND CONNECTING ROD INSPECTION [WL-C, WEC].)
Piston Pin Disassembly Note
1. Remove the piston pin using the SST.
,.
. ..
DBG110BEB096
Main Bearing Cap Disassembly Note

1. Before removing the main bearing cap, inspect the crankshaft end play. (See 01-1 OB-28 CRANKSHAFT END
PLAY INSPECTION/REPAIR [WL-C, WE-C].)
2. Loosen the main bearing cap bolts in two or three
Crankshaft Disassembly Note

1. Before removing the crankshaft, inspect the main journal oil clearance. (See 01-1 OB-28 CRANKSHAFT OIL
CLEARANCE INSPECTION/REPAIR [WL-C, WE-C].)
CYLINDER HEAD INSPECTION/REPAIR [WL-C, WE-C]
1. Inspect the cylinder head surface for cracks. Replace the cylinder head if necessary.
2. Inspect for the following and repair or replace.
(1) Sunken valve seats
(2) Excessive camshaft oil clearance and end play
3. Measure the cylinder head for distortion in the
seven directions as shown in the figure.
Y
DCF011 01 01 00W02

X distortion: 0.02 mm {o.oooa in} max.
Y distortion: 0.05 mm {0.0020 in} max.
4. If the cylinder head distortion exceeds the
maximum, replace the cylinder head. Do not
attempt to repair a cylinder head by milling or
grinding.
DBG110BEB080
01-108-16
-5. Measure the manifold contact surface distortion as shown in the figure.
0.05 mm {0.002 in} max.
6. If the distortion exceeds the maximum, grind the

surface or replace the cylinder head.

0.15 mm {0.0059 in} max.
DBG110BEB140
VALVE INSPECTION [WL-C, WE-C]
DCF011012111W04
1. Measure the valve head margin thickness of each

valve. Replace the valve if necessary.

IN: 1.55-1.85 mm {0.061-0.072 in}
EX: 1.80-2.10 mm {0.070-0.082 in}
2. Measure the length of each valve. Replace the

valve if necessary.
THICKNESS
-Ii
r------.L..,~
LENGTH

IN: 111.65-112.25 mm {4.394-4.413 in}
EX: 111.6-112.2 mm {4.390-4.409 in}
DBG110BEB098

IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
3. Measure the stem diameter of each valve in the X
and Y directions at the three points (A, B, and C)
shown in the figure. Replace the valve if
necessary.

IN: 5.970-5.985 mm {0.2350-0.2356 in}
EX: 5.965-5.980 mm {0.2348-0.2354 in}
IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
DBG110BEB099
01-108-17

VALVE GUIDE INSPECTION [WL-C, WE-C]
DCF011010280W03
1. Measure the inner diameter of each valve guide in

the X and Y directions at the three pOints (A, B,
and C) shown in the figure. Replace the valve
guide if necessary.
A

S.025-S.045 mm {0.2372-0.2379 in}
C
DBG110BEB100
2. Measure the protrusion height (dimension A) of

each valve guide without lower valve spring seat.
Replace the valve guide if necessary.
IN: 15.0-15.5 mm {0.59-0.S1 in}
EX: 17.0-17.5 mm {0.S7-0.S9 in}
@..L..-__ I_-U
DBG110BEB101
VALVE GUIDE REPLACEMENT [WL-C, WE-C]
DCF011 01 0280W04
Valve Guide Removal

Remove the valve guide from the combustion
chamber side using the SST.
DBG110BEB102
Valve Guide Installation

1. Mark the dimension L position on the valve guide.
Depth L
IN: 15.0-15.5 mm {0.59-0.S1 in}
EX: 17.0-17.5 mm {0.S7-0.SS in}
VALVE
GUID~!
I
I
I
I
I
I
I
I
: r--
I
I
I
I
I
I
I
I
\.L..L
THE CYLINDER HEAD SIDE
DBG110BEB110
01-108-18
-2. When the valve guide nears the dimension L
position while it is being tapped in, verify the

dimension L position again with vernier calipers to
prevent deviation in insertion.
3. Verify that the valve guide projection height is

IN: 1S.0-1S.S mm {0.S9-0.61 in}
EX: 17.0-17.S mm {0.67-0.68 in}
VALVE SEAT INSPECTION/REPAIR [WL-C, WE-C]

1. Measure the seat contact width. If necessary,
resurface the valve seat using a 4So valve seat
cutter and/or resurface the valve face.
DCF011 01 01 02W02

1.3-1.9 mm {0.OS2-0.074 in}
SEAT CONTACT
WIDTH
DBG110AEB109
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 using a 60 cutter, and then a 4So cutter.
2. If the seating position is too low, correct the
valve seat using a 30 cutter, and a 4So cutter.
Valve seat angle

IN: 4So
EX: 4So
IN
EX
oo
~
45
30
DBG110AEB078
3. Measure the receded amount from the cylinder

head surface. If it exceeds the maximum, replace
the cylinder head.

IN: 0.79-1.27 mm {0.039-0.0S0 in}
EX: 0.84-1.32 mm {0.033-0.0S1 in}
IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
DBG110AEB112
01-108-19
1
I,
:".,1,. ..
!
'Ii

VALVE SPRING INSPECTION [WL-C, WE-C]
DCF011012125W02
1. Apply a pressing force to the pressure spring and

check the spring height. Replace the valve spring
if necessary.

172.9-195.6 N {15.67-17.74 kgf, 34.4839.02Ibf}
39.0 mm {1.53 in}
DBG0110AEB11
2. Measure the amount the valve spring is out-ofsquare. Replace the valve spring if necessary.

2.0 0 (1.60mm {0.062 in})
DBG110AEB079
CAMSHAFT INSPECTION [WL-C, WE-C]
DCF011012420W04
1. Set the No.1 and No.5 journals on V-blocks.

Measure the camshaft runout. Replace the
camshaft if necessary.
Maximum camshaft run out

0.03 mm {0.001 in} max.
DBG110AEB114
2. Measure the cam lobe height at the two points as

shown in the figure. Replace the camshaft if
necessary.

IN: 42.067-42.167 mm {1.6561-1.6601 in}
EX: 41.949-42.049 mm {1.6515-1.6554 in}
IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
D o=r
++
++
DBG110AEB080
01-108-20

directions at the two points (A and 8) as shown in
the figure. Replace the camshaft if necessary.

No.1: 31.940-31.965 mm {1.2575-1.2582
in}
No.2-No.4: 25.910-25.935 mm {1.02011.0210 in}
No.5: 25.940-25.965 mm {1.0212-1.0222
in}
No.1: 31.890 mm {1.2555 in}
No.2-No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
CAMSHAFT OIL CLEARANCE INSPECTION [WL-C, WE-C)
1.
2.
3.
4.

Install the camshaft cap. (See 01-108-49 Camshaft Cap Upper Assembly Note.)
Remove the camshaft cap. (See 01-108-7 Camshaft Cap Upper Disassembly Note.)
Measure the oil clearance. Replace the cylinder
head if necessary.
DBG110AEB081
DCF011012420W05

No.1: 0.035-0.081 mm {0.0014-0.0031 in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043
in}
No.5: 0.056-0.081 mm {0.0014-0.0031 in}
No.1: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
No.5: 0.16 mm {0.0063 in}
CAMSHAFT END PLAY INSPECTION [WL-C, WE-C)
DBG110BEB053
DCF011012420W06
1. Install the camshaft cap. (See 01-108-49 Camshaft Cap Upper Assembly Note.)
2. Measure the camshaft end play. Replace the
,---------------------,
cylinder head or camshaft if necessary.

0.030-0.160 mm {0.0012-0.0062 in}
0.20 mm {0.0078 in}
3. Remove the camshaft cap. (See 01-108-7
Camshaft Cap Upper Disassembly Note.)
DBG110BEB109
01-108-21

CYLINDER BLOCK INSPECTION/REPAIR [WL-C, WE-C]
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown in the
figure. Replace if necessary.
DCF011010300W02

DBG110AEB115
2. Measure the cylinder bore using the cylinder gauge. Measurement positions are in the X and Y directions at 83
mm {3.27 in} (WL-C) or 88 mm {3.46 in} (WE-C) below the top surface of the cylinder.
If the cylinder bore exceeds the wear limit,
replace the cylinder block or rebore the
cylinder and install the oversized pistons so
WL-C 83.0 mm {3.27 in}
that the specified piston-to-cylinder clearance
WE-C 88.0 mm {3.46 in}
is obtained.
Note
Base the boring diameter on the diameter of
an oversized piston. All cylinders must be
the same diameter.
Cylinder bore size [WL-C]
Standard: 93.000-93.022 mm {3.66153.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
ffi
W
Yll
DBG110BEB047
Cylinder bore size [WE-C]

Standard: 96.000-96.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 96.250-96.272 mm {3.7893-3.7902 in}
0.50 {0.02} oversize: 96.500-96.522 mm {3.7992-3.8000 in}
0.15 mm {0.0059 in}
DUAL-MASS FLYWHEEL INSPECTION [WL-C, WE-C]
DCF011011500W01
Caution
Do not rework the flywheel if it is distorted.
Do not clean the dual mass flywheel with any kind of fluid. Clean the flywheel with a dry cloth only.
Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
Note
Correct slight scratches and discoloration
using sandpaper.
Inspect the runout of the surface that
contacts the clutch disc with the flywheel
installed to the crankshaft.
1. Inspect the flywheel.
Cracks
Worn ring gear teeth
Chipped or cracked ring gear teeth
Surface that contacts the clutch disc for
scratches, nicks, and discoloration.
If there is any malfunction, replace the
flywheel.
01-108-22
C3U0510W004
2. Verify that the center of the flywheel does not move.

(1) Rotate the flywheel or attempt to move it up
and down, and left and right to verify that the
center of the flywheel does not move.
If there is any movement as indicated by
the arrows in the figure, replace the
flywheel with a new one.
3. Verify that the secondary mass rotates by 15

teeth or more.
If it rotates by 15 teeth or more, replace the
dual-mass flywheel.
D3E510ZW8001
4. Inspect for locating dowels touching the primary

mass of the flywheel.
Caution
Make sure that the three locating dowels
are installed.
If the locating dowels are touching the primary
mass of the flywheel, replace the flywheel
with a new one.
5. Visually inspect the secondary mass.
If there is any damage, replace the dual-mass
flywheel.
6. Visually inspect the ring gear on the dual-mass
flywheel.
flywheel.
1r1nnnnnnnnr
--:---
B3E0510W056
RING GEAR
D3E510ZW8002
01-108-23

7. Inspect the welded area of the dual-mass
flywheel for grease leakage.
If there is grease leakage, replace the dualmass flywheel.
8. Inspect the dual-mass flywheel runout.

Flywheel maximum runout
1.5 mm {O.059 in}
If it is more than the maximum specification,

replace the dual-mass flywheel.
9. Inspect the dual-mass flywheel for the amount of

guide pin projection.
If not within the specification, replace the
dual-mass flywheel.
11mm {O.4330}
D3E510ZWB005
10. Rotate the secondary mass left and right and

verify that it rotates within a range of five teeth
without resistance.
If there is any malfunction, replace the dualmass flywheel.
11. Inspect the dual-mass flywheel for cracks.
If there are cracks, replace the dual-mass
flywheel.
D3E510ZWB006
01-108-24
-OIL JET VALVE, NOZZLE INSPECTION [WL-C, WE-C]
DCF011 01 0730W02
1. Apply compressed air to oil jet valve A and verify that air passes through oil jet valve B. If not, replace the oil jet
valve.
137.6-196.4 kPa {1.4-2.0 kgf/cm 2 , 20-28 psi}
2. Check the oil jet nozzle for clogs. Replace the

nozzle if necessary.
DBG110AEB085
PISTON INSPECTION [WL-C, WE-C]
DCF011011010W06
1. Measure the outer diameter of each piston at right angle (90 0 ) to the piston pin, 20 mm {0.79 in} below the oil
ring land lower edge.
Piston diameter [WL-C]

Standard: 92.918-92.944 mm {3.65823.6592 in}
0.25 {0.010} oversize: 93.153-93.179 mm
{3.6675-3.6684 in}
0.50 {0.020} oversize: 93.403-93.429 mm
{3.6773-3.6782 in}
20mm
Piston diameter [WE-C]

{O.79 in}
Standard: 95.918-95.944 mm {3.77633.7773 in}
0.25,{0.010} oversize: 96.153-96.179 mm
{3.7856-3.7865 in}
0.50 {0.020} oversize: 96.403-96.429 mm {3.7954-3.7964 in}
PISTON CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
DBG110AEBR86
DCF011011010W07
1. Measure the piston-to-cylinder clearance. Replace the piston or rebore the cylinders to fit the oversized piston
if necessary.
Standard piston clearance
0.071-0.089 mm {0.0015-0.0022 in}
0.15 mm {0.0059 in}
2. If the piston is replaced, the piston rings must also be replaced.
01-108-25

PISTON RING CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011010WOS
1. Measure the piston ring-to-ring land clearance

around the entire circumference. Replace the
piston and piston ring if necessary.
Standard piston ring clearance [WL-C]
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.02-0.06 mm {0.0012-0.0023 in}
Standard piston ring clearance [WE-C]
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
DBG110AEBl16

0.15 mm {0.0059 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 with a feeler
gauge. Replace the piston ring, if necessary.
Standard piston ring end gap [WL-C]
Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.49-0.64 mm {0.0193-0.0251 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
Standard piston ring end gap [WE-C]
Top: 0.23-0.33 mm {0.0091-0.0129 in}
Second: 0.50-0.65 mm {0.0197-0.0255 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
1.0 mm {0.039 in}
PISTON PIN CLEARANCE INSPECTION [WL-C, WE-C]
DCF011011010W09
1. Measure each piston pin bore diameter in the X

and Y directions at the four points (A, B, C, and D)
33.997-34.007 mm {1.3384-1.3388 in}
u:d
y
DBG110AEB088
2. Measure each connecting rod small end inner

diameter in the X and Y directions as shown in the
figure.
Standard connecting rod small end inner
diameter
34.012-34.033 mm {1.3391-1.3398 in}
~-+--~IY
DBG110AEB117
01-108-26
-3. Measure each piston pin diameter in the X and Y
l
-o--y
directions at the four points (A, B, C and D) as


33.994-34.000 mm {1.3384-1.3385 in}
4. Calculate the piston pin-to-piston pin bore

clearance. Replace the piston and/or piston pin if
necessary.
Standard piston pin-to-piston pin bore

clearance
-0.003-0.013 mm {-0.0001-0.0005 in}
DBG110AEBl18
5. Calculate the connecting rod small end-to-piston pin clearance. Replace the connecting rod or piston pin.
Standard connecting rod small end-to-piston pin clearance

0.012-0.039 mm {0.00048-0.0015 in}
CRANKSHAFT INSPECTION [WL-C, WE-C]
DCF011011301W04
1. Measure the crankshaft runout. Replace the

crankshaft if necessary.
Maximum crankshaft runout

0.05 mm {0.002 in}
DBG110AEB089
2. Measure the journal diameter in the X and Y

directions at the two points (A and B) as shown in
the figure. Replace the crankshaft or grind the
journal and install the undersize bearing if
necessary.
Main journal diameter [No.1 ,2,4,5]

Standard: 66.937-66.955 mm {2.63542.6360 in}
0.25 {0.010} undersize: 66.687-66.705 mm
{2.6255-2.6261 in}
0.50 {0.020} undersize: 66.437-66.455 mm
{2.6157-2.6163 in}
0.75 {0.030} undersize: 66.187-66.205 mm
{2.6058-2.6064 in}
x
I---+--.... jy
DBG 11 OAEB090
Main journal diameter [No.3]

Standard: 66.920-66.938 mm {2.6347-2.6353 in}
0.25 {0.010} undersize: 66.670-66.688 mm {2.6367-2.6373 in}
0.50 {0.020} undersize: 66.420-66.438 mm {2.6150-2.6156 in}
0.75 {0.030} undersize: 66.170-66.188 mm {2.6052-2.6058 in}
0.05 mm {0.002 in}
Main journal out-of-round
0.03 mm {0.001 in}
01-108-27

Crank pin diameter [WL-C]
Standard: 54.940-54.955 mm {2.1630-2.1635 in}
0.25 {0.010} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
0.50 {0.020} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.030} undersize: 54.190-54.205 mm {2.1335-2.1340 in}
Crank pin diameter [WE-C]

Standard: 56.940-56.955 mm {2.2417-2.2423 in}
0.25 {0.010} undersize: 56.690-56.705 mm {2.2318-2.2324 in}
0.50 {0.020} undersize: 56.440-56.455 mm {2.2220-2.2226 in}
0.75 {0.030} undersize: 56.190-56.205 mm {2.2122-2.2128 in}
0.05 mm {0.0020 in}
Crank pin out-of-round
0.03 mm {0.0012 in}
CRANKSHAFT OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
1.
2.
3.
4.
DCF011011301WOS

Install the main bearing cap. (See 01-1 OB-35 Main Bearing Cap Assembly Note.)
Remove the main bearing cap. (See 01-10B-16 Main Bearing Cap Disassembly Note.)
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.
No.1, 2, 4, 5: 0.027-0.045 mm {0.0010-0.0017 in}
No.3: 0.044-0.062 mm {0.0017-0.0024 in}
0.08 mm {0.003 in}
Standard: 2.006-2.021 mm {0.0789-0.0794 in}
0.25 {0.010} undersize:.2.124-2.134 mm {0.0836-0.0838 in}
0.50 {0.020} undersize: 2.249-2.259 mm {0.0885-0.0888 in}
0.75 {0.030} undersize: 2.374-2.384 mm {0.0934-0.0937 in}
CRANKSHAFT END PLAY INSPECTION/REPAIR [WL-C, WE-C]
DCF011011301W06
1. Install the main bearing cap. (See 01-1 OB-35 Main Bearing Cap Assembly Note.)
2. Measure the crankshaft end play. If the end play
,-----------;--;----------,
exceeds the maximum, replace the thrust bearing
or grind the crankshaft and install an oversized
bearing so that the specified end play is obtained.
0.040-0.282 mm {0.0016-0.0111 in}
0.3 mm {0.01 in}
Standard: 2.455-2.505 mm {0.0967-0.986
in}
0.35 {0.010} oversize: 2.630-2.680 mm {0.1036-0.1055 in}
3. Remove the main bearing cap. (See 01-10B-16 Main Bearing Cap Disassembly Note.)
01-108-28
DBG110AEB120
-CONNECTING ROD INSPECTION [WL-C, WE-C]

1. Measure each connecting rod for bending and
distortion. Replace the connecting rod if
necessary.
DCF011011211W04
Connecting rod bending

0.075 mm {0.0030 in} max./50 mm {1.968 in}
Connecting rod distortion
0.18 mm {0.0070 in} max./50 mm {1.968 in}
[WL-C]
162.96-163.04 mm {6.416-6.418 in}
DBG110AEB119
Connecting rod center-to-center distance [WE-C]

157.96-158.04 mm {6.219-6.222 in}
CONNECTING ROD OIL CLEARANCE INSPECTION/REPAIR [WL-C, WE-C]
1.
2.
3.
4.

Install the connecting rod cap. (See 01-108-36 Piston, Connecting Rod Assembly Note.)
Remove the connecting rod cap.
Measure the crankpin oil clearance. If the
clearance exceeds the maximum, replace the
connecting rod bearing or grind the crankpin and
use undersized bearings so that the specified
clearance is obtained.
DCF011011211W05

0.025-0.052 mm {0.0009-0.0020 in}
0.08 mm {0.003 in}
Standard: 1.507-1.516 mm {0.0592-0.0595
in}
0.25 {0.010} undersize: 1.624-1.634 mm {0.0638-0.0642 in}
0.50 {0.020} undersize: 1.749-1.759 mm {0.0687-0.0691 in}
0.75 {0.030} undersize: 1.874-1.884 mm {0.0737-0.0740 in}
CONNECTING ROD SIDE CLEARANCE INSPECTION [WL-C, WE-C]
1. Install the connecting rod cap. (See 01-108-36 Piston, Connecting Rod Assembly Note.)
2. Measure the connecting rod large end side
clearance. Replace the connecting rod and cap if
necessary.
DBG110AEB121
DCF011011211W06

0.110-0.262 mm {0.0043-0.01 03 in}
0.35 mm {0.014 in}
3. Remove the connecting rod cap.
DBG110AEB122
01-108-29

PISTON AND CONNECTING ROD INSPECTION [WL-C, WE-C]
DCF011011010W10
Check the oscillation torque as shown. If the large

end does not drop by its own weight, replace the
piston or the piston pin.
DBG110AEB093
BALANCE SHAFT INSPECTION [WL-C, WE-C]
DCF011 01 0300W03
1. Install the balance shaft and tighten the thrust plate fitting bolt.
Tightening torque
7.85-10.8 Nm {80-110 kgfm, 70-95 inlbf}
2. Measure the balance shaft end play. Replace the
balance shaft and/or cylinder block if necessary.
Balance shaft Standard end play

0.04-0.16 mm {0.002-0.006 in}
DBG110AEB094

directions at the two points (A and 8) as shown in
the figure. Replace the balance shaft if necessary.
Standard diameter
Front: 41.945-41.960 mm {1.6514-1.6519
in}
Center: 39.945-39.960 mm {1.5727-1.5732
in}
Rear: 37.975-37.990 mm {1.4951-1.4956
in}
A B
x
I----j----/ Y
DBG110AEB095
4. Measure the balance shaft bore in the cylinder

block. Calculate the balance shaft-to-balance
shaft bore clearance. Replace the balance shaft
and/or cylinder block if necessary.
Standard clearance
Front, rear: 0.050-0.115 mm {0.00200.0045 in}
Center: 0.080-0.145 mm {0.0032-0.0057 in}
DBG110AEB096
i
i
I:
i:
1:11.1
01-108-30
f)
BOLT INSPECTION [WL-C, WE-C]

Measure the length of each bolt. Replace the bolt
if necessary.
DCF011010135W02

Bolt head mark W
Standard length: 101.2-101.8 mm {3.9854.007 in}
Bolt head mark N
Bolt head mark I
DBG110AEB097

Connecting rod cap bolt length
VALVE CLEARANCE INSPECTION [WL-C, WE-C]
DCF011012111W05

2. Turn the crankshaft and align the timing mark so that the piston of the No.1 or NO.4 cylinders is at TDC of
..
compression.

B
A
B
A
cylinder at TDC of compression, and those of 8
with the No.4 cylinder at TDC of compression.
EX
recl:leck the valve clearance. (See 01-108-32
VALVE CLEARANCE ADJUSTMENT [WL-C,
WE-C].)
IN
A
DBG110BEB023
Valve clearance [Engine cold]

IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
5. Install the cylinder head cover.
CAMSHAFT
FEELER
GAU\_E___
~~~~f!!
ROCKER ARM
DBG110BTBRR5
01-108-31

VALVE CLEARANCE ADJUSTMENT [WL-C, WE-C]
Caution
Loosening the locknut and the adjust
screw while the cam lobe is not pressing
down the rocker arm will damage the
claw of the rocker arm. When loosening
the locknut and the adjust screw, rotate
the crankshaft clockwise and be sure that
the cam lobe presses down the rocker
arm firmly as shown in the figure.
DCFOll012111W06
CAM LOBE
CLAW

TOC of compression.
cylinder at TOC of compression, and those of B
with the No.4 cylinder at TOC of compression.
ROCKER ARM
DBGll0BTBRR6
DBG 11 OBEB023

IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
Tightening torque (lock nut)
20-24 Nm {2.1-2.4 kgf.m, 15-17 ft.lbf}
5. Install the cylinder head cover.
FEELER
GAU\_E_____
~~~-..,...g~
ROCKER ARM
DBG110BTBRR5
,.!
. 'i
Ii 1;
01-108-32
GEAR CLEARANCE INSPECTION [WL-C, WE-C]
.a
.;
~.

If it exceeds the maximum specification, replace the gear and/or pump body.
DCF011019220W02

0.10-0.19 mm {0.0040-0.0074 in}
0.20 mm {0.008 in}
DBG110AEB101

0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
DBG110AEB102
PLUNGER SPRING INSPECTION [WL-C, WE-C]

1. Apply pressing force to the pressure spring and
check the spring height. Replace the plunger
spring if necessary.
DCF011014116W02

43.8 mm {1.72 in}
DBG110AEB103
01-108-33
MECHANICAL [WL-C, WE-C)

CYLINDER BLOCK ASSEMBLY <I> [WL-C, WE-C]
DCF0110020001lV24
46.5-51.5
{4.8-5.2,34.1-37.9}
+82.5 -97.5
7.8-10.8 Nm
{80-11 0 kgfcm,
70-95 inlbf}
12-18 Nm {123-183 kgf.cm,

107-159 inlbf}
14.5-34.5 {1.5-3.5, 11-25}

+74.0-82.0 {7.6-8.3, 55-60}
Loosen all the bolts (until bolts are torquefree)
+ 14.5-34.5 {1.5-3.5, 11-25}
+42.5-45.5 {4.4-4.6, 32-33}
+90-105
Nm {kgfm, ttlbf}
DBG110BEB052
1
2
Crankshaft
~!:!
Piston
(8ee01-108-35 Piston, Connecting Rod, Piston Pin
Assembly Note.)
Piston pin
Assembly Note.)
3
5
II
Cylinder block
Main bearing cap

(8ee01-108-35 Main 8earing Cap Assembly
Note.)
10
11
Connecting rod
Assembly Note.)
12
01-108-34
Piston pin clip

Piston ring
(8ee01-108-36 Piston Ring Assembly Note.)
'-13
14
piston, connecting rod

(8ee01-10B-36 Piston, Connecting Rod Assembly
Note.)
15
16
IConnecting rod cap

Balance shaft
Main Bearing Cap Assembly Note

1. Apply clean engine oil to the bolt threads and seat faces of the lower cylinder block bolts.
8
4
1
shown in the ~igure.
Tightening procedure
(1) 14.5-34.5 Nm {1.5-3.5 kgf.m, 11-25
ftlbf}
(2) 74.0-82.0 Nm {7.6-8.3 kgfm, 55-60
ftlbf}
(3) Loosen all the bolts (until bolts are
torque-free).
(4) 14.5-34.5 Nm {1.5-3.5 kgfm, 11-25
ft.lbf}
(5) 42.5-45.5 Nm {4.4-4.6 kgf.m, 32-33
ft.lbf}
DBG110AEB271

by turning each 90-105 as in Step 2.
PAINT MARK
DBG110AEB072
Piston, Connecting Rod, Piston Pin Assembly Note

1. Install one piston pin clip.
2. Assemble the piston and connecting rod in the direction indicated in the figure.
3. Apply clean engine oil to the piston pin.
4. Install the piston pin until the pin contacts the clip
FMARK
as shown. If the pin cannot be installed easily,
heat the piston.
PROJECTION FOR ALIGNING

CONNECTIOG ROD BEARING
DPE110ZE1R18
01-108-35

Piston Ring Assembly Note
1. Install the oil ring.
2. Install the second ring with R mark side upward.
3. Install the top ring with tapered face side upward.
SECTION OF TOP RING
==(
SECTION OF SECOND RING
DBG110AEBR96
Piston, Connecting Rod Assembly Note

1. Insert the piston and connecting rod assembly
into the cylinder with the F mark facing the front of
the engine.
2. Tighten the connecting rod cap bolts in two or
three steps.
Tightening torque
46.5-51.5 Nm {4.8-5.2 kgf.m, 34.3-37.9
ft.lbf}
FMARK
3. Put a paint mark on each bolt.

DBG110AEBRR5

by turning each 82.5-97.5
PAINT MARK
DBG110AEBRR3
01-108-36
-CYLINDER BLOCK ASSEMBLY (II) [WL-C, WE-C]
DCF011002000W25
96.1-102.9
{9.B-10, 71-75}
7.8-10.B Nm
{B0--11 0 kgfcm,
70--95 inlbf}
392-441
{40--44,290--325}
7.8-10.B Nm
{B0--110 kgfcm,
70--95 inlbf}
mI
iii
mI
Nm {kgf.m, ftlbf}
DBG 11 OBEB001
Oil pump body

Control plunger
Plunger spring
Plug
Driven gear
Oil pump cover
(8ee01-108-38 Oil Pump Cover Assembly Note.)
r-~~~--------------~--------~----~
7
Rear cover
(8ee01-108-38 Rear Cover, End Plate Assembly
Note.)
2
3
4
5
6
End plate
(8ee01-108-38 Rear Cover, End Plate Assembly
Note.)
Dual-mass flywheel
9
(8ee01-108-39 Dual-mass Flywheel Assembly
Note.)
10 8eal plate
11 , Timing gear case
(8ee01-108-39 Timing Gear Case Assembly
Note.)
12 8upply pump
01-108-37

13
14
15
16
Timing gear
(See01-108-40 Timing Gear, Supply Pump Gear
Assembly Note.)
Supply pump gear
(See01-108-40 Timing Gear, Supply Pump Gear
Assembly Note.)
Oil pump
Timing gear cover
(See01-108-42 Timing Gear Cover Assembly
Note.)
17
18
19
Supply pump pulley

(See01-108-42 Supply Pump Pulley Assembly
Note.)
Seal plate
Crankshaft pulley
(See01-108-43 Crankshaft Pulley Assembly Note.)
Oil Pump Cover Assembly Note

Rear Cover, End Plate Assembly Note

hammer
cover and the face of the oil seal.
Rear oil seal press-in amount
0-0.5 mm {0-0.01 in}
+.2:-0.5 mm {0-0.01 in}
t~ REAR OIL SEAL

DBG110BEB059
5. Apply silicone sealant to the rear cover as shown.

Thickness
~2.0-3.0
mm {0.07-0.12 in}
DBG 11 OBEB003
01-108-38
-6. Apply silicone sealant to the rear cover as shown

in the figure.
Thickness
~2.0-3.0
mm {O.07-0.12 in}
7. Install the end plate.
DBG110AEBR94
Dual-mass Flywheel Assembly Note

2. Tighten the bolts in the order shown in the figure.
DBG110BEB051
.. Timing Gear Case Assembly Note

"
1. Install the new O-ring.
2. Apply silicone sealant to the timing gear case as
shown in the figure. Do not apply sealant to the 0ring.
Thickness
~2.0-3.0
mm {O.07-0.12 in}
DBG110BEB104

/
DBG110BEB072
01-108-39

Timing Gear, Supply Pump Gear Assembly Note
1. Put a paint mark on the chip cut gear of the
supply pump gear.
SUPPLY PUMP
GEAR (HELICAL
GEAR)
PAINT MARK
DBG110AEBR93
2. Put a paint mark on the 10th and 11 th teeth of the

helical gear counting clockwise from the chip cut
gear.
CHIP CUT GEAR

SUPPLY
PUMP GEAR
VIEWA
PAINT MARK
DBG110BEB141
3. Verify that the 10th and 11 th teeth of supply pump

gear (helical gear) and the teeth of the scissors
gear are aligned, then put a paint mark on the
scissors gear.
SCISSORS GEAR
HELICAL GEAR
~I
~~10TEETH
~~11
TEETH
PAINT MARK
DBG110BEB103

approximately 30 0 BTOC (13 teeth on the gear).
BTDC30
DBG110AEBR59
01-108-40

6. Align the timing marks. For the supply pump gear, align the timing mark as shown in the figure (View A).
Note
The helical gears except for the supply pump gear have a punch mark as the timing mark. The timing
mark of each gear can be aligned easily if the paint mark is made on the punch mark.
TIMING MARK (WHITE PAINT)
SUPPLY PUMP GEAR
)~--------------------------------------~~
DBG110BEB078
7. Remove the lock bolt.
DBG110AEBR97
8. Tighten the bolts using the SST.
01-108-41

Timing Gear Cover Assembly Note
hammer.
0.0-0.40 mm {0.0-0.015 in}
0.0-0.40 mm {0.0-0.015 in}
DBGll0BEB012

shown.
Thickness
~2.0-3.0
mm {0.079-0.118 in}
DBGll0BEB071

Supply Pump Pulley Assembly Note

1. Install the supply pump pulley using the SST.
~.
' I
DBGll0BEB054
01-108-42
MECHANICAL [WL-.C, WE-C]
crankshaft Pulley Assembly Note

1. Install the crankshaft pulley using the SST.
DBG110BEB055
CYLINDER BLOCK ASSEMBLY (III) [WL-C, WE-C]
DCF011002000W26
7.85-10.8 Nm
{80-110 kgfcm,
70-95 in.lbf}
Nm {kgfm, ftlbf}
DBG110BEB074
Oil pipe
(8ee01-108-44 Oil Pipe Assembly Note.)
Oil strainer
3
4
Oil pan
(8ee01-108-44 Oil Pan Assembly Note.)
Oil drain plug
01-108-43
:,i!!:
: '!!
IT"'."'"'''''' "
}1
Oil Pipe Assembly Note

DBG110BEB076
Oil Pan Assembly Note

1. Apply silicone sealant to the oil pan as shown in
the figure.
Thickness
~2.0-3.0
.-
mm {O.07-0.12 in}
2. Tighten the oil pan bolts A as shown in the figure.

Caution
bolt hole damage.

passes.
A
o
o
DBG110BEB056
!o'
)~@i=E
~
OLD SEALANT
CHU0111W004
01-108-44
CYLINDER HEAD ASSEMBLY (I) [WL-C, WE-C]
DCF011002000W27
CD
18.6-25.5 {1.9-2.6, 14-18}
Nm {kgfm, ftlbf}
DBG110BEB065
2
3
4
5
6
Water outlet pipe

Valve seal
(8ee01-108-46 Valve 8eal Assembly Note.)
Valve
Valve spring
8
9
10
Valve keeper
(8ee01-108-46 Valve Keeper Assembly Note.)
Valve cap
"
Pivot
(8ee01-108-46 Pivot Assembly Note.)
Rocker arm
(8ee 01-108-46 Rocker Arm Assembly Note.)
01-108-45

Valve Seal Assembly Note
1. Tap the SST using a plastic hammer.
\;:'l:::~"";"';''''''':''''---'H-
VALVE SEAL
DBGll0BEB008
Valve Keeper Assembly Note

1. Install the valve keeper using the SST.
Pivot Assembly Note

1. Apply adhesive to the thread of the pivot.
Rocker Arm Assembly Note
1. If a new rocker arm is used, set dimension A as
follows.
Dimension A
0.0-4.0 mm {0.0-0.115 in}
DBGll0BWB92
01-108-46
:1
CYLINDER HEAD ASSEMBLY (II) [WL-C, WE-C]
1\
I
DCF011002000W28
7.8-10.8 Nm
{80-110 kgfcm,
70-S5 inlbf}
~~qb
' ~~ c;]
~~
~~S
123-140 {12.6-14.2, SO.8-103.2}
{3.0, 21}
17.6-1S.6
{1.8-1.S, 13-14}
CD
7.8-10.8 Nm
{80-110 kgfcm,
70-S5 in.lbf}
Nm {'kgf.m, ftlbf}
DBG110BEB026
2
3
4

(See 01-108-48 Cylinder Head Gasket Assembly
Note.)
Cylinder head
(See 01-108-48 Cylinder Head Assembly Note.)
ECT sensor
Camshaft cap lower
(See 01-108-49 Camshaft Cap Lower Assembly
Note.)
6
7
8
Camshaft
Camshaft cap upper
(See 01-108-49 Camshaft Cap Upper Assembly
Note.)
Seal plate
(See 01-108-50 Seal Plate Assembly Note.)
Camshaft pulley
(See 01-108-50 Camshaft Pulley Assembly Note.)
01-108-47

Cylinder Head Gasket Assembly Note
1. Measure the piston topping of all the cylinders.
+TOPPING
CYLINDER
BLOCK
PISTON
DPEll0ZE1R02

piston topping.

identification mark
0.080-0.190 {0.004-o.007}
--+'
0.135-0.255 {0.006-o.01 O}
,---J
0.200-0.310 {0.008-0.012}
IDENTIFICATION MARK
POSITION
DPEll0BEBR94

Thickness
02.0-3.0 mm {0.08-0.11 in}
~,.-t-+
16.0 mm
{0.63 in}
44.0mm
{1.73 in}
39.5mm
{1.56 in}
ENGINE
FRONT
~;II--!- 23.5 mm
{0.93 in}
DBGll0BWBR9
Cylinder Head Assembly Note

1. Before installing the cylinder head bolts, inspect their length. (See01-10B-31 BOLT INSPECTION [WL-C, WEC].)
3. Tighten the bolts in two or three steps in the order shown in the figure.
Tighten torque
29 Nm {3.0 kgfm, 21 ft.lbf}
{3.0 kgfm, 2.1 ftlbf}.
DBGll0BEB027
I j:
IL I
01-108-48

by turning each 90-105 in the sequence
a shown.
" 7. Further tighten each bolt by turning another 90105.
8. Further tighten each bolt by turning another 90105.
9. Apply adhesive to the thread of bolt A.
10. Tighten bolts A.
Tighten torque
17.6-19.6 Nm {1.8-1.9 kgfm, 13-14 ft.lbf}
PAINT MARK
PAINT MARK
DBG110AWB311
Camshaft Cap Lower Assembly Note

DBG110BEB105
Camshaft Cap Upper Assembly Note

1. Apply adhesive to the front camshaft cap
mounting surfaces as shown in the figure.
2. Tighten the camshaft cap bolts gradually in three
or four steps in the order shown in the figure.
Caution
-Because there is little camshaft thrust
applied to the thrust area, causing burrs
cylinder head journal. To avoid this, the
t t - - - 4 ADHESIVE
DBG110BWB86

oil seal.
01-108-49

5. Tap the oil seal lightly into the cylinder head using
the SST and a hammer.
CYLINDER
HEAD

0.5-1.0 mm {0.020-0.039 in}
0.5-1.0 mm {0.02-0.03 in}
HAMMER
Ii
OIL SEAL
DPE110ZE1R41
Seal Plate Assembly Note

in the figure.
SEAL PLATE
DBG110BEB041
Camshaft Pulley Assembly Note

1. Install the camshaft pulleys, positioning the knock
pins as shown in the figure.
INTAKE
CAMSHAFT
PULLEY
KNOCK PIN
EXHAUST
CAMSHAFT
PULLEY
DBG110BWB85
2. Hold the camshaft using a wrench on the cast hexagon.
Caution
damage them.
CAMSHAFT PULLEY
DBG110BEBR17
01-108-50
TIMING BELT ASSEMBLY [WL-C, WE-C]
DCF011002000VV29

21-26 {2.2-2.6, 16-19}
")
_,f;.>4
1.8-1" Nm (80--110 kgl.,m,
~ ,.....,5;".,b"~
1S.6-25.5 {1.9-2.6, 14-1S}
\(a.
.'1
35-52 {3.5-5.3,
25-3S}
~~
6
70-95 in.lbf}
7.S-10.S Nm {SO-110 kgfcm,
70-95 in'lbf}
Nm {kgf'm, ttlbf}
DBG110BEB046
ICylinder head cover

Injector
Auto tensioner
(8ee01-10B-52 Timing Belt Assembly Note.)
01-108-51
MECHANICAL [WL-C, WE-C] .

4
5
Timing belt
(See01-108-52 Timing 8elt Assembly Note.)
Idler
(See01-108-52 Timing 8elt Assembly Note.)
7
8
Timing belt cover

(See 01-108-53 Timing 8elt Cover Assembly
Note.)
Water pump
Vacuum pump
I.fi:
I"
Cylinder Head Cover Assembly Note

Thickness
02.0-3.0 mm {0.08-0.11 in}
DBG110BWB84

DBG110BEB005
Timing Belt Assembly Note

1. Align the timing marks as shown in the figure.
2. Verify that the supply pump attaching bolts and
nuts are tightened to the specified torque. This
must be done to prevent over-tensioning of the
timing belt after it has been installed.
INTAKE
CAMSHAFT
PULLEY
EXHAUST
CAMSHAFT
PULLEY
TIMING MARK
TIMING
MARK
~@\-SUPPLY PUMP
~
PULLEY
DBG110BWB97
3. Install the tensioner and hand-tighten lock bolts A

and B.
5. Install the idler.
6. Tighten the lock bolt A.
7. Tighten the lock bolt B.
8. Remove the set pin from the tensioner.
camshaft pully timing marks. If they are not
aligned, remove the timing belt and repeat from
Step 1.
DBG110BWB96
01-108-52
-Timing Belt Cover Assembly Note

DBG110BEB043
01-108-53
-01-50A
TECHNICAL DATA [WL-3]
ENGINE TECHNICAL DATA [WL-3] .... 01-50A-1
,----------------------------------------ENGINE TECHNICAL DATA [WL-3]

Item

Maximum combustion chamber recession
Maximum combustion chamber projection
Combustion chamber crack
Valve seat angle
Cylinder bore size
DCF015000000W01
Specification
X distortion: 0.02 mm {0.0008 in}
Y distortion: 0.05 mm {0.0020 in}
0.02 mm {0.0008 in}
0.005 mm {0.0002 in}
Limit: 10mm {0.39 in}
0.05 mm {0.0020 in}
0.15 mm {0.0059 in}
IN: 1.5 mm {0.059 in}
EX: 0.75 mm {0.030 in}
IN: 111.6-112.1 mm {4.394-4.413 in}
EX: 111.5-112.0 mm {4.390-4.409 in}
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
IN: 6.970-6.985 mm {0.2745-0.2749 in}
EX: 6.965-6.980 mm {0.2743-0.2748 in}
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
7.025-7.045 mm {0.2766-0.2773 in}
14.0-14.5 mm {0.552-0.570 in}
IN: 1.6-2.2 mm {0.063-0.086 in}
EX: 1.7-2.3 mm {0.067-0.090 in}
IN: 45
EX: 45
IN: 0.61-1.09 mm {0.025-0.042 in}
EX: 0.71-1.19 mm {0.028-0.046 in}
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
238-269 N {25-27 kgf, 54-60 Ibf}
35.5 mm {1.40 in}
2.0 (1.70mm {0.067 in})
0.03 mm {0.0012 in}
IN: 42.400-42.500 mm {1.6692-1.6732 in}'
EX: 42.395-42.495 mm {1.6691-1.6730 in}
IN: 42.050 mm {1.6555 in}
EX: 42.045 mm {1.6711 in}
'"
No.1, No.5: 25.940-25.965 mm {1.0213-1.0222 in}
No.2-No.4: 25.910-25.935 mm {1.0201-1.0210 in}
No.1, No.5: 25.890 mm {1.0193 in}
No.2-No.4: 25.860 mm {1.0181 in}
No.1, 5: 0.035-0.081 mm {0.0014-0.0031 in}
No.2-4: 0.065-0.111 mm {0.0026-0.0043 in}
No.1, 5: 0.12 mm {0.0047 in}
No.2-4: 0.15 mm {0.0059 in}
0.030-0.160 mm {0.0012-O.0062 in}
0.20 mm {0.0079 in}
Standard: 93.000-93.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
0.15 mm {0.0059 in} .
137.6-196.4 kPa {1.5-2.0 kgf/cm 2 , 20-28 psi}
01-50A-1

Item
Piston diameter
Standard piston clearance
Standard piston ring clearance
Standard piston ring end gap
Standard connecting rod small end inner diameter
Standard piston pin-to-piston pin bore clearance
Standard connecting rod small end-to-piston pin
clearance
Maximum crankshaft runout
Main journal diameter

Main journal out-ot-round
Crank pin diameter
Crank pin out-ot-round
Maximum connecting rod bending
Maximum connecting rod distortion
Standard connecting rod bolt length
Maximum connecting rod bolt length
01-50A-2
Specification
Standard: 92.951-92.977 mm {3.6595-3.6605 in}
0.25 {0.0098} oversize: 93.186-93.212 mm {3.6688-3.6697 in}
0.50 {0.02} oversize: 93.436-93.462 mm {3.6786-3.6795 in}
0.055-0.073 mm {0.0022-0.0028 in}
0.15 mm {0.0059 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.03-0.07 mm {0.0012-0.0027 in}
0.15 mm {0.0059 in}
Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.32-0.47 mm {0.0126-0.0185 in}
Oil: 0.22-0.37 mm {0.0087-0.0145 in}
1.0 mm {0.039 in}
31.997-32.007 mm {1.2598-1.2601 in}
32.012-32.033 mm {1.2604-1.2611 in}
31.994-32.000 mm {1.25961-1.25984 in}
-0.003-0.013 mm {-0.00011-0.00051 in}
0.012-0.039 mm {0.00048-0.00153 in}

0.05 mm {0.0020 in}
Standard
No.1, 2, 4, 5: 66.937-66.955 mm {2.6354-2.6360 in}
NO.3: 66.920-66.938 mm {2.6347-2.6353 in}
No.1, 2, 4, 5: 66.687-66.705 mm {2.6255-2.6261 in}
NO.3: 66.670-66.688 mm {2.6248-2.6255 in}
No.1, 2, 4, 5: 66.437-66.455 mm {2.6157-2.6163 in}
NO.3: 66.420-66.438 mm {2.6150-2.6156 in}
No.1, 2, 4, 5: 66.187-66.205 mm {2.6058-2.6064 in}
NO.3: 66.170-66.188 mm {2.6052-2.6058 in}
0.05 mm {0.0020 in}
0.03 mm {0.0012 in}
Standard: 54.940-54.955 mm {2.1630-2.1635 in}
0.25 {0.01} undersize: 54.690-54.705 mm {2.1532-2.1537 in}
0.50 {0.02} undersize: 54.440-54.455 mm {2.1434-2.1438 in}
0.75 {0.03} undersize: 54.190-54.205 mm {2.1335-2.134 in}
0.05 mm {0.0020 in}
0.03 mm {0.0012 in}
No.1, 2, 4, 5: 0.027-0.046 mm {0.0011-0.0018 in}
No.3: 0.044-0.063 mm {0.0018-O.0025 in}
0.08 mm {0.0031 in}
Standard: 2.006-2.021 mm {0.0790-0.0795 in}
0.25 {0.01} undersize: 2.124-2.134 mm {0.0837-0.0840 in}
0.50 {0.02} undersize: 2.249-2.259 mm {0.0886-0.0889 in}
0.75 {0.03} undersize: 2.374-2.384 mm {0.0935-0.0938 in}
0.040-0.282 mm {0.0016-0.0111 in}
0.3 mm {0.012 in}
Standard: 2.454-2.506 mm {0.0967-0.0986 in}
0.35 {0.014} oversize: 2.629-2.681 mm {0.1036-0.1055 in}
0.075 mm {0.0030 in} /50 mm {2.0 in}
0.18 mm {0.0071 in} /50 mm {2.0 in}
151.96-152.04 mm {5.9827-5.9858 in}
67.5-68.5 mm {2.66-2.69 in}
69 mm {2.7 in}
0.025-0.052 mm {0.001 0-0.0020 in}
0.08 mm {0.0031 in}
..
~~
--

Item
. Connecting rod bearing thickness


Valve clearance (engine cold)
Specification
Standard: 1.507-1.516 mm {0.0594-0.0596 in}
0.25 {0.01} undersize: 1.624-1.634 mm {0.0640-0.0643 in}
0.50 {0.02} undersize: 1.749-1.759 mm {0.0689-0.0692 in}
0.75 {0.03} undersize: 1.874-1.884 mm {0.0738-0.0741 in}
0.110-0.262 mm {0.0044-0.01 03 in}
0.35 mm {0.014 in}

Bolt head mark W
Bolt head mark N
63.0 mm {2.48 in}

IN: 0.05-0.15 mm {0.0020-0.0059 in}
EX: 0.15-0.25 mm {0.0060-0.0098 in}
0.95-1.05 mm {0.038-0.041 in}
0.10-0.19 mm {0.004Q-0.0074 in}
0.20 mm {0.0079 in}
0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
43.8 mm {1.72 in}
0-0.4 mm {0-0.01 in}
0-0.4 mm {0-0.01 in}
0.5-1.0 mm {0.02-0.03 in}
"
01-50A-3
,,.il
,. '.. . i
'I'i
!
.
,'. .,1'1
.
TECHNICAL DATA [WL-C, WE-C]
01-508 TECHNICAL DATA [WL-C, WE-C]
ENGINE TECHNICAL DATA

[WL-C, WE-C] .................... 01-508-1
ENGINE TECHNICAL DATA [WL-C, WE-C]

Item

Valve seat angle

Cylinder bore size [WL-C]
DCF015000000W02
Specification
X distortion: 0.02 mm {0.0008 in} max.
Y distortion: 0.05 mm {0.0020 in} max.
0.05 mm {0.002 in} max.
0.15 mm {0.0059 in} max.
IN: 1.55-1.85 mm {0.061-0.072 in}
EX: 1.80-2.10 mm {0.070-0.082 in}
IN: 111.65-112.25 mm {4.394-4.413 in}
EX: 111.6-112.2 mm {4.390-4.409 in}
IN: 111.50 mm {4.390 in}
EX: 111.45 mm {4.388 in}
IN: 5.970-5.985 mm {0.2350-0.2356 in}
EX: 5.965-5.980 mm {0.2348-0.2354 in}
IN: 5.920 mm {0.2330 in}
EX: 5.915 mm {0.2328 in}
6.025-6.045 mm {0.2372-0.2379 in}
IN: 15.0-15.5 mm {0.59-0.61 in}
EX: 17.0-17.5 mm {0.67-0.69 in}
IN: 15.0-15.5 mm {0.59-0.61 in}
EX: 17.0-17.5 mm {0.67-0.68 in}
1.3-1.9 mm {0.052-0.074 in}
IN: 45
EX: 45
IN: 0.79-1.27 mm {0.039-0.050 in}
EX: 0.84-1.32 mm {0.033-0.051 in}
IN: 1.68 mm {0.066 in}
EX: 1.73 mm {0.062 in}
172.9-195.6 N {15.67-17.74 kgf, 34.48.,.-39.02Ibf}
39.0 mm {1.53 in}
2.0 (1.60mm {0.062 in})
0.03 mm {0.001 in} max.
IN: 42.067-42.167 mm {1.6561-1.6601 in},
EX: 41.949-42.049 mm {1.6515-1.6554 in}
IN: 41.717 mm {1.6424 in}
EX: 41.599 mm {1.6377 in}
No.1: 31.940-31.965 mm {1.2575-1.2582 in}
No.2-No.4: 25.910-25.935 mm {1.0201-1.0210 in}
No.5: 25.940-25.965 mm {1.0212-1.0222 in}
No.1: 31.890 mm {1.2555 in}
No.2-No.4: 25.860 mm {1.0181 in}
No.5: 25.890 mm {1.0193 in}
No.1: 0.035-0.081 mm {0.0014-0.0031 in}
NO.2-4: 0.065-0.111 mm {0.0026-0.0043 in}
No.5: 0.056-0.081 mm {0.0014-0.0031 in}
No.1: 0.12 mm {0.0047 in}
NO.2-4: 0.15 mm {0.0059 in}
No.5: 0.16 mm {0.0063 in}
0.030-0.160 mm {0.0012-O.0062 in}
0.20 mm {0.0078 in}
Standard: 93.000-93.022 mm {3.6615-3.6622 in}
0.25 {0.01} oversize: 93.250-93.272 mm {3.6713-3.6721 in}
0.50 {0.02} oversize: 93.500-93.522 mm {3.6811-3.6819 in}
01-508-1
Cylinder bore size [WE-C]
96.000-96.022 mm {3.6615-3.6622 in}

0.25 {0.01} oversize: 96.250-96.272 mm {3.7893-3.7902 in}
0.50 {0.02} oversize: 96.500-96.522 mm {3.7992-3.8000 in}

Piston diameter [WL-C]
0.25
0.50
Piston diameter [WE-C]
0.25
0.50
Standard piston ring clearance [WL-C]
Standard piston ring clearance [WE-C]
Standard piston ring end gap [WL-C]
Standard piston ring end gap [WE-C]
137.6-196.4 kPa {1.4-2.0 kgf/cm 2 , 20-28 psi}

Standard: 92.918-92.944 mm {3.6582-3.6592 in}
{0.010} oversize: 93.153-93.179 mm {3.6675-3.6684 in}
{0.020} oversize: 93.403-93.429 mm {3.6773-3.6782 in}
Standard: 95.918-95.944 mm {3.7763-3.7773 in}
{0.010} oversize: 96.153-96.179 mm {3.7856-3.7865 in}
{0.020} oversize: 96.403-96.429 mm {3.7954-3.7964 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}

Second: 0.06-0.08 mm {0.0024-0.0031 in}
Oil: 0.02-0.06 mm {0.0012-0.0023 in}
Top: 0.06-0.10 mm {0.0024-0.0039 in}
Second: 0.04-0.08 mm {0.0016-0.0031 in}
Oil: 0.02-0.06 mm {0.0008-0.0023 in}
Top: 0.22-0.32 mm {0.0087-0.0125 in}
Second: 0.49-0.64 mm {0.0193-0.0251 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
Top: 0.23-0.33 mm {0.0091-0.0129 in}
Second: 0.50-0.65 mm {0.0197-0.0255 in}
Oil: 0.22-0.52 mm {0.0087-0.0204 in}
0.012-0.039 mm {0.00048-0.0015 in}
Main journal diameter [No.1 ,2,4,5]
Main journal diameter [No.3]
Crank pin diameter [WL-C]
Crank pin diameter [WE-C]
Standard: 66.937-66.955 mm {2.6354-2.6360 in}

0.25 {0.01 O} undersize: 66.687-66.705 mm {2.6255-2.6261
0.50 {0.020} undersize: 66.437-66.455 mm {2.6157-2.6163
0.75 {0.030} undersize: 66.187-66.205 mm {2.6058-2.6064
Standard: 66.920-66.938 mm {2.6347-2.6353 in}
0.25 {0.01 O} undersize: 66.670-66.688 mm {2.6367-2.6373
0.50 {0.020} undersize: 66.420-66.438 mm {2.6150-2.6156
0.75 {0.030} undersize: 66.170-66.188 mm {2.6052-2.6058
Standard: 54.940-54.955 mm {2.1630-2.1635 in}

0.25 {0.010} undersize: 54.690-54.705 mm {2.1532-2.1537
0.50 {0.020} undersize: 54.440-54.455 mm {2.1434-2.1438
0.75 {0.030} undersize: 54.190-54.205 mm {2.1335-2.1340
Standard: 56.940-56.955 mm {2.2417-2.2423 in}
0.25 {0.010} undersize: 56.690-56.705 mm {2.2318-2.2324
0.50 {0.020} undersize: 56.440-56.455 mm {2.2220-2.2226
0.75 {0.030} undersize: 56.190-56.205 mm {2.2122-2.2128
No.1, 2, 4, 5: 0.027-0.045 mm {0.001 0-0.0017 in}

No.3: 0.044-0.062 mm {0.0017-0.0024 in}
01-508-2
in}
in}
in}
in}
in}
in}
in}
in}
in}
in}
in}
in}

Item

Connecting rod bending
Connecting rod distortion
Connecting rod center-to-center distance [WL-C]
Connecting rod center-to-center distance [WE-C]
Balance shaft Standard end play
Standard diameter
Standard clearance
t

Connecting rod cap bolt length
Specification
Standard: 2.006-2.021 mm {0.0789-0.0794 in}
0.25 {0.010} undersize: 2.124-2.134 mm {0.0836-0.0838 in}
0.50 {0.020} undersize: 2.249-2.259 mm {0.0885-0.0888 in}
0.75 {0.030} undersize: 2.374-2.384 mm {0.0934-0.0937 in}
0.040-0.282 mm {0.0016-O.0111 in}
0.3 mm {0.01 in}
Standard: 2.455-2.505 mm {0.0967-0.986 in}
0.35 {0.01 O} oversize: 2.630-2.680 mm {0.1 036-0.1 055 in}
0.075 mm {0.0030 in} max.l50 mm {2.0 in}
0.18 mm {0.0070 in} max.l50 mm {1.968 in}
162.96-163.04 mm {5.983-5.986 in}
157.96-158.04 mm {5.983-5.986 in}
0.025-0.052 mm {0.0009-0.0020 in}
0.08 mm {0.003 in}
Standard: 1.507-1.516 mm {0.0592-0.0595 in}
0.25 {0.010} undersize: 1.624-1.634 mm {0.0638-0.0642 in}
0.50 {0.020} undersize: 1.749-1.759 mm {0.0687-0.0691 in}
0.75 {0.030} undersize: 1.874-1.884 mm {0.0737-0.0740 in}
0.110-0.262 mm {0.0043-0.01 03 in}
0.35 mm {0.014 in}
0.04-0.16 mm {0.002-0.006 in}
Front: 41.945-41.960 mm {1.6514-1.6519 in}
Center: 39.945-39.960 mm {1.5727-1.5732 in}
Rear: 37.975-37.990 mm {1.4951-1.4956 in}
Front, rear: 0.050-0.115 mm {0.0020-0.0045 in}
Center: 0.080-0.145 mm {0.0032-0.0057 in}
Bolt head mark W
Bolt head mark N
Bolt head mark I
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
0.10-0.19 mm {0.004G-0.0074 in}
0.20 mm {0.008 in}
0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
43.8 mm {1.72 in}
0.0-0.40 mm {0.0--0.015 in}
0.0-0.40 mm {0.0-0.015 in}
0.5-1.0 mm {0.020-O.039 in}
01-508-3
SERVICE TOOLS [WL-3]
01-60A SERVICE TOOLS [WL-3]

ENGINE [WL-3] . ................... 01-60A-1
t-----------------------------------------ENGINE [WL-3]
DCF016000000W01
1: Mazda SST number

2: Global SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 0107 680A

2:-
1:49 L010 1AO

2:-
Engine stand
Engine hanger
set
1:49 B012 OA2

2:-
1:498120170
2:-
Pivot
Valve seal
remover
1:498010001
2:-
1 :49 E011 1AO

2:-
1:498120 215B
2:-
Oil seal installer
Ring gear brake

set
Pulley puller
1:49 8011 103

2:-
1 :498010301
2:-
1 :49 F027 009

2:-
Oil seal installer
Oil seal installer
Oil seal installer
1:49 G011 001

2:-
1 :49 L012 001

2:-
1:49 L012 002A

2:-
Piston pin
replacer
Installer
(Part of 49 L012
OAOB)
1:49 L012 005
1 :49 L012 003A

2:-
1 :49 L012 004A

2:-
Installer
(Part of 49 L012
OAOB)
Nut
(Part of 49 L012
OAOB)
2:-
8pacer
(Part of 49 L012
OAOB)
1:49 0636 100B

2:-
~ ~
1:49 B012 015
2:-
~3
Installer
(Part of 49 B012
OA3)
Body
(Part of 49 L012
OAOB)
~
01-60A-1
SERVICE TOOLS [WL-3]

1:49 UN30 3050
2:303-050
1:49 L017 5AO

2:-
Engine lifting
brackets
Support hanger
01-60A-2
1:499140074
2:-
Cam lift
measuring
device
-01-608
J
SERVICE TOOLS [WL-C, WE-C]
ENGINE SERVICE TOOLS

[WL-C, WE-C] .................... 01-608-1
ENGINE SERVICE TOOLS [WL-C, WE-C]
DCF016000000W02
1: Mazda SST number

Example
1:49 UN30 3050

2:303-050
Engine lifting
brackets
1:49 0107 680A

2:-
1:49 L010 1AO

2:-
Engine stand
Engine stand
hanger set
oJ
~
0
..
ftp
-, &
~
.',
-"~
1 :49 0636 1008

2:Valve spring
lifter arm
1:4980120A2
2:-
1:49 8120 170

2:-
Pivot
Valve seal
remover
1:49 8Q10 001

2:-
1 :49 E011 1AO

2:-
1 :4981202158
2:-
Oil seal installer
Ring gear brake

set
Pulley puller
1:49 8011 103

2:-
1 :49 8010 301

2:-
1 :49 UN30 3050

2:-
Oil seal installer
Oil seal installer
Engine lifting
brackets
1:49 G011 001

2:-
1:498012015
2:-
1:49 L017 5AO

2:-
Piston pin
replacer
Valve guide
remover and
installer
8upport hanger
1:49 F027 009

2:-
Oil seal installdr
e
~
~~
~
01-608-1

1:498012016
2:Valve seal
installer
01-608-2
DRIVELINE/AXLE
03
SECTION
ta-----------------------------------TRANSFER . . . . . . . . . . . . . . . 03-16
TECHNICAL DATA ......... 03-50
03-16
SERVICE TOOLS ........... 03-60
TRANSFER
TRANSFER CLEANING ............. 03-16-1

TRANSFER DiSASSEMBLy .......... 03-16-2
TRANSFER ASSEMBLy ............. 03-16-8
TRANSFER CLEANING
Cleaning Precautions
1. Clean the surface of the transfer using steam and cleaning fluids when disassembly.
DCF031600000W01
Warning
Always wear safety glasses when using compressed air since the foreign material could be blown
by the compression air and damage your eyes.
2. Clean removed components with cleaning fluids and use compressed air to blow off the oil. Clean the oil holes
and passages with compressed air.
03-16-1
TRANS FE
TRANSFER DISASS
Before ServO
EMBLY
R
Ice Prec
.
a prevent fa . autlons
li
environment reIgn material from
.
Inspect Ihe each
.
entering th e Iransfer' pertorm dis
Transfer Disasse part while d'lSassembling.
assembly and servicin .
1. Disassembl e mbly
.n the order sh
g .n a clean ' du slfree
.
own
In
-....;
"",",,"00",,,,,,
the figure.
601mB
69
-----
03-16-2
DBG316BMB026
TRANSFER
34
35
36
37
38
39
40
41
42
43
44
45
46
47
15
16
Mainshaft rear bearing

(See 03-16-5 Mainshaft Rear Bearing Disassembly
Note.)
2W/4W clutch hub
(See 03-16-5 2W/4W Clutch Hub Disassembly
Note.)
t~~~--------------~
24
25
26
27
28
Chain
(See 03-16-6 Chain, Front Drive Shaft and
Sprocket Disassembly Note.)
Front drive shaft
Front drive shaft bearing (center case side)
(See 03-16-6 Front Drive Shaft Bearing
UlsaSE;errlDlV Note.)
Front drive shaft bearing (rear case side)
(See 03-16-6 Front Drive Shaft Bearing
Disassembly Note.)
Sprocket
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
. 64
65
66
67
68
69
Retaining ring
H/L clutch hub
Low gear
Needle bearing
Retaining ring
Retaining ring
Mainshaft center bearing
(See 03-16-7 Mainshaft Center Bearing
Disassembly Note.)
Mainshaft
Needle bearing
Retaining bolt
Spring
Steel ball
2W/4W shift rod
2W/4W shift end
Interlock pin
Snap ring
H/L shift rod
Snap ring
Plain washer
Spring
Plunger
H/L shift fork
H/L hub sleeve
Adjustment shim
Countershaft
Countershaft front bearing (front case side)
(See 03-16-7 Countershaft Bearing Disassembly
Note.)
Countershaft rear bearing (center case side)
(See 03-16-7 Countershaft Bearing Disassembly
Note.)
Baffle plate
Retaining bolt
Retaining ring
Maindrive gear bearing
(See 03-16-7 Maindrive Gear Bearing DJsassembly
Note.)
Retainer
Maindrive gear
Oil seal (control rod)
Oil seal (front case)
Front case
03-16-3
TRANSFER
Companion Flange Disassembly Note
1. Hold the companion flange using the SST.
Center case side
Rear case side
2. Remove the locknut.

3. Remove the companion flange using the SST.
Center case side
Rear case side
03-16-4
DBG316BMB0Q3
TRANSFER
(Rear Case) Disassembly Note
~,(;l,Clm'[)VI:j the oil seal (rear case) using

",..r,r:!W(mVI~r as shown in the figure.
a flathead
Oil Seal (Center Case) Disassembly Note

1. Remove the oil seal (center case) using a
flathead screwdriver as shown in the figure.
DBG316BMB040
Rear Bearing Disassembly Note

t Mainshaft
1. Remove the mainshaft rear bearing using the
SSTs.
DBG316BMB005
2W/4W Clutch Hub Disassembly Note

1. Remove the 2W/4W clutch hub using the SSTs.
DBG316BMB006
03-16-5
TRANSFER
Chain, Front Drive Shaft and Sprocket Disassembly Note

1. Remove the front drive shaft using the plastic
r--------------------_
hammer.
DBG316BMB042
2. Remove the chain, front drive shaft and sprocket

as a single unit.
Front Drive Shaft Bearing Disassembly Note

1. Remove the front drive shaft bearing using the SSTs and press.
Center case side
:I.
Rear case side
II
DBG316BMB007
DBG316BMB008
03-16-6
J
-Mainshaft Center Bearing Disassembly Note
TRANSFER
1. Remove the mainshaft front bearing using the

press.
DBG316BMB012
Countershaft Bearing Disassembly Note

1. Remove the countershaft bearing using the SSTs and press.
Front case side
t Center case side
DBG316BMB010
DBG316BMB011
Maindrive Gear Bearing Disassembly Note

1. Remove the maindrive gear bearing using the
SST, press and steel plate.
Note
Steel plate height: 10 mm {O.39 in} or more.
STEEL PLATE
l'
,
DBG316BMB009
03-16-7
TRANSFER
Oil Seal (Control Rod) Disassembly Note
1. Remove the oil seal (control rod) using a flathead
screwdriver as shown in the figure.
DBG316BMB043
Oil Seal (Front Case) Disassembly Note

1. Remove the oil seal (front case) using a flathead
screwdriver as shown in the figure.
DBG316BMB041
TRANSFER ASSEMBLY
DCF031600000W03
Before Service Precautions

Assemble with bare hands or using vinyl gloves. To prevent foreign material from entering the transfer, do not
use cotton work gloves or a rag.
Apply sufficient gear oil to the sliding surfaces and O-rings, and be careful not to damage when assembling.
Replace the transfer with a new one if the case alignment surface is damaged. Be careful not to damage it
since it may cause oil leakage.
When installing silicone sealant, clean off the old sealant adhering to the sealing area and clean the sealing
area with cleaning fluids.
After installing a seal, leave the parts alone for 2 h or more. Do not add oil or operate the vehicle during this
time.
03-16-8
..
TRANSFER
J[ransfer Assembly
15-19--1
{1.6-1.9,
Ci.!lI
'~W ~
~Aro
~
1~1~15.7-21.6
{1.61-220
______
1 I
[
~~;::-___
Front case
11.6-15.9}'
Nm {kgf.m, ftlbf}
control rod)
DBG316BMB027
s
011 seal (
y
ee 03-16- 11 Oil Seal (control rod) A
(_-'--_
_ _ I Note.)
_ _ _ _:..-=::ssEsembl
03-16-9
TRANSFER
3
4
5
6
7
8
9
10
11
12
.13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
Oil seal (front case)

(See 03-16-11 Oil Seal (front case) Assembly
Note.}
Maindrive gear
Retainer
Maindrive gear bearing
(See 03-16-11 Maindrive Gear Bearing Assembly
Note.)
Retaining ring
(See 03-16-11 Maindrive Gear Bearing Assembly
Note.)
Retaining bolt
Baffle plate
Countershaft rear bearing (center case side)
(See 03-16-12 Countershaft Bearing Assembly
Note.)
Countershaft front bearing (front case side)
(See 03-16-12 Countershaft Bearing Assembly
Note.)
Countershaft
(See 03-16-12 Countershaft Assembly Note.)
Adjustment shim
(See 03-16-12 Countershaft Assembly Note.)
H/L hub sleeve
H/L shift fork
Plunger
Spring
Plain washer
Snap ring
H/L shift rod
Snap ring
Interlock pin
2W/4W shift end
2W/4W shift rod
Steel ball
Spring
Retaining bolt
Needle bearing
Mainshaft
(See 03-16-13 Mainshaft and Mainshaft Center
Bearing Assembly Note.)
Retaining ring
Retaining ring
Needle bearing
Low gear
H/L clutch hub
Retaining ring
Center case
(See 03-16-13 Center Case Assembly Note.)
Oil passage
(See 03-16-14 Oil Passage Assembly Note.)
Oil catcher
(See 03-16-14 Oil Catcher Assembly Note.)
Center bearing retainer
03-16-10
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
Sprocket
Sprocket Assembly Note.)
Front drive shaft bearing (rear case side)
(See 03-16-15 Front Drive Shaft Bearing Assembly
Note.)
Front drive shaft bearing (center case side)
(See 03-16-15 Front Drive Shaft Bearing Assembly
Note.)
Front drive shaft
Chain
Needle bearing
Snap ring
Collar
Spring
2W/4W hub sleeve
2W/4W shift fork
Spacer
Snap ring
2W/4W clutch hub
(See 03-16-15 2W/4W Clutch Hub Assembly
Note.)
(See 03-16-16 Mainshaft Rear Bearing Assembly
Note.)
Speed drive gear
Rear case
(See 03-16-16 Rear Case Assembly Note.)
Oil seal (center case)
(See 03-16-16 Oil Seal (center case) Assembly
Note.}
Companion flange (center case side)
Oil seal (rear case)
(See 03-16-17 Oil Seal (rear case) Assembly
Note.}
Companion flange (rear case side)
Control rod
Control rod end
Guide plate
Reverse gate lever
Reverse gate spring
Spacer
E-ring
Control case
(See 03-16-17 Control Case Assembly Note.)
-.
TRANSFER
Oil Seal (control rod) Assembly Note
t,
caution
Assemble the oil seal being careful not to assemble it in the incorrect direction.
1. Apply specified grease to the lip of a new oil seal.

2. Install the oil seal (control rod) using the SST.
Installation depth A: 0 mm {O in}
A
..
DBG316BMB030
Oil Seal (front case) Assembly Note

2. Install the oil seal (front case) using the SST.
Installation depth A: 2.4-3.0 mm {0.0950.118in}
"
DBG316BMB013
Maindrive Gear Bearing Assembly Note

1. Assemble the maindrive gear bearing using the
SST and press.
2. Install the retaining ring.
DBG316BMB021
03-16-11
TRANSFER
3. Measure the clearance between the retaining ring
and groove of the maindrive gear.
If not within the specification, adjust by
choosing the proper retaining ring.
RETAINING RING
Maindrive gear bearing end play

0-0.15 mm {0.0-0.0059 in}
MAINDRIVE GEAR END PLAY
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.1 02}

2.67 {0.105}
2.74 {0.108}
DBG316BMB033
Countershaft Bearing Assembly Note

1. Assemble the countershaft bearing using the SSTs and press.
Front case side
DBG316BMB019
Center case side

I
~.
~.
I ,
DBG316BMB020
Countershaft Assembly Note

1. Assemble the countershaft to the front case.
2. Measure the depth A as shown in the figure.
3. Select the correct countershaft adjustment shim
thickness.
Countershaft adjustment shim selective chart

Dimension A (mm {in})
Shim thickness (mm {in})
25.0-25.1
{0.985-0.988}
25.1-25.2
{0.989-0.992}
25.2-25.3
{0.993-0.996}
25.3-25.4
{0.997-1.000}
25.4-25.5
{1.000-1.003}
25.5-25.6
{1.004-1.007}
4. Install the adjustment shim.
03-16-12
0.5 {0.020}
0.4 {0.016}
0.3 {0.012}
0.2 {0.008}
0.1 {0.004}
DBG316BMB032
TRANSFER
-Mainshaft and Mainshaft Center Bearing Assembly Note
1. Assemble the mainshaft center bearing using the

SST and press.
r----------------------,
DBG316BMB018

and groove of the mainshaft.
MAINSHAFT CENTER BEARING

RETAINING RING
MAINSHAFT
Mainshaft center bearing end play

0-0.15 mm {0.0-0.0059 in}
Mainshaft center bearing retaining ring
Thickness (mm {in})
3.1 {O.122}
3.2 {O.126}
3.3 {O.130}
MAINSHAFT CENTER BEARING

END PLAY
DBG316BMB031
3. Assemble the mainshaft to the center case using the plastic hammer.
Center Case Assembly Note
1. Apply sealant to the contact surfaces of the front
case and center case as shown in the figure.
DBG316BMB028
2. Assemble the center case.

Bolt length (measured from below the head)
43 mm {1.69 in}
DBG316BMB038
03-16-13
TRANSFER
Oil Passage Assembly Note
1. Assemble the oil passage to the center case.
Note
Align the oil passage of the center case
groove as shown in the figure.
OIL PASSAGE
CENTER CASE
DBG316BMB035
Oil Catcher Assembly Note

1. Align the oil catcher groove as shown in the
figure.
DBG316BMB016
3. Install the oil catcher using the SST.

DBG316BMB017
Chain, Front Drive Shaft and Sprocket Assembly Note

1. Assemble the chain, front drive shaft and sprocket
as a single unit.
Note
Assemble the front drive shaft using the
plastic hammer.
DBG316BMB036
03-16-14
TRANSFER
2. Install the needle bearings while turning the

mainshaft.
Front Drive Shaft Bearing Assembly Note

1. Assemble the front drive shaft bearing using the SSTs and press.
Center case side
DBG316BMB023
Rear case side
DBG316BMB022
2W/4W Clutch Hub Assembly Note

1. Assemble the 2W/4W clutch hub using the SST.
DBG316BMB024
03-16-15
TRANSFER
Mainshaft Rear Bearing Assembly Note
1. Assemble the mainshaft rear bearing using the
SST.
Rear Case Assembly Note

1. Apply sealant to the contact surfaces of the center
case and rear case as shown in the figure.
DBG316BMB029
2. Assemble the rear case.

Bolt length (measured from below the head)
A: 58 mm {2.28 in}
B: 113 mm {4.45 in}
DBG316BMB034
Oil Seal (center case) Assembly Note

2. Install the oil seal (center case) using the SST.
DBG316BMB014
03-16-16
TRANSFER
Oil Seal (rear case) Assembly Note

2. Install the oil seal (rear case) using the SST.
Installation depth A: 6.7-7.3 mm {0.270.28 in}
Control Case Assembly Note

1. Apply sealant to the contact surfaces of the
control case and transfer case as shown in the
figure.
2. Install the control case to the transfer case.
m:!!.1S1
DBG511BMB021
03-16-17
TRANSFER [5R55S]
TRANSFER CASE CLEANING
[5R55S] ......................... 03-16-1
TRANSFER CASE DISASSEMBLY
[5R55S] ......................... 03-16-2
TRANSFER CASE CLEANING[5R55S]
TRANSFER CASE ASSEMBLY

[5R55S] . ........................ . 03-16-14
TRANSFER CASE INSPECTION
[5R55S] . ........................ . 03-16-26
id0316c1501000
Note
Before cleaning, check the magnet for the presence of metal particles which indicate internal chipping of
the transfer case.
1. Using a cleaning solvent, clean the old oil and dirt deposits.
2. After cleaning dry the parts with low pressure (138 kPa {1.41 kgf/cm 2 , 20 psi maximum}) compressed air.
3. Lubricate the ball bearings and needle bearing with oil. Protect lubricated bearings from dust.
03-16-1
TRANSFER!.!:[5~R5~5S~]_ __
TRANSFER CASE DISAS SEMBLY[5R55S]
Exploded
1
2
3
4
V"ew
_ _ _ _~
Center transfer
case
.
Dowel pm
Bearing
Snap ring
03-16-2
id0316c1501100
5
--=6
78
==___
Oil seal
component
"Center transfer case
Front transfer case
;::;::-.
Dowel~
TRANSFER [5R55S]
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
Snap ring
Front transfer case component
Clip
Bolt
Input shaft component
Input shaft
Needle bearing
Bushing
Thrust washer
Planetary gear component
Sun gear
Thrust plate
Snap ring A
Ball bearing
Snap ring B
Reduction shift fork component
Reduction shift fork
Reduction shift fork facing
Lockup shift fork component
Lockup shift fork
Lockup shift fork facing
Spring
Spacer
Cam
Shift shaft
Rail shift
Return spring
Output shaft and gerotor pump component
Output shaft component
Gerotor pump component
Reduction hub
Pump hose
Hose clamp
Oil strainer
Magnet
Lockup component
Lockup hub
Spring
Lockup collar
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
Snap ring
Drive sprocket
Drive chain
Driven sprocket
Snap ring
Spacer
Lower output shaft
Front output flange
Deflector
Oil seal
Washer
Locknut
Rear transfer case
Needle bearing
Sleeve
Seal
Snubber
Bolt
Clutch coil
Nut
Clutch housing
Breather pipe
Bracket
Bolt
Spacer
Oil plug
Motor component
Bracket
Terminal connector
Clip
Bracket
Clip
Bolt
Bolt
03-16-3
TRANSFER [5R55S]
Disassembly Procedure
1. Using the SST, set the transfer case as shown in
the figure.
b5r5za00000426
2. Secure the rear companion flange component

using the SST.
3. Remove the nut and washer.
NUT-~
WASHER
4. Remove the rear companion flange using the

pulley.
REAR
COMPANION
FLANGE
5. Remove the deflector from the flange.

@---DEFLECTOR
'>----FLANGE
arnffv00000616
03-16-4
TRANSFER [5R55S]
-6. Remove the oil seal from the output shaft.
OILSEAL~
b5r5za00000456
7. Remove the bracket and speed sensor.
8. Remove the motor component.

MOTOR
COMPONENT
arnffv00000619
9. Remove the oil seal.
_ - - - O I L SAEL
03-16-5
TRANSFER [SRSSS]
10. Remove the clutch coil terminal from the
connector and pull out the wiring harness from
the sleeve.
b5r5za00000304
11. Remove the two oil plugs from the rear transfer
case.
b5r5za00000305
12. Remove the 14 bolts and the identification tag.
BRACKET
b5r5za00000429
13. Pry at the transfer case projection as shown in the

figure a flathead screwdriver, and remove the rear
transfer case from the center transfer case.
Caution
When prying at the transfer case, be
careful not to damage the case.
03-16-6
-14 Remove the spacer..
TRANSFER [SRSSS]
15: Using a flathead screwdnver, remove the
.
011
seal.
b5r5za00000457
16. Remove the snap ring.

17. Pull out the ball bearing from the rear transfer
case.
SNAPRING~
BALL BEARING
b5r5za00000430
18. Pull out the needle bearing from the rear transfer
case.
b5r5za00000431
19. Remove the return spring.
b5r5za00000309
20. Remove the 3 nuts.

21. Remove the clutch coil from the rear transfer
case.
NUT
b5r5za0000031 0
03-16-7
TRANSFER [5R55S]
22. Remove the snubber from the rear transfer case.

23. Clean and remove the sealant of the rear transfer
case and center transfer case.
Caution
Be careful not to damage the metal
surface.
b5r5za00000412
24. Remove the clutch housing from the output shaft.
b5r5za00000312
25. Slide the lockup component and the lockup shift

fork component as a single unit to remove the
lockup component from the output shaft.
26. Remove the lockup shift fork component from the
lockup component.
b5r5za00000448
27. Remove the two fork facings from the lockup shift
fork.
FROK FACING
b5r5za00000459
28. Remove the snap ring, lockup hub and return

spring from the lockup collar.
~SNAPRING
~LOCKUPHUB
- R E T U R N SPRING
~
~~
03-16-8
LOCKUP COLLAR
b5r5za00000449
TRANSFER [SRSSS]
-29. Remove the snap ring and spacer from the output
shaft.
b5r5za00000450
30. Remove the drive chain, driven sprocket and drive

sprocket from the output shaft at a time.
31. Separate the drive chain and sprockets.
DRIVE
SPROCKET
DRIVEN
-id!lI.~
b5r5za00000406
32. Remove the magnet from the slot in the center

transfer case.
33. Remove the strainer from the center transfer
case.
~---o-
' -_ _-
STRAINER
34. Remove the output shaft component and gerotor

pump component from the center transfer case.
35. Remove the gerotor pump component from the

output shaft.
36. Loosen the hose clamp and remove the pump
hose from the gerotor pump component.
OUTPUT SHAFT
b5r5za00000408
03-16-9
TRANSFER [5R55S]
37. Remove the hose clamp, pump hose and strainer.

GEROTOR PUMP
COMPONENT
b5r5za00000460
38. Remove the reduction hub, reduction shift fork

component, rail shaft and shift shaft component
from the center transfer case.
RAIL SHAFT
SHIFT SHAFT
REDUCTION SHAFT
FORK COMPONENT
\~
REDUCTION HUB
b5r5za00000320
39. Remove the two shift fork facings from the

reduction shift fork component.
b5r5za00000432
40. Disassemble the cam, spring, spacer, and shift

shaft.
CAM
~~c
SPRING
SPACER
SHlmHAB
'~
b5r5za0000045B
03-16-10
TRANSFER [SRSSS]
41 Secure the flange using the SST.

42: Remove the nut and washer.
LOWER OUTPUT SHAFT

arnffv00000555
43. Remove the deflector from the flange.

44. Pull out the front output flange component.
45. Remove the lower output shaft.
@----DEFLECTOR
't----FLANGE
t 46.
Remove the oil seal from the lower output shaft.
47. Remove the deflector from the flange only when
replacement is necessary.
arnffv00000616
OIL SEAL
OUTPUT SHAFT
@-~]~
b5r5za00000467
48. Remove the breather pipe.
BREATHER PIPE
b5r5za00000421
03-16-11
TRANSFER [SRSSS]
49. Remove the front transfer case six bolts.

50. Remove the front transfer case by separating the
adapter sealer bond using a flathead screwdriver.
Caution
When prying at the transfer case, be
careful not to damage the case.
arnffv00000620
51. Remove the input shaft component and planetary

gear component from the front transfer case.
Note
Expand the snap ring using the SST, and
separate the planetary gear component and
the input shaft component from the front
transfer case.
52. Remove the snap ring and oil seal from the front
transfer case.
b5r5za00000409
53. Remove the snap ring A.

54. Pull out the input shaft component and sun gear
from the planetary gear component.
55. Remove the snap ring B.
SNAP RING A
SNAP RING B
PLANETARY GEAR COMPONENT

b5r5za00000324
56. Remove the ball bearing, thrust washer, thrust

plate and from the input shaft using the press.
arnffv00000603
57. Remove the needle bearing and bushing from the

input shaft component.
BUSHING
NEEDLE BEARING
arnffv0000 0621
03-16-12
TRANSFER [5R55S]
58. Using a flathead sc.rewdriver, remove the oil seal.

59 Remove the snap ring.
60: Remove the ball bearing.
BEARING
OIL SEAL
DOWEL PIN
b5r5za00000416
61. Remove the dowel pins from the center transfer

case.
Note
Do not remove the ring gear from the center
transfer case.
b5r5za00000326
03-16-13
TRANSFER [SRSSS]
TRANSFER CASE ASSEMBLY[5R55S]
Exploded View
Center transter_cas_e
Snap ring
03-16-14
id0316C1S012OQ
TRANSFER [SRSSS]
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
Snap ring
Drive sprocket
Drive chain
Driven sprocket
Snap ring
Spacer
Lower output shaft
Front output flange
Deflector
Oil seal
Washer
Locknut
Rear transfer case
Needle bearing
Sleeve
Seal
Snubber
Bolt
Clutch coil
Nut
Clutch housing
Breather pipe
Bracket
Bolt
Spacer
Oil plug
Motor component
Bracket
Terminal connector
Clip
Bracket
Clip
Bolt
Bolt
03-16-15
TRANSFER [SRSSS]
Assembly Procedure
.
1. Insert two new dowel pins.
BEARIMG
OIL SEAL
b5r5za00000410
2 . Pre ss the ball bearing

T into the center transfer
case using the SS .
3. Install the snap ring.
arnffv00000596
4 Install the new oil seal, by pressing it into the

. center transfer case using the SST.
b5r5za00000462
5. Press the new nee die bearing into the input shaft
using the SST.
:rr(OjJ
NEEDLE BEARING
03-16-16
TRANSFER [5R55S]
6. Press the new bushing into the input shaft using

the SST.
7. Assemble the sun gear and thrust plate to the

input shaft.
SN6l~~!~EJ]~:~
SUN
It_U---~/-j I
GROOVE
GEAR
THRUST WASHER
~:~e'r
PLANETARY GEAR
COMPONENT
arnffv00000625
8. Assemble the thrust washer and ball bearing to

the input shaft using the SST.
9. Install the snap ring B.
.1:
b5r5za00000437
10. Assemble the planetary gear component to the

planet carrier as shown in the figure.
Note
Verify that the retaining ring is assembled to
the upper groove of the planetary gear
component on the workbench.
11. Install the snap ring A to the planetary gear

component.
b5r5za00000329
12. Press the new oil seal into the front transfer case
using the SST.
b5r5za00000463
03-16-17
TRANSFER [5R55S]
13. Install the snap ring by making sure that the snap
ring is correctly installed into the groove.
b5r5za00000331
14. Place the input shaft component onto the front

transfer case, and assemble the planetary gear
component to the groove while expanding the
ends of the snap ring using the SST.
b5r5za00000464
15. Apply sealant to the front transfer case as shown

in the figure.
b5r5za00000333
16. Install the front transfer case on the center

transfer case.
17. Install the six bolts and clip.
Tightening torque
34-41 Nm {3.5-4.1 kgfm, 26-30 ft.lbf}
arnflv00000620
18. Install the breather pipe on the center transfer

case.
Tightening torque
4-7 Nm {41-71 kgfcm,36-61 inlbf}
BREATHER PIPE
b5r5za00000422
03-16-18
TRANSFER [SRSSS]
19. Press in the new deflector to the flange using the

SST.
I
arnffv00000597
20. Assemble the lower output shaft to the center

transfer case.
21. Assemble the front output flange component, oil
seal, washer, and nut.
22. Secure the flange using the SST.
23. Tighten the nut.
Tightening torque
305-332 Nm {31.2-33.8 kgf.m, 225-244

ft.lbf}
LOWER OUTPUT SHAFT
I 24. Install the two-fork facing on the reduction shift
b5r5za00000466
fork component.
b5r5za00000438
25. Install the reduction hub to the shift fork.

26. Install the reduction hub and shift fork component
to the planetary gear component.
b5r5za00000336
03-16-19
TRANSFER [5R55S]
27. Insert the spacer torsion spring and cam into the
shift shaft.
b5r5za000004
28. Press them in until area A of the cam contacts

area B of the torsion spring, and area C of the
torsion spring contacts area D of the shift shaft.
b5r5za000004
29. Rotate the cam to the position indicated in the

figure, and press it to the shift shaft side until it
contacts the torsion spring.
b5r5za000004,
30. Install the cam component in the case as shown

in the picture.
31. Verify that the reduction fork roller is seated in the
cam groove as shown in the figure.
32. Assemble the rail shift to the reduction fork bore.
CAM COMPONENT
0;:;::
I
b5r5za0000 041
03-16-20
...
TRANSFER [5R55S]
33 Using a hose clamp, tighten the pump hose at the

. end where it is coupled with the strainer.
GEROTOR PUMP
COMPONENT
b5r5za00000452
39
34. Align the gerotor pump rotor slot and the pump
body slot so that they are in a single line.
arnffv00000598
40
35. Slide the gerotor pump component on the output

shaft over pump pin.
OUTPUT SHAFT
b5r5za00000419
11
36. Assemble the output shaft from the center

transfer case.
3? Assemble the output shaft spline to the reduction

hub.
38. Engage the output shaft end with the input shaft
bearing.
17
39. Couple the strainer with the case and insert the
magnet into the transfer case slot.
40. Assemble the drive sprocket to the output shaft.
41. Assemble the lower output shaft to the driven
sprocket.
~---o-
\--_ _-
STRAINER
03-16-21
TRANSFER [SRSSS]
42. Install the drive chain onto the sprockets.
43. While keeping the tension of the drive chain,
assemble the transfer case and drive chain
component in parallel.
44. While rotating the driven sprocket, engage it with
the front output shaft spline.
DRIVE
SPROCKET
DRIVEN
~1"'n'"'1!"m
b5r5za000OO4Q
45. Assemble the spacer to the front output shaft.

46. Assemble the snap ring into the groove.
b5r5za0000045
47. Install the lockup hub and return spring to the lock
up collar and insert the snap ring.
~SNAPRING
~LOCKUPHUB
--
RETURN SPRING
~I~
~ LOCKUP COLLAR
b5r5za0000044
48. Install the two new facings to the fork.
FROK FACING
b5r5za0000041
49. Assemble the lockup component to the lockup

fork, and assemble them to the drive shaft and the
rail shaft.
LOCKUP SHIFT
FORK COMPONENT
b5r5za000 0044 ;
03-16-22
TRANSFER [SRSSS]
50. Install the clutch housing on the output shaft.
b5r5za00000312
51. Position the end of the new needle bearing with

the identification mark facing upwards and press
it into the cover using the SST.
b5r5za00000442
52. Press the ball bearing into the rear transfer case
using the SST and install the snap ring.
b5r5za00000443
53. Install the coil inside the rear transfer case.

54. Install the three nuts.
Tightening torque
8-11 Nm {82-112 kgfcm, 71-97 in.lbf}
NUT
b5r5za00000310
55. Install the snubber.
Tightening torque
8-11 Nm {82-112 kgfcm, 71-97 in.lbf}
,
56. Install the return spring over rail shaft in the rear
transfer case.
o
b5r5za00000412
03-16-23
Md,!
,],1'1"'"
TRANSFER [5R55S]
57. Apply a 1.6 mm {O.063 in} bead of sealant to the

transfer case mounting surface, and assemble the
cover and the transfer case.
Caution
Do not use excessive force.
Note
For installation of cover, align the cover with
transfer case.
58. Install the rear transfer case onto the center
transfer case as follows.
(1) Align the cover holes with the transfer case
dowel pins.
(2) Align the cover bearings with output shafts.
(3) Align the shift shaft with cover boss.
(4) Align the cover blind hole with rail shaft and
make sure that return spring is not cocked.
59. Install the 14 bolts identification tag and bracket.
b5r5za00000350
BRACKET
b5r5za00000429
60. Install the new oil seal.
61. Align the motor component with the shift shaft

and assemble it to the rear transfer case.
62. Rotate the motor in clockwise direction to check
correct engagement.
_ _--OIL SAEL
MOTOR
COMPONENT
arnffv00000615
03-16-24
TRANSFER [SRSSS]
-63. Install the speed sensor in the rear transfer case.

64. Install the bracket and bolts to the motor
component.
Tightening torque
8-11 Nm {82-112 kgfcm, 71-97 inlbf}
65. Pass the clutch coil wiring harness through the

sensor harness sleeve, and connect the coil
terminal to the connector.
66. Install the motor connector and sensor connector
to the motor bracket.
<
b5r5za00000352
67. Bundle the wiring harness between the

speedometer component and terminal connector
using a wiring harness protector and tie wraps.
68. Install the oil plug to the rear transfer case.
Tightening torque
19-30 Nm {2.0-3.0 kgfm, 15-22 ft.lbf}
03-16-25
TRANSFER [SRSSS]
69. Install the spacer over output shaft spline.
SP~ER~
"""-"...,.....'-
b5r5za00000454
70. Press the new oil seal into the rear transfer case
component using the SST.
I
b5r5za00000445
71. Press in the new deflector to the flange using the

SST.
arnffv00000597
72. Install the rear companion flange component, oil

seal, washer and nut.
73. Holding the rear companion flange using the SST,
tighten the nut.
Tightening torque
305-332 Nm {31.2-33.8 kgf.cm, 225-244
in.lbf}
NUT~
WASHER'@)
OILSEAL"@
b5r5za00000355
TRANSFER CASE INSPECTION[5R55S]
id0316c1501300
Note
Always replace the hose coupling, O-ring and oil seal with new parts.
1. Visually check all the parts for damage.
2. Referring to normal gear tooth face, specifically inspect the uneven wear and chips of gear tooth, replace if
necessary.
03-16-26
TECHNICAL DATA
03-50
TECHNICAL DATA
TeCHNICAL DATA ................. 03-50-1
TeCHNICAL DATA
DCF035000000W01
Item
Specification
0{}'-15 mm {0.OM059 in}
0{}'-15 mm {0.OM059 in}
Maindrive gear bearing end play

Mainshaft center bearing end play
Maindrive gear bearing retaining ring

Thickness (mm {in})
2.60 {0.102}
2.67 {0.1 05}
2.74 {0.108}
Countershaft adjustment shim selective chart

Dimension A (mm {in})
25.025.1
{0.985M88}
25.125.2
{0.989M92}
25.225.3
{0.993M96}
25.325.4
{0.997WOO}
25.425.5
{1.000W03}
25.525.6
{1.004W07}
I I
0.5 {0.020}
0.4 {0.016}
0.3 {0.012}
0.2 {0.008}
0.1 {0.004}
Mainshaft center bearing retaining ring

Thickness (mm {in})
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
,,
03-50-1
-03-60
I
SERVICE TOOLS
SERVICE TOOLS
SERVICE TOOLS .................. 03-60-1
t-
SERVICE TOOLS
49 H017 101
Hook
49 E032 303
Bearing
Remover
cY
490727415
490839425C
Bearing Installer
Bearing puller
set
49 S120 710
49 F401 336B
Coupling flange
holder
Attachment
49 H027 002
49 F026103
Bearing
remover
Wheel Hub
Puller
~
49 G028 203
Support
t t
49 H001 628
49 F401 331
49 U025 001
Guide Pin
Body
Installer
Protector
49 F027 009
49 T019 005
49 G033107A
Support Block
Installer Dust
Cover
Attachment 68
And 77
49 M005 797
Installer oil seal
03-60-1
SERVICE TOOLS [SRSSS]
-.......
, SERVICE TOOLS[5R55S]
id0360e1 SOo 1G;
307-611
307-605
Repair fixture
Snap ring pliersadapter
307-610
Drift ball
bearing
c::r
<:
307-608
307-606
Drift bush input
shaft
307-607
(p
c@
Drift ball
bearing input
shaft
307-613
307-615
Flange holder
rear
Dust deflector
press tool
307-609
307-612
Seal driver
Drift NRB input

shaft
Drift NRB fitting

cover
c====W
307-614
c((
.~
Flange holder
front
()
c=CD
03-60....2
,"MANUAL TRANSMISSION
[R1SM-D] ................ OS-11 A
MANUAL TRANSMISSION
[S1SM-D, S1SMX-D] ....... OS-118
TECHNICAL DATA
[R1SM-D] ................ OS-SOA
05
SECTION
TECHNICAL DATA
[S1SM-D, S1SMX-D] ........ OS-S08
SERVICE TOOLS
[R1SM-D] ................ OS-60A
SERVICE TOOLS
[S1SM-D, S1SMX-D] ........ OS-608
05-11-1
-05-118
PRECAUTION [S15M-D, S15MX-D] ... 05-11B-1

.TOP COVER COMPONENT AND
, EXTENSION HOUSING DISASSEMBLY
[S15M-D, S15MX-D] ........... 05-11B-2
REVERSE GEAR COMPONENT AND
3RD/4TH GEAR COMPONENT
DISASSEMBLY
[S15M-D, S15MX-D] .......... 05-11B-9
MAINS HAFT COMPONENT,
COUNTERSHAFT COMPONENT AND
TRANSMISSION CASE DISASSEMBLY
[S15M-D, S15MX-D] ........ 05-11B-13
1ST/2ND GEAR COMPONENT, 3RD/4TH
GEAR COMPONENT AND
COUNTERSHAFT DISASSEMBLY
[S15M-D, S15MX-D] ....... 05-11B-16
SHIFT COMPONENT DISASSEMBLY
[S15M-D, S15MX-D] ........... 05-11 B-19
PRECAUTION [S15M-D, S15MX-D]
MANUAL TRANSMISSION PARTS

INSPECTION [S15M-D, S15MX-D] ... 05-11 B-21
SHIFT COMPONENT ASSEMBLY
[S15M-D, S15MX-D] ........... 05-11 B-23
1ST/2ND GEAR COMPONENT, 3RD/4TH
GEAR COMPONENT AND
COUNTERSHAFT ASSEMBLY
[S15M-D, S15MX-D] ........... 05-11 B-26
MAINS HAFT COMPONENT,
COUNTERSHAFT COMPONENT AND
TRANSMISSION CASE ASSEMBLY
[S15M-D, S15MX-D] .......... 05-11 B-31
REVERSE GEAR COMPONENT AND
3RD/4TH GEAR COMPONENT
ASSEMBLY [S15M-D, S15MX-D] ... 05-11B-37
TOP COVER COMPONENT AND
EXTENSION HOUSING ASSEMBLY
[S15M-D, S15MX-D] ........... 05-11 B-44
DCF051100000W04
1. Clean the transmission exterior thoroughly using a steam cleaner or cleaning solvents before disassembly.
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.
Caution
Cleaning sealed bearings using cleaning fluids or a steam cleaner can wash the grease out of the
bearing.
2.
3.
4.
5.
6.
7.
8.
Clean the removed parts using cleaning solvent, and dry them using compressed air.
Clean out all holes and passages using compressed air, and check that there are no obstructions.
Make sure each part is cleaned before assembling.
Coat all movable parts with the specified oil.
Replace parts whenever required.
Remove old sealant from contact surfaces before applying new sealant.
Assemble the parts within 10 min after applying sealant. Allow all sealant to cure at least 30 min after
assembling before filling the transmission with transmission oil.
Warning
Although the stand has a self-locking brake system, there is a possibility that the brake may not
hold when the transmission is held in a lopsided position on the stand. This would cause the
transmission to turn suddenly, causing serious injury. Never keep the transmission tilted to one
side. Always hold the rotating handle firmly when turning the transmission.
05-118-1

TOP COVER COMPONENT AND EXTENSION HOUSING DISASSEMBLY [S15M-D, S15MX-D]
DCF051117011W06
Caution
Remove the oil seal (extension housing and control rod) only if there is a malfunction.
1. Disassemble in the order indicated in the table.

4x2
~\
~
B
DBG511 BMB001
05-118-2

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Release fork
Release collar
Dust boot
Top cover, shift component
(See 05-11 B-5 Top Cover Disassembly Note.)
Oil passage
Control lever
Dust boot
Gasket
Wave washer
Change bush
Shift lever
Change seat
Control case
Control rod end
Blind cover
Neutral switch
Vehicle speed sensor
Back-up light switch
Select spindle component
20
21
22
23
24
25
26
27
28
29
30
31
32
33
Spring cap
Select lock spindle spring
Select lock spindle
Oil seal (extension housing)
(See 05-11 B-5 Oil Seal (extension housing)
Removal Note.)
Extension housing
(See 05-118-6 Extension Housing Disassembly
Note.)
Funnel
Control rod
Oil passage
(See 05-11 B-6 Oil Seal (control rod) Disassembly
Note.)
Bush
(See 05-11 B-7 Bush Disassembly Note.)
Sealing cap
(See 05-11B-7 Sealing Cap Disassembly Note.)
Retaining ring
Speed drive gear
Steel ball
05-118-3

4x4
DBG511BMB063 ~
2
3
4
Release fork
Release collar
Dust boot
(See 05-118-5 Top Cover Disassembly Note.)
05-118-4
6
7
8
9
Oil passage
Control rod end
Dust boot
Gasket
Wave washer
('
10
11
12
13
14
15
16
17
18
19
20
21
22
Change bush
Shift lever
Transfer shift lever
Change seat
Switch pin
Spring
Steel ball
4x4 indicator switch
Neutral switch
Breather dust boot
23
24
25
26
27
28
29
30
Breather
Transfer
Blind cover
Extension housing
(See 05-11 B-6 Extension Housing Disassembly
Note.)
Funnel
(See 05-11 B-5 Oil Seal (extension housing)
Removal Note.}
(See 05-11 B-6 Oil Seal (control rod) Disassembly
Note.}
Bush
(See 05-11 B-7 Bush Disassembly Note.)
Oil Seal (extension housing) Removal Note

1. Remove the oil seal using a flathead screwdriver as shown in the figure.
4x2
DBG511 BMB003
4x4
DBG511 BMB077
Top Cover Disassembly Note

1. Pry the seal open at the projection on the case
using a flathead screwdriver or similar tool as
shown in the figure, and then remove the top
cover.
DBG511 BMB004
05-118-5
MANUAL TRANSMISSION [S15M-D, S15MX-D]

Extension Housing Disassembly Note
1. Remove the extension housing component.
Note
Pry open the seal at the projection on the
case using a flathead screwdriver or similar
tool as shown in the figure, and then remove
the extension housing.
DBG511 BMB005
Oil Seal (control rod) Disassembly Note

1. Using a flathead screwdriver, remove the oil seal as shown in the figure.
4x2
4x4
DBG511 BMB006
DBG511 BMB068
05-118-6

Sealing Cap Disassembly Note
1. Remove the sealing cap using the SST.
Caution
Remove the sealing cap only if there is
malfunction.
DBG511 BMB007
Bush Disassembly Note

4x2
1. Remove the bush using the SST.
DBG511 BMB075
2. Remove the bush using the suitable steel bar

through the sealing cap hole as shown in the
figure.
Distance A: Approx. 200 mm {7.87 in}

Oistance B: Approx.17.0-17.5 mm {0.6700.688 in}
DBG511 BMB074
05-118-7

4x4
1. Remove the bush using the SST ..
Front side
DBG511 BMB073
Rear side
05-118-8

REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT DISASSEMBLY [S1SM-D, S1SMX-Dl
DCF05111 t030W11
t~
____________________~______________~~
DBG511 BMB019
Locknut
(See 05-11 B-1 0 Mainshaft Rear Bearing locknut
and Countershaft Rear Bearing locknut
Disassembly Note.)
Countershaft rear bearing

Thrust washer
05-118-9

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Locknut
(See 05-11 B-1 0 Mainshaft Rear Bearing locknut
and Countershaft Rear Bearing locknut
Disassembly Note.)
(See 05-11 B-11 Mainshaft Rear Bearing
Disassembly Note.)
Reverse counter gear
Spacer
Retaining bolt
Reverse idler gear shaft c;:omponent
(See 05-11 B-11 Reverse Idler Gear Shaft
Component Disassembly Note.)
Retaining ring
Thrust washer
Reverse idler gear
Needle bearing
Thrust washer
Reverse idler gear shaft
Friction damper
(See 05-11 B-11 Reverse Idler Gear Friction
Damper Disassembly Note.)
Reverse gear
Needle bearing
Thrust washer
Thrust washer
Synchronizer ring
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Retaining ring
Washer
Counter lever
(See 05-11 B-12 Counter Lever Disassembly Note.)
Retaining bolt
Counter lever shaft component
(See 05-11 B-12 Counter Lever Disassembly Note.)
Retaining bolt
5th/reverse clutch hub and shift fork component
(See 05-118-12 5thlreverse Shift Fork
Disassembly Note.)
5thlreverse shift fork
5th/reverse shift rod
Detent ball
Detent spring
Clutch hub sleeve
Synchronizer key
Synchronizer key spring
5thlreverse clutch hub
Synchronizer ring
5th gear
Needle bearing
5rd gear bearing inner race
Steel ball
5th counter gear
Mainshaft Rear Bearing locknut and Countershaft Rear Bearing locknut Disassembly Note
1. Slide the 3rd/4th and 1st/2nd clutch hub sleeves
to lock the transmission into 4th and 2nd gears.
2. Remove the countershaft rear bearing locknut by

rotating it clockwise.
DBG511 BMB027
05-118-10
C~

3. Remove the mainshaft rear bearing locknut by
rotating it counterclockwise using the SST.
Mainshaft Rear Bearing Disassembly Note

1. Using the SSTs remove the mainshaft rear
bearing.
E5U511 BM5014
Reverse Idler Gear Shaft Component Disassembly Note
ita 1. Remove the reverse idler gear shaft retaining bolt

VI
and then remove the reverse idler gear shaft
,.----------------------,
component from the transmission case.
E5U511 BM5015
Reverse Idler Gear Friction Damper Disassembly Note

1. Remove the friction damper using a flathead
screwdriver.
E5U511 BM5019
05-118-11

Counter Lever Disassembly Note
Caution
To prevent the shaft position from
deviating when removing the counter
lever, remove the counters haft lever
component without loosening the
locknut unless it is necessary.
~I~
~~
D0
,
~I
~
, I
PLATE
COUNTER LEVER
SHAFT
)~LOCKNUT
~
DBG511 BMB016
5th/reverse Shift Fork Disassembly Note

1. Remove the 5th/reverse shift rod retaining bolt.
2. Remove the 5th/reverse shift fork component and

5th/reverse clutch hub component at the same
time.
05-118-12

MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE DISASSEMBLY
[S15M-D, S15MX-D]
DCF051117030W12
DBG511 BMB024
Bearing cover
Front cover
(See 05-118-14 Front Cover Disassembly Note.)
Pivot pin
Bearing shim
Oil baffle
Bearing shim
. Maindrive gear bearing race
(See 05-11 B-14 Bearing Race Disassembly Note.)
Mainshaft bearing race

(See 05-11 B-14 Bearing Race Disassembly Note.)
Countershaft front bearing
05-118-13

10
11
12

Mainshaft component
(See 05-118-14 Mainshaft Component and
Countershaft Component Disassembly Note.)
Maindrive gear
(See 05-118-14 Mainshaft Component and
13
14
15
Countershaft component
(See 05--118-14 Mainshaft Component and
Front oil seal
Transmission case
It
Front Cover Disassembly Note

1. Remove the front cover.
Caution
Insert the front cover tightening bolts
into the bolt holes for the front cover
disassembly, tighten the two bolts
uniformly and, then remove the front
cover.
DBG511 BMB025
Bearing Race Disassembly Note

1. Grasping the mainshaft and countershaft, move
them forward and back to remove the bearing
races.
Mainshaft Component and Countershaft Component Disassembly Note

1. Tilt the mainshaft component as shown in the
r------=:-------------------,
figure and remove it from the transmission case.
2. Remove the maindrive gear.
DBG511 BMB049
05-118-14

3. Tilt the countershaft component as shown in the
figure and remove it from the transmission case.
05-118-15
1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT DISASSEMBLY [S15MD, S15MX-D]
DCF051117030W13
Caution
Remove the countershaft center bearing race only if there is a malfunction.
DBG511 BMB026
2
3
4
Needle bearing
Scoop ring
Maindrive gear shaft bearing
(See 05-11 B-18 Maindrive Gear Shaft Bearing
Disassembly Note.)
Maindrive gear shaft
Needle bearing
05-118-16
6
7
8
9
Retaining ring
(See 05-11 B-17 3rd/4th Clutch Hub Component
Disassembly Note.)
Spacer
Synchronizer ring
Clutch hub sleeve

3rd/4th clutch hub
(See 05-11 B.,...17 3rd/4th Clutch Hub Component
Disassembly Note.)
25
26
27
28
29
30
31
32
33
34
35
36
37
Clutch hub sleeve

1stl2nd clutch hub
(See 05-11 B-17 1stl2nd Clutch Hub Component
Disassembly Note.)
Synchronizer key
Synchronizer ring
Double cone
Inner cone
2nd gear
Needle bearing
Countershaft center bearing race
(See 05-11 B-18 Countershaft Center Bearing Race
Disassembly Note.)
Countershaft front bearing race
(See 05-11 B-18 Countershaft Front Bearing Race
Disassembly Note.)
Countershaft
Mainshaft
3rd/4th Clutch Hub Component Disassembly Note

1. Remove the retaining ring using the two flathead
screwdrivers.
Caution
Do not reuse the retaining ring.
FLATHEAD SCREW
DRIVERS
RETAINING RING
E5U5118M5010
2. Supporting the 3rd/4th clutch hub with your hand

as shown in the figure, tap the mainshaft with a
plastic hammer to remove the 3rd/4th clutch hub.
E5U5118M5022
1st/2nd Clutch Hub Component Disassembly Note

1. Using a press, remove the mainshaft center
bearing, 1st gear, 1st synchronizer ring
component, 1stl2nd clutch hub component, 2nd
synchronizer ring component and 2nd gear at the
same time.
Caution
Be sure to support the mainshaft
component so that it does not fall.
05-118-17

Maindrive Gear Shaft Bearing Disassembly Note
1. Remove the maindrive gear shaft bearing using
the SST and press.
DBG511 BMB029
Countershaft Center Bearing Race Disassembly Note

1. Remove the countershaft center bearing race
using the SST and press.
Caution
Be sure to support the countershaft so
that it does not fall.
Countershaft Front Bearing Race Disassembly Note

1. Remove the countershaft front bearing race using
the SST.
E5U511 BM5026
05-118-18

SHIFT COMPONENT DISASSEMBLY [S15M-D, S15MX-D]
DCF051117030W14

4X2
DBG511 BMB031
2
3
4
5
6
7
8
9
10
Retaining bolt
Detent ball, spring
Rubber plug .
5th/reverse shift rod end
(See 05-118-21 Shift Rod Disassembly Note.)
Interlock pin
Interlock pin
Stopper block
3rd/4th shift rod end
3rd/4th shift rod
(See 05--118-21 Shift Rod Disassembly Note.)
11
12
13
14
15
16
17
18
19
Interlock pin
3rd/4th shift fork
Detent ball, spring seat, spring
1stl2nd shift rod end
1stl2nd shift rod
(See 05--118-21 Shift Rod Disassembly Note.)
1stl2nd shift fork
8affle plate
8reather
.~
05-118-19
DBG511 BMB036
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Retaining bolt
Detent ball, spring
Rubber plug
5thlreverse shift rod end
Retaining ring
Plain washer
Spring
Push pin
Retaining ring
Detent ball, spring
(See 05-11 B-21 Shift Rod Disassembly Note.)
Interlock pin
Interlock pin
Stopper block
05-118-20
16
17
18
19
20
21
22
23
24
25
26
27
28
29
3rd/4th shift rod

Interlock pin
3rd/4th shift fork
1stl2nd shift rod end
Retaining ring
Plain washer
Spring
Push pin
1stl2nd shift rod
1stl2nd shift fork
Baffle plate
Breather
Shift Rod Disassembly Note

1. Remove the spring pins from each of the shift
rods using a pin punch.
2. Place the shift mechanism in the neutral position.
Caution
When pulling out the shift rods, press the
top of each detent ball so that it doesn't
spring out.
DBG511 BMB033
3. Pull out the shift rods from the top cover.
DBG511 BMB034
MANUAL TRANSMISSION PARTS INSPECTION [S15M-D, S15MX-D]

Clutch Hub Component
1. Measure the clearance between each shift fork
and clutch hub sleeve groove using a feeler
gauge.
If not within the specification, replace the shift
fork and clutch hub sleeve as a set.
DCF051100000W05
Standard clearance between shift fork and

clufch hub sleeve groove
0.05-0.40 mm {0.002-0.015 in}
Maximum clearance between shift fork and
clutch hub sleeve groove
0.5 mm {0.020 in}
BHJ0511M018
Synchronizer Ring
1. Measure the clearance between the synchronizer
ring and flank surface of the gear using a feeler
gauge around the entire circumference .
synchronizer ring.
Standard clearance between synchronizer
ring and flank surface of gear
1.5 mm {0.059 in}
Maximum clearance between synchronizer
ring and flank surface of gear
0.8 mm {0.031 in}
BHJ0511 M020
Note
Set the synchronizer ring squarely in the gear.
05-118-21
Spring
1. Measure the free length of each spring.
spring.
Detent ball springs for 1st/2nd and 3rd/4th
shift rods
Standard length: 22.5 mm {0.886 in}
Detent ball spring for 5th/reverse shift rod
1st/2nd select lock spindle spring [4x2]
BHE0511 M023
Push pin spring for 1st/2nd shift rod end [4x4]

Standard length: 32.8 mm {1.29 in).
Push pin spring for 5th/reverse shift rod end [4x4]
Detent ball spring for 5th/reverse shift rod end [4x4]
Mainshaft
1. Measure the mainshaft runout using a dial gauge.
replace the mainshaft.
Mainshaft maximum runout
0.03 mm {0.0012 in}
1
DBG511 BMB035
Shift Rod End, Control Lever

1. Measure the clearance between the shift rod end
and control lever using a feeler gauge.
If not within the specification, replace the shift
rod end or control lever as a set.
Standard clearance between shift rod end and
control lever
0.5 mm {0.020 in} or less
DBG511 BMB022
05-118-22
,
tri

SHIFT COMPONENT ASSEMBLY [S15M-D, S15MX-D]
DCF051117030W15

4x2
1
7.8-11.8 Nm {80-120 kgfcm, 70-104 inlbf}
DBG511 BMB037
1
2
3
4
5
6
7
8
9
Breather
Baffle plate
1sV2nd shift rod
(See 05-11 B-25 Shift Rod Assembly Note.)
1sV2nd shift fork
1sV2nd shift rod end
Interlock pin
3rd/4th shift rod
(See 05-118--25 Shift Rod Assembly Note.)
10
11
12
13
14
15
16
17
18
19
3rd/4th shift fork

Interlock pin
Interlock pin
"
Stopper block
Rubber plug
Detent ball, spring
Retaining bolt
05-118-23
4x4
1
7.8-11.8 Nm {80-120 kgfcm, 70-104 inlbf}
Nm {kgf.m, ftlbf}
DBG511 BMB038
Breather
Baffle plate
1st/2nd shift rod
.
4
1st/2nd shift fork
5
6
Push pin
7
Spring
Plain washer
8
9
Retaining ring
10 1st/2nd shift rod end
11
Interlock pin
12 Detent ball, spring seat, spring
3rd/4th shift rod
13 (See 05-11 B-25 Shift Rod Assembly Note.)
14' 3rd/4th shift fork
15 3rd/4th shift rod end
2
3
05-118-24
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Interlock pin
Interlock pin
Stopper block
Detent ball, spring
Retaining ring
Push pin
(See 05-11 B-25 Push Pin Assembly Note.)
Spring
Plain washer
Retaining ring
Rubber plug
Detent ball, spring
Retaining bolt

Shift Rod Assembly Note
1. Install each shift rod.
Caution
Do not forget to insert the interlock pins.
Note
Insert the shift rod while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
DBG511 BMB039
Push Pin Assembly Note

1. Install the push pin.
Note
Insert the push pin while pressing the detent
ball with a flathead screwdriver as shown in
the figure.
DBG511 BMB040
05-118-25

1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT ASSEMBLY [S15M-D,
S15MX-D]
DCF051117040VV07
r1_,_A_S_S_e~m~b=le=in~th_e_O_rd_e_r_in_d_iC_a_te_d__
in_th_e_t_a_b_le_,__________________________________________"
-.-.-
APPLY SPECIFIED OIL TO INDIVIDUAL PARTS

DBG511 BMB041
1
2
3
4
5
6
Mainshaft
Needle bearing
2nd gear
Inner cone
Double cone
Synchronizer ring
05-118-26
7
8
9
10
1st/2nd clutch hub

(See 05-118-27 1st/2nd Clutch Hub Component
Assembly Note,)
Synchronizer key
Clutch hub sleeve
18
19
20
21
22
23
24
25
Synchronizer ring
Double cone
Inner cone
1st gear
Needle bearing
1st gear bearing inner race
(See 05-11 B-27 1st/2nd Clutch Hub Component
Assembly Note.)
Needle bearing
3rd gear
Inner cone
Double cone
Synchronizer ring
Clutch hub
Assembly Note.)
Synchronizer key
Assembly Note.)
Assembly Note.)
26
27
28
29
30
31
32
33
34
35
36
37
Clutch hub sleeve

Assembly Note.)
Synchronizer ring
Spacer
Retaining ring
Assembly Note.)
Needle bearing
Maindrive gear
Maindrive gear shaft bearing
(See 05-11 B-29 Maindrive Gear Shaft Bearing
Assembly Note.)
Scoop ring
Needle bearing
Countershaft
Countershaft center bearing race
(See 05-11 B-29 Counters haft Center Bearing Race
Assembly Note.)
Countershaft front bearing race
(See 05-11 B-30 Counters haft Front Bearing Race
Assembly Note.)
1stl2nd Clutch Hub Component Assembly Note

Caution
Be sure to assemble the clutch hub
components and synchronizer ring
components while aligning the
synchronizer ring grooves with the
synchronizer" keys.
,. The standard synchronizer key
dimensions are as follows:
F:A=Jg
_1=
mm {in}
1st/2nd
117.0
~.669}
1 5.9
~.23}
5.0
~.20}
1
A6E5110M131
Be sure to align the synchronizer ring

projections with the inner cone notches.
Be sure to assemble the gears and the
synchronizer ring components while
aligning the double cone projections with
the gear holes as shown in the figure.
DBG511 BMB042
05-118-27

Align the clutch hub sleeve alignment
mark with the clutch hub synchronizer
key installation position and assemble.
_o::::=-....,----ALIGNMENT MARK
~~~~~,,-SYNCHRONIZER KEY
Caution
When using a press, be careful not to
damage the parts.
E5U511 BM5058
1. Using a SSTs and press, assemble the needle

bearing, 2nd gear, synchronizer ring component
(2nd), 1sV2nd clutch hub component,
synchronizer ring component (1 st), 1st gear,
needle bearing, needle bearing race and
mainshaft center bearing to the mainshaft at the
same time.
"
II
DBG511 BMB043
3rd/4th Clutch Hub Component Assembly Note

1. Assemble the 3rd/4th clutch hub component.
Caution
The standard synchronizer key
3rd/4th
A
17.0 {0.669}
B
5.9 {0.23} ,
mm {in}
C
5.0 {0.20}
A6E5110M131
Be sure to align the synchronizer ring

projections with the inner cone notches.
Be sure to assemble the gears and the
synchronizer ring components while
aligning the double cone projections with
the gear holes as shown in the figure.
DBG511 BMB042
05-118-28

_O=:",-<:~_-ALIGNMENTMARK
~~~~~~SYNCHRONIZER KEY
2. Install the 3rd/4th clutch hub component to the

mainshaft.
3. Install the spacer.
5. Measure the clearance between retaining ring

and spacer.
chOOSing the proper retaining ring.
3rd/4th clutch hub end play
0-0.05 mm {0.0-0.0019 in}
3rd/4th clutch hub retaining ring
Thickness (mm {in})
1.50 {0.0591}
1.55 {0.0610}
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
DBG511 BMB044
Maindrive Gear Shaft Bearing Assembly Note

1. Assemble the maindrive gear shaft bearing using
the SSTs.
DBG511 BMB062
Countershaft Center Bearing Race Assembly Note

1. Assemble tile countershaft center bearing race
using the SSTs.
DBG511 BMB046
05-118-29
Countershaft Front Bearing Race Assembly Note

1. Assemble the countershaft front bearing race
using the SSTs.
II
DBG511 BMB047
05-118-30
MAINSHAFT COMPONENT, COUNTERSHAFT COMPONENT AND TRANSMISSION CASE ASSEMBLY

[S1SM-D, S1SMX-D]
DCF051117040W08
31-46
{3.2-4.6, 23-33}
17.7-26.4
{1.81-2.69,13.1-19.4}
Nm {kgf.m, ft.lbf}
DBG511 BMB048
1
2
Transmission case
Counters haft component
(See 05-118-32 Maindrive Gear Component,
Mainshaft Component and Countershaft
Component Assembly Note.)
Mainshaft component
(See 05-118-32 Maindrive Gear Component,
05-118-31

4
5
6
7
8
9
Maindrive gear
(See 05-11 B-32 Maindrive Gear Component,
Countershaft front bearing
Maindrive gear bearing race
Mainshaft bearing race
Bearing cover
10
11
12
13
14
15
Front oil seal

(See 05-11 B-32 Front Oil Seal Assembly Note.)
Bearing shim
Bearing shim
Oil baffle
Pivot pin
Front cover
(See 05-11 B-32 Maindrive Gear Component,
Front Oil Seal Assembly Note

2. Install the oil seal to the front cover using the
SST.
~.
I:
Maindrive Gear Component, Mainshaft Component and Countershaft Component Assembly Note
1. Install the countershaft component.
2. Install the maindrive gear.
E5U511 BM5073
3. Install the mainshaft component.
DBG511 BMB049
05-118-32
,;

4. Assemble the Mainshaft component and
Maindrive gear.
5. Install the countershaft front and rear bearing.
E5U511 BM5046
6. Install the maindrive gear bearing race and

mainshaft center bearing race.
E5U511 BM5047
7. Install the bearing cover with the arrow painting to

the top of the case.
Tightening torque:
17.7-26.4 Nm {1.81-2.69 kgfm, 13.1-19.4

ft.lbf}
E5U511 BM5048
05-118-33

8. Select the mainshaft component and countershaft component bearing shims according to the following
procedure.
(1) Set the clutch housing side upward and level the transmission case.
Caution
Securely assemble the mainshaft, maindrive gear component, and countershaft component so
that there is no looseness or play.
(2) Using a depth gauge, measure the maindrive
gear bearing outer race height A.
DBG511 BMB054
(3) Using a depth gage, measure the main drive

gear bearing retainer depth B.
(4) Calculate and select the correct maindrive
gear bearing shim thickness.
DEPTH GAUGE
Formula: C = B - A
C: Dimension between the maindrive gear
bearing and bore in the front cover
B: Depth of the maindrive gear bearing bore
in the front cover
A: Maindrive gear bearing height
Refer to the maindrive gear bearing shim
selective chart.
Maindrive gear bearing shim selective chart

Dimension C (mm {in})
1.45-1.55
{0.0571-0.0610}
1.55-1.65
{0.0611-0.0649}
1.65-1.75
{0.0650-0.0688}
1.75-1.85
{0.0689-0.0728}
1.85-1.95
{0.0729-0.0767}
1.95-2.05
{0.0768-0.0807}
2.05-2.15
{0.0808-0.0846}
2.15-2.25
{0.0847-0.0885}
2.25-2.35
{0.0886-0.0925}
2.35-2.45
{0.0926-0.0964}
2.45-2.55
{0.0965-0.1003}
2.55-2.65
{0.1 004-0.1 043}
05-118-34
1.4 {0.055}
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.8 {0.071}
1.9 {0.075}
2.0 {0.079}
2.1 {0.083}
2.2 {0.087}
2.3 {0.090}
2.4 {0.094}
2.5 {0.098}
DBG511 BMB055
MANUAL TRANSMISSION [S15M-O, S15MX-O]

2.65-2.75
{0.1 044-0.1 082}
2.75-2.85
{0.1083-0.1122}
2.85-2.95
{0.1123-0.1161}
2.95-3.05
{0.1162-0.1200}
3.05-3.15
{0.1201-0.1240}
2.6 {0.102}
2.7 {0.106}
2.8 {0.110}
2.9 {0.114}
3.0 {0.118}
Maindrive gear shaft total end play

0.05-0.15 mm {0.002-0.0059 in}
(5) Using a depth gauge, measure the

countershaft front bearing depth D.
Note
The countershaft bearing is located below
the contact surface of the case and front
cover.
DBG511 BMB056
(6) Using a depth gauge, measure the

countershaft front bearing retainer depth 'E.
(7) Calculate and select the correct countershaft
front bearing shim thickness.
Formula: F = E + D
F: Dimension between the countershaft
front bearing and bore in the front cover
E: Depth of the countershaft front bearing
bore in the front cover
D: Countershaft front bearing depth
Refer to the countershaft front bearing

shim selective chart.
DBG511 BMB057
Countershaft front bearing shim selective chart

Dimension F (mm {in})
3.15-3.25
{0.124Q-0.1279}
3.25-3.35
{0.128Q-0.1318}
3.35-3.45
{0.1319-0.1358}
3.45-3.55
{0.1359-0.1397}
3.55-3.65
{0.1398-0.1437}
3.65-3.75
{0.1438-0.1476}
3.75-3.85
{0.1477-0.1515}
3.85-3.95
{0.1516-0.1555}
3.0 {0.118}
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
3.4 {0.134}
3.5 {0.138}
3.6 {0.142}
3.7 {0.147}
Counters haft total end play

0.15-0.25 mm {0.006-0.0098 in}
05-118-35
....
9. Position the maindrive gear bearing shim, oil baffle, and the countershaft bearing shim onto the front cover.
Note
If necessary, apply a light coat of petroleum jelly to the shims and oil baffle.
transmission case and front cover as shown in the
figure.
11. Install the pivot pin.
Tightening torque:
31-46 Nm {3.2-4.6 kgf.m, 23-33 ftlbf}
DBG511 BMB053
12. Install the front cover to the transmission case.
Tightening torque:
19-25 Nm {2.0-2.5 kgfm, 15-18 ft.lbf}
Note
To prevent damage to the oil seal lip during
assembly, tape maindrive gear shaft splines.
DBG511 BMB052
05-118-36

REVERSE GEAR COMPONENT AND 3RD/4TH GEAR COMPONENT ASSEMBLY [S15M-D, S15MX-0l
DCFt'!51117040W09
211-269
{21.6-27.4,156-198}
SELECTIVE
IAPPLY SPECIFIED OIL TO INDIVIDUAL PARTS
127-196
{13.D-19.9,94-144}
Nm {kgf.m, ftlbf}
DBG511 BMB058
15th counter gear

Steel ball
5rd gear bearing inner race

(See 05-11 B-38 5th Gear Bearing Inner Race
Assembly Note.)
05-118-37

4
Needle bearing
55th gear
6
Synchronizer ring
75th/reverse clutch hub
8
Synchronizer key
9
10 Clutch hub sleeve
Detent spring
11
12 Detent ball
13 5th/reverse shift rod
14 5th/reverse shift fork
5th/reverse clutch hub and shift fork component
(See 05-11 B-39 5th Counter Gear, 5th/Reverse
15
Clutc~ Hub Component and 5th/Reverse Shift Fork
Assembly Note.)
16 Retaining bolt
Counter lever shaft component
17 (See 05-11 B-41 Counter Lever Shaft Assembly
Note.)
18 Retaining bolt
19 Counter lever
20 Washer
21
Retaining ring
Thrust
washer
22
23 Thrust washer
24 Spacer
25 Needle bearing
Reverse gear
26
(See 05-11 B-40 Reverse Gear Assembly Note.)
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Friction damper
Reverse idler gear shaft
Thrust washer
Needle bearing
Reverse idler gear
Thrust washer
Retaining ring
Reverse idler gear shaft component
(See 05-11 B-41 Reverse Idler Gear Component
Assembly Note.)
Retaining bolt
Spacer
Reverse counter gear
(See 05-11 B-42 Mainshaft Rear Bearing and
Counters haft Rear Bearing Locknut Assembly
Note.)
Locknut
(See 05-11 8-42 Mainshaft Rear Bearing and
Countershaft Rear Bearing Locknut Assembly
Note.)
Thrust washer
(See 05-11 B-42 Mainshaft Rear Bearing and
Counters haft Rear Bearing Locknut Assembly
Note.)
Locknut
(See 05-118-42 Mainshaft Rear Bearing and
Countershaft Rear Bearing Locknut Assembly
Note.)
5th Gear Bearing Inner Race Assembly Note

1. Install the steel ball to the countershaft.
2. Align the ball groove position of the 5rd gear
bearing inner race and assemble it to the
countershaft.
E5U511 BM5032
05-118-38

5th Counter Gear, 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note
1. Assemble the 5th drive gear and 5th/reverse clutch hub component.
Caution
Be sure to assemble the clutch hub components and synchronizer ring components while aligning
the synchronizer ring grooves with the synchronizer keys.
The standard synchronizer key
r---------------------,
mm {in}
5th/6th
A
18.0 {0.709}
B
5.45 {0.215}
6.0 {0.236}
A6E5110M131

_o:=:::-..::----ALIGNMENTMARK
~~~~~,,-SYNCHRONIZER KEY
E5U511 BM5058
2. Assemble the 5th counter gear component, 5th/

reverse clutch hub component, and 5th/reverse
shift fork component as a single unit.
3. Install the 5th/reverse shift rod retaining bolt.

Tightening torque:
21.6-30.4 Nm {2.21-3.09 kgfm, 16.0-22.4
ft.lbf}
4. Install the thrust washer.
05-118-39
5. Measure the clearance between thrust washer

and groove of the countershaft.
choosing the proper thrust washer.
5th/Reverse clutch hub end play

0-0.05 mm {0.0-0.0019 in}
5TH/REVERSE
CLUTCH HUB
END PLAY
5th/Reverse clutch hub thrust washer

Thickness (mm {in})
3.00 {0.11B}
3.05 {0.120}
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.12B}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}
DBG511 BMB060
Reverse Gear Assembly Note

1. Measure the clearance A and B.
(1) Calculate and select the thrust washer
thickness.
Formula: C = A - B
C: Dimension between the 5th/Reverse
clutch hub and reverse gear
B: Reverse gear height
A: Dimension between the 5th/Reverse
clutch hub and thrust washer
Refer to the reverse gear thrust washer

selective chart.
Reverse gear thrust washer

Thickness (mm {in})
7.70-7.BO
7.45 {0.293}
7.BO-7.90
{0.30B-0.311}
7.90-B.00
7.55 {0.297}
B.00-8.10
{0.315-0.31B}
7.75 {0.305}
{0.304-0.307}
{0.312-0.314}
7.65 {0.301}
Reverse gear end play

0.25-0.35 mm {0.002-0.0059 in}
2. Install the thrust washer.
3. Install the reverse gear.
05-118-40
REVERSE GEAR
DBG511 BMB061

Counter Lever Shaft Assembly Note
1. Install the counter lever shaft component.
Caution
If the counter lever shaft has been
replaced or the locknut is loose,
assemble the counter lever shaft with the
chamfer side of the shaft pOinted straight
upward.
Apply sealant to the threads of the
locknut.
If there is an abnormality in the 3rd/4th
shift stroke after assembling, loosen the
locknut and readjust.
E5U511 BM5072
Locknut tightening torque:

37.3-51.9 Nm {3.81-5.29 kgfm, 27.6-38.2 ft.lbf}
Reverse Idler Gear Component Assembly Note
1. Using the SSTs, install the friction damper to the
reverse idler gear.
ICTION DAMPER
DBG511 BMB078
Verify the depth of the friction damper

installation position.
1.0-1.6 mm {0.040-0.062 in}
FRICTION DAMPER
2. Assemble the reverse idler gear component.

and thrust washer.
Reverse idler gear end play
0.1-0.2 mm {0.0040-0.0078 in}
Reverse idler gear retaining ring
Thickness (mm {in})
1.5 {O.059}
)"
1.6 {O.063}
1.7 {O.067}
r---------------~~~~--------------~
1.8 {O.071}
1.9{O.075}
05-118-41

4. Install the reverse idler gear component to the
transmission case.
E5U511 BM5070
5. Install the reverse idler gear shaft retaining bolt.
Tightening torque
78.5-117 Nm {8.01-11.9 kgfm, 57.9-86.2
ft.lbf}
E5U511 BM5015
Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note
1. Slide the 3rd/4th and 1sV2nd clutch hub sleeves
r----------------------,
to lock the transmission into 4th and 2nd gears.
2. Insert the mainshaft rear bearing into the
mainshaft and install the locknut.
3. Attach the SST to the locknut and tighten the nut to the specified torque.
Caution
Attach the SST with the locknut seated in
the bearing.
Tightening torque:
211-269 Nm {21.6-27.4 kgf.m, 156-198
ftlbf}
DBG511 BMB028
05-118-42

4. Tighten the countershaft locknut in the
counterclockwise direction.
Tightening torque:
127-196 Nm {13.0-19.9 kgfm, 94-144

ft.lbf}
5. Using the pin punch, stake the mainshaft rear

bearing locknut.
6. Using the pin punch, stake the countershaft rear

bearing locknut.
05-118-43

TOP COVER COMPONENT AND EXTENSION HOUSING ASSEMBLY [S15M-D, S15MX-D]
--..e
DCF051117011W07

4r-X_2_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
15.7-22.5
{1.60-2.29,11.6-16.5}
19
1i'
7.S-11.0 Nm
{S0-112 kgf.cm,
70-97 in.lbf}
J~~~
~m
~
7.9-9.S N.m
{S1-99 kgfcm,
1/
15.7-22.5
{1.60-2.29, ,
11.6-16.5}
70-86 ;".Ib"~
~\\~
~~~
7.S-11.0Nm
{S0-112 kgfcm,
70-97 in.lbf}
~ _./'1
.............. __ ---...J
~
I
f\..
iii"
6.9-9.S Nm
{71-99 kgfcm, 61-S6 in.lbf}
7.8-11.0 Nm
{S0-112 kgf.cm,
70-97 inlbf}
25-34
{2.55-3.46,
1S.5-25.0}
Nm {kgfm, ttlbf}
DBG511 BMB002
ISteel ball
05-118-44
IRetaining ring

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Bush
(see 05-11 B-47 Bush Assembly Note.)
(see 05-11 B-48 Oil Seal (control rod) Assembly
Note.)
Sealing cap
(see 05-11 B-49 Sealing Cap Assembly Note.)
Control rod
Oil passage
Funnel
Extension housing
(see 05-11 B-50 Extension Housing Assembly
Note.)
Control rod end
Select spindle component
Select lock spindle
Select lock spindle spring
Spring cap
(see 05-11 B-49 Oil Seal (Extension Housing)
Assembly Note.)
Control lever
Oil passage
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33

(see 05-11 B-50 Top Cover Assembly Note.)
Blind cover
(see 05-11 B-51 Blind Cover Assembly Note.)
Control case
Change seat
Shift lever
Change bush
Wave washer
Gasket
Dust boot
Neutral switch
Dust boot
Release fork
(see 05-11 B-51 Release Collar, Release Fork
Assembly Note.)
Release collar
Assembly Note.)
05-118-45

4x4
15.7-22.5
{1.60-2.29,11.6-16.5}
.----1I
~K m
~o
7.8-11.0Nm
{80-112kgf.cm,
7_"'~
7.8-11.0 Nm
{80-112 kgf.cm,
70-97 infbf}
f
ti
~ ~
'">\
7.9-9.8Nm
{81-99 kgf.cm,
70--116
Jil3m
~ ~
25-34
{2.6-3.4, 19-25}
~~m
~ ~;;;:'~.4, 19-25}
Nm {kgf.m, ttfbf}
DBG511 BMB064
Bush
(see 05-11 B-47 Bush Assembly Note.)
(see 05-11B-48 Oil Seal (control rod) Assembly
Note.)
05-118-46
3
4

(see 05-11 B-49 Oil Seal (Extension Housing)
Assembly Note.)
Funnel
f'

5
6
7
8
9
10
11
12
13
14
15
16
17
18
Extension housing
(see 05-11 B-:-50 Extension Housing Assembly
Note.)
Blind cover
(see 05-118-51 Blind Cover Assembly Note.)
Transfer
Breather
(see 05-118-51 Breather Assembly Note.)
Breather dust boot
Neutral switch
4X4 indicator switch
Steel ball
Spring
Switch pin
Change seat
19
20
21
22
23
24
25
26
27
28
29
30
Transfer shift lever

Shift lever
Change bush
Wave washer
Gasket
Dust boot
Control rod end
Oil passage
(see 05-11 B-50 Top Cover Assembly Note.)
Dust boot
Release collar
Assembly Note.)
Release fork
Assembly Note.)
Bush Assembly Note

4x2
1. Install the bush using the SST.
Installation depth A: 1-2 mm {0.040-0.078
in}
DBG511 BMB069
2. Install the bush using the suitable steel bar

through the sealing cap hole as shown in the
figure.
Distance A: Approx. 200 mm {7.87 in}

Distance B: Approx.17.0-17.5 mm {0.S700.S88 in}
Installation depth C: 1-2 mm {0.040-0.078
in}
DBG511 BMB070
OS-11B-4J:

4x4
1. Install the bush using the SST.
Front side
Installation depth A: 0-1 mm {0.0-0.039 in}
DBG511 BMB071
Rear side
Installation depth A: 1-2 mm {0.040-0.078
in}
DBG511 BMB072
Oil Seal (control rod) Assembly Note

4x2
2. Install the oil seal using the SSTs through the
sealing cap hole as shown in the figure.
Installation depth A: 109.5-110.5 mm
{4.312-4.350 in}
05-118-48

4x4
2. Install the oil seal using the SST.
Installation depth A: 2.0-3.0 mm {0.079-
0.118 in}
DBG511 BMB066
Sealing Cap Assembly Note

1. Install the sealing cap using the SSTs.
Caution
Apply silicone sealant to the sealing cap.
<I.
I:
DBG511 BMB015
Oil Seal (Extension Housing) Assembly Note

2. Install the oil seal evenly and gradually using the SST and a hammer.
4x2
05-118-49

4x4
DBG511 BMB06?
Extension Housing Assembly Note

extension housing and transmission case as
2. Install the extension housing to the transmission
case.
Tightening torque:
31.4-46.0 Nm {3.21-4.69 kgfm, 23.2-33.9
ft.lbf}
DBG511 BMB008
Top Cover Assembly Note

transmission case and top cover as shown in the
figure.
2. Install the top cover component to the
transmission case.
Tightening torque:
15.7-22.5 Nm {1.60-2.29 kgfm, 11.6-16.5
ftlbf}
DBG511 BMB009
Control Case Assembly Note

control case and extension housing as shown in
the figure.
2. Install the control case to the extension housing.
Tightening torque:
15.7-22.5 Nm {1.60-2.29 kgfm, 11.6-16.5
ftlbf}
DBG511BMB010
05-118-50

Blind Cover Assembly Note
1. Apply sealant to the contact surfaces of the blind
cover and extension housing as shown in the
figure.
2. Install the blind cover to the extension housing.
Tightening torque:
7.9-9.8 Nm {81-99 kgfcm, 70-86 inlbf}
DBG511BMB011
Breather Assembly Note

1. Install the new breather using the SST.
DBG316BMB044
.
,
Release Collar, Release Fork Assembly Note

1. Apply specified grease to the areas shown in the
figure.
2. Install the release collar and release fork.
-Ii'
11
DBG511 BMB023
05-118-51
05-13
DISASSEMBLY[5R5SS] .........
FLUID PUMP DISASSEMBLY
,. [SRSSS] ...............
IFLUID PUMP ASSEMBLY[SRSSS] .....
OVERDRIVE BRAKE AND COAST
CLUTCH DRUM COMPONENT
DISASSEMBLY/ASSEMBLY
[SRSSS] ................
INTERMEDIATE BRAKE AND DIRECT
CLUTCH DRUM COMPONENT
[SRSSS] ..............
FORWARD CLUTCH
[SRSSS] ..............
OS-13-2
05-13-24
OS-13-26
OS-13-30
OS-13-34
05-13-39
OVERDRIVE PLANETARY GEAR AND

ONE-WAY CLUTCH COMPONENT
[SRSSS] ................. OS-13-43
OUTPUT SHAFT RING GEAR AND HUB
SHAFT COMPONENT
[SR55S] ................... 05-13-48
FORWARD RING GEAR COMPONENT
[SRSSS] .................. OS-13-49
LOW/REVERSE BRAKE SERVO
COMPONENT DISASSEMBLY/ASSEMBLY
[SRSSS] ................. OS-13-50
CONTROL VALVE BODY
[SRSSS] ................ OS-13-S4
AUTOMATIC TRANSMISSION ASSEMBLY
[SR5SS] ................ OS-13-S7
05-13-1
AUTOMA:
AUTOMATIC TRANSM
TIC TRANSMIS
Exploded View
ISSION DlSASSEMBLYI5R55S]
SION [5R55S]
id0513c1260100
b5r5za00000382
05-13-2
-~-
b5r5za00000383
05-13-3
148
b5r5za00000384
2
3
4
5
Torque converter installation nut

Torque converter
Input shaft
Fluid pump seal
Fluid pump seal ring
05-13-4
6
7
8
9
10
Bolt and washer

Fluid pump cover
Fluid pump adapter plate
Fluid pump gasket
Seal ring
f;
AUTOMATIC TRANS MISSION [5R55S]

11
;)
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
Stator support seal

Fluid pump support
O-ring
Fluid pump control valve
Fluid pump component
Bolt
Seal ring
Thrust washer (No.1)
Intermediate and overdrive brake band anchor strut
Intermediate and overdrive brake band
Intermediate and overdrive brake band apply strut
Intermediate and overdrive brake band adjusting
screw
Locknut
Overdrive brake drum
Direct clutch and coast clutch piston outer seals
Direct clutch and coast clutch piston inner seals
Direct clutch and coast clutch pistons
Direct clutch and coast clutch piston spring
Direct clutch and coast clutch piston spring retainer
Retaining ring
Coast clutch external spline plate (steel)
Coast clutch internal spline friction plate (friction)
Direct clutch and coast clutch pressure plate
Retaining ring (select fit)
Carrier adapter
Overdrive sun gear
Overdrive planetary gear carrier component
Thrust bearing (No.2)
Overdrive ring gear
Overdrive one-way clutch
Overdrive center shaft
Retaining ring
Overdrive center shaft and ring gear component
Thrust bearing (No.3, No.5, NO.8 and No.9)
Retaining ring
Center support
Nut and cage component
Bolt
Intermediate brake drum
Direct clutch external spline plate (steel)
Direct clutch internal spline plate (friction)
Forward clutch cylinder
Forward clutch piston
Forward clutch piston spring component
Retaining ring
Forward clutch external spline plate (steel)
Forward clutch internal spline plate (friction)
Forward clutch pressure plate
Thrust bearing (No.6A)
Thrust washer (No.6B)
Retaining ring
Forward ring gear hub
Forward ring gear
66
67
68
69
70
71
72
73
74
75
76
"..

Forward planetary component
Input shell and sun gear component
Spacer
Retaining ring
Lower/reverse planetary component
Output shaft sleeve
Retaining ring
Output shaft ring gear
Output shaft hub
Retaining ring
77 Output shaft hub seal
78 Thrust bearing (No.10)
Low/reverse brake drum and one-way clutch
79
component
80 Low/reverse brake band
81
Output shaft needle bearing
82 Thrust washer (No.11)
83 Parking gear
84 Output shaft (4x2)
85 Parking pawl
86 Parking pawl return spring
87 Parking pawl shaft
88 Extension housing gasket
89 Extension housing (4x2)
90 Bolt (4x2)
91
Extension housing seal (4x2)
94 Extension housing seal (4x4)
95 Bolt (4x4)
96 Oil pipe connector component
97 Retaining ring
98 Overdrive brake servo cover seal
99 Overdrive brake servo cover
100 Overdrive brake servo piston
101 Spring
102 Retaining ring
103 Intermediate brake servo cover seal
104 Intermediate brake servo cover
105 Intermediate brake servo piston
106 Transmission case
107 TSS sensor, ISS sensor and OSS sensor
108 O-ring
109 Bolt
110 Vent tube (4x2)
111 Low/reverse brake actuating lever
112 Low/reverse brake band actuating lever shaft
Pressure tap plug (pressure control solenoid C
113
circuit)
114 Fluid fill plug
115. Manual shaft retaining pin
116 Parking pawl actuating rod
117 Manual shaft outer and inner nut
118 Manual valve inner lever
119 Manual shaft seal
I.
05-13-5
i iWI

120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
Manual shaft
Digital transmission range (TR) sensor
Bolt and washer
Manual shaft lever
Reverse brake servo component
Reverse brake servo plate
Spring
Reverse brake servo piston and seal
O-ring
Reverse brake servo cover
Bolt
Control valve spring retainer
Spring
Reverse brake servo check valve
Bolt
Separating plate (bonded)
Bolt
Bolt
Detent spring
Bolt
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
Bolt
Control valve body component
O-ring
Solenoid body
Bolt
Bolt
Transmission fluid filter
Transmission fluid pump gasket
Magnet
Bolt
Transmission fluid pump
Drain plug
Bolt
Fluid level indicating plug (short hex)
Overdrive brake and coast clutch drum component
Intermediate brake and direct clutch drum
component
Forward clutch component
Overdrive brake servo
Intermediate brake servo
Disassembly
Note
Tag and identify all parts during disassembly.
1. Place the transmission on a workbench.
Warning
The torque converter is heavy, especially
when full of fluid.
arnffv00000559
2. Using the SSTs, remove the torque converter.
arnffv00000519
05-13-6

3. Remove the input shaft.
05
4 Using the SST, install the transmissio.n into
~he
. bench with the torque converter housing facing

up.
arnffv00000520
5. Remove the sensors.

TSSSENSOR
ISS SENSOR
OSS SENSOR
b5r5za00000363
6. Remove the manual shaft lever.
MANUAL SHAFT
LEVER
b5r5za00000364
7. Remove the digital transmission range (TR)

sensor.
DIGITAL TR
SENSOR
arnffv00000521
05-13-7

8. Using the SST, remove the extension housing
seal. (4x2)
Caution
The parking pawl, parking pawl return
spring and parking pawl shaft could fall
out during removal of the extension
housing.
arnffv00000522
9. Remove the extension housing. (4x2)
b5r5zaOOOOOOll
10. Using the SSTs, remove the extension housing

seal. (4x4)
Caution
The parking pawl, parking pawl return
spring and parking pawl shaft could fall
out during removal of the extension
housing.
11. Remove the extension housing. (4x4)

Note
4x2 shown, 4x4 similar.
12. Remove the parking pawl component and discard

the gasket.
(1) Remove the parking pawl shaft.
(2) Remove the parking pawl.
(3) Remove the parking pawl return spring.
(4) Remove and discard the gasket.
Note
The transmission fluid pan gasket is
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should
be reused.
05-13-8
b5r5zaOOOOOQ13

13. Remove the screws, transmission fluid pan and
gasket.
14. Remove the transmission fluid filter and seal

component and discard.
15. Remove the detent spring.
Warning
The upper and lower servo covers are
under spring tension. Use care when
removing the piston and cover
component. Failure to follow these
instructions can result in personal injury.
16. Remove the low/reverse brake servo component.
Caution
Do not damage solenoid body connector
pins.
b5r5za00000017
17. Remove the solenoid body component by lifting

on the body and pushing the connector from the
other side of the case.
b5r5za00000018
05-13-9

18. Remove the main control valve body, separator
plate and gasket.
b5r5za00000019
19. Using the SST, remove the fluid pump seal.

Caution
Failure to loosen the overdrive brake
band adjusting screw prior to pump
removal may cause damage to the pump
and overdrive brake band.
Throw the locknut away. The locknut are
not reusable for assembly.
b5r5za00000295
20. Remove and discard the locknut, and loosen the

overdrive brake band adjusting screw.
21. Remove and tag the overdrive brake band anchor

strut for assembly.
Caution
The screws are not reusable for
assembly. Discard the screws. If the
screws are reused, the housing may
become separated from the
transmission.
b5r5za00000022
22. Remove and discard the screws.
b5r5za00000023
05-13-10
24. Using the SST, remove the fluid pump.
Caution
Servo cover is under spring tension.
25. Using the SST, remove the retaining ring and

overdrive brake servo cover.
26. Remove the overdrive brake servo piston and

spring.
27. Remove the screw.
b5r5za00000030
05-13-11

28. Compress the overdrive brake band and remove
the apply strut.
Note
Tag and identify parts for reassembly.
Caution
Identify the anchor and apply ends of the
overdrive brake band.
b5r5za00000031
29. Remove and inspect the overdrive brake band.

Check the following conditions for installing a new
band:
Inspect for glazing.
Inspect for missing friction material.
Inspect for material flaking.
Inspect for damage to the anchor pins.
Note
The new overdrive brake band is dark in
color. This is a normal condition of the band.
Hairline cracks in the band are also
considered normal. Do not install a new
band based solely on the color.
30. Remove the overdrive brake and coast clutch
drum component.
Caution
Do not bend the trigger wheel.
31. Remove the overdrive planetary gear carrier.

Note
The thrust bearing (No.12) is in this
component.
b5r5za00000034
05-13-12

Remove the thrust bearing (No.2).
33. Remove the overdrive ring gear, overdrive oneway clutch component and center shaft as an
assembly.
b5r5za00000036
34. Remove the thrust bearing (No.3).
Note
Tag and identify the thrust bearing (No.3) for
assembly.
Caution
The center support nut could fall into the
remaining assembly if not removed.
b5r5za00000038
36. Remove the nut and cage.
05-13-13
37. Remove the retaining ring.
b5r5za00000040
38. Remove the center support.
Note
The center support is repaired as an
assembly. Any damage requires installing a
new component.
When removing the center support, pull
evenly around the center support web.
39. Inspect the center support component for wear or

damage.
(1) Inspect the thrust surfaces for wear or
damage.
(2) Inspect the center support sealing surface.
(3) Inspect the fluid passage for blockage or
damage.
b5r5za00000042
40. Inspect the seal rings for damage.
/~----------==b5r5za00000043
41. Inspect the bearing for missing rollers or damage.
/~----------==b5r5za000000 44
05-13-14

42. Inspect the direct clutch feed hole for blockage or
damage.
(1) Rotate the center support bearing to locate
the direct clutch feed hole.
(2) Inspect the direct clutch feed hole for
blockage or damage.
05
b5r5za00000045

Note
Tag and identify the thrust bearing (No.4).
Caution
Failure to loosen the intermediate brake
band adjusting screw prior to pump
removal may cause damage to the pump
and intermediate brake band.
Throw the locknut away. The locknut are
not reusable for assembly.
44. Remove and discard the locknut, and loosen the
intermediate brake band adjusting screw.
Caution
Servo cover is under spring tension.
45. Using the SST, remove the retaining ring and

intermediate brake servo cover.
46. Remove the intermediate brake servo piston and

spring .
05-13-15
-~~
:'I

47. Remove and tag the intermediate brake band
anchor strut for assembly.
Caution
Identify the anchor and apply ends of the
intermediate brake band.
Note
The new intermediate brake band is dark in
b5r5za00000047
48. Remove and inspect the intermediate brake band.

Check the following conditions for installing a new
band:
Inspect for glazing.
Inspect for missing friction material.
Inspect for material flaking.
Inspect for damage to the anchor pins.
b5r5za00000048
49. Remove and tag the intermediate brake band

apply strut for assembly.
b5r5za00000049
b5r5za00000050
05-13-16

51. Remove the intermediate brake and direct clutch
drum component.
Note
The thrust bearing (No.5) may come out with
the intermediate brake and direct clutch
drum.
52. Remove the thrust bearing (No.5), tag and

identify.
53. Remove the forward clutch cylinder.
Note
The thrust bearing (No.6A) may come out
with the cylinder. Tag for reassembly.
54. Remove the thrust bearing (No.6A).
Note
The thrust bearing (No.6A) may have come
out with the forward clutch cylinder.
55. Remove the forward ring gear and hub as an

assembly.
Note
the forward ring gear and hub component.
05-13-17

56. Remove the thrust washer (No. 68) from the
forward ring gear hub.
b5r5zaOOOOOOS6
Note
the forward ring gear and hub component.
58. Remove the forward planetary component.
59. Remove the input shell and sun gear component.
b5r5za00000059
60. Remove the spacer.
bSr5za000000 60
05-13-18

Note
63. Remove low/reverse planetary component.
b5r5za00000063

Note
b5r5za00000064
65. Using a small pick, remove the output shaft

sleeve.
Note
Use slots located around the outside of the
sleeve.
Warning
The output shaft may fall out after
removing the retaining ring. Failure to
follow these instructions may result in
personal injury.
b5r5za00000065
05-13-19

Caution
Discard the retaining ring. A new retaining ring must be used for assembly.
66. While holding the output shaft, remove and

discard the retaining ring.
b5r5za00000066
67. Remove the output shaft and park gear.
b5r5za00000074
68. Remove the output shaft thrust washer.

Note
Tag and identify the thrust washer (No.11).
b5r5za00000075
69. Remove the output shaft ring gear and hub.
05-13-20
-70. Remove the thrust bearing (No.10).
Caution
Do not pry on the outer edge of the case
or damage to the gasket sealing surface
could occur.
05
71. Using a pair of vice grips, hold the flat spots on
the low/reverse brake band actuating lever shaft,
wiggle it back and forth and remove the low/
reverse brake band actuating lever shaft.
Note
It may be necessary to grind flat spots on the
edges of the low/reverse brake band
actuating lever shaft in order to remove it.
LOW/REVERS BRAKE
BAND ACTUATING
LEVER SHAFT
b5r5za00000389
72. Remove the low/reverse brake band actuating

lever component.
73. Remove the low/reverse brake drum and one-way

clutch component by rotating it clockwise.
Note
The inner race of the rear one-way clutch is
not removable. It is repaired in the case.
74. Inspect the low/reverse brake drum component

and install a new low/reverse brake drum
component if damaged.
(1) Inspect the low/reverse brake drum sprags.
(2) Inspect the low/reverse brake drum rollers.
(3) Inspect the low/reverse brake drum.
Note
The reverse one-way clutch is part of the
low/reverse brake drum component. Install a
new low/reverse brake drum as an assembly
only.
b5r5za00000072
05-13-21
-)
75. Remove the low/reverse brake band.

Caution
To avoid damage, make sure the wrench
does not strike the manual valve inner
lever pin.
b5r5zaOOOOO073
76. Remove the nut.
---~------
b5r5za00000076
77. Remove the manual shaft retaining pin.
b5r5za00000077
78. Remove the manual shaft.
---~<
~ \~~On~()~
b5r5za00000078
79. Disconnect the manual valve inner lever from the

parking lever actuating rod.
b5r5za000000 79
05-13-22

Remove the manual valve inner lever.
05
b5r5za00000080
81. Remove the parking lever actuating rod.
Caution
Do not damage the bore.
82. Remove the manual shaft seal.
b5r5za00000082
05-13-23

FLUID PUMP D1SASSEMBLY[5R55S]
id0513C1262600
1. Remove the fluid pump gasket, fluid pump seal

ring and the No.1 thrust washer.
(1) Remove and discard the fluid pump gasket.
(2) Remove and discard the fluid pump seal ring
(square cut).
(3) Remove and tag the thrust washer (No.1).
b5r5za00000087
2. Remove the fluid pump support seal ring.
b5r5za00000088
3. Remove the seal rings.
a
b5r5za00000089
4. Remove the fluid pump support from the fluid

pump cover.
b5r5za00000423
...
05-13-24
'?

Remove the fluid pump gears.
Note
A rough casting on the pump surface
crescent is not a flaw.
The fluid pump gears are part of the pump
component and are not repaired separately.
6. Remove the drive gear seal ring and discard.

Inspect the fluid pump gears for cracks and
scoring.
b5r5za00000092
7. Inspect the overdrive pump.

Inspect the overdrive pump support gear
pockets for scoring and wear.
Clean and inspect the overdrive and rear
input shaft bushings.
b5r5za00000093
8. Inspect the fluid pump adapter plate for scoring

and wear.
b5r5za00000094
9. Remove and discard the fluid pump control valve.
b5r5za00000095
05-13-25
10. Inspect the fluid pump-to-converter housing

bushing.
b5r5za00000096
FLUID PUMP ASSEMBLV[5R55S]
Id0513c1262700
1. Inspect the fluid pump components for the following:

Pump body and case for burrs
. Fluid passages for obstructions
Note
Minor burrs and scoring may be removed with crocus cloth. If damage is found, install a new assembly.
2. Install a new seal onto the SST.
Note
Check and make sure that the garter spring
in the seal has not popped off of the
converter hub seal.
" .
b5r5za00000097
3. Using the SST, install the converter hub seal.
b5r5za00000098
4. Install a new seal ring in fluid pump drive gear.

Caution
Lubricate the SST with multi-purpose
grease.
b5r5za00000099
05-13-26

5. Using the SST, seat the O-ring in the pump gear.
Caution
The chamber on the inside edge of the
small gear must be UP when in the pump
housing gear pocket. The dimple on the
larger gear must be DOWN when in the
pump housing gear pocket.
5:
05
b5r5za00000100
6. Install the pump gears into the fluid pump

housing. Apply multi-purpose grease to the pump
gear to prevent scoring at start up.
b5r5za00000101
7. Install a new O-ring on the new fluid pump control

valve.
bn
b5r5za00000102
8. Install a new valve with the tab facing down.
b5r5za00000103
9. First install the fluid pump adapter plate and then

the alignment pins in their correct location.
Caution
The SST must be used to correctly align
the pump with the adapter plate to reduce
gear noise, bushing failure and leakage.
arnffv00000524
05-13-27

10. Using the SST, align the fluid pump to the adapter
plate.
b5r5zaOOOOO105
11. Using the SST, assemble the fluid pump.
arnffv00000525
12. Loosely install the fluid pump housing screws in

their correct location and remove the SSTs.
13. Install the 2 remaining screws and tighten all the

screws in a star pattern.
Tightening torque
22-28 Nm {2.3-2.8 kgfm, 17-20 ft Ibf}
arnffv00000527
14. Install a new fluid pump seal ring.
b5r5za00000109
05-13-28

15. Install the new seal rings.
Caution
Be careful not to overstretch the seal ring
past the seal ring groove. Damage to the
seal will occur.
16. Using the SST, install the fluid pump seal ring.
Caution
Verify correct seal installation.
.-.
b5r5za00000111
17. Verify that the seal is installed correctly.

Note
Make sure seal grooves are clean and free
of burrs. Make sure that the seal is seated
into the groove.
Caution
Failure to correctly size the seal will
cause damage to the seal when the
~torque converter is installed.
b5r5za00000112
18. Using the SST, size the seal to the correct size.
Leave the SST on the seal ring for 2 min to obtain
the correct seal size.
b5r5za00000113
05-13-29

OVERDRIVE BRAKE AND COAST CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY[5R55S1
idO'!;13c1262100
Overdrive Brake and Coast Clutch Drum Component
b5r5za00000114
2
3
4
5
6

Coast clutch piston outer seal ring
Coast clutch piston inner seal ring
Coast clutch piston
Overdrive piston spring
Coast clutch piston spring retainer
7
8
9
10
11
Retaining ring
Coast clutch internal spline plate (friction)
Coast clutch pressure plate
Disassembly
1. Remove the coast clutch pressure plate.
(1) Remove the retaining ring.
(2) Remove the coast clutch pressure plate.
b5r5za00000115
2. Remove the coast clutch disc pack.

Inspect for wear, install a new pack as
necessary.
Warning
Use caution when releasing tool pressure
on the piston spring. Failure to follow
these instructions may result in personal
injury.
Caution
Do not fully compress the SST or damage
to the spring retainer may occur.
05-13-30
b5r5za00000116

3. Using the SST, remove the retaining ring.
4. Relieve the coast clutch spring tension and
remove the SST.
05
arnffv00000528
5. Remove the coast clutch piston springs.

(1) Remove the coast clutch piston spring
retainer.
(2) Remove the coast clutch piston springs.
Warning
Air pressure must not exceed 138 kPa
{1.4 kgf/cm 2 , 20 psi}. Wear safety glasses
when using compressed air and make
sure the drum is facing down as shown.
Failure to follow these instructions may
result in personal injury.
b5r5za00000118
6. Remove the coast clutch piston .

Apply air pressure to the hole in the drum to
remove the coast clutch piston while blocking
the other hole with a finger.
b5r5za00000119
7. Remove and discard the coast clutch piston inner

seal and the coast clutch piston outer seal.
b5r5za00000120
Assembly
Caution
The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
05-13-31

1. Install the new coast clutch piston inner and outer
seal.
b5r5za00000121
2. Verify the check ball is free to move.

Caution
Care must be taken to prevent damage to
the seals during installation.
b5r5za00000122
3. Using the SST, install the coast clutch piston.

Lubricate the seals with transmission fluid.
arnffv00000529
4. Install the coast clutch piston springs.

(1) Install the coast clutch piston springs.
(2) Install the coast clutch piston spring retainer.
Caution
to the coast clutch piston spring retainer
may occur.
b5r5za00000124
5. Using the SST, install the spring retainer ring.

Caution
Coast clutch friction plates are
directional and must be installed with
grooves clockwise (10 to 00). The word
TOP should face up.
If new clutch plates are being used, they
should be soaked in clean ATF before
assembly.
arnffv00000528
05-13-32

6. When installing friction plates, the word TOP
should face up. If reusing plates, grooves must be
installed clockwise. Install the coast clutch disc
pack.
05
b5r5za00000126
7. Install the 2 steel clutch plates and 2 friction
clutch plates in alternating order starting with a

steel clutch plate.
Caution
The retaining ring is select fit.
b5r5za00000127
8. Install the coast clutch pressure plate.
(1) Install the coast clutch pressure plate.

(2) Install the original retaining ring.
Warning
when using compressed air and make
sure drum is facing down as shown.
b5r5za00000128
9. Air check the assembly.
Apply air pressure to the hole in the drum

while blocking the other hole with a finger.
b5r5za00000119
10. Check the coast clutch disc pack free play.
(1) Push down on the coast pressure plate.

(2) Check clearance between the coast clutch
retaining ring and coast pressure plate.
Clearance should be 1.3-2.0 mm {0.0510.079 in}. If clearance is not within the
specification, install a correct coast clutch
retaining ring that will provide the correct free
play adjustment.
Coast clutch clearance

Standard: 1.3-2.0 mm {0.051-0.079 in}
1.3-2.0 mm
{0.051-0.079 in}
b5r5za00000129
05-13-33

Retaining ring size for coast dutch clearance
Thickness
in
mm
0.0539
1.37
0.0681
1.73
0.0819
2.08
0.0961
2.44
Diameter
mm
130.1
130.1
130.1
130.1
in
5.122
5.122
5.122
5.122
INTERMEDIATE BRAKE AND DIRECT CLUTCH DRUM COMPONENT DISASSEMBLY/ASSEMBLY[5R55S1
id0513cl:tS2200
Intermediate Brake and Direct Clutch Drum Component
b5r5za00000130
1
2
3
4
5
6

Direct clutch piston outer seal ring
Direct clutch piston inner seal ring
Direct clutch piston
Direct clutch piston spring (20 required)
Direct clutch piston spring retainer
7
8
9
10
11
Retaining ring
Direct clutch internal spline plates (friction)
Direct clutch pressure plate
Disassembly
Caution
The retaining ring is a select fit. See assembly procedure if installation of new ring or clutch pack
is required.
1. Remove the retaining ring and the direct clutch

pressure plate.
(2) Remove the direct clutch pressure plate.
Caution
Clutch plates are directional. Note the
direction of the grooves for installation.
b5r5za00000131
05-13-34
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2. Remove the direct clutch disc pack.
Inspect and install new friction plates if worn,
damaged or overheated.
Measure and record the thickness of the steel
plates for assembly.
Warning
After removing the retaining ring, use
care when releasing the pressure on the
springs. Failure to follow these
instructions may result in personal injury.
Caution
b5r5za00000132

4. Relieve the direct clutch spring tension and
remove the SST.
arnffv00000530
5. Remove the direct clutch piston spring retainer

and the direct clutch piston springs.
(1) Remove the direct clutch piston spring
retainer.
(2) Remove the direct clutch piston springs.
Warning
{1.4 kgflcm 2 , 20 psi}. Wear safety glasses
when using compressed air, and make
sure the drum is facing down as shown.
b5r5za00000134
6. Using compressed air, remove the direct clutch

piston from the intermediate brake drum.
b5r5za00000135
05-13-35

7. Remove and discard the direct clutch piston inner
and outer seal.
(1) Remove and discard the direct clutch piston
inner seal ring.
(2) Remove and discard the direct clutch piston
outer seal ring.
Clean the components as necessary.
b5r5za00000136
Assembly
Caution
The lip seals must be positioned as shown. Care must be taken to prevent rollover of the lip seal.
1. Install the new direct clutch piston inner seal ring

and the direct clutch piston outer seal ring.
Note
Use new seals to help prevent seal failures.
Caution
Lubricate the direct clutch piston inner
and outer seal rings with clean ATF.
b5r5za00000137
2. Install the direct clutch piston into the SST.
b5r5za00000138
3. Inspect the clutch components for damage or

wear. Install new components as necessary.
Inspect the drum surface for damage.
Inspect the clutch piston bore and piston.
Check the fluid passages for obstructions.
All fluid passages must be clean and free of
obstructions.
Inspect the clutch plates for damage.
Inspect the clutch springs.
Verify the check ball is free to move.
b5r5za00000139
05-13-36

4. Carefully remove the direct clutch piston from the
SST.
Caution
the seals during installation.
5. Using the SST, install the direct clutch piston .

Lubricate the seals with transmission fluid
before installing.
.....arnffv00000531
6. Install the direct clutch piston springs and the

retainer.
Warning
After removing the retaining ring, use
care when releasing the pressure on the
springs. Failure to follow these
instructions may result in personal injury.
Caution
b5r5za00000141
7. Using the SST, install the retaining ring.

8. Relieve the direct clutch spring tension and
remove the SST.
Caution
The. direct clutch friction plates are
grooves pointing clockwise (10 to 00)
and the word TOP facing up.
If new plates are used, they should be
soaked in clean ATF before assembly.
9. When installing friction plates, the word TOP
should face up. If reusing plates, grooves must be
installed clockwise. Install the direct clutch disc
pack.
,.,
b5r5za00000142
05-13-37
.J
10. Install the steel clutch plates and friction clutch

plates in alternating order starting with a steel
clutch plate.
&:
Caution
The retaining ring is a select fit.
b5r5za00000143
11. Install the direct clutch pressure plate using the

original retaining ring.
Warning
when using compressed air, and make
sure drum is facing down as shown.
Note
The direct clutch piston must apply with air
pressure and release when air is removed.
b5r5za00000144
12. Air check the assembly.

b5r5za00000135
05-13-38

13. Push down on the direct clutch disc pack and
check the gap between the direct clutch retaining
ring and the direct clutch pressure plate with a
feeler gauge.
If the specifications do not match, use a select
fit direct clutch retaining ring to match
specifications and verify with a feeler gauge.
Direct clutch clearance

Standard: 1.3-2.0 mm {0.051-0.079 in}
Retaining ring size for direct clutch clearance
Diameter
Thickness
mm
in
mm
in
1.37
1.73
2.08
2.44
0.0539
0.0681
0.0819
0.0961
130.1
130.1
130.1
130.1
5.122
5.122
5.122
5.122
FORWARD CLUTCH DISASSEMBLY/ASSEMBLY[5R55S]
id0513c1262300
Forward Clutch Component
b5r5za00000146
2
3
4

5
6
7
8
Retaining ring
Disassembly
1. Remove the pressure plate.
(2) Remove the pressure plate.
b5r5za00000147
05-13-39

2. Remove the forward clutch disc pack.
Inspect the forward clutch plates for wear,
damage or overheating.
.,,
>.
Warning
Use caution when releasing tool pressure
on the clutch piston springs. Failure to
follow these instructions may result in
personal injury.
Caution
Do not fully depress the SST or damage
b5r5za00000148

4. Relieve the forward clutch spring tension and
remove the SST.
arnffv00000532
5. Remove the forward clutch piston spring

component.
Warning
{1.4 kgfm, 20 psi}. Wear safety glasses
when using compressed air. Make sure
the cylinder is facing down as shown.
b5r5za00000150
6. Remove the forward clutch piston.

(1) Place the forward clutch cylinder with forward
clutch piston facing down.
(2) Install the center support on the forward
clutch cylinder.
(3) Apply air pressure to the left port of the center
support.
.-
b5r5za00000 151
05-13-40

Assembly
1. Inspect the clutch components for damage or wear. Install new components as necessary.
Check the fluid passages for obstructions. All fluid passages must be clean and free of obstructions.
Inspect the clutch plates for damage.
Inspect the clutch piston springs.
Inspect the needle bearing and seal rings for damage.
Check clutch hub thrust surfaces for damage.
Check clutch plates for flatness and fit on the clutch hub serrations.
2. Inspect the forward clutch piston and seals.
,-----------------------,
Note
If the seals on the forward clutch piston show
any signs of damage, a new forward clutch
piston will need to be installed.
b5r5za00000152
3. Inspect the forward clutch drum component.

(1) Inspect the forward clutch cylinder surfaces
for scores or burrs.
(2) Inspect the forward clutch piston for scores or
burrs.
(3) Verify the check ball is free to move in the
piston.
b5r5za00000153
4. Install the SST on the forward clutch piston.

Note
The SST must be installed on the forward
clutch piston for a couple of minutes prior to
installing it into the forward clutch cylinder.
Caution
the seals.
arnffv00000533
5. Using the SST, install the forward clutch piston

component into the forward clutch cylinder.
Note
Lubricate the forward clutch piston inner and
outer seal with clean ATF.
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Ii
\'
05-13-41

6. Install the forward clutch piston spring
component.
Caution
Do not fully depress the clutch piston
spring compressor or damage to the
spring retainer may occur.
b5r5za00000150
7. Using the SST, install the spring retaining ring.

Caution
The forward clutch friction plates are
grooves pointing counterclockwise.
If new plates are used, they should be
soaked in clean ATF before assembly.
8. If reusing plates, grooves must be installed

counterclockwise. Install the direct clutch disc
pack.
b5r5za00000156
9. Install the steel clutch plates and friction clutch

plates in alternating order starting with a steel
clutch plate.
Caution
The retaining ring is a select fit.
b5r5za00000148
05-13-42

10. Install the original selective retaining ring.
(1) Install the forward clutch pressure plate.
(2) Install the original selective retaining ring.
Warning
when using compressed air. Make sure
the cylinder is facing down as shown.
11. Air check the forward clutch piston.
(1) Place the forward clutch cylinder with forward
clutch piston facing down.
(2) Install the transmission center support on the
forward clutch cylinder.
(3) Apply air pressure to the left port of the center
support.
--
b5r5za00000296
12. Check the forward clutch disc pack free play.

(1) Press down on the forward clutch disc pack.
(2) Using a feeler gauge, check the gap between
the forward clutch retaining ring and the
forward clutch pressure plate.
If the clearance is not within
specifications, install the correct size
retaining ring.
Forward clutch clearance

Standard: 1.3-2.0 mm {0.OS1-0.079 in}
Retaining ring size for forward clutch clearance
Thickness
in
mm
0.0681
1.73
0.0819
2.08
0.0961
2.44
b5r5za00000158
Diameter
mm
in
141.45
5.65
141.45
5.65
141.45
5.65
OVERDRIVE PLANETARY GEAR AND ONE-WAY CLUTCH COMPONENT DISASSEMBLY/ASSEMBLyrSRSSSl
idO's13c126240~
2
3
4
5
6
7
Retaining ring
Overdrive ring gear
Overdrive sun gear
Carrier adapter
05-13-43
..

Overdrive Center Shaft Component Disassembly
1. Remove the overdrive center shaft from the
overdrive ring gear.
(2) While rotating counterclockwise remove the
overdrive center shaft from the ring gear.
Note
The overdrive one-way clutch is serviced
with the overdrive center shaft component.
Caution
Do not remove the overdrive one-way
clutch. Damage to the clutch may occur if
it is removed.
b5r5za00000160
2. Clean and inspect the overdrive one-way clutch

and overdrive center shaft.
Inspect for cracks in the roller cage and wear
on the roller clutch and the press fit of the
one-way clutch to the overdrive center shaft.
b5r5za00000161
3. Inspect the one-way clutch.

Temporarily insert the overdrive planetary
gear carrier component into the one-way
clutch rollers for verification of the one-way
clutch.
The planetary gear must rotate
counterclockwise and hold when rotated
clockwise.
Remove the planetary gear carrier
component.
b5r5za00000162
Overdrive Center Shaft Component Assembly

1. Install the overdrive center shaft and one-way
clutch.
(1) Install the overdrive center shaft and one-way
clutch.
(2) Install the retaining ring.
b5r5za00000424
05-13-44
',

Overdrive Planetary Gear Component Disassembly
1. Before installing a planetary component, the shaft
retaining pins should be checked for adequate
staking. Check the pins and shafts in the
planetary assemblies for loose fit and/or complete
disengagement. Install a new planetary
component if necessary.
Note
Individual parts of the planetary carriers are
not serviceable.
b5r5zaOOOOO 163
2. Inspect the pinion gears for damaged or

excessively worn teeth and for free rotation.
b5r5za00000164
3. Inspect the overdrive one-way clutch inner race

and the inner and outer races for scored or
damaged surface areas where the rollers contact
the races.
b5r5za00000165
4. Remove and inspect the No.2 overdrive planetary

thrust bearing on the nose of the overdrive
planetary gear carrier component.
b5r5za00000166
05-13-45

5. Remove the carrier adapter.
Note
Inspect the sun gear for damaged or worn
teeth.
b5r5za00000167
6. Remove and inspect the overdrive sun gear.

Caution
Do not attempt to remove the thrust
bearing (No.12) from behind the pinion
gears.
b5r5za00000168
7. Inspect the thrust bearing (No. 12) for damage.
b5r5za00000169
Overdrive Planetary Gear Component Assembly

1. Install the No.2 overdrive planetary thrust bearing.
Note
Thoroughly clean all parts and blow dry with
moisture-free compressed air.
Use petroleum jelly to hold the thrust
bearing (NO.2) in place.
b5r5za00000166
05-13-46

2. Install the overdrive planetary gear carrier into the
center shaft and overdrive.
Caution
Make sure that the No.12 bearing is in
place in the overdrive planetary prior to
installing the overdrive sun gear.
3. Install the overdrive sun gear with the recessed

gear teeth facing toward the adapter.
Caution
Adapter part number must not be visible
after installation.
b5r5za00000168
4. Install the carrier adapter.
Note
Inspect the sun gear for damaged or worn
teeth.
b5r5za00000167
05-13-47

OUTPUT SHAFT RING GEAR AND HUB SHAFT COMPONENT DISASSEMBLY/ASSEMBLY[5R55S]
1
2
3
4
id0513c1264500
Retaining shaft ring gear

Center shaft hub
Retaining ring
Output shaft hub seal
b5r5za00000171
Disassembly
1. Inspect the output shaft ring gear and hub shaft component for damage.
If repair is necessary, use the following procedure.
2. Remove the seal.
__t__
b5r5za00000172
3. Remove the output shaft ring gear from the output

shaft hub.
(2) Remove the output shaft ring gear.
I,
~-~
~
b5r5za00000173
Assembly
1. Install the output shaft ring gear onto the output
shaft hub.
(1) Install the output shaft ring gear.
~~
b5r5za00000174
05-13-48

2. Install the seal.
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-----FORWARD RING GEAR COMPONENT DISASSEMBLY/ASSEMBLY[5R55S]

Disassembly
1. Inspect the forward ring gear and hub component for damage.
If repair is necessary, use the following procedure.
2. Remove the forward ring gear hub from the
forward ring gear.
(2) Remove the forward ring gear hub.
Id0513c1264900
~RETAINING
'=--1)
RING
FORWARD RING~9~
GEAR HUB
~
FORWARD
RING GEAR
arnffv00000623
Assembly
1. Install the forward ring gear hub onto the forward ring gear.
(1) Install the forward ring gear hub
05-13-49

LOW/REVERSE BRAKE SERVO COMPONENT D1SASSEMBLY/ASSEMBLY[5R55S]
id0513c1264600
10 Nm {102 kgfcm, 89 in.lbf}

b5r5za00000360
2
3
4

Spring
Low/reverse brake servo check valve
Low/reverse brake servo plate
5
6
7
8
Spring
Low/reverse brake servo piston and seal
O-ring
Low/reverse brake servo cover
Disassembly
1. Remove the control valve spring retainer.
b5r5za00000176
2. Remove the low/reverse brake servo spring and

check valve.
Warning
separating the 2 halves. Failure to follow
these instructions can result in personal
injury.
b5r5za00000177
05-13-50
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3. Remove the low/reverse brake servo plate by
turning in either direction to release.
Align the arrow on the servo plate with any
slot on the cover.
Note
Tabs on servo plate mate with slots on cover
every 120 degrees.
4. Remove the spring.
b5r5zaOOOOO 179
5. Remove the low/reverse brake servo piston and

seal component.
Inspect the seal for damage, install a new low/
reverse brake servo piston if necessary.
b5r5za00000180
6. Remove and discard the low/reverse brake servo

piston seal.
b5r5za00000181
05-13-51

Assembly
1. Lubricate and install a new low/reverse brake
servo piston seal.
Note
Try not to roll the seal onto the housing when
installing the seal, or damage to the seal can
occur.
b5r5za00000181
2. Lubricate and install the low/reverse brake servo

piston and seal component.
b5r5za00000180
3. Install the spring.

Warning
assembling the 2 halves. Failure to follow
these instructions can result in personal
injury.
Caution
The arrow on the servo plate must be
aligned evenly between any 2 slots on the
cover.
b5r5za00000179
4. Install the low/reverse brake servo plate.
b5r5za00000182
05-13-52

5. Install the spring and low/reverse brake servo
check valve.
6. Install the control valve spring retainer.

Tightening torque
b5r5za00000176
05-13-53

CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY[5R55S]
id0513c1261800
b5r5za00000083
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
Retainer clip
Retainer plug
Thermo valve component
Fluid cooler bypass valve
Fluid cooler bypass spring
Retainer clip
Retainer plug
Converter clutch control valve spring
Converter clutch control valve
Plate
Coast clutch control spring
Coast clutch control valve
Retainer clip
Retainer plug
Converter clutch back pressure valve
Converter clutch back pressure spring
Retainer clip
Retainer plug
Retainer clip
Retainer plug
Intermediate servo release valve
Intermediate servo release valve spring
Plate
High clutch control spring
High clutch control Valve
Retainer plug
05-13-54
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
Retainer clip
Reverse modulator valve
Reverse modulator valve spring
Retainer clip
Retainer plug
Reverse engagement valve
Reverse engagement valve spring
Retainer clip
Retainer plug
Retainer clip
Sleeve
Booster valve
Booster valve
Inner spring
Outer spring
Retainer spring
Retainer clip
Retainer plug
Converter limit spring
Converter limit valve
Plate
Solenoid regulator valve spring
Solenoid regulator valve
Manual valve
Retainer clip
I;'

57
58
59
60
61
62
63
64
65
66
67
68
Retainer plug
Rear servo control valve spring
Rear servo control valve
Retainer clip
Retainer plug
RS ISA select valve spring
RS ISA select valve
Retainer clip
Retainer plug
Forward engagement control valve spring
Forward engagement control valve
Plate
69
70
71
72
73
74
75
76
77
78
79
80
Overdrive servo control spring

Overdrive servo control valve
Clip retainer
Converter clutch modulator control sleeve
Converter clutch modulator control valve
Converter clutch modulator valve
Converter clutch modulator control spring
Separator plate
Lubrication check ball
Shuttle valve ball
Bolt
Disassembly
1. Remove and discard the separator plate.
Note
The valve body separator plate has a
bonded gasket. Do not reuse. Discard the
plate.
b5r5za00000084
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2. Remove the check balls.

3. Disassemble the control valve body only if
cleaning is required.
Note
Refer to the disassembled view.
b5r5za00000085
Assembly
Caution
Do not lose parts when cleaning or repairing.
1. Thoroughly clean all parts in solvent and blow dry with moisture-free compressed air.
Caution
Do not stone, file or sand the valves. This will remove the anodized finish and may result in further
main control or transmission damage.
2. After cleaning the control valve body, carry out the following:
Inspect all valve and plug bores for scoring or burrs
Check all fluid passages for obstructions
Inspect all valves and plugs for burrs
Inspect all mating surfaces for burrs or distortion
Inspect all springs for distortion
Check all valves and plugs for free movement in their respective bores
- Valves and plugs, when dry, must fall from their own weight into their respective bores
Roll the manual valve on a flat surface to check for a bent condition
3. Assemble the main control valve body.
05-13-55

4. Install the control valve body check balls.
b5r5za00000297
5. Using the SSTs, install a new separator plate.
Tightening torque
6-8 Nm {62-81 kgfcm, 54-70 inlbf}
Note
Use a new valve body separator plate for
main control valve body installation.
arnflv00000523
e
05-13-56
AUTOMATIC TRANSMIS
AUTOMATIC TRANSMISS
Exploded View .
SION ASSEMBLYI5R55S1
ION
---~ ...
[5R55S]
.-_.--
.--
id0513c1261900
................ """\
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I
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b5r5za00000382
05-13-57
_.l'lv.
b5r5za00000383
05-13-58
b5r5za00000384
~:---T=To-rq-ue-c-o-nv-ert-:-e-ri:--ns-:-ta-::-lIa-:-:ti-on-n~ut:----------'
2
3
4
5
Torque converter
Input shaft
Fluid pump seal
Fluid pump seal ring
P
7
8
9
10
Bolt and washer

Fluid pump cover
Fluid pump adapter plate
Fluid pump gasket
Seal ring
05-13-59

11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
Stator support seal

Fluid pump support
O-ring
Fluid pump control valve
Fluid pump component
Bolt
Seal ring
Thrust washer (No.1)
Intermediate and overdrive brake band anchor strut
Intermediate and overdrive brake band
Intermediate and overdrive brake band apply strut
Intermediate and overdrive brake band adjusting
screw
Locknut
Direct clutch and coast clutch piston outer seals
Direct clutch and coast clutch piston inner seals
Direct clutch and coast clutch pistons
Direct clutch and coast clutch piston spring
Direct clutch and coast clutch piston spring retainer
Retaining ring
Coast clutch internal spline friction plate (friction)
Direct clutch and coast clutch pressure plate
Carrier adapter
Overdrive sun gear
Overdrive ring gear
Retaining ring
Overdrive center shaft and ring gear component
Thrust bearing (No.3, No.5, No.8 and No.9)
Retaining ring
Center support
Nut and cage component
Bolt
Direct clutch internal spline plate (friction)
Retaining ring
Thrust bearing (No.6A)
Thrust washer (No.6B)
Retaining ring
Forward ring gear hub
Forward ring gear
05-13-60

Forward planetary component
Input shell and sun gear component
Spacer
Retaining ring
Lower/reverse planetary component
Output shaft sleeve
Retaining ring
Output shaft ring gear
Output shaft hub
Retaining ring
Output shaft hub seal
Thrust bearing (No.1 0)
Low/reverse brake drum and one-way clutch
79
component
80 Low/reverse brake band
81
Output shaft needle bearing
82 Thrust washer (No.11)
83 Parking gear
85 Parking pawl
86 Parking pawl return spring
87 Parking pawl shaft
88 Extension housing gasket
90 Bolt (4x2)
Extension housing seal (4x2)
91
94 Extension housing seal (4x4)
95 Bolt (4x4)
96 Oil pipe connector component
97 Retaining ring
98 Overdrive brake servo cover seal
99 Overdrive brake servo cover
100 Overdrive brake servo piston
101 Spring
102 Retaining ring
103 Intermediate brake servo cover seal
104 Intermediate brake servo cover
105 Intermediate brake servo piston
106 Transmission case
107 TSS sensor, ISS sensor and OSS sensor
108 O-ring
109 Bolt
110 Vent tube (4x2)
111 Low/reverse brake actuating lever
112 Low/reverse brake band actuating lever shaft
Pressure tap plug (pressure control solenoid C
113
circuit)
114 Fluid fill plug
115 Manual shaft retaining pin
116 Parking pawl actuating rod
117 Manual shaft outer and inner nut
118 Manual valve inner lever
119 Manual shaft seal
66
67
68
69
70
71
72
73
74
75
76
77
78

120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
Manual shaft
Bolt and washer
Manual shaft lever
Reverse brake servo component
Reverse brake servo plate
Spring
Reverse brake servo piston and seal
O-ring
Reverse brake servo cover
Bolt
Spring
Reverse brake servo check valve
Bolt
Separating plate (bonded)
Bolt
Bolt
Detent spring
Bolt
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
Bolt
Control valve body component
O-ring
Solenoid body
Bolt
Bolt
Transmission fluid filter
Transmission fluid pump gasket
Magnet
Bolt
Transmission fluid pump
Drain plug
Bolt
Fluid level indicating plug (short hex)
Overdrive brake and coast clutch drum component
Intermediate brake and direct clutch drum
component
Forward clutch component
Assembly
1. Thoroughly clean the transmission case and extension housing in solvent and blow dry with compressed air.
2. Inspect the transmission case for the following:
Stripped bolt hole threads
Gasket and mating surfaces for burrs or nicks
Obstructions to vent and fluid passages
Cracks or warpage
b5r5zaOOOOO 186
3. Inspect the extension housing for cracks, burrs or

warpage.(4x2)
b5r5za00000187
05-13-61

4. Inspect the extension housing for cracks, burrs or
warpage. (4x4)
b5r5za00000188
5. Inspect the case bearing for damage. If damage

to the case bearing is indicated, install a new
case.
Warning
Make sure the lockpin on bench-mounted
holding fixture is secure. Failure to follow
these instructions may result in personal
injury.
b5r5za00000189
6. Using the SST, install the transmission into the

bench with the converter housing facing up.
arnffv00000520
7. Using the SST, install the manual shaft seal and

lubricate it with petroleum jelly.
arnffv00000535
8. Install the parking lever rod.
b5r5za00000192
05-13-62

9. Install the manual control lever.
10. Assemble the manual valve inner lever and

parking lever actuating rod as shown.
Caution
Align the flats on the manual valve inner
lever with the flats on the manual shaft.
b5r5za00000194
11. Install the manual shaft.
~1 ~
___
~ \~~on~n~
b5r5za00000195
12. Install the manual valve inner lever onto the

manual shaft and loosely install the nut.
Caution
Use care not to damage the transmission
fluid pump rail surface when installing
the retaining pin.
-::=====~ 0
b5r5za00000196
13. Install the manual shaft retaining pin.

Tap the manual shaft retaining pin into the
transmission case.
Note
Align the manual shaft alignment groove with
the manual shaft retaining pin bore in the
transmission case.
Caution
To avoid damage, do not allow the
wrench to strike the manual valve inner
lever pin.
b5r5zaOOOOO 197
05-13-63

14. Tighten the nut.
Tightening torque
41-54 Nm {4.2-5.5 kgfm, 31-39 ft.lbf}
Caution
Make sure band is resting on the 2
anchor pins in the case.
15. Install the low/reverse brake band.
16. Install the low/reverse brake drum and one-way

clutch component.
Rotate the low/reverse brake drum clockwise
to install.
b5r5za00000388
17. Install the low/reverse brake band actuating lever

into the low/reverse brake band.
Note
The reverse band actuating lever must fit
into the notches in the band.
18. Install the low/reverse brake band actuating lever

shaft into the case and into the low/reverse brake
band actuating lever.
LOW/REVERS BRAKE
BAND ACTUATING
LEVER SHAFT
b5r5za00000389
05-13-64

19. Install the thrust bearing (No.10) into the case.
Caution
Do not damage the seal against the case
during assembly.
20. Install the output shaft ring gear, hub and seal.
Caution
The tabs on the output shaft thrust
washer (No.11) point into the case. Make
sure the thrust washer is correctly
seated.
21. Install the output shaft thrust washer (No.11).

Coat the output shaft thrust washer with
petroleum jelly.
b5r5zaOOOOO 199
22. Install the park gear on the output shaft.
b5r5za00000200
23. Install the output shaft and park gear.

Caution
Always install a new retaining ring.
b5r5za00000201
05-13-65

24. Install a new retaining ring.
b5r5za00000208 .
25. Install the output shaft sleeve.
Note
Install the output shaft sleeve with the cone
facing up. This sleeve will snap into place
when correctly installed.
26. Install the thrust bearing (No.9) onto the output

shaft ring gear and hub component.
Caution
Make sure the needle bearings stay in
place.
b5r5za00000210
27. Install the low/reverse planetary component.
Caution
The low/reverse brake drum must be
pulled forward to install the retaining
ring.
b5r5za00000211
b5r5za00000212
05-13-66

29. Install the thrust bearing (No.8).
30. Install the spacer on the input shell, using

petroleum jelly to hold it in place.
b5r5za00000214
31. Install the input shell and sun gear component.
32. Install the forward planetary component.
Note
The bearing (No.13) must be correctly
seated in the forward planet component so
the sun gear can be installed correctly.
b5r5za00000216
33. Install the thrust bearing (No.7) into the forward

ring gear and hub component. Use petroleum jelly
to hold the bearing in place.
05-13-67

34. Install the thrust washer (No.68) onto the forward
ring gear hub.
b5r5za00000218
35. Install the forward ring gear and hub as an

assembly.
36. Install the thrust bearing (No.6A) into the forward

ring gear and hub.
37. Install the forward clutch cylinder.
b5r5za00000222
05-13-68

39. Install the intermediate brake servo piston and
spring.
Lubricate the servo bore with clean ATF.
40. Using the SST, install the intermediate brake

servo cover and retaining ring.
41. Install the intermediate brake and direct clutch

drum component.
42. Using a depth micrometer with an appropriate

length extension, measure from the top of the
gauge bar to the center support ledge in the case
at 4 places 90 degrees apart.
Add the 4 measurements, divide by 4 and
record as dimension A.
Caution
The torque specifications are critical for
this procedure. Failure to use the correct
torque specifications may cause
transmission damage.
b5r5za00000226
43. Install the SST.

(1) Install the SST and the bolts using the 2 pump
bolt locations at approx. 6 and 12 o'iock
positions.
Tightening torque
15 Nm {1.5 kgfm,11 ft.lbf}
(2) Tighten the center bolt.
Tightening torque
1.13 Nm {11.5 kgf.cm,10.0 inlbf}
05-13-69

44. Measure the distance from the top of the gauge
bar to the drum bearing surface through the hole
in the disc and record as dimension B. Repeat the
measurement 180 degrees on the opposite side
of the SST and record as dimension C.
Note
Align the disc holes on SST with the slot in
gauge bar for correct measurement.
45. Add dimension B to C, divide by 2 and record as
dimension D.
46. Subtract A from D and record as dimension E.
47. Select the bearing from the following chart, using
dimension E.
,I'
I,
b5r5za00000228
Thrust bearing (No.4) size (intermediate brake drum)

Dimension E
1.69-1.87 mm {0.066-O.074 in}
1.88-2.04 mm {0.073-O.080 in}
2.05-2.22 mm {0.081- 0.088 in}
2.23-2.43 mm {0.088-O.096 in}
Bearing Thickness
2.65-2.80 mm {0.1 04-0.11 0 in}
2.83-2.98 mm {0.111-0.116 in}
3.01-3.16 mm {0.118-0.124 in}
3.21-3.36 mm {0.126-0.132 in}
Identification (Notches)
None
2
3
48. Install the intermediate brake band.

Note
Make sure that the intermediate brake band
apply strut is aligned with the band notch.
If the intermediate brake band is reused, it
must be installed in the same position as it
was when removed.
The new intermediate brake band is dark in
b5r5za00000229
Caution
To avoid a fall out condition of the strut from the screw during assembly and function, the small Ushaped notch should be toward the band and the large U-shaped notch toward the main control
side.
05-13-70
49. Install the intermediate brake band anchor strut.

(1) Band/case side of anchor (small U notch).
(2) Main control side of anchor (large U notch).
Caution
If the strut is installed incorrectly,
transmission damage will occur.
b5r5za00000230
50. Check to make sure that the intermediate brake

band anchor strut is installed in the correct
orientation to the case and adjustment screw.
b5r5za00000231
51. Loosely install the screw.
b5r5za00000232
52. Install the intermediate brake band apply strut.

Caution
05-13-71

53. Check to make sure that the intermediate brake
band apply strut is installed in the correct
orientation to the case and piston rod.
b5r5za00000234
54. Install the selected thrust bearing (No.4) on the

direct clutch drum.
Coat the thrust bearing with petroleum jelly.
55. Install the center support.

Note
Align the center support bolt hole with
correct case hole.
56. Install the nut and cage.
57. Loosely install the bolt.

Caution
Install the retaining ring with the tapered
side facing up.
Make sure the notch opening is not
obstructed by the retaining ring.
b5r5za00000238
05-13-72

(1) Make sure the retaining ring is installed with
the tapered side facing up.
(2) Make sure the opening of the retaining ring is
positioned correctly.
b5r5za00000239
60. Install the overdrive ring gear, overdrive one-way

clutch and center shaft component.
Caution
Do not bend the trigger wheel. Make sure
that the thrust bearing (No.2) is in this
assembly.
61. Install the overdrive planetary gear carrier.
05-13~73

62. Install the overdrive brake and coast clutch drum
component.
b5r5za00000243
63. Install the overdrive brake servo piston and

spring.
Lubricate the servo bore with clean ATF.
64. Using the SST, install the overdrive brake servo

cover and retaining ring.
65. Install the overdrive brake band.

Note
If the overdrive brake band is reused, it must
be installed in the same position as when
removed.
Make sure that the overdrive brake band
apply strut is aligned with the band notch.
The new overdrive brake band is dark in
Caution
To avoid a fall out condition of the strut from the screw during assembly and function, the small Ushaped notch should be toward the band and the large U-shaped notch toward the main control
side.
05-13-74

66. Install the overdrive brake band anchor strut.
(1) Band/case side of anchor (small U notch).
(2) Main control side of anchor (large U notCh).
Caution
b5r5za00000298
67. Check to make sure that the overdrive brake band

anchor strut is installed in the correct orientation
to the case and adjustment screw.
b5r5za00000231
68. Loosely install the screw.
69. Install the overdrive brake band apply strut.

Caution
b5r5za00000248
05-13-75

70. Check to make sure that the overdrive brake band
apply strut is installed in the correct orientation to
the case and piston rod.
Caution
The torque specifications are critical for
this procedure. Failure to use the correct
torque specifications may cause
transmission damage.
b5r5za00000249
71. Install the SST.

(1) Install the SST and the bolts using the 2 pump
bolt locations at approx. 6 and 12 o'iock
positions.
Tightening torque
(2) Tighten the center bolt.
Tightening torque
1.13 Nm {11.5 kgfcm, 10.0 in.lbf}
b5r5za00000250
72. Measure the distance from the top of the gauge

bar to the drum bearing surface through the hole
in the disc and record as dimension A. Repeat the
measurement 180 degrees on the opposite side
of the SST and record as dimension B.
Note
Align the disc holes on SST with the slot in
gauge bar for correct measurement.
73. Add dimension A to B, divide by 2 and record as
dimension C.
74. Subtract the thickness of the gauge bar 17.78
mm {0.70 in} from dimension C and record as
dimension D.
75. Select the thrust washer (No.1) from the following chart using dimension D.
b5r5za00000251
Thrust washer (No.1) size (overdrive brake drum) .

Dimension E
38.05-38.13 mm {1.50 in}
38.14-38.28 mm {1.50-1.51 in}
38.29-38.42 mm {1.51 in}
38.43-38.61 mm {1.51-1.52 in}
38.63-38.74 mm {1.52-1.53 in}
Bearing Thickness
1.55-1.60 mm {0.061-0.063 in}
1.75-1.80 mm {0.069-0.071 in}
1.85-1.90 mm {0.073-0.075 in}
2.05-2.10 mm {0.081-0.083 in}
2.15-2.20 mm {0.095-0.097 in}
Identification (ColorIlD)
White
Green
Red
Black
Yellow
76. Install the selected thrust washer (No.1).

Coat the thrust washer with petroleum jelly.
b5r5za00000252
05-13-76

77. Install the SSTs into the transmission case.
78. Install the pump gasket.
Caution
Make sure that the fluid pump inlet thrust
washer (No.1), selective thrust washer,
fluid pump gasket and the fluid pump-tocase O-ring remain in the correct position
throughout this step.
b5r5za00000254
79. Install the fluid pump.
Caution
The special tools must be used to
correctly align the pump with the adapter
plate to reduce gear noise, bushing
failure and leakage.
80. Using the SST, align the fluid pump to the adapter
plate.
81. Install the 6 screws. Tighten the screws in a star

pattern.
Tightening torque
22-28 Nm {2.3-2.8 kgf.m, 17-20 ft.lbf}
05-13-77

82. Remove the SSTs and install the 2 remaining
screws.
Tightening torque
22-28 Nm {2.3-2.8 kgfm, 17-20 ftlbf}
Caution
Do not allow overdrive brake band
adjustment screw to back out. Band strut
could fall out of position.
Install, but do not tighten, a new locknut
on the band adjustment screw. Apply
petroleum jelly to the locknut seal.
83. Install a new locknut on the band adjustment
screw.
Caution
The overdrive servo must be installed
prior to band adjustment.
b5r5za00000259
84. Using the SST, tighten the intermediate brake

band adjustment screw.
Tightening torque
12-14 Nm {123-142 kgfcm, 107-123
inlbf}
Then back off the screw exactly 2 turns and
hold that position.
85. Tighten the locknut.

(1) Hold the overdrive brake band adjustment
screw stationary.
(2) Tighten the locknut.
Tightening torque
47-61 Nm {4.8-6.2 kgfm, 35-44 ftlbf}
Caution
Do not allow the intermediate brake band
adjusting screw to back out. Band strut '
could fall out of position.
Install, but do not tighten, a new locknut
on the band adjustment screw. Apply
petroleum jelly to the locknut seal.
05-13-78
b5r5za00000261

86. Install a new locknut on the baM adjustment
screw.
Caution
The intermediate brake servo must be
installed prior to band adjustment.
87. Using the SST, tighten the overdrive brake band

adjustment screw.
Tightening torque
12-14 Nm {123-142 kgfcm, 107-123
inlbf}
Then back off the screw exactly 2 turns and
hold that position.
.
88. Tighten the locknut.
(1) Hold the intermediate brake band adjustment
screw stationary.
(2) Tighten the locknut.
Tightening torque
47-61 Nm {4.8-6.2 kgf.m,
~5-44
ft.lbf}
b5r5za00000264
89. Tighten the center support bolt.
Tightening torque
9-13 Nm {92-132 kgfcm, 80-115 inlbf}
90. Using the SSTs, Carry out the air pressure test
procedure.
0
0
0
0
0
,0
0
0
0
0
arnffv00000541
05-13-79
II
II
II
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arnffv00000542
92. Using the SSTs, Install the control valve body and
loosely install the bolts.
(1) Install the short bolt.
(2) Install the bolt with the larger head.
(3) Install the remaining bolts.
93. Remove the SSTs and loosely install the screw.
05-13-80

94. Tighten the bolts in the sequence shown.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 inlbf}
b5r5za00000270
95. With the manual lever in the N position, install the

detent spring.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 inlbf}
96. Install new O-rings on the solenoid body

connector. Lubricate the O-rings with clean ATF.
Caution
Inspect the transmission case bore to
make sure it is free of foreign material
and not damaged. If damaged,
transmission leak may occur.
b5r5za00000272
05-13-81

97. Install the solenoid body. Tighten bolts in the
sequence shown.
Tightening torque
7-9 Nm {72-91 kgfcm, 62-79 inlbf}
b5r5za00000273
98. Install the reverse servo. Tighten the bolts in the

sequence shown in 2 stages.
Tightening torque
5 Nm {51 kgfcm, 44 inlbf}
10-12 Nm {102-122 kgfcm, 89-106
inlbf}
Caution
Lubricate the transmission fluid filter
seals with clean ATF or they may be
damaged.
b5r5za00000274
99. Lubricate the seals and install the transmission

fluid filter.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 in.lbf}
Note
Make sure that the transmission fluid filter
seals are correctly seated on the filter.
f)
1OO.lnstali the transmission fluid pump and gasket,

magnet and loosely install the bolts.
Note
The transmission fluid pump gasket is
reusable. Clean and inspect for damage. If
not damaged, the gasket should be reused.
101.Tighten the bolts in a crisscross sequence.

Tightening torque
9.5-11.5 Nm {97-117 kgfcm, 85-101
inlbf}
05-13-82

102.lnstall the parking pawl component and gasket.
(1) Install the parking pawl shaft.
(2) Install the parking pawl return spring.
(3) Install the parking pawl.
(4) Install a new gasket.
103.1nstall the extension housing.(4x2)

Tightening torque
28-32 Nm {2.9-3.2 kgf.m, 21-23 ft.lbf}
b5r5za00000278
104.Using the SST, install the extension housing

seal. (4x2)
arnffv00000545
105.lnstall the extension housing.(4x4)

Tightening torque
28-32 Nm {2.9-3.2 kgfm, 21-23 ftlbf}
106.Using the SST, install the extension housing

seal. (4x4)
Caution
The digital TR sensor must fit flush
against the boss on the case to prevent
damage to the switch.
b5r5za00000280
05-13-83

107.1nstall the digital TR sensor and loosely install the
bolts.
Caution
Tightening one bolt before tightening the
other may cause the sensor to bind or
become damaged.
DIGITAL TR
SENSOR
arnffv00000521
1OB.Using the SST, align the digital TR sensor and

tighten the bolts in an alternating sequence.
Tightening torque
6.5-9.5 Nm {67-96 kgfcm, 58-84 inlbf}
Note
The manual lever must be in the N position.
109.1nstall the manual shaft lever.
Tightening torque
41-54 Nm {4.2-5.5 kgfm, 31-39 ftlbf}
J
arnffv00000592
Caution
The splines of the input shaft are not the
same length on both ends. The shaft end
with the shorter splines goes into the
fluid pump.
MANUAL SHAFT
LEVER
b5r5za00000394
110.1 nstall the in put shaft.
05-13-84

111.Using the SST, make sure that the fluid pump
gear seal ring is fully seated.
112.Remove the SST.
Caution
Do not damage the fluid pump gear 0ring when installing torque converter.
Make sure the converter hub is fully
engaged in the pump support and gear
and rotates freely. Do not damage the
hub seal.
If the torque converter slides out, the hub
seal may be damaged.
113.Lubricate the converter hub with clean ATF.
Warning
The torque converter can fall out if the
transmission is tipped. Failure to follow
these instructions may cause personal
injury.
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b5r5za00000286
114.Using the SST, install the torque converter by

pushing and rotating.
115.Lubricate the torque converter pilot hub with

multi-purpose grease.
b5r5za00000288
05-13-85

116.Using one of the sensor holes, fill the
transmission with 8.5 L {g.O US qt, 7.5 Imp qt} of
ATF.
Note
Inspect O-rings for damage. Install new 0rings if damaged. Lubricate the O-rings with
petroleum jelly to prevent damage to the 0rings.
b5r5za00000291
117.lnstall the sensors.
Tightening torque
TSS sensor, ISS sensor:
8-12 Nm
{82-122 kgfcm, 71-106 in.lbf}
OSS sensor:
12-16 Nm
{123-163 kgf.cm, 107-141 in.lbf}
TSS SENSOR
ISS SENSOR
OSS SENSOR
b5r5za00000396
118.1nstall the SST.
TORQUE
CONVERTER
05-13-86
TECHNICAL DATA [SRSSS]
05-50
TECHNICAL DATA [5R55S]
TECHNICAL DATA[5R55S) ........... 05-50-1
TECHNICAL DATA[5R55S)
id0550h 1800500
Specification
Item
Type: Mercon V
Capacity (Approx. quantity): Refer to Repair Manual.
Standard: 1.3-2.0 mm {0.051-0.079 in}
Standard: 1.3-2.0 mm {0.051-0.079 in}
Standard: 1.3-2.0 mm {0.051-O.079 in}
ATF
Coast clutch clearance
Direct clutch clearance
Forward clutch clearance
Retaining ring size for coast clutch clearance

Diameter
Thickness
in
0.0539
0.0681
0.0819
0.0961
mm
1.37
1.73
2.08
2.44
mm
130.1
130.1
130.1
130.1
in
5.122
5.122
5.122
5.122
Retaining ring size for direct clutch clearance

Thickness
Diameter
in
0.0539
0.0681
0.0819
0.0961
mm
1.37
1.73
2.08
2.44
mm
130.1
130.1
130.1
130.1
in
5.122
5.122
5.122
5.122
Retaining ring size for forward clutch clearance

Thickness
mm
1.73
2.08
2.44
Diameter
in
0.0681
0.0819
0.0961
in
5.65
5.65
5.65
mm
141.45
141.45
141.45
Thrust bearing (No.4) size (intermediate brake drum)

Dimension E
1.69-1.87 mm {0.066-0.074 in}
1.88-2.04 mm {0.073-0.080 in}
2.05-2.22 mm {0.081- 0.088 in}
2.23-2.43 mm {0.088-0.096 in}
Bearing Thickness
2.65-2.80 mm {0.104-0.110 in}
2.83-2.98 mm {0.111-0.116 in}
3.01-3.16 mm {0.118-0.124 in}
3.21-3.36 mm {0.126-0.132 in}
Identification (Notches)
None
2
3
Thrust washer (No.1) size (overdrive brake drum)

Dimension E
38.05-38.13 mm {1.50 in}
38.14-38.28 mm {1.50-1.51 in}
38.29-38.42 mm {1.51 in}
38.43-38.61 mm {1.51-1.52 in}
38.63-38.74 mm {1.52-1.53 in}
Bearing Thickness
1.55-1.60 mm {0.061-0.063 in}
1.75-1.80 mm {0.069-O.071 in}
1.85-1.90 mm {0.073-0.075 in}
2.05-2.10 mm {0.081-0.083 in}
2.15-2.20 mm {0.095-O.097 in}
Identification (Color/ID)
White
Green
Red
Black
Yellow
05-50-1
TECHNICAL DATA [S1SM-D, S1SMX-D]
05-50B TECHNICAL DATA [S15M-D, S15MX-D]

TECHNICAL DATA
[S15M-D, S15MX-D] ............... 05-508-1
TECHNICAL DATA [S15M-D, S15MX-D]

Item
Standard clearance between shift fork and clutch hub
sleeve groove
Maximum clearance between shift fork and clutch hub
sleeve groove
Standard clearance between synchronizer ring and
flank surface of gear
Maximum clearance between synchronizer ring and

flank surface of gear
Detent ball springs for 1st/2nd and 3rd/4th shift rods
Detent ball spring for 5th/reverse shift rod
1st/2nd select lock spindle spring [4x2]
Push pin spring for 1st/2nd shift rod end [4x4]
Push pin spring for 5th/reverse shift rod end [4x4]
Detent ball spring for 5th/reverse shift rod end [4x4]
Mainshaft maximum runout
Standard clearance between shift rod end and control
lever
3rd/4th clutch hub end play
Maindrive gear shaft total end play
DCF055000000W05
Specification
0.05-0040 mm {0.002-0.015 in}

0.5 mm {0.020 in}
1.5 mm {0.059 in}
0.8 mm {0.031 in}
0.03 mm {0.0012 in}
0.5 mm {0.020 in} or less
0-0.05 mm {0.0-0.0019 in}
0.05-0.15 mm {0.002-0.0059 in}
~C_o~u=n_te_rs_h_a_ft~to-ta~l~e~n~d~p-la~y~--------------~--------____o_.1~5~0~.2~5~m--m~{~0.~0-06---0~.0~09~8~in~}----------~
5th/Reverse clutch hub end play
Reverse gear end play
Reverse idler gear end play
0-0.05 mm {0.0-0.0019 in}

0.25-0.35 mm {0.002-0.0059 in}
0.1-0.2 mm {0.0040-0.0078 in}
3rd/4th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.061 O}
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}
,
05-508-1
-,
I'
TECHNICAL DATA [S1SM-D, S1SMX-D]

Maindrive gear bearing shim selective chart
1.45-1.55
{0.0571-0.0610}
1.55-1.65
{0.0611-0.0649}
1.65-1.75
{0.0650-0.0688}
1.75-1.85
{0.0689-0.0728}
1.85-1.95
{0.0729-0.0767}
1.95-2.05
{0.0768-0.0807}
2.05-2.15
{0.0808-0.0846}
2.15-2.25
{0.0847-0.0885}
2.25-2.35
{0.0886-0.0925}
2.35-2.45
{0.0926-0.0964}
2.45-2.55
{0.0965-0.1003}
2.55-2.65
{0.1 004-0.1 043}
2.65-2.75
{0.1 044-0.1 082}
2.75-2.85
{0.1083-0.1122}
2.85-2.95
{0.1123-0.1161}
2.95-3.05
{0.1162-0.1200}
3.05-3.15
{0.1201-0.1240}

1.4 {0.055}
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.8 {0.071}
1.9 {0.075}
2.0 {0.079}
2.1 {0.083}
2.2 {0.087}
2.3 {0.090}
2.4 {0.094}
2.5 {0.098}
2.6 {0.102}
2.7 {0.106}
2.8 {0.110}
2.9 {0.114}
3.0 {0.118}
Countershaft front bearing shim selective chart

Dimension F (mm {in})
3.15-3.25
{0.1240-0.1279}
3.25-3.35
{0.1280-0.1318}
3.35-3.45
{0.1319-0.1358}
3.45-3.55
{0.1359-0.1397}
3.55-3.65
{0.1398-0.1437}
3.65-3.75
{0.1438-0.1476}
3.75-3.85
{0.1477-0.1515}
3.85-3.95
{0.1516-0.1555}
05-508-2
3.0 {0.118}
3.1 {0.122}
3.2 {0.126}
3.3 {0.130}
3.4 {0.134}
3.5 {0.138}
3.6 {0.142}
3.7 {0.147}
TECHNICAL DATA [S15M-D, S15MX-D]

5th/Reverse clutch hub thrust washer
Thickness (mm {in})
3.00 {0.11B}
3.05 {0.120}
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.12B}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}
Reverse gear thrust washer

Thickness (mm {in})
7.60-7.70
{0.300-0.303}
7.70-7.BO
{0.304-0.307}
7.BO-7.90
{0.30B-0.311}
7.90-8.00
{0.312-0.314}
8.00-B.10
{0.315-0.31B}
7.35 {0.2B9}
7.45 {0.293}
7.55 {0.297}
7.65 {0.301}
7.75 {0.305}
Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.B {0.071}
1.9{0.075}
05-508-3
SERVICE TOOLS [5R55S]
05-60
SERVICE TOOLS [5R55S]
(e SERVICE TOOLS[5R55S] ............ 05-60-1

SERVICE TOOLS[5R55S]
id0560h 1500400
100-001
303-0026
307-003
Slide Hammer
Depth
Micrometer
Holding Fixture,
Transmission
307-015
307-049
307-050
Compressor,
Clutch Spring
Protector, Piston
Seal
Installer, Shift
Shaft Fluid Seal
307-051
307-091
307-309
Protector, Piston
Seal
Handle, Torque
Converter
307-334
307-336
307-338
Aligner, Valve
Body (2
required)
Sizer, Piston
Seal
Sizer, Piston
Seal
307-34&
307-349
307-351
Retainer, Torque
Converter
Installer, Torque
Converter Fluid
Seal
Alignment
Gauge, TR
Sensor
308-375
307-397
307-398
Remover, Input
Shaft Oil Seal
Remover,
Transmission
Fluid Pump
Alignment Pins,
Transmission
Pump
307-399
307-400
307-401
Alignment Pins,
Transmission
Pump
Gauge Bar
Compressor,
Cushion Spring
307-402
307-431
307-432
Aligner, Fluid
Pump Handle
Aligner, Fluid
Pump Pilot
Compressor,
Servo Cover
'0
~
e
@)
@)
))
))
~
~
Remover,
Torque
Converter Fluid
Seal
~t
v-.;::
~
05-60-1
SERVICE TOOLS [SRSSS]

307-433-01
307-433-02
307-433-03
Transmission
Test Plate and
Gasket
b1h]
'0
.
.'...
.
0\
'0'
..
...~ .
. ..
'0'
.... \
0 .
307-434
Bonded Piston
Seal Sizer
307-451/1
307-451/2
Transmission
Fluid Pump Seal
Aligner
Transmission
Fluid Pump Seal
Sizer
QD
307-435
Installer,
Transmission
Extension
Housing Fluid
Seal
307-451/3
(I
-j
Transmission
Fluid Pump Seal
Installer
307-S022
307-S039
308-002
Adjustment Set,
Transmission
Band
Alignment Set,
Fluid Pump
Installer,
Transmission
Extension
Housing Oil
Seal
05-60-2
SERVICE TOOLS [S15M-D, S15MX-D]
05-608 SERVICE TOOLS [S1SM-D, S1SMX-D]

~
SERVICE TOOLS [S15M-D, S15MX-D] . 05-608-1
SERVICE TOOLS [S15M-D, S15MX-D]

DCF056000000W04
1: Mazda SST number

Example
1 :49 UN01 011
2:308-168
Socket
1 :49 0839 425C
1 :49 H027 002
1:49 G033 106
2:-
2:-
2:-
Bearing Puller
Set
Remover,
Bearing
Attachment
1 :49 G033 102
1:49 H017101
2:-
Handle
1:49 0710 520
~
.~
1 :490813235
2:-
2:-
Hook
Main Bearing
Puller & Installer
1:49 H025 003A
1 :49 G028 203
2:-
2:-
2:-
Bearing Puller
Bearing Installer
Support
1:49 F401 331
1:49 B034 201
1 :49 G030 338
2:-
2:-
2:-
Body
Support Block
Attachment E
1:49 B032 308
1 :490221 251A
1 :49 D032 326A
2:-
2:-
2:-
Attachment A
Valve Guide
Installer
Attachment A
05-608-1
SERVICE TOOLS [S1SM-D, S1SMX-D]

2:-
1:49 F401 337A
1:49 UN01 011

2:308-168
Attachment C
Socket
1 :49 G030 797
1 :49 F017 1AO
2:-
2:-
Handle
Wrench
1 :49 H025 001
498012004
Installer
Valve seal
pusher
2:-
(j
@
1 :49 0636 040

2:Piston Pin
Installer
1:49 G030 728

2:Attachment 8
e
05-608-2
211-04-24 A
Steering Column
211-04-24 A
PROCEDURE FOR INSERTING KEY BARREL INTO REPLACEMENT

STEERING COLUMN
Models:
2002-05 Model Year Focus (excluding 8T170)
Summary:
The procedure outlined below should be followed to ensure the Focus steering
column is not inadvertently locked when installing the key barrel into the steering
column.
Information:
2002-05 Model Year Focus (excluding 8T170) steering columns can inadvertently be
permanently locked if the correct procedure for installing the key barrel is not
followed.
Note: If the steering column is locked with the white spacer removed and no key
barrel inserted, the column will be permanently locked. The column will then need
to be scrapped.
Follow the procedure below to ensure the column does not become locked:
1. Confirm the ignition switch spindle is in the "accessories" position
(as per Figure 1). When the ignition switch spindle is the accessories position the
column is able to be turned freely.
If the ignition switch spindle is in the "locked" position (as per Figure 2), depress the
spindle and turn the spindle clockwise to the "accessories" position. Do not remove
the white spacer when the spindle is in the "locked" position as the anti-theft locking
mechanism will be triggered and the column will be permanently locked.
G17608 en
02/2002.50 Focus
2110424 A
Steering Column
2110424 A
Figure 1: Ignition switch spindle is in the "accessories" position
Figure 2: Ignition switch spindle is in the "locked" position - DO NOT remove white
spacer whilst spindle is in "locked" position
2. With the spindle in the "accessories" postion, carefully rotate the white plastic
spacer in the clockwise direction. Whilst rotating the white plastic spacer, watch the
ignition switch spindle and ensure that the spindle is not rotated out of the
"accessories" position. Rotate the white plastic spacer until it hits the stop position,
as per Figure 3.
G17608 en
02/2002.50 Focus
211-04-24 A
Steering Column
211-04-24 A':~
Figure 3: White spacer has been rotated clockwise until stop position. Spindle is
now in correct position to be pulled out from steering column key barrel slot.
3. Carefully pull the white plastic spacer out from key barrel slot.
4. Confirm that the key barrel to be inserted into the column is in the "accessories"
position. Carefully insert key barrel into the key barrel slot in the steering column.
5. When the key barrel is correctly inserted the locking pin in the key barrel will pop
into the hole provided in the steering column lock assembly.
6. Confirm that column is able to be turned freely after inserting the key barrel.
G17608 en
02/2002.50 Focus
"
GENERAL INFORMATION
GENERAL INFORMATION ... 00-00
00-00
GENERAL INFORMATION

(VIN) CODE . .....................
(VIN) . ...........................
HOW TO USE THIS MANUAL. ........
UNITS ...........................
SERVICE CAUTIONS ...............
INSTALLATION OF RADIO SYSTEM ...
ELECTRICAL SySTEM ..............
JACKING POSiTIONS ...............
00-00-1
00-00-1
00-00-2
00-00-11
00-00-12
00-00-18
00-00-19
00-00-25
VEHICLE LIFT (2 SUPPORTS) AND

SAFETY STAND (RIGID RACK)
POSITION . ...................... . 00-00-26
TOWING ......................... . 00-00-27
IDENTIFICATION NUMBER
LOCATIONS . .................... . 00-00-29
NEW STANDARDS . ................ . 00-00-30
ABBREVIATIONS . ................. . 00-00-32
PRE-DELIVERY INSPECTION . ....... . 00-00-33
SCHEDULED MAINTENANCE ....... . 00-00-34
MNBBS1 D1 060123456
=====I==l
dcfOOOOOOOOOw16
I~
___
_
Serial No. _
'--_ _ _ _ _ _ _ _P_a_nt_ _ W=A. A. Thailand

Model Yesr
Production year
Check Digit
Plant
L -_ _ _ _ _ _ _ _~N~o~m~e~a~nin~g~
Engine type
'-------------~-L -_ _ _ _..:::;G.:...:ro..::.;ss::....;v:...:.e~hic=le=_w:..:..;e:..:..;ig~h..:..t_ _ _ _ _
7= 2007, 8=2008, 9=2009 .. .

6= 2006, 7=2007, 8=2008 .. .
0 to 9, X
W= A. A. Thailand
0
1=WL-C (2.5 L-DI)
9= WE-C (3.0 L-DI)
D= 2268-2721 kg {5001-6000 Ibs}
E= 2722-3175 kg {6001-7000 Ibs}
1= Stretch cab.
2= Stretch cab.
Body style
M=Thaiiand
'--_ _ _ _ _ _ _ _ _ _ _ _P_r_od_u_ct_s_or_ce_ S= Japan
Air bag
L -_ _ _ _ _ _ _ _ _..:...:W..:..;or.;..:ld;...;.;m""a;;.;.nu:;.;.fa:;.:c..:;;tu;.;...:re:..;..r.;.:;id..:..;en.;.:;ti.;.:.:fic:..:.;at.:;.:io..;.;,n_
D= with Air bag (Driver side)

arnffw00001644

MNA 8S
MNA OS
MNA LS
MNA US
arnffw00001612
00-00-1
GENERAL INFORMATION
dcfOOOOOOOOOw18
Range of Topics
This manual contains procedures for performing all required service operations. The procedures are divided
into the following five basic operations:
Removal/Installation
Disassembly/Assembly
Replacement
Inspection
Adjustment
Simple operations which can be performed easily just by looking at the vehicle (i.e., removal/installation of
parts, jacking, vehicle lifting, cleaning of parts, and visual inspection) have been omitted.
Service Procedure
Inspection, adjustment
Inspection and adjustment procedures are
divided into steps. Important points regarding the
location and contents of the procedures are
explained in detail and shown in the illustrations.

FOR SE VICE
E1E9~
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
Connect the gauge set from under

the vehicle to prevent contact with
the drive belt and the cooling fan.
WGIWXX0009E
00-00-2
GENERAL INFORMATION
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 removal/installation procedures that 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 requiring the use of special service tools or equivalent are also
shown.
3. Procedure steps 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 additional information concerning a
procedure. Refer to this information when servicing the related part.
SHOWS SERVICE
ITEM (S)
Procedure
"
."
Removaillnstallation
Portion
.~~~~~~~~~~~~
LOWER TRAILING LINK UPPER TRAILING LINK REMOVAUINSTALLATION
--------------------,-r,2
--
"Inspection After
Installation" Portion
1. Jack up the rear of the vehicle and support it with safety stands.
2. Remove the undercover. (See 01-10-4 Undercover Removal
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5. Inspect the rear wheel alignment and adjust it If necessary.

FOR SERVICE
INSTALL THE PARTS BY

PERFORMING STEPS
1-31N REVERSE ORDER
INDICATES RELEVANT
REFERENCES THAT NEED
TO BE FOLLOWED DURING
INSTALLATION
~G---(j
~'J.v-'"",
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS DETAILS
94-116 {9.5-11.9, 69-86}
SHOWS TIGHTENING
TORQUE UNITS
CD iii
SHOWS REFERRAL
NOTES FOR SERVICE
1
"-2
5
6
Split pin
Nut
ower tral In In
a I Jomt
(See 0214-5 Lower Trailing Link Ball Joint Removal Note)
7
6
9
Bolt
Lower trailing link
Dust boot (tower trailing link)
10
11
12
Slit in
Nut
Upper trailing link ball joint
(See 02~145 Upper Trailing Link Ball Joint Removal Note)
Nut
Upper trailing link
Dust boot (upper trailing link)
LowerTraliing Link Ball Joint, Upper Trailing Link

Ball Joint Removal Note
Remove the ball joint using the SSTs.
UPPER TRAILING LINK
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
DHUOOOZW5002
00-00-3
m.
GENERAL INFORMATION
Symbols
There are eight symbols indicating oil, grease, fluids, sealant, and the use of SST or equivalent. These symbols
show application points or use of these materials during service.
Symbol
Meaning
-,.....-
Kind
Apply oil
New appropriate
engine oil or gear
oil
Apply brake fluid
New appropriate
brake fluid
Apply automatic
transaxlei
transmission fluid
New appropriate
automatic
transaxlei
transmission fluid
Apply grease
Appropriate
grease
1r.m:l!iQ1
Apply sealant
Appropriate
sealant
Apply petroleum
jelly
Appropriate
petroleum jelly
Replace part
O-ring, gasket,
etc.
Use SST or
equivalent
Appropriate tools
II
-A
iii
ED
Advisory Messages
You will 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 or parts 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 indicate 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.
00-00-4
GENERAL INFORMATION
Troubleshooting Procedure
Basic flow of troubleshooting
~-----------------------------~
CUSTOMER ARRIVES
I
WARNING LIGHT'
ON/FLASHING
NO WARNING LlGHT*
WITH SYMPTOM
CHECK FOR
PRIORITIZED DTC
DTC
DIAGNOSE BY DTC
(ON-BOARD DIAGNOSTIC)
DTCTABLE
DTC
TROUBLESHOOTING
FLOW
*: INDICATOR LIGHTS AND WARNING
CHECK DTC
IGNITION ON TEST, IDLING
TEST
WITHOUTDTC
DIAGNOSE BY SYMPTOM
(SYMPTOM TROUBLESHOOTING)
1. DIAGNOSTIC INDEX
2. QUICK DIAGNOSIS CHART
(IF MENTIONED)
3. SYMPTOM
TROUBLESHOOTING
LIGHTS THAT INDICATE MALFUNCTIONS
WGIWXX0001E
DTC troubleshooting flow (on-board diagnostic)

Diagnostic trouble codes (DTCs) are important hints for repairing malfunctions that are difficult to simulate.
Perform the specific DTC diagnostic inspection to quickly and accurately diagnose the malfunction.
The on-board diagnostic function is used during inspection. When a DTC is shown specifying the cause of a
malfunction, continue the diagnostic inspection according to the items indicated by the on-board diagnostic
function.
Diagnostic index
The diagnostic index lists the symptoms of specific malfunctions. Select the symptoms related or most closely
relating to the malfunction.
Quick diagnosis chart (If mentioned)
The quick diagnosis chart lists diagnosis and inspection procedures to be performed specifically relating to the
cause of the malfunction.
Symptom troubleshooting
Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
00-00-5
GENERAL INFORMATION
Procedures for Use
Using the basic inspection (section 05)
Perform the basic inspection procedure before symptom troubleshooting.
Perform each step in the order shown.
The reference column lists the location of the detailed procedure for each basic inspection.
Although inspections and adjustments are performed according to the reference column procedures, if the
CFlIJSe of the malfunction is discovered during basic inspection, continue the procedures as indicated in the
action column.
SHOWS INSPECTION
ORD ER
SHOW POINTS REQUIRING

ATTENTION BASED ON
INSPECTION R ESULTS
SHOWS ITEM NAMES FOR

DETAILED PROCEDURES
BAS C INSPECTION
S EP
1
REFERENCE
COLUMN
INSPECTION
ACTION
/
r
Perform the mechanical system test.

(See 05-13-3 MECHANICAL SYSTEM TEST.)
Is mechanical system normal?
Yes
Go to the next step.
No
Repair or replace any malfunctioning parts according to

the inspection result.
Turn the ignition switch to the ON position.

When the seleelor lever is moved, does the seleelor
illumination indicate synchronized position to the
lever location? Also, when other ranges are selected
Irom N or P during Idling, does the vehicle move
within 1-2 s?
Yes
Go to next step.
No
Inspect the selector lever and TR switch Rereir or

replace malfunctioning parts.
(flep. Ofi-14-fi flELECTOR LEVER INSPECTION.)
(See 05-13-10 TRANSMISSION RANGE (TR) SWITCH
INSPECTION.)
If the selector lever and TR switch are normal, go to the
next step.
Inspect the ATF color condition.

(See 05-13-8 AUTOMATIC TRANSMISSION
FLUID (ATF) INSPECTION.)
Are ATF color and odor normal?
Yes
No

the inspAr.tinn rARlllt.
Flush ATX and cooler line as necessary.
Perform the line pressure test.

(See 05-13-3 Line Pressure Test.)
Is the line pressure normal?
Yes
No
Perform the stall test.

(See 05-13-4 Stall Speed Test.)
Is the stall speed normal?
Yes
No

Inspect the voltage at the following TCM terminals.

(See 05-13-29TCM INSPECTION.)
Is
Terminal 2J (TFT sensor)

Terminals 1 D, 2B. 2C, 2E (TR switch)
Terminal 2G (turbine sensor)
Terminal2D (down switch)
Terminal 21 (up switch)
Terminal 1E (M range switch)
Terminal 1W (steering shift switch)
the voltage normal?

Yes
Go to the next steo.
No

DDAOOOZW4030
00-00-6
GENERAL INFORMATION
Using the DTC troubleshooting flow
DTC troubleshooting flow shows diagnostic procedures, inspection methods, and proper action to take for each ~
DTC.
Ii6iiI
DETECTION CONDITION
describes the condition
under which the DTC is
detected.
TROUBLE CONDITION
DTC P0103
DTC P0103
MAF circuit high input

PCM monitors input voltage from TP sensor after ignition key is turned on. If input voltage at PCM terminal 68 is
above 8.25 V, PCM determines that TP circuit has malfunction.
DETECTION
CONDITION
POSSIBLE
CAUSE
describes
possible
point(s) of
malfunction
Diagnostic support note

This is a continuous monitor (CeM).
MIL illuminates if PCM detects the above malfunction during first drive cycle. Therefore,
PENDING CODE is not available.
FREEZE FRAME DATE is available.
DTC is stored in the PCM memory.
POSSIBl
CAUSE
MAF sensor malfunction

Connector or terminal malfunction
Open circuit in wiring between MAF sensor terminal 0 and PCM terminal 36
Indicates the
circuit to be
inspected
(01 and 05
section)
en circuit in MAF sensor round circuit

FROM
MAIN RELAY
PCM
TERMINALD
Indicates the
inspection step
No. to be
performed
(01 and 05
section)
MAFSENSOR
HARNESS SIDE CONNECTOR
Indicates the
connector
related to the
inspection
PCM
1P
STEP shows
the order of
troubleshooting
---=-
Diagnostic procedure
STEP
1
INSPECTION
ACTION
VERIFV FREEZE FRAME DATA HAS BEEN

RECORDED
Ves
Go to next step.
No
Record FREEZE FRAME DATA on repair order, then go

to next step.
Ves
Pertorm repair or diagnosis according to available repair

information.
If vehicle is not repaired, then go to next step.
No
Go to next step.
Ves
Intermittent concern is existing. Go to INTERMITIENT

CONCERNS TROUBLESHOOTING procedure.
(See 01-03-33 INTERMITIENT CONCERN _
TROUBLESHOOTING)
Has FREEZE FRAME DATA been recorded?

2
VERIFV RELATED REPAIR INFORMATION

AVAilABiliTY
Are related Service Bulletins and/or
reDair information available?
INSPECTION
describeS the
method t 0 ,./
quickly
determin e the
malfunct ioning
part(s).
on~line
VERIFY CURRENT INPUT SIGNAL STATUS IS

CONCERN INTERMITIENT OR CONSTANT
Connect diagnostic tool to DLC~2.
Start engine.
Access MAF V PID using diagnostic tooi.
No
Go to next step.
Ves
Repair or replace terminals, then go to Step 8.
Is MAF V PID within 0.2 - B.3 V?
INSPECT POOR CONNECTION OF MAF

SENSOR CONNECTOR
ACTION
describes the
appropriate
i1'action to be taken
/
according to
the result
(Yes/No) of the
INSPECTION.
Reference
item(s) to
perform
ACTION.
Turn ignition key to OFF.

Disconnect MAF sensor connector.
Check for poor connection (damaged, pulledout terminals, corrosion etc.).
Are there any malfunctions?
DCFOOOZWB003
00-00-7
GENERAL INFORMATION
Using the diagnostic index
Malfunction symptoms are listed in the diagnostic index under symptom troubleshooting.
The exact malfunction symptoms can be selected by following the index.
No.
TROUBLESHOOTING ITEM
DESCRIPTION
Page
(See 01-03-6 MELT NO_l MAIN OR

OTHER FUSE)
Melting of main or other fuses
MIL comes on
MIL is illuminated incorrectly.
(See 01-03-7 NO.2 MIL COMES ON)
Will not crank
Starter does not work.
(See 01-03-8 NO.3 WILL NOT CRANK)
Hard startilong crank/erratic starVerratic

crank
Starter cranks engine at normal

speed but engine requires excessive
cranking time before starting.
(See 01-03-9 NO.4 HARD START/

LONG CRANK/ERRATIC CRANK)
Engine stalls.
Engine stops unexpectedly at idle

andlor after start.
(See 01-03-11 NO.5 ENGINE-STALLS

AFTER START/AT IDLE)
Cranks normally but will not start
Starter cranks engine at normal

speed but engine will not run.
(See 01-03-15 NO.6 CRANKS

NORMALLY BUT WILL NOT START)
Slow return to idle
Engine takes more time than normal

to return to idle speed.
(See 01-03-19 NO.7 SLOW RERUN

TO IDLE)
Engine runs rough/rolling
Fast idle/runs on
10
Low idle/stalls during deceleration
After start/at idle
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 key is
turned to OFF.
Engine stops unexpectedly at beginning of deceleration or recovery
from deceleration.
(See 01-03-20 NO.8 ENGINE RUNS

ROUGH/ROLLING IDLE)
(See 01-03-23 NO.9 FAST IDLE/RUNS

ON)
(See 01-03-24 NO.l0 LOW IDLE/
STALLS DURING DECELERATION)
BHEOOOOW102
00-00-8
GENERAL INFORMATION
Using the quick diagnosis chart
The chart lists the relation between the symptom and the cause of the malfunction.
The chart is effective in quickly narrowing down the relation between symptom and cause of the malfunction. It
also specifies a range of common causes when multiple malfunction symptoms occur.
The appropriate diagnostic inspection relating to a malfunction cause 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
,-~
-------------~------------X: Applied
Possible factor
,;
<ii
~
Q)
Qi
PART WHICH MAYBE

THE SYMPTOM
"X
0.
0
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s=
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.
Q)
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
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,; ~
Q)
:
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CHOOSE THE
ACTUALSYM PTOM
<ii
Cl
" ~
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'6
0
;::
Qi
15
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0.
"'" "'- rx
'iii"
Q)
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Cl
Q)
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0.

MIL illuminates
Will not crank
Hard to start/long crank/erratic start/erratic x
crank
After start/at idle
Engine stalls.
Slow return to idle
Enaine runs rOlJgh/rollinQ idle
Fast idle/runs on
Low idle/stalls durin deceleration
EnQine stalls/auits. Acceleration/cruise
Engine runs rough. Acceleration/cruise
Acceleration/cruise
Misses
Buck/jerk
Acceleration/cruise!
deceleration
Hesitation/stumble Acceleration
Acceleration/cruise
Suraes
Lack/loss of power Acceleration/cruise
Acceleration/cruise
KnockinQ/pinQinQ
Poor fuel economy
Emission comoliance
High oil consumption/leakage
Overheating
CoolinQ system concerns
Coolina system concerns
Runs cold
Exhaust smoke
Fuel odor in engine compartment
EnQine noise
Vibration concerns enQine
NC does not work sufficient! .
NC is always on or Ale compressor runs
continuously.
NC is not cut off under WOT conditions.
Exhaust sulfur smell
Fuel refill concerns
Fuel fillinQ shut off issues
Constant voltaQe
Soark olua condition
UpshitVdownshift
ATX concerns
enaaaement
10
<Ii
Q)
Q)
"0
...J
0.
0.
(J)
Q)
0.
0.
0.
"0
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Q)
0.
'"
Cl
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s=
5"
1;;
~~
a;Q)
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12
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~ 120.
" "
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-g" ""'
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-;nf
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x
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x
x
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x
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x
x
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x
x
x
x
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x
x
x
x
x
x
x
x
x
x
x
x
x
x
See Section 05-03A, TROUBLESHOOTING
BHEOOOOW105
00-00-9
m
I I
GENERAL INFORMATION
Using the symptom troubleshooting
Symptom troubleshooting shows diagnostic procedures, inspection methods, and proper action to be taken for
each trouble symptom.
DESCRIPTION
describes what
kind ofTROUBLE
SYMPTOM
........
JROUBLE SYMPTOM
14~
Engine flares up or slips when upshifting or down shifting
........ When accelerator pedal is depressed for driveway, engine speed increase but vehicle speed increase
slowly.
DESCRIPTION
When accelerator is depressed while driving, engine speed increases but vehicle not.
There is clutch slip because clutch is stuck or line pressure is low.
_ Clutch stuck, slippage (forward clutch, 34 clutch, 2-4 brake band, one-way clutch 1, one-way clutch 2)
Line pressure low
Malfunction or mis-adjustment ofTP sensor
Malfunction of VSS
Malfunction of input/turbine speed sensor
Malfunction of sensor ground
Malfunction of shift solenoid A, B or C
Malfunction of TCC solenoid valve
POSSIBLE
Malfunction of body ground
CAUSE
Malfunction of throttle cable
Malfunction of throttle valve body
Poor operating of mechanical pressure
Selector lever position disparity
TR switch position disparity
POSSIBLE
CAUSE
describes
possible
point of
malfunction
Note
Before following troubleshooting steps, make sure that Automatic Transaxle On-board Diagnostic and
Automatic Transaxle Basic Inspection are conducted.
STEP shows
the order of
troubleshooting.
STEP
1
Reference
item(s) for
additional
informatio n
to perform
INSPECTIO N.
- -=--
N _
INSPECTIO
describes th e
method to
quickly
determine t he
malfunction ing
partes).
INSPECTION
Is line pressure okay?
Is shift point okay?

_ (See 05-17-5 ROAD TESD
Stop engine and turn ignition switch on.
Connect diagnostic tool to DLC-2.
-----
ACTION
Ves
No
Go to next step.
Repair or replace any defective parts according to
inspection results.
Ves
Go to next step
No
Go to symptom troubleshooting NO.9 "Abnormal shift".
Ves
Overhaul control valve body and repair or replace any

defective parts.
(See ATX Workshop Manual GF4A-EL (1666-1A-99F))
Simulate SHIFT A, SHIFT B and SHIFT C PIDs

forON.
Is operating sound of shift solenoids heard?
If problem remains, replace or overhaul transaxle and

repair or replace defective parts.
(See 05-17-15 AUTOMATIC TRANSAXLE
REMOVEVAUINSTALLATION)
No
Inspect for bend, damage, corrosion or loose

connection if shift solenoid A, B, or C terminal on ATX.
Inspect for shift solenoid mechanical stuck.

(See 05-17-14 Inspection of Operationr
If shift solenoids are okay, inspect for open or short
circuit between PCM connector terminal A, B or C.
4
Verify test results.
If okay, return to diagnostic index to service any additional symptoms.

If malfunction remains, inspect related Service Bulletins and/or On-line Repair Information and perform repair or
diagnosis.
If vehicle is repaired, troubleshooting completed.
If vehicle is not repaired or additional diagnostic information is not available. replace or reprogram PCM.
ACTION
describes the
appropriate
'- action to be
/>'
taken according
to the result
(Yes/No) of the
INSPECTION .
--r-. How to
perform
ACTION is
described in
the relative
material
shown.
Reference
item(s) to
perform
ACTION.
DCFOOOZWB004
00-00-10
GENERAL INFORMATION
UNITS
dcfOOOOOOOOOw19
Electric current
Electric power
A (ampere)
W (watt)
Electric resistance
Electric voltage
ohm
V (volt)
Length
mm (millimeter)
in (inch)
kPa (kilo pascal)
Negative pressure

kPa (kilo pascal)
Positive pressure
Number of
revolutions
centimeter)
rpm (revolutions per minute)
Nm (Newton meter)
Torque

L (liter)
Volume
US qt (U.S. quart)
ml (milliliter)
cu in (cubic inch)
Weight
fl oz (fluid ounce)
g (gram)
oz (ounce)

from these values.
Rounding Off
an upper limit, and rounded up if the 81 unit value is a lower limit. Therefore, converted values for the same 81
210-260 kPa {2.1-2.7 kgf/cm 2 , 30-38 psi}
270-310 kPa {2.7-3.2 kgflcm 2 , 39-45 psi}
00-00-11
m!I
GENERAL INFORMATION
SERVICE CAUTIONS
dcfOOOOOOOOOw20
Protection of the Vehicle

Always be sure to cover fenders, seats and floor
areas before starting work.
BHJ0014W001
Preparation of Tools and Measuring Equipment

Be sure that all necessary tools and measuring
equipment are available before starting any work.
BHJ0014W002
Special Service Tools

Use special service tools or the equivalent when
they are required.
WGIWXX0024E
Disconnection of the Negative Battery Cable

When working with the negative battery cable disconnected, wait for 1 min or more to allow the back up power
supply of the SAS control module to deplete its stored power after the cable is disconnected.
Disconnecting the battery cable will delete the memories of the clock, audio, and DTCs, etc. Therefore, it is
necessary to note down the information stored in those memories before disconnecting the cable.
If the battery had been disconnected during vehicle maintenance or for other reasons, the window will not fully
close automatically. Initialize the power window system for the power window main switch.
00-00-12
GENERAL INFORMATION
Oil Leakage Inspection
Use either of the following procedures to identify the type of oil that is leaking.
id000000800200
Injury/damage Prevention Precautions

Depending on the vehicle, the cooling fan may operate suddenly even when the engine switch is turned off.
Therefore., keep hands and tools away from the cooling fan even if the cooling fan is not operating to prevent
injury to personnel or damage to the cooling fan. Always disconnect the negative battery cable when servicing
the cooling fan or parts near the cooling fan.
Malfunction Diagnosis System
Use the current diagnostic tool for malfunction diagnosis.
00-00-12a
,
GENERAL INFORMATION
Using UV light (black light)
1. Remove any oil on the engine or transaxle/transmission.
......
Note
...
Referring to the fluorescent dye instruction manual, mix the specified amount of dye into the engine oil or i,
ATF (or transaxle/transmission oil).
2.
3.
4.
5.
6.
Pour the fluorescent dye into the engine oil or ATF (or transaxle/transmission oil).
Allow the engine to run for 30 min.
Inspect for dye leakage by irradiating with UV light (black light), and identify the type of oil that is leaking.
If no dye leakage is found, allow the engine to run for another 30 min. or drive the vehicle then reinspect.
Find where the oil is leaking from, then make necessary repairs.
Note
To determine whether it is necessary to replace the oil after adding the fluorescent dye, refer to the
fluorescent dye instruction manual.
Not using UV light (black light)

1. Gather some of the leaking oil using an absorbent white tissue.
2. Take samples of engine oil and ATF (or transaxle/transmission oil), both from the dipstick, and place them next
to the leaked oil already on the tissue.
3. Compare the appearance and smell, and identify
the type of oil that is leaking.
4. Remove any oil on the engine or transaxlel
transmission.
ATFOR
5. Allow the engine to run for 30 min.
TRANSAXLEI
~
6. Check the area where the oil is leaking, then
TRANSMISSION OIL
~
ENGINE OIL
make necessary repairs.
~~,,~
~r~
~/~1 ;;fi
LEAKED OIL
CDAOOOZWA003
Removal of Parts
While correcting a problem, also try to determine
its cause. Begin work only after first learning
which parts and sUb-components must be
removed and disassembled for replacement or
repair. After removing the part, plug all holes and
ports to prevent foreign material from entering.
BHJ0014W005
Disassembly
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.
WGIWXX0027E
00-00-13
GENERAL INFORMATION
Inspection During Removal, Disassembly

When removed, each part should be carefully
inspected for malfunction, deformation, damage
and other problems.
WGIWXX0028E
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.
WGIWXX0029E
Cleaning of Parts
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.
C5UOOOOW001
Reassembly
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:
Oil seals
Gaskets
a-rings
Lock washers
Cotter pins
Nylon nuts
WGIWXX0031E
00-00-14
GENERAL INFORMATION
Depending on location:
Sealant and gaskets, or both, should be
applied to specified locations. When sealant
is applied, parts should be installed before
sealant hardens to prevent leakage.
Oil should be applied to the moving
components of parts.
Specified oil or grease should be applied at
the prescribed locations (such as oil seals)
before reassembly.
CHU0014W006
Adjustment
Use suitable gauges and testers when making
adjustments.
BHJ0014W012
Rubber Parts and Tubing

Prevent gasoline or oil from getting on rubber
parts or tubing.
WGIWXX0034E
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.
WGlWXX0035E
00-00-15
GENERAL INFORMATION
Torque Formulas
When using a torque wrench-SST or equivalent
combination, the specified torque must be
recalculated due to the extra length that the SST.
~.I. or equivalent adds to the torque wrench.
Recalculate the torque by using the following
formulas. Choose the formula that applies to you.
Torque Unit
Nm
kgfm
kgfcm
ftlbf
inlbf
Formula
Nm x [U(L+A)]
kgfm x [U(L+A)]
kgfcm x [U(L+A)]
ftlbf x [U(L+A)]
inlbf x [U(L+A)]
~~----~L~------~I
WGIWXX0036E
A : The length of the SST past the torque wrench drive.

L : The length of the torque wrench.
Vise
When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
PROTECTIVE PLATES
CHU0014W010
Dynamometer
When inspecting and servicing the power train on the dynamometer or speedometer tester, pay attention to the
following:
Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
Make sure the vehicle is in a facility with an exhaust gas ventilation system.
Since the rear bumper might deform from the heat, cool the rear with a fan. (Surface of the bumper must be
below 70C {158F} degrees.)
Keep the area around the vehicle uncluttered so that heat does not build up.
Watch the water temperature gauge and do not overheat the engine.
Avoid added load to the engine and maintain normal driving conditions as much as possible.
Note
When only the front or rear wheels are rotated on a chassis dynamometer or equivalent, the ABS CM
determines that there is a malfunction in the ABS and illuminates the following lights:
Vehicles with ABS
ABS warning light
Brake system warning light
If the above lights are illuminated, dismount the vehicle from the chassis dynal1')ometer and turn the
ignition switch to the LOCK position. Then, turn the ignition switch back to the ON position, run the vehicle
at 10 km/h or more and verify that the warning lights go out. In this case, a DTC will be stored in the
memory. Clear the DTC from the memory by following the memory clearing procedure [ABS] in the onboard diagnostic system. (See 04-02A-2 ON-BOARD DIAGNOSIS [REAR ABS].)(See 04-02B-2
ON-BOARD DIAGNOSIS [4W-ABS]
00-00-16
GENERAL INFORMATION
4WD inspection/service
Speedometer tester measurement
Caution
Install the tension bar (chain wire) to the tie down hook and secure the vehicle to prevent it from
rolling and running off.
Do not accelerate suddenly from a standstill or accelerate/decelerate rapidly.
Free roller type

1. Align the free rollers with the wheel base and tread, then set them on the floor properly.
2. Drive the vehicle slowly onto the tester roller and
free rollers.
3. Start the engine and accelerate gradually to
inspect the speedometer.
4. After inspection, decelerate gradually with gentle
braking.
Propeller shaft removal type
1. Remove the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAU
INSTALLATION.)
DBGOOOZWB022
2. Place the front wheels on the tester roller.

3. Accelerate gradually and inspect the
speedometer.
4. After inspection, decelerate gradually with gentle
braking.
5. Install the propeller shaft. (See 03-15-2
PROPELLER SHAFT REMOVAU
INSTALLATION.)
DBGOOOZWB023
Brake tester measurement

1. Place the wheels (front or rear) to be measured
on the tester roller.
2. Shift to the N position/neutral.
3. Activate the tester roller and measure braking
force.
If there is a large amount of brake drag force, the
electronic control system coupling may be
affected. Jack up all four wheels to eliminate the
effect of the coupling and rotate each wheel by
hand to verify the rotation condition.
DBGOOOZWB024
00-00-17
..
";
GENERAL INFORMATION
Wheel balancer (on the vehicle balancer)
1. Jack up all four wheels.
2. Support the wheels (front or rear) on the side to be measured (near the wheels) using a wheel balancer sensor
~
stand.
'3. Support the wheels on the side not to be
, measured (near the wheels) using safety stands.
4. Set up the wheel balancer and rotate the wheels
using engine drive to measure the wheel balance.
DBGOOOZWB025
SST
Some global SST or equivalent are used as SSTs necessary for vehicle repair. Note that these SSTs are
marked with global SST numbers.
Note that a global SST number is written together with a corresponding Mazda SST number as shown below.
Example (SERVICE TOOLS)
1: 49 UN303 009
2: 303-009
Crankshaft Damper Remover
1: Mazda SST number

B6EOOOZWC001
Example (Except SERVICE TOOLS)
-Global SST Number

303-009
(49 UN30 3009) -Mazda SST Number
B6EOOOZWC002
INSTALLATION OF RADIO SYSTEM
dcfOOOOOOOOOw21
If a radio system is installed improperly or if a high-powered type system is used, the CIS and other systems
may be affected. When the vehicle is to be equipped with a radio, observe the following precautions:
Install the antenna at the farthest point from control modules.
Install the antenna feeder as far as possible from the control module wiring harnesses.
Ensure that the antenna and feeder are properly adjusted.
Do not install a high-powered radio system.
00-00-18
GENERAL INFORMATION
ELECTRICAL SYSTEM
dcfOOOOOOOOOW22B:
Electrical Parts
Battery cable
Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
WGIWXX0039E
NO GOOD
Caution
Do not remove the wiring harness
protective tape. Otherwise, the wires
could rub against the body, which could
result in water penetration and electrical
shorting.
CHUOOOOW010
Connectors
Disconnecting connectors
When disconnecting a connector, grasp the
connectors. not the wires.
GOOD
NO GOOD
CHUOOOOW014
00-00-19
GENERAL INFORMATION
WGIWXX0042E
Locking connector
When locking connectors, listen for a click
indicating they are securely locked.
WGIWXX0043E
Inspection
measuring voltage, insert the tester probe from
the wiring harness side.
GOOD
NO GOOD
CHUOOOOW011
Inspect the terminals of waterproof connectors

from the connector side since they cannot be
accessed from the wiring harness side.
Caution
To prevent damage to the terminal, wrap
a thin wire around the tester probe before
inserting into terminal.
00-00-20
GOOD
NO GOOD
GENERAL INFORMATION
Terminals
Inspection
Pull lightly on individual wires to verify that they
are secured in the terminal.
~----------~BDI
WGIWXX0064E
Replacement
Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to
insert it until it locks securely.
Insert a thin piece of metal from the terminal side
of the connector and with the terminal locking tab
pressed down, pull the terminal out from the
connector.
WGIWXX0046E
Sensors, Switches, and Relays

Handle sensors, switches, and relays carefully.
Do not drop them or strike them against other
objects.
NO GOOD
CHUOOOOW013
00-00-21
GENERAL INFORMATION
Wiring Harness
Wiring color codes
Two-color wires are indicated by a two-color code
~I
symbol.
i The first letter indicates the base color of the wire
and the second is the color of the stripe.
COLOR
Black
CODE
COLOR
BR
G
Brown
Green
Orange
Pink
GY
L
Gray
Blue
LB
LG
Light Blue
Light Green
CODE
R
W
Y
BIR
BRIY
Red
Violet
White
Yellow
WGIWXX0048E
Fuse
Replacement
When replacing a fuse, be sure to replace it with
one of the same capacity. If a fuse malfunctions
again, the circuit probably has a short and the
wiring should be inspected.
Be sure the negative battery terminal is
disconnected before replacing a main fuse.
DCF921ZWB005
When replacing a pullout fuse, use the fuse puller.
PULLER
WGIWXX0050E
Viewing Orientation for Connectors

The viewing orientation for connectors is indicated with a symbol.
The figures showing the viewing orientation are the same as those used in Wiring Diagrams.
The viewing orientations are shown in the following three ways.
00-00-22
GENERAL INFORMATION
Part-side connector
The viewing orientation for part-side connectors is
from the terminal side.
* : Part names are shown only when there are
multiple connector drawings.
_______ PART NAME'

I
PCM
~I:
I~I
1
1111011111
I
VIEWING
CONNECTO~
"
(.
....
CORIENTATION
SYMBOL
PART
VIEWING ORIENTATION
PART-SIDE CONNECTOR
DBGOOOZWB015
Vehicle harness-side connector

The viewing orientation for vehicle wiring harnessside connectors is from the wiring harness side.
* : Part names are shown only when there are
multiple connector drawings.
NAME OF CONNECTING
PART'
PCM
~I
1 1 1 1 1
I
CONNECTOR
1 1 1 1 {I
VIEWING
ORIENTATION
SYMBOL
VEHICLE WIRING
HARNESS-SIDE
CONNECTOR
VIEWING ORIENTATION
VEHICLE WIRING HARNESS

DBGOOOZWB016
Other
When it is necessary to show the terminal side of the
vehicle wiring harness-side connectors, such as the
following connectors, the viewing orientation is from
the terminal side.
Main fuse block and the main fuse block relays
Data link connector
Check connector
Relay box
DLC-2
CONNECTOR
~~t
/~____
VEHICLE WIRING HARNESS
VIEWING
ORIENTATION
SYMBOL
VIEWING ORIENTATION
DBGOOOZWB017 _.
00-00-23
GENERAL INFORMATION
Electrical Troubleshooting Tools
Jumper wire
.,-.....
Caution
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.
A jumper wire is used to create a temporary

circuit. Connect the jumper wire between the
terminals of a circuit to bypass a switch.
WGIWXX0067E
Voltmeter
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 will be
measured and the negative (-) probe (black lead
wire) to a body ground.
POWER SOURCE LINE
Ohmmeter
Caution
Do not connect the ohmmeter to any circuit where voltage is applied. This will damage the
ohmmeter.
The ohmmeter is used to measure the resistance

between two points in a circuit and to inspect for
continuity and short circuits.
NO GOOD
POWER SOURCE LINE
CHUOOOOW005
00-00-24
GENERAL INFORMATION
Precautions Before Welding
A vehicle has various electrical parts. To protect the parts from excessive current generated when welding, be s u r e .
to perform the following procedure.

1. Turn the ignition switch to the LOCK position.
.
. . _
2. Disconnect the battery cables.
3. Securely connect the welding machine ground

near the welding area.
4. Cover the peripheral parts of the welding area to
protect them from weld spatter.
JACKING POSITIONS
dcfOOOOOOOOOw23
Warning
Lifting a vehicle that is not stabilized is dangerous. The vehicle can slip off the lift and cause
serious injury and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by
adjusting the height of the support at the end of the arm of the lift.
Use safety stands to support the vehicle after it has been lifted.
Front
Near the center of the crossmember.
2WD
00-00-25
GENERAL INFORMATION
4WD
DBGOOOZWB007
Rear
At the center of the rear differential.
VEHICLE LIFT (2 SUPPORTS) AND SAFETY STAND (RIGID RACK) POSITION
dcfOOOOOOOOOw24
Vehicle Lift Positions

Warning
Unstably lifting a vehicle is dangerous. The vehicle can slip off the lift and cause serious injury
and/or vehicle damage. Make sure that the vehicle is on the lift horizontally by adjusting the height
of support at the end of the arm of the lift.
Front
DBGOOOZWB003
Rear
DBGOOOZWB004
00-00-26
GENERAL INFORMATION
Safety Stand Positions
Front
DBGOOOZWB009
Rear
TOWING
dcfOOOOOOOOOw25
Proper lifting and towing are necessary to prevent damage to the vehicle.
Particularly when towing a 4WD vehicle, where all the wheels are connected to the drive train, proper
transporting of the vehicle is absolutely essential to avoid damaging the drive system. Government and local
laws must be followed.
A towed vehicle usually should have its rear
wheels off the ground. If excessive damage or
other conditions prevent this, use wheel dollies.
~~
WHEEL DOLLIES
~
DBGOOOZWB018
Caution
Do not tow with sling-type equipment.
This could damage the vehicle. Use
wheel-lift or flatbed equipment.
Caution
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.
1. Shift to neutral.
2. Turn the ignition switch to the ACC
pOSition.
3. Release the parking brake.
Remember that power assist for the
brakes and steering will not be available when the engine is not running.
DBGOOOZWB019
00-00-27
GENERAL INFORMATION
If the transmission, 4WD system, 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 or flatbed equipment.
Caution
Follow these instructions when towing the 4WD vehicle with all wheels on the ground or with the
front wheels on the ground and the rear wheels raised.
1. Put the transfer shift lever in 2H.
2. Set the remote free-wheel system to FREE mode.
Remember that power assist for the brakes and steering will not be available when the engine is
not running.
If towing service is not available in an emergency, the vehicle may be towed with all four wheels on the ground
using the towing hook at the front of the vehicle.
Only tow the vehicle on paved surfaces for short distances at low speeds.
TowinglTiedown Hooks
Caution
The towing hook should be used in an emergency (to get the vehicle out of a ditch for example).
When using the towing hooks, always pull the cable or chain in a straight direction with respect to
the hook. Apply no sideways force.
Don't use the tiedown hooks under the front for towing. They are designed ONLY for tying down
the vehicle when it's for towing will damage the bumper.
Note
When towing with chain or cable, wrap the chain or cable with a soft cloth near the bumper to prevent
damage to the bumper.
Towing Hooks
2WD (EXCEPT HI-RIDER)
DCFOOOZWB009
4WD (HI-RIDER)
TIEDOWN HOOKS
DCFOOOZWB006
00-00-28
GENERAL INFORMATION
Tiedown Hooks
Caution
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.
,---------------.D
2WD (EXCEPT HI-RIDER)
DCFOOOZWB007
4WD (HI-RIDER)
DCFOOOZWB008
IDENTIFICATION NUMBER LOCATIONS
dcfOOOOOOOOOw26
Vehicle Identification Number (VIN)
nRGnnn7WRnn?
Engine Identification Number
DBGOOOZWB005
00-00-29
GENERAL INFORMATION
NEW STANDARDS
dcfOOOOOOOOOw27

New Standard
Abbreviation
AP
APP
ACL
AlC
BARO
B+
Name
Accelerator Pedal
Air Cleaner
Air Conditioning
Barometric Pressure
Brake Switch
Calculated Load Voltage
LOAD
Charge Air Cooler
CAC
CLS
Closed Loop System
CTP
CPP
CIS
CS sensor Control Sleeve Sensor
Data Link Connector
DLC
DTM
DTC
DI
DLI
Electronic Ignition
EI
ECT
Engine Modification
EM
EVAP
EGR
Fan Control
FC
Flexible Fuel
FF
4GR
Fourth Gear
Fuel Pump Relay
-
FSO
solenoid
GEN
GND
H02S
lAC
Generator
Ground
Idle Air Control
IDM Relay
Injection Pump
InputlTurbine Speed Sensor
IAT
Knock Sensor
KS
MIL
MAP
Mass Air Flow
MAF
MFL
On-Board Diagnostic
OBD
OL
Open Loop
00-00-30
Previous Standard
Abbreviation
Accelerator Pedal
Air Cleaner
Air Conditioning
VB
Battery Voltage
Stoplight Switch
Crank Angle Sensor
Remark
Name
#6
Intercooler
Feedback System
Fully Closed
Clutch Position
EGI
Electronic Gasoline Injection System
CSP sensor Control Sleeve Position Sensor
Diagnosis Connector
Test Mode
Service Code(s)
Spark Ignition
Direct Ignition
Water Thermo
Engine Modification
Engine RPM Signal
Fan Control
Flexible Fuel
Overdrive
FCV
-
With heater
Open Loop
#3
Alternator
Ground/Earth
Oxygen Sensor
Idle Speed Control
Spill Valve Relay
#2
#6
Fuel Injection Pump

Pulse Generator
Intake Air Thermo
Knock Sensor
Intake Air Pressure
Mass Air Flow
Airflow Sensor
Diagnosis/Self Diagnosis
#1
Fuel Cut Valve
FIP
#6
#6
#6
GENERAL INFORMATION
New Standard
Abbreviation
Name
Previous Standard
Abbreviation
Output Speed Sensor

Catalytic Converter
Oxygen Sensor
Oxygen Sensor
Park/Neutral Range
PCM Control Relay
Main Relay
PSP
PCM
OC
02S
PNP
PIO
PAIR

ECU
Engine Control Unit
Pulsed
injection
#6
NE Sensor
AIR
Reed Valve
SFI
Shift Solenoid A
Shift Solenoid B
SAPV

Shift Solenoid C
3rd Gear
Catalytic Converter
Throttle Body
Throttle Position
Throttle Body
TCV
Throttle Position Sensor

Timer Control Valve
TCC
TWC
TB
TP
TP sensor
TCM
-
TCV
Throttle Sensor
Lockup Position

Module
Temperature Sensor
EC-AT Control Unit
ATF Thermosensor
TR
Inhibitor Position
TC
Turbocharger
Turbocharger

Voltage Regulator

IC Regulator
Air Flow Sensor
Catalytic Converter
Fully Open
VSS
VR

WUTWC
Converter
Wide Open Throttle
WOT
Injection
with air
pump

Third Gear
3GR
#4
Random Access Memory
Pump Speed Sensor
#6
RAM
Remark
Name
#6
#5
#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).
#4: Device that controls engine and powertrain
#5: Directly connected to exhaust manifold
#6: Part name of diesel engine
00-00-31
GENERAL INFORMATION
ABBREVIATIONS
id0000001572a2
Overdrive
CAN
Controller Area Network
OlD
OSS
PCM
PCV
PDS
PID
PRC
CM
Control Module
PIS
Power Steering
P/w
Power Window
Right Front
lABS
',AlC
Air Conditioning
IAT
ATDC
Automatic Transmission
After Top Dead Center
ATF
BTDC
Automatic Transmission Fluid

ECT
ELR
ESA
EX
GND
HI
HLA
HU
IDS
Emergency Locking Retractor

Electronic spark advance
Exhaust
Ground
High
Hydraulic lash adjuster
Hydraulic Unit
Integrated Diagnostic Software
Intake
RF
RFW
RH
RR
SAS
SST
SW
TDC
Output Shaft Speed

Positive crankcase ventilation
Portable Diagnostic Software
Pressure regulator control
Remote Freewheel
Right Hand
Right Rear
Sophisticated Air Bag Sensor
Switch
Top Dead Center
Transmission Fluid Temperature
Interm ittent
Intermediate Shaft Speed
TFT
TNS
TSS
Key On Engine Off

Key On Engine Running
VBC
VENT
LCD
LED
Liquid Crystal Display

Light Emitting Diode
VSC
WDS
LF
LH
Left Front
Left Hand
Low
W/M
Left Rear
Limited Slip Differential
3GR
4GR
Second Gear
Third Gear
Fourth Gear
Load Sensing Proportioning Valve

Motor
5GR
4W-ABS
4x2
4x4

4-wheel 2-d rive
4-wheel 4-drive
IN
INT
ISS
KOEO
KOER
LO
LR
LSD
LSPV
M
MAX
MIL
Maximum
MIN
Minimum
00-00-32
1GR
2GR
Tail Number Side Lights

Turbine Shaft Speed
Variable Boost Control
Ventilation
Variable Swirl Control
Worldwide Diagnostic System
Workshop Manual
First Gear
Fifth Gear
GENERAL INFORMATION
PRE-DELIVERY INSPECTION
dCfOOOOOOOOOW31,ID
Pre-Delivery Inspection Table

Exterior
INSPECT and ADJUST, if necessary, the following part to specification:
OGlass, exterior bright metal and paint for damage
OWheel lug nuts
OAII weatherstrips for damage or detachment
OOperation of bonnet release and lock
OOperation of fuel-filler lid
ODoor operation and alignment
OHeadlight aiming
TRUNK ROOM
OCheck spare tire and air pressure
INSTALL the following part:
OWheel caps (if equipped)
OMast antenna (if equipped)
I,
J'
Under bonnet-engine off

INSPECT and ADJUST, if necessary, the following part to, specification:
OFuel, engine coolant, and hydraulic lines, fittings, connections, and components for leaks
OEngine oil level
OPower steering fluid level (if equipped)
OBrake and clutch master cylinder fluid level
OWasher tank fluid level
ORadiator coolant level and specific gravity
OTightness of battery terminals
ODrive belt tensions
Interior
INSPECT the operations of the following part:
OSeat controls (slide and recline)
OSeat belts
OAir bag system using warning light
OCruise control system (if equipped)
OEngine switch and steering lock
OStarter interlock (if equipped)
OPower door lock (if equipped)
ODoor locks
OAII lights including warning, and indicator lights
OHorn, wipers, and washers
OWiper blades performance
OAudio system
OPower windows (if equipped)
ODefroster, and air conditioner at various mode selections (if equipped)
INSPECT the following part:
OPresence of spare fuse
OUpholstery and interior finish
INSPECT and ADJUST, if necessary, the following part:
OPedal height and free play of brake and clutch pedal
OParking brake
Under bonnet-engine running at operating temperature
INSPECT the following items:
Olgnition timing
On hoist
OUnderside fuel, engine coolant and hydraulic lines, fittings, connections, and components for leaks
OTires for cuts or bruises
OSteering linkage, suspension, exhaust system, and all underside hardware for looseness or damage
OManual transmission oil level
ODifferential oil level
OTransfer oil level
00-00-33
GENERAL INFORMATION
Road test
OBrake operation
~ OClutch operation
. .:WSteering control
OEngine general performance
OOperation of transfer
OEmergency locking retractors
OCruise control system (if equipped)
OOperation of meters and gauges, squeaks, rattles, and unusual noises
After road test
INSPECT for necessary owner information materials, tools, and spare tire in vehicle
The following part must be completed just before delivery to your customer.
OLoad test battery and charge if necessary (Load test result: Volts)
OAdjust tire pressure to specification
OClean outside of vehicle
Olnstall fuses for accessories
ORemove seat and cabin carpet protective covers
OVacuum inside of vehicle
Olnspect installation of option parts with invoice
SCHEDULED MAINTENANCE
Scheduled Maintenance Table for Australia.
Number of months or kilometers, whichever comes first
Months
12
18
24 30
36
42
48
x1000 km
10
20
30
40 50
60
70
80
Maintenance Interval
Engine valve clearance
54 60
10
90
0
66
11
0
72
12
78
13
0
84
14
0
90
15
96
16
0
I
Replace every 120,000 km
Engine timing belt *1

Engine oil *2
Engine timing belt auto tensioner

R

R
R
R
R
R
R
Engine oil filter *2
Drive belts *3
Cooling system (Including coolant level

adjustment)
Engine coolant
Others
C
Fuel filter
I
Brake lines, hoses and connections

Brake fluid *6
00-00-34
R
C
Fuel injection pump inlet filter

Fuel lines and hoses
Air intake system
Battery electrolyte level and specific gravity
Replace at first 200,000km or 10 years;

after that, every 100,000 km or 5 years
Replace at first 80,000 km or 4 years; after that, every 2 years
FL22 type *4
Air cleaner element *5
R
C
I
C
I
C
I
C
I
C
I
C
I
I
I
I
I
I
I
I
I
I
I
I
I
R
C
I
I
I
I
I
I
I
GENERAL INFORMATION
Parking brake
Power brake unit (Brake booster) and hoses
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Disc brakes *7
Drum brakes *7
Power steering fluid, lines, hoses and
connections
Steering operation and linkages
Manual transmission oil
I
I
*7
I
I
I
I
*8
Automatic transmission fluid
*8 *9
Rear differential oil (for 4x2)
*8
Front and rear differential oil (for 4x4) *8

for Manual
Transmission *8
Transfer oil (for 4x4)
for Automatic
Transmission *8 *9
Driveshaft dust boots (for 4x4)
Front and rear propeller shaft joints (for 4x4)
Front and rear suspension and ball joints
Front wheel bearing grease (for 4x2 except
Hi-Rider)
Wheel bearing lateral play (frqnt) and axial
play (rear)
Exhaust system and heat shields
Bolts and nuts on chassis and body
Body condition (for rust, corrosion and
perforation)
Tires (including spare tire)(with inflation
pressure adjustment)
Tire rotation *9
Road test
Diagnostic check of Vehicle Management and
Safety Systems
I
I
I
I
I
I
I
I

R

L
I
I
L
I
L
I
I
L
I
L
I
I
L
I
L
I
I
L
I
Inspect every 80,000km

T
T
T
Inspect annually
I
Rotate every 10,000 km or 6 months

I
I
I
I
I
I
I
I
I
I
I
I
I
Chart symbols
I: Inspect: Inspect and clean, repair, adjust, or replace if necessary.
R: Replace
C: Clean
L: Lubricate
T: Tighten
Remarks
Emission control and related systems
The ignition and fuel systems are highly important to the emission control system and to efficient engine
operation.
All inspections and adjustments must be made by an expert repairer, we recommend an Authorized Ford
Repairer.
After the prescribed period, continue to follow the described maintenance at the recommended intervals.
Refer below for a description of items marked* in the maintenance chart.
*1: Replacement of the timing belt is required at every 120,000 km. Failure to replace the timing belt may result
in damage to the engine.
*2: If the vehicle is operated primarily under any of the following conditions, replace the engine oil and oil filter
more often than the recommended intervals.
a. Driving in dusty conditions
b. Extended periods of idling or low speed operation
c. Driving for long period in cold temperatures or driving regularly at short distance (less than 8 km) only
*3: Also inspect and adjust the power steering and air conditioner drive belts, if installed.
00-00-35
GENERAL INFORMATION
*4: Use FL22 type coolant in vehicles with the inscription "FL22" on the radiator cap itself or the surrounding
area. Use FL22 when replacing the coolant.
*5: If the vehicle is operated in very dusty or sandy areas, clean the air cleaner element at every 5,000 km or 3
months.
~'6: If the brakes are used extensively (for example, continuous hard driving or mountain driving) or if the vehicle
/ is operated in extremely humid climates, replace the brake fluid annually.
*7: If the vehicle is operated primarily under any of the following conditions, inspect the these items more often
than the recommended intervals.
a. Driving on bumpy roads, gravel roads, snowy roads or dirt roads
b. Driving uphill and downhill frequently
c. Repeated short-distance driving
*8: If this component(s) has been submerged in water, the oil should be replaced.
*9: If the vehicle is operated primarily under any of the following conditions, replace the fluid as follows.
- Automatic transmission: Every 50,000 km.
- Transfer case (attached to automatic transmission): Every 100,000 km.
a. Towing a trailer
b. Extension idling and/or low speed driving for long distances as in heavy commercial use such as
delivery, taxi, patrol car or livery
c. Operating in dusty conditions such as unpaved or dusty roads
d. Off-road operations
*10: If the vehicle is operated primarily under any of the following conditions, rotate the tires more often than the
recommended intervals.
a. Driving on bumpy roads, gravel roads, snowy roads or dirt roads
b. Driving uphill and downhill frequently
c. Repeated short-distance driving
00-00-36
GENERAL INFORMATION
Scheduled Maintenance Service (Specific Work Required)
The specific work required for each maintenance item is listed in the following table. (Please refer to the section
applicable to the model serviced.)
Specific Work Required
Maintenance Item
ENGINE
Engine valve clearance

Engine timing belt
Engine timing belt auto tensioner
Drive belts
Engine oil
Engine oil filter
Inspect engine vale clearance.

Replace engine timing belt.
Replace engine timing belt auto tensioner.
Inspect for wear, cracks, fraying and tension.
Replace engine oil and inspect for leakage.
Replace engine oil filter and inspect for leakage.
COOLING SYSTEM
Cooling system (Including coolant level

adjustment)
Radiator cap
Engine coolant
Check engine coolant level and quality, and inspect for leakage.
Inspect radiator cap.
Replace engine coolant.
FUEL SYSTEM
Idle speed
Idle mixture
Choke system
Air cleaner element
Fuel filter
Fuel injection pump inlet filter
Fuel lines and hoses
Fuel lines, hoses and connections
Fuel injection system
Fuel system (Drain water)
Diesel particulate filter
Fuel additive for diesel particulate filter
Check engine idle rpm.

Inspect the CO and HC concentrations (see W/M).
Check system operation.
Inspect dirt, oil and damage.
Clean air cleaner element (by blowing air).
Replace air cleaner element.
Replace fuel filter.
Clean fuel injection pump inlet filter.
Inspect for cracks, leakage and loose connection.
Update to injection amount correction with current diagnostic tool (see W/M).
Drain water in fuel system.
Replace diesel particulate filter.
Fill up fuel additive.
IGNITION SYSTEM
Initial ignition timing

Spark plugs
Ignition cables condition/security
Check initial ignition timing.

Inspect for wear, damage, carbon, plug gap and high-tension lead condition.
Replace spark plugs.
Inspect for damage, condition and connection.
EMISSION CONTROL SYSTEM
Evaporative system
Evaporative emission control system
Crankcase emission control system
E.G.R system
Air intake systom
Throttle positioner system
Dash pot
Check system operation (see W/M), vapor lines, vacuum fitting hoses and
connection.
Check system operation (see W/M), PCV valve, blow-by lines, vacuum fitting
hoses and connection.
Check system operation (see W/M), vacuum fitting hoses and connection.
MZR-CD (RF turbo) engine: Update to MAF correction for E.G.R control with
current diagnostic tool (see W/M).
Update to MAF correction (see W/M).
Check the diaphragm and system operation, vacuum fitting hoses and connection.
Check system operation.
ELECTRICAL SYSTEM
Battery electrolyte level and specific

gravity
Battery condition
Battery
All electrical system
Lighting system and windshield wipers
and washer
Head light alignment
Check battery electrolyte level and specific gravity.

Check battery for corroded or loose connections and cracks.
Check battery for leakage and corrosion.
Check function of lighting system, windshield wiper (including wiper blade
condition), washer and power windows.
Check head light alignment.
CHASSIS AND BODY
Brake and clutch pedals

Brake pedals
00-00-37
Check pedal height and free play.
GENERAL INFORMATION
Brake fluid
Clutch fluid
Brake lines, hoses and connections
Parking brake
Power brake unit and hoses
Power brake unit (Brake booster) and
hoses
Disc brakes
Drum brakes
Manual steering gear oil
Power steering fluid, lines, hoses and
connections
Power steering fluid and lines
Steering operation and gear housing
Steering linkages tie rod ends and arms
Steering operation and linkages
Front and rear suspension and ball joints

Front suspension ball joints
Front and rear suspension, ball joints and
wheel bearing axial play
Wheel bearing axial play
Manual transmission/transaxle oil
Automatic transmission/transaxle fluid
level
Automatic transmission/transaxle fluid
Front and rear differential oil
Front differential oil
Front axle oil
Rear differential oil
Rear axle oil
Transfer oil
Front and rear wheel bearing grease
Front wheel bearing grease
Check brake fluid level and for leakage.

Replace brake fluid.
Check Clutch fluid level and for leakage.
Inspect for cracks, damage, chafing, corrosion, scars, swelling and fluid leakage.
Check parking lever stroke.
Check vacuum lines, connections, and check valve for improper attachment, air
tightness, cracks chafing and deterioration.
Inspect caliper for correct operation and fluid leakage, brake pads for wear. Check
disc plate condition and thickness. Test for judder and noise.
Inspect brake drum for wear and scratches: brake lining for wear, peeling and
cracks; wheel cylinder for fluid leakage. Test for judder and noise.
Check manual gear oil level.
Check power steering fluid level and lines for improper attachment, leakage,
cracks, damage, loose connections, chafing and deterioration.
Check that the steering wheel has the specified play. Be sure to check for
changes, such as excessive play, hard steering or strange noises. Check gear
housing and boots for looseness, damage and grease/gear oil leakage. Check ball
joint, dust cover and other components for looseness, wear, damage and grease
leakage.
Inspect for grease leakage, crack, damage and looseness.
Inspect for grease leakage, crack, damage, looseness and wheel bearing play/
noise.
Inspect for wheel bearing play/noise.
Check manual transmission/transaxle oil level and for leakage.
Replace manual transmission/transaxle oil.
Check automatic transmission/transaxle fluid level.
Replace automatic transmission/transaxle fluid.
Check front and rear differential oil level and inspect for leakage.
Replace front and rear differential oil.
Check transfer oil level inspect for leakage.

Replace transfer oil
Remove wheel bearing and replace wheel bearing grease.
Inspect wheel bearing play and noise.

_ Wheel bearing axial play
Wheel bearing axial play (rear) and lateral
play (front)
Lubricate propeller shaft joints.
Propeller shaft joints
Front propeller shaft joints
Rear propeller shaft joints
Inspect for grease leakage, crack, damage and looseness.
Driveshaft dust boots
Tighten wheel nuts.
Wheel nuts
Bolts and nuts on chassis and body
Bolts and nuts on seats
Body condition (for rust, corrosion and
perforation)
Exhaust system and heat shields
Exhaust pipe connections
Tighten bolts and nuts fastening suspension components, members and seat
frames.
Inspect body surface for paint damage, rust, corrosion and perforation.
Tire rotation
Tires (Including spare tire)(with inflation
pressure adjustment)
Rotate tires.
Check air pressure and inspect tires for tread wear, damage, cracks; and wheels
for damage and corrosion.
Flat tire repair kit
Check tire repair fluid expiration date.
Hinges and catches

Underside of vehicle
Lubricate hinges and catches of doors, trunk lid and hood.
Inspect for damage, corrosion, looseness of connections and gas leakage.
Inspect underside of vehicle (floor pans, frames, fuel lines, around exhaust system
etc.) for damage and corrosion.
00-00-38
GENERAL INFORMATION
Road test
Check brake operation/clutch operation/steering control/operation of meters and

gauges/squeaks, rattles, or unusual noises/engine general performance/
emergency locking retractors.
Check diagnostic trouble code with current diagnostic tool (see W/M).
Diagnostic trouble code by current

diagnostic tool
Diagnostic check of Vehicle Management Check the items below with WDS (see W/M).
and Safety Systems
(1) Retrieve All CMDTCs
(2) PCM function test (except diesel engine models)
(3) PCM InpuVOutput Data Monitor (except diesel engine models)
(4) Adviser Comment (except diesel engine models)
AIR CONDITIONER SYSTEM
Cabin air filter
00-00-39
Replace cabin air filter.
01
ENGINE
OUTLINE .................
ON-BOARD DIAGNOSTIC
[WL-3] . . . . . . . . . . . . . . . . ..
ON-BOARD DIAGNOSTIC
[WL-C, WE-C] . . . . . . . . . . . .
SYMPTOM
TROUBLESHOOTING
[WL-3] . . . . . . . . . . . . . . . . . .
SYMPTOM
TROUBLESHOOTING
[WL-C, WE-C] . . . . . . . . . . ..
MECHANICAL [WL-3] .......
MECHANICAL
[WL-C, WE-C] . . . . . . . . . . . .
LU BRICATION [WL-3]. . . . . ..
LUBRICATION
[WL-C, WE-C] . . . . . . . . . . ..
COOLING SYSTEM [WL-3] ...
COOLING SYSTEM
[WL-C, WE-C] . . . . . . . . . . . .
INTAKE-AIR SYSTEM
[WL-3] . . . . . . . . . . . . . . . . ..
01-00
01-02A
01-02B
01-03A
01-03B
01-10A
01-10B
01-11 A
01-11 B
01-12A
01-12B
01-13A
SECTION
INTAKE-AIR SYSTEM
[WL-C, WE-C] ............. 01-13B
FUEL SYSTEM [WL-3] ....... 01-14A
FUEL SYSTEM
[WL-C, WE-C] ............. 01-14B
EXHAUST SYSTEM [WL-3] ... 01-15A
EXHAUST SYSTEM
[WL-C, WE-C] ............. 01-15B
EMISSION SYSTEM [WL-3] ... 01-1SA
EMISSION SYSTEM
[WL-C, WE-C] ............. 01-1S.B
CHARGING SYSTEM ........ 01-17
STARTING SYSTEM ......... 01-19
CONTROL SYSTEM [WL-3] ... 01-40A
CONTROL SYSTEM
[WL-C, WE-C] ............. 01-40B
TECHNICAL DATA [WL-3] .... 01-50A
TECHNICAL DATA
[WL-C, WE-C] ............. 01-50B
SERVICE TOOLS [WL-3] ..... 01-S0A
SERVICE TOOLS
[WL-C, WE-C] ............. 01-S0B
\.
01-00
OUTLINE
ENGINE TECHNICAL DATA [WL-3] ... 01-00-1
ENGINE TECHNICAL DATA [WL-3]
dcf01000000Ow01
Drive Belt Deflection

Drive Belt
Generator
a
Ale
b
(mm {in})
New*
Used
7.4-9.4
{0.30-D.37}
6.1-6.9
{0.24-D.27}
10.0-11.0
{0.40-D.43}
8.7-10.4
{0.35-0.40}
7.1-8.0
{0.28-0.31}
11.3-12.6
{0.45-0.49}
Limit
14.3 {0.56} or more
11.3{0.44} or more
17.4 {0.69} or more
01-00-1
OUTLINE
Drive Belt Tension
Drive Belt
New
490-637
{50.0-64.9, 111-143}
Generator
455-572
{46A-58.3,103-128}
AlC
(N {kgf, Ibf})
Used
Limit
431-539
{44.0-54.9,96.9-121}
353-431
{36.0-43.9, 79A-96.8}
225 {22.9, 50.6} or less

156 {15.9, 35.1} or less
Specification
Item

Compression (kPa {kgf/cm 2 , psi} [rpm])

IN: 0.05 - 0.15 mm {0.0020 - 0.0059 in}

EX: 0.15 -0.25 mm {0.0060 - 0.0098 in}
Standard: 2,942 {30, 427} [200]
Minimum: 2,648 {27, 384} [200]
63.0 mm {2A8 in}
Bolt head mark W
Bolt head mark N
Standard length: 113.2-113.8 mm {4A57-4A80 in}
0.50-1.0 mm {0.020-0.039 in}
0.0-0040 mm {0.0-0.015 in}
0.95-1.05 mm {0.038-0.041 in}
410-570 kPa {4.19-5.81 kgf/cm 2 , 59.6-82.6 psi}
Oil pressure [2,500 rpm]

Specification
API CO, CE or CF-4
5W-30,10W-30
Item
Grade
Viscosity (SAE)
Item
Oil capacity (approx. quantity)

Engine coolant capacity (approx. quantity)
Cooling system cap valve opening pressure
Initial-opening temperature and lift of the valve
Full open temperature
Full open life
Battery electrolyte specific gravity [20C {68 OF}]
Battery load test current
Battery back-up current
Battery slow charge current
Battery quick charge current [30 min.]
Tightening torque:
Generator standard voltage [Engine switch ON]
01-00-2
Specification
Oil replacement: 5.5 {5.8 US qt, 4.8 Imp qt}
Oil and oil filter replacement: 6.2 {6.6 US qt, 5.5 Imp qt}
Total (dry engine): 6.7 {7.1 US qt, 5.9 Imp qt}
0.0-0040 mm {0.0-0.015 in}
0.0-0040 mm {0.0-0.015 in}
0.10-0.19 mm {0.0040-0.0074 in}
0.20 mm {0.0079 in}
0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
43.8 mm {1.72 in}
8.8 L {9.3 US qt, 7.7 Imp qt}
93.2-122.6 kPa {0.95-1.25 kgf/cm 2 , 13.5-17.8 psi}

80-84 C {176-183 OF}
95C {203 OF}
8.5 mm {0.33 in} or more
1.22-1.29
65031R (56): 165 A
95031 R (64): 250 A
Vehicles with immobilizer system: 5-25 mA
Vehicles without immobilizer system: 10 mA or less
65031 R (56): 4.0-5.0 A
95031 R (64): 6.5-8.0 A
65031 R (56): 30 A
95031 R (64): 40 A
12-25 Nm {123-254 kgfcm, 107-221 inlbf}
Terminal B: B+
Terminal L: Approx. 1 V
Terminal S: B+
OUTLINE
Item
Generator standard voltage [Idle, 20C {68 OF}]
Specification
Terminal B: 14.1-14.7 V
Terminal L: 13.0-14.0 V
Terminal S: 14.1-14.7 V
Generator generated current (reference value) [Conditions] Ambient temperature: 20C {68 OF}, Voltage:
13.5 V, Engine hot
Engine speed (rpm)
Terminal B current (Lower limit of current must be more than 0 A.)
1,000
2,000
Item
Generator rotor resistance (between slip rings) [20C
{68 OF}]
Generator brush length

Generator brush spring force
Starter no load test voltage
Starter no load test current
Starter pinion gap
Starter armature runout
Starter commutator diameter
Segment groove depth of starter commutator
Starter brush length
Starter brush spring force
Q-55A
Q-70A
Specification
2.3-2.7 ohms
Standard: 18.5 mm {0.73 in}
Minimum: 5.0 mm {0.2 in}
Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-1.34 Ibf}
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
11 V
130 A or less
o mm {O in}
0.1 mm {0.039 in} max.
Standard: 32 mm {1.26 in}
Minimum: 11 mm {0.43 in}
Standard: 26.7-36.1 N {2.73-3.68 kgf, 6.01-8.11Ibf}
Minimum: 14.7 N {1.5 kgf, 3.3Ibf}
01-00-3
01-02B ON-BOARD DIAGNOSTIC [WL-C, WE-C]

ON-80ARD DIAGNOSTIC
WIRING DIAGRAM [WL-C, WE-C] 01-028-2
FOREWORD [WL-C, WE-C] ...... 01-028-6
PENDING TROU8LE CODES
[WL~C, WE-C] ............ 01-028-6
FREEZE FRAME DATA [WL-C, WE-C] . 01-028-6
READ/CLEAR DIAGNOSTIC
TEST RESULTS [WL-C, WE-C] ..... 01-028-6
PARAMETER IDENTIFICATION
(PID) ACCESS [WL-C, WE-C] ....... 01-028-6
ON-80ARD DIAGNOSTIC TEST
[WL-C, WE-C] ................. 01-028-7
AFTER REPAIR PROCEDURE
[WL-C, WE-C] . . . . . . . . . . . . . . 01-028-10
KOEO/KOER SELF TEST
[WL-C, WE-C] .............. 01-028-10
DTC TA8LE [WL-C, WE-C] ........ 01-028-11
DTC P0016 [WL-C, WE-C] ....... 01-028-15
DTC P0045 [WL-C, WE-C] ........... 01-028-16
DTC P0046 [WL-C, WE-C] ........... 01-028-18
DTC P0047 [WL-C, WE-C] ........... 01-028-19
DTC P0048 [WL-C, WE-C] ....... 01-028-21
DTC P0088 [WL-C, WE-C] ....... 01-028-23
DTC P0093 [WL-C, WE-C] ......... 01-028-24
DTC P0097 [WL-C, WE-C] ......... 01-028-25
DTC P0098 [WL-C, WE-C] . . . . . . . 01-028-27
DTC P0102 [WL-C, WE-C] ...... 01-028-29
DTC P0103 [WL-C, WE-C] ........... 01-028-31
DTC P0106 [WL-C, WE-C] ........... 01-028-33
DTC P0107 [WL-C, WE-C] . . . . . . . . 01-028-35
DTC P0108 [WL-C, WE-C] ....... 01-028-38
DTC P0112 [WL-C, WE-C] ....... 01-028-41
DTC P0113 [WL-C, WE-C] ........ 01-028-42
DTC P0117 [WL-C, WE-C] ......... 01-028-44
DTC P0118 [WL-C, WE-C] ........ 01-028-46
DTC P0122 [WL-C, WE-C] ...... 01-028-48
DTC P0123 [WL-C, WE-C] ........... 01-028-50
DTC P0182 [WL-C, WE-C] ........... 01-028-52
DTC P0183 [WL-C, WE-C] .......... 01-028-54
DTC P0191 [WL-C, WE-C] ........ 01-028-56
DTC P0192 [WL-C, WE-C] ......... 01-028-57
DTC P0193 [WL-C, WE-C] ......... 01-028-59
DTC P0201 [WL-C, WE-C] ....... 01-028-61
DTC P0202 [WL-C, WE-C] ....... 01-028-62
DTC P0203 [WL-C, WE-C] ........ 01-028-64
DTC P0204 [WL-C, WE-C] ........ 01-028-66
DTC P0222 [WL-C, WE-C] .......... 01-028-68
DTC P0223 [WL-C, WE-C] ....... 01-028-71
DTC P0227 [WL-C, WE-C] ..... 01-028-74
DTC P0228 [WL-C, WE-C] ......... 01-028-76
DTC P0300 [WL-C, WE-C] ........... 01-028-78
DTC P0301, P0302, P0303,
P0304 [WL-C, WE-C] ...... 01-028-80
DTC P0335 [WL-C, WE-C] ....... 01-028-81
DTC P0340 [WL-C, WE-C] ......... 01-028-84
DTC P0380 [WL-C, WE-C] .......... 01-028-86

DTC P0403 [WL-C, WE-C] ............ 01-028-89
DTC P0405 [WL-C, WE-C] ........ 01-028-91
DTC P0406 [WL-C, WE-C] ....... 01-028-93
DTC P0489 [WL-C, WE-C] ......... 01-028-95
DTC P0490 [WL-C, WE-C] ......... 01-028-96
DTC P0500 [WL-C, WE-C] ...... 01-028-98
DTC P0563 [WL-C, WE-C] ..... 01-028-100
DTC P0602 [WL-C, WE-C] ....... 01-028-102
DTC P0606, P2530 [WL-C, WE-C] ... 01-028-102
DTC P0607 [WL-C, WE-C] ....... 01-028-102
DTC P0610 [WL-C, WE-C] .... 01-028-103
DTC P0627 [WL-C, WE-C] .......... 01-028-104
DTC P0628 [WL-C, WE-C] ......... 01-028-106
DTC P0629 [WL-C, WE-C] ........ 01-028-107
DTC P0642 [WL-C, WE-C] ..... 01-028-109
DTC P0643 [WL-C, WE-C] ....... 01-028-112
DTC P0652 [WL-C, WE-C] .......... 01-028-116
DTC P0653 [WL-C, WE-C] ........ 01-028-119
DTC P0660 [WL-C, WE-C] ........ 01-028-123
DTC P0661 [WL-C, WE-C] ........... 01-028-125
DTC P0662 [WL-C, WE-C] ........ 01-028-127
DTC P0663 [WL-C, WE-C] ........ 01-028-128
DTC P0664 [WL-C, WE-C] ....... 01-028-130
DTC P0665 [WL-C, WE-C] ......... 01-028-132
DTC P0685 [WL-C, WE-C] .......... 01-028-134
DTC P0698 [WL-C, WE-C] .......... 01-028-136
DTC P0699 [WL-C, WE-C] ......... 01-028-138
DTC P1196 [WL-C, WE-C] .......... 01-028-141
DTC P1259 [WL-C, WE-C] ........... 01-028-142
DTC P1260 [WL-C, WE-C] ........ 01-028-144
DTC P1391 [WL-C, WE-C] ..... 01-028-144
DTC P1392 [WL-C, WE-C] ....... 01-028-147
DTC P1602 [WL-C, WE-C] ......... 01-028-149
DTC P1603 [WL-C, WE-C] ......... 01-028-149
DTC P1604 [WL-C, WE-C] ....... 01-028-150
DTC P1621, P1622, P1623,
P1624 [WL-C, WE-C] ............. 01-028-150
DTC P1675 [WL-C, WE-C] ......... 01-028-151
DTC P1676 [WL-C, WE-C] ..... 01-028-152
DTC P2135 [WL-C, WE-C] .......... 01-028-152
DTC P2136 [WL-C, WE-C] ........ 01-028-153
DTC P2143 [WL-C, WE-C] ...... 01-028-154
DTC P2144 [WL-C, WE-C] ........ 01-028-156
DTC P2145 [WL-C, WE-C] .......... 01-028-158
DTC P2146 [WL-C, WE-C] ....... 01-028-160
DTC P2147 [WL-C, WE-C] ..... 01-028-160
DTC P2148 [WL-C, WE-C] ........ 01-028-162
DTC P2149 [WL-C, WE-C] ......... 01-028-164
DTC P2150 [WL-C, WE-C] ....... 01-028-165
DTC P2151 [WL-C, WE-C] .... 01-028-167
DTC P2227 [WL-C, WE-C] ......... 01-028-170
DTC P2228 [WL-C, WE-C] ......... 01-028-170
DTC P2229 [WL-C, WE-C] ...... 01-028-171
01-028-1

ON-BOARD DIAGNOSTIC WIRING DIAGRAM [WL-C, WE-C]
dcf010200000w23

r-------~-o------_{D
-+--+-+LOCK
Hf-I--HH
ACC
IG1
-I::-+-----{ E
IG2
STA
DLC
IG-
FEN
KLN
TEN
DLC-2
KLN
L----iTEN
PCM
(BUILT INTO
BARO SENSOR)
GLOW INDICATOR
LIGHT
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG 102BWBY01
01-028-2
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
ECT
SENSOR
CMPSENSOR
L.!:::t---\
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKP SENSOR
PCM
BLOWER '------'
MOTOR
1- ............ ..
REFRIGERANT
PRESSURE
SWITCH (LOW)
..
~~-;-~ ~-+~~
AlC
COMPRESSOR
--------- .. - .... _-------- .... ---,
VARIABLE SWIRL :
CONTROL
:
SOLENOID VALVE :
AlC RELAY
:AlC
: SWITCH
THERMO SWITCH
'- - - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - - -
DBG102BWBY02
01-028-3

..J--f-----i E
STA
DLC
IG-
FEN
KLN
TEN
DLC-2
KLN
'----iTEN
CAN_H
CAN_L
GLOW INDICATOR
LIGHT
~--I--------1f--------(
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.4
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-028-4
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
ECT
SENSOR
CMP SENSOR
L':::':t----;
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
11---+--0 o---+--+-... GLOW
BLOWER
MOTOR
L...-_----I
PLUG
RELAY
1-"""""" ..
:AlC
REFRIGERANT
PRESSURE
SWITCH (LOW)
~~-;-~ o--+~~
AlC
..
---------------------------.
VARIABLE SWIRL :
CONTROL
:
SOLENOID VALVE :
COMPRESSOR
AlC RELAY
:SWITCH
:
THERMO SWITCH
'- - - - - - - - - - - - - - - . WITH AlC - - - - - - - - - - - - - - DBG102BWBY02
01-028-5

FOREWORD [WL-C, WE-C]
dcf010200000w24
When the customer reports a vehicle malfunction, check the malfunction indicator light (MIL) indication and
diagnostic trouble code (DTC), then diagnose the malfunction according to following flowchart.
If the DTC exists, diagnose the applicable DTC inspection. (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
If the DTC does not exist and the MIL does not illuminate, diagnose the applicable symptom
troubleshooting.
CUSTOMER ARRIVES
~~======~Q~======~~
~------~----------~
NO WARNING LIGHT'
WITH SYMPTOM
WARNING LIGHT'
ON/FLASHING
CHECK FOR
PRIORITIZED DTC
11::
CHECK DTC
ENGINE ON TEST, IDLING TEST
DTC
!I
~================={,.
DIAGNOSE BY DTC
DTCTABLE
DTC
TROUBLESHOOTING
FLOW
WITHOUT DTC
DIAGNOSE BY SYMPTOM
1. DIAGNOSTIC INDEX
3. SYMPTOM TROUBLESHOOTING
DPE102BW1074
*: Malfunction Indicator Light (MIL), Generator Warning Light, Security Light

PENDING TROUBLE CODES [WL-C, WE-C]
dcf010200000w25
The MIL is illuminated when a malfunction is detected in two consecutive drive cycles. The code for a failed
system is stored in the PCM memory in the first drive cycle. This code is called the pending code. If the
malfunction is not found in the second drive cycle, the PCM determines that the system returned to normal or
the malfunction was mistakenly detected, and deletes the pending code. If the malfunction is found in the
second drive cycle too, the PCM determines that the system has failed, deletes the pending code, illuminates
the MIL and stores the DTC.
FREEZE FRAME DATA [WL-C, WE-C]
dcf010200000w26
This is the technical data which indicates the engine's condition at the time of the first malfunction. This data
will remain in the memory.
READ/CLEAR DIAGNOSTIC TEST RESULTS [WL-C, WE-C]
dcf010200000w27
This retrieves all stored DTCs in the PCM and clears the DTC, Freeze Frame Data, MIL, Distance Travelled
While MIL and Pending Trouble Codes.
PARAMETER IDENTIFICATION (PID) ACCESS [WL-C, WE-C]
dcf010200000w28
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, inspect each
device to identify which output devices are malfunctioning.
01-028-6

ON-BOARD DIAGNOSTIC TEST [WL-C, WE-C]
dcf010200000w15
DTC Reading Procedure

Using PDS/IDS
1. Connect the PDS/IDS to the DLC-2.
2. After the vehicle is identified, select the following
items from the initial screen of the PDS/IDS.
When using the IDS (notebook PC)
1. Select the "Toolbox" tab.
2. Select "SelfTest".
3. Select "Module".
4. Select "PCM".
When using the PDS (pocket PC)
1. Select "Module Tests".
2. Select "PCM".
3. Then, select the "Retrieve CMDTCs" and perform
procedures according to directions on the PDSI
IDS screen.
4. Verify the DTC according to the directions on the PDS/IDS screen.
If any DTCs are displayed, perform troubleshooting according to the corresponding DTC inspection.
5. After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
Using WDS
1. Perform the necessary vehicle preparation and visual inspection.
r'---------------------,
2. Connect the WDS to the DLC-2.
3. Retrieve the DTCs using the WDS.
DBG110BWBA01
Pending Trouble Code Access Procedure

Using PDS/IDS
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
IDS screen.
4. Retrieve the pending trouble codes according to the directions on the PDS/IDS screen.
DBG110BWBA01
01-028-7

Using WDS
,-------------------,
3. Retrieve the pending trouble codes using the
WDS.
DBG110BWBA01
Freeze Frame PID Data Access Procedure

Using PDSIIDS
items from the initial screen of the PDS/IDS .
3. Select "Module".
4. Select "PCM" .
2. Select "PCM".
procedures according to directions on the PDS/
IDS screen.
4. Retrieve the freeze frame PID data according to the directions on the PDS/IDS screen.
DBG110BWBA01
Using WDS
,-------------------,
3. Record the freeze frame PID data using the WDS.
DBG110BWBA01
PID/DATA Monitor And Record Procedure

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.
01-028-8

Using PDSIIDS
2. Select "DataLogger".
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
3. Select the PID from the PID table.
4. Verify the PID data according to the directions on
the PDS/IDS screen.
Using WDS
,--------------------,
3. Access and monitor the PIDs using the WDS.
DBGll0BWBAOl
Simulation Function Procedure

USing PDS/IDS
1. Connect the PDS/I DS to the DLC-2.
1. Select the ''Toolbox'' tab.
2. Select "Data Logger" .
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
DBGll0BWBAOl
3. Select the simulation items from the PID table.
4. Perform the simulation function, inspect the
operations for each parts.
If there is no operation sound from the relay, motor, and solenoid after the simulation function inspection is
performed, it is possible that there is an open or short circuit in the wiring harness, relay, motor or solenoid,
or sticking and operation malfunction.
01-028-9

Using WDS
r---------------------,
2. Connect the WOS to the OLC-2.
3. Select the simulation items from the PIO table.
If there is no operation sound from the relay,
motor, and solenoid after the simulation
function inspection is performed, it is possible
that there is an open or short circuit in the
wiring harness, relay, motor or solenoid, or
sticking and operation malfunction.
DBG110BWBA01
AFTER REPAIR PROCEDURE [WL-C, WE-C]

Using PDS/IDS
1. Connect the POS/IOS to the OLC-2.
items from the initial screen of the POS/IOS.
When using the lOS (notebook PC)
3. Select "Module".
4. Select "PCM".
When using the POS (pocket PC)
2. Select "PCM".
3. Verify the OTC according to the directions on the
POS/IOS screen.
4. Press the clear button on the OTC screen to clear the OTC.
5. Verify that no OTCs are displayed.
dcf010200000w16
DBG110BWBA01
Using WDS
1. Connect the WOS to the DLC-2.
2. Turn the engine switch to the ON position.
(Engine off)
3. Record OTC if retrieved.
4. Erase all diagnostic data using the WOS.
DBG110BWBA01
KOEO/KOER SELF TEST [WL-C, WE-C]

Using PDS/IDS
1. Connect the POS/IOS to the OLC-2.
items from the initial screen of the POS/IOS.
3. Select "Module".
4. Select "PCM".
2. Select "PCM".
01-028-10
dcf01020000Ow17
DBG110BWBA01

3. Then, select the "KOEO On Demand SelfTest" or "KOER On Demand SelfTest" and perform procedures
according to directions on the PDS/IDS screen.
4. Verify the DTC according to the directions on the PDS/IDS screen.
5. 'After completion of repairs, clear all DTCs stored in the PCM, while referring to "AFTER REPAIR
PROCEDURE".
UsingWDS

,--------------------,
3. Retrieve the KOEO/KOER DTCs using the WDS.
01-028-11

DTC TABLE[WL-C, WE-C]
id0102c4801500
x: Applicable - : Not applicable

Condition
DTC
POO16
CKpCMP correlation
POO88
Variable boost control (VBC) solenoid valve

control circuit open
circuit rangelperformance malfunction
control circuit low input
control circuit high input
POO93
POO45
POO46
POO47
POO48
MIL
DC
Selftest
type*1
ON
C/R
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
ON
ON
ClaiR
ON
ClaiR
ON
Memory
function
Page
P0102
Intak~ air temperature (IAT) sensor No.2 circuit

low input
Intake air temperature (IAT) sensor No.2 circuit
high input
Mass air flow (MAF) sensor rangelperformance
problem
ON
ON
C/R
C/R
P0103
P0106
Boost sensor rangelperformance malfunction
ON
P0107
ON
ON
ClaiR
ClaiR
P0108
ON
ON
ClaiR
ON
ClaiR
ON
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
P0183
ON
ClaiR
ClaiR
P0191
Fuel pressure sensor rangelperformance

malfunction
ON
P0192
ON
P0193
ON
P0201
Fuel injector No.1 circuit openlshort
ON
P0202
ON
P0203
Fuel injector NO.3 circuit openlshort
ON
P0204
ON
POO97
POO98
P0101
P0111
P0112
P0113
P0116
P0117
P0118
P0122
P0123
P0182
P0222
P0223
Intake air temperature (IAT) sensor No.1 rangel

perfomance malfunction
low input
high input
Engine coolant temperature (ECT) sensor rangel
performance problem
Engine coolant temperature (ECT) sensor circuit
low input
Engine coolant temperature (ECT) sensor circuit
high input
Accelerator pedal position (APP) sensor No.1
circuit low input
circuit high input

circuit low input
circuit high input
(See 0102C9 DTC

P0111 [WLC, WE-C].)
ClaiR
ClaiR
C/R
C/R
C/R
C/R
ON
ON
x
x
x
x
ClaiR
ClaiR
P0227
ON
P0228
ON
01-028-12

Condition
DTC
MIL
DC
P0300
ON
P0301
ON
P0302
ON
P0303
ON
P0304
ON
P0380

Crankshaft position (CKP) sensor circuit
malfunction
Camshaft position (CMP) sensor circuit
malfunction
P0401
Selftest
type*1
Memory
function
x
C/R
C/R
C/R
C/R
C/R
ON
ON
Page
-
x
x
C/R
C/R
ON
cia
EGR flow insufficient detected
ON
P0402
EGR flow excessive detected
ON
P0403
ON
EGR valve stuck
ON
P0405
ON
P0406
ON
P0489
ON
P0490
ON
1/2
1/2
ClaiR
C/R
ClaiR
ClaiR
cia
cia
P0404
P0500
ON
P0562
ON
P0563
ON
ClaiR
ClaiR
P0602
ON
P0606
PCM malfunction
ON
P0607
ON
1/2
P0610
ON
P0627
ON
P0628
ON
P0629
ON
P0685

Fuel pressure sensor and boost sensor 5 V
circuit low input
Fuel pressure sensor and boost sensor 5 V
circuit high input
CMP sensor and APP sensor 5 V circuit high
input
Intake shutter solenoid valve (half) control circuit
open
low input
high input
Intake shutter solenoid valve (full) control circuit
open
low input
high input
P0698
ON
P0699
ON
P1196
P1259
P1260
P1391
ON
P0335
P0340
P0642
P0643
P0652
P0653
P0660
P0661
P0662
P0663
"P0664
P0665
x
x
x
x
x
ClaiR
ClaiR
C/R
C/R
C/R
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
ClaiR
ON
cia
ON
cia
ON
cia
ON
cia
ON
cia
ON
cia
C/O/R
C/O/R
cia
cia
cia
01-028-13

Condition
DTC
P1392
MIL
DC
Selftest
type*1
Memory
function
ON
CIO
P1528
P1602
P1603
ID Number Unregistered
P1604
P1621
P1622
Immobilizer ID does not match
1
-
CIO
CIO
CIO
CIO
CIO
CIO
CIO
CIO
(See 01-02C-11 DTC

P1528[WL-C, WE-C).)
P1623
Immobilizer code word/lD number write failure
P1624
Anti-theft system
P1675
P1812

Injection quantity adjustment value checksum
error
P1813
P1814
P1815
P1878
P1879
RFW Free solenoid valve open circuit
P1880
P1885
RFW Free solenoid valve circuit/short to ground
P1676
ON
P2228
P2229
SARO sensor circuit high input
ON
C/O/R
C/O/R
P2263
Air charging system performance malfunction
P2530
ON
P2009
P2010
P2135
P2136
P2143
P2144
P2145
P2146
P2147
P2148
P2149
P2150
P2151
P2227
ON
CIO
ON
CIO
ON
CIO
ON
C/O/R
ON
C/O/R
ON
1/2
CIO
ON
1/2
C/O/R
ON
1/2
C/O/R
ON
C/R
ON
C/R
ON
C/R
ON
C/R
ON
C/R
ON
C/R
ON
ON
*1 : C; CMDTC self test, 0; KOEO self test, R; KOER self test
01-028-14
ON
Variable swirl control (VSC) solenoid valve circuit

open
low input
high input
No.2 voltage correlation problem
idle switch voltage correlation problem
EGR control solenoid valve control circuit low
input
EGR control solenoid valve control circuit high
input
Fuel injector No.1 and No.4 power supply circuit
malfunction
low input
high input
malfunction
low input
high input
SARO sensor circuit rangelperformance
malfunction
SARO sensor circuit low input
P2008
Page

DTC P0016 [WL-C, WE-C]
DTC P0016
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200001w01
CKP-CMP correlation
The PCM monitors the input pulses from the CKP and CMP sensors. If the pick-up timing input pulses do
not match each other, the PCM determines that the camshaft position does not coincide with the crankshaft
position.
Poor connection of connector

CMP sensor malfunction
CKP sensor malfunction
Damaged or scratched CMP sensor pulse wheel
Damaged or scratched CKP sensor pulse wheel
Foreign material on CMP sensor
Foreign material on CKP sensor
Improper valve timing
Has the FREEZE FRAME DATA been

recorded?
VERIFY RELATED REPAIR INFORMATION
Yes
AVAILABILITY
Verify related service repair information
availability.
No
Is any related repair information available?
INSPECT CMP SENSOR CONNECTOR FOR
POOR CONNECTION
Turn the engine switch off.
Disconnect the CMP sensor connector.
Inspect for poor connection (such as damaged/
pulled-out pins, corrosion).
Is there any malfunction?
INSPECT CMP SENSOR FOR FOREIGN
Yes
MATERIAL
Remove the CMP sensor.
No
Inspect the CMP sensor for foreign material.
Is there any foreign material on the CMP
sensor?
INSPECT CMP SENSOR PULSE WHEEL
Yes
Visually inspect the CMP sensor pulse wheel.
Is there any damage or scratching to the CMP
sensor pulse wheel?
INSPECT CMP SENSOR
Inspect the CMP sensor.
(See 01-40B-37 CAMSHAFT POSITION
(CMP) SENSOR INSPECTION [WL-C, WEC].)
Is the CMP sensor normal?
INSPECT CKP SENSOR CONNECTOR FOR
POOR CONNECTION
Disconnect the CKP sensor connector.
INSPECT CKP SENSOR FOR FOREIGN
Yes
MATERIAL
Remove the CKP sensor.
No
Inspect the CKP sensor for foreign material.
Is there any foreign material on the CKP
sensor?
INSPECT CKP SENSOR PULSE WHEEL
Yes
Visually inspect the CKP sensor pulse wheel.
Is there any damage or scratching to the CKP
sensor pulse wheel?
Record the FREEZE FRAME DATA on the repair order,

then go to the next step.
Perform the repair or diagnosis according to the available
repair information.
If the vehicle is not
go to the next
Remove foreign material from the CMP sensor, then go to

Step 13.
Replace the camshaft, then go to Step 13.

(See 01-10B-9 CYLINDER HEAD GASKET
REPLACEMENT [WL-C, WE-C].)
Remove foreign material from the CKP sensor, then go to

Step 13.
Replace the CKP sensor pulse wheel, then go to Step 13.

(See 01-10B-7 TIMING BELT REMOVAUINSTALLATION
[WL-C, WE-C].)
01-028-15

STEP
INSPECTION
10
INSPECT CKP SENSOR
Inspect the CKP sensor.
(See 01-40B-39 CRANKSHAFT POSITION
(CKP) SENSOR INSPECTION [WL-C, WE-C].)
Is the CKP sensor normal?
11
INSPECT PCM CONNECTOR FOR POOR
CONNECTION
Disconnect the PCM sensor connector.
INSPECT VALVE TIMING
12
Inspect valve timing.
(See 01-10B-7 TIMING BELT REMOVAU
INSTALLATION [WL-C, WE-C].)
Is valve timing normal?
13
VERIFY TROUBLESHOOTING OF DTC POO16
COMPLETED
Make sure to reconnect all disconnected
connectors.
Turn the engine switch to the ON position
(Engine off).
Clear the DTC from the memory using the
current diagnostic tool.
Run the vehicle under the FREEZE FRAME
DATA stored condition.
Is the same DTC present?
VERIFY AFTER REPAIR PROCEDURE
14
Perform the "After Repair Procedure".
(See 01-02B-10 AFTER REPAIR
PROCEDURE [WL-C, WE-C].)
Are any DTCs present?
ACTION
Yes
No
Replace the CKP sensor, then go to Step 13.

(See 01-40B-38 CRANKSHAFT POSITION (CKP)
SENSOR REMOVAUINSTALLATION [WL-C, WE-C].)
Yes
No
Repair or replace the terminal, then go to Step 13.

Yes Go to the next step.

No Adjust the valve timing properly, then go to the next step.
(See 01-10B-7 TIMING BELT REMOVAUINSTALLATION
[WL-C, WE-C].)
Yes
Replace the PCM, then go to the next step.

. (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)
No Go to the next step.
Yes
No
Go to the applicable DTC inspection.

(See 01-02B-11 DTC TABLE [WL-C, WE-C].)
DTC troubleshooting completed.
dcf01 0200001 w02
Variable boost control (VBC) solenoid valve control circuit open

The PCM monitors the VBC solenoid valve control signal. If the VBC solenoid valve control voltage is less
DETECTION
than 5 V for 2 s when the VBC solenoid valve is off, the PCM determines that there is a VBC solenoid
CONDITION
valve control circuit malfunction (open circuit).
VBC solenoid valve malfunction
POSSIBLE
Open circuit in wiring harness between main relay and VBC solenoid valve terminal A
CAUSE
Open circuit in wiring harness between VBC solenoid valve terminal Band PCM terminal 178
PCM malfunction
DTC POO45
01-028-16
VBC SOLENOID VALVE
PCM
MAIN RELAY
@@
t-*--------~H178
VBC SOLENOID VALVE

WIRING HARNESS-SIDE
CONNECTOR
PCM
WIRING HARNESS-SIDE CONNECTOR
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA HAS BEEN
RECORDED
AVAILABILITY
availability.
VERIFY CURRENT SIGNAL STATUS: IS

CONCERN INTERMITTENT OR CONSTANT?
Connect the current diagnostic tool to the DLC-
ACTION
Yes Perform repair or diagnosis according to the available
repair information.
If the vehicle is not repaired, go to the next step.
Yes
No
Yes
No
2.
Clear the DTC from the PCM memory using

the current diagnostic tool.
INSPECT VBC SOLENOID VALVE CONNECTOR Yes

FOR POOR CONNECTION
No
Disconnect the VBC solenoid valve connector.
INSPECT VBC SOLENOID VALVE CONTROL
Yes
CIRCUIT FOR OPEN CIRCUIT
No
(Engine off).
Measure the voltage between VBC solenoid
valve terminal A (wiring harness-side) and
body ground.
Is the voltage B+?
INSPECT VBC SOLENOID VALVE
Yes
Inspect
the
VBC
solenoid
valve.
(See 01-13B-6 VARIABLE BOOST CONTROL

(VBC) SOLENOID VALVE INSPECTION [WLNo
C, WE-C).)

Intermittent concern exists.
Perform the "INTERMITTENT CONCERN
TROUBLESHOOTING".
(See Of-03B-60 INTERMITTENT CONCERN
TROUBLESHOOTING [WL-C, WE-C].)


Repair or replace the wiring harness for a possible open
circuit, then go to Step 9.
Replace the VBC solenoid valve, then go to Step 9.

(See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
01-028-17

STEP
INSPECTION

Yes
CONNECTION
No
Turn the engine switch off .
Disconnect the PCM connector.
..

Inspect for continuity between VBC solenoid
valve terminal B (wiring harness-side) and
PCM terminal 178 (wiring harness-side).
Is there continuity?
, __ '~\1.
ACTION
<.-
10

COMPLETED
connectors.
(Engine offt
ylear the 0+9. from the memory using the
current diagrltYstic tool.
Is the same DTC pre,l:>ent?
Yes
No


circuit, then go to the next step.
Yes

(See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)
No
Yes

(See 01-02B-11 DTC TABLE [WL-C, WE-C).)
No

DTC POO46
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 0200001 w03
Variable boost control (VBC) solenoid valve circuit range/performance malfunction
The PCM monitors the driver IC temperature of the VBC solenoid valve. If the temperature of the VBC
solenoid valve driver IC in the PCM exceeds 150 C{320 OF} while the VBC solenoid valve is operating, the
PCM determines that there is a VBC solenoid value malfunction.

PCM malfunction
STEP
1
INSPECTION
RECORDED
recorded?
AVAILABILITY
availability.

Connect the current diagnostic tool to the DLC2.
01-028-18
ACTION
Yes
No
Yes

Perform repair or diagnosis according to the available
repair information.
No
Yes
No

Perform the "INTERMITTENT CONCERNS
TROUBLESHOOTING".
(See 01-03B-60 INTERMITTENT CONCERN

INSPECTION
STEP
4
INSPECT OPERATION OF VBC SOLENOID
VALVE
Connect the current diagnostic tool to DLC-2.
Start the engine at idle.
Access VBCV PID.
Visually inspect the guide blade actuator (rod)
operation using the VBCV PID of simulation
function.
Does the guide blade actuator (rod) move
smoothly?

Inspect the VBC solenoid valve.
(VBC) SOLENOID VALVE INSPECTION [WLC, WE-C].)
VERIFY THAT DTC P0046 TROUBLESHOOTING
IS COMPLETED
connectors.
(Engine off).
ACTION
Yes
No

Clean the guide blade actuator, then go to the next step.
Yes
Replace the VBC solenoid valve, then go to the next step.
No
Yes

WE-C).)
No
Yes

No

DTC POO47
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 0200001 w04
Variable boost control (VBC) solenoid valve control circuit low input
The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve off but the
voltage at PCM terminal 178 still remains low, the PCM determines that the VBC solenoid valve circuit has
a malfunction (circuit short to ground).
Short to ground in the wiring harness between VBC solenoid valve terminal Band PCM terminal 178
PCM malfunction
01-028-19

DTC P0047 I Variable boost control (VBC) solenoid valve control circuit low input
PCM
VBC SOLENOID VALVE

MAIN RELAY
Gt~
PCM
WIRING HARNESS-SIDE
CONNECTOR
VBC SOLENOID VALVE

WIRING HARNESS-SIDE
CONNECTOR
w]
rJ)
124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158 157 156155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
Gt~
INSPECTION
STEP
1
RECORDED
recorded?
2
AVAILABILITY
availability.
3

ACTION
Yes
No
Yes

repair information.
Yes
No

TROUBLESHOOTING".
2.
01-028-20

No

FOR POOR CONNECTION
No
Yes
No
CIRCUIT FOR SHORT TO GROUND
Disconnect the PCM connector and VBC
solenoid valve connector.
Inspect for continuity between VBC solenoid
body ground.
Yes
No


Repair or replace the wiring harness for a short to ground

between VBC solenoid valve terminal A (wiring harnessside) and PCM terminal 178, then go to Step 8.

INSPECTION
STEP
7
ACTION
Repair or replace the terminal, then go to the next step.

Yes
CONNECTION
VERIFY THAT DTC P0047 TROUBLESHOOTING Yes Replace the PCM, then go to the next step.
IS COMPLETED
WE-C].)
connectors.
(Engine off).
Is
the same DTC present?
Yes

No

DTC P0048
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200001w05
Variable boost control (VBC) solenoid valve control circuit high input
The PCM monitors the VBC solenoid valve control signal. If the PCM turns VBC solenoid valve on but the
current at PCM terminal 178 still remains high, the PCM determines that the VBC solenoid valve circuit has
a malfunction (circuit short to power supply).

Short to power supply in the wiring harness between VBC solenoid valve terminal Band PCM terminal 178
PCM malfunction
PCM
VBC SOLENOID VALVE
MAIN RELAY
'-----"'*1
VBC SOLENOID VALVE

WIRING HARNESS-SIDE
CONNECTOR
~--------~178
PCM
WIRING HARNESS-SIDE
CONNECTOR
01-028-21

INSPECTION
STEP
1

RECORDED
recorded?
AVAILABILITY
availability.

ACTION
Yes
No
Yes
No

repair information.
Yes
No

TROUBLESHOOTING".
2.

CLASSIFY MALFUNCTION FOR INSPECT VBC Yes
SOLENOID VALVE CONTROL CIRCUIT OR
No
OTHER
(Engine off).
Measure the voltage between VBC solenoid
body ground.
Is the voltage B+?
Yes
CIRCUIT FOR SHORT TO POWER SUPPLY
No
Disconnect the PCM connector and VBC
solenoid valve connector.
(Engine off).
Measure the voltage between PCM terminal
178 (wiring harness-side) and body ground.
Is the voltage B+?
Yes
CONNECTION
No
Yes
No
FOR POOR CONNECTION
No
01-028-22


Go to Step 7.
Repair or replace the wiring harness for a short to power

between VBC solenoid valve terminal A and PCM terminal
178, then go to Step 9.
Repair or replace the terminal, then go to Step 9 .

Go to Step 9.


THAT DTC P0048 TROUBLESHOOTING Yes Replace the PCM, then go to the next step.
IS COMPLETED
I--_+-W_E_-C-=]c..:,.)_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _---l
connectors.
(Engine off).
Yes Go to the applicable DTC inspection.
No DTC troubleshooting completed.

DETECTION
running. If the fuel pressure is more than the preprogrammed criteria, the PCM determines that the fuel
CONDITION
pressure is too high.
Supply pump malfunction
Fuel pressure sensor malfunction
POSSIBLE
Fuel pressure limiter malfunction
CAUSE
Fuel pipe improper connection on fuel tank
PCM malfunction
DTC P0088
INSPECTION
STEP
1
RECORDED
2
ACTION
Service Information.
AVAILABILITY
Verify
related
service
information
availability.

No Intermittent concern exists.
TROUBLESHOOTING".
Start the engine.
IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the applicable DTC inspection.
DATA
Is
P0628,
P0629,
P0191,
P0192
or
P0193
on
No
Go
to the next step.
FREEZE FRAME DATA?

INSPECT FUEL PIPE CONNECTION ON FUEL
TANK
No Reconnect fuel pipes properly, then go to Step 9.
(See 01-14B-7 Fuel Hose Installation Note.)
Inspect the fuel pipes for supply and return
connection at fuel tank.
Are fuel pipes connected properly?
INSPECT FUEL LINE
Yes Repair or replace suspect fuel line, then go to Step 9.
Inspect for fuel leakage or clogging in the
following fuel lines for each cylinder:
- Supply pump and common rail.
- Common rail and fuel injector
Yes
No
01-028-23

STEP
10
INSPECTION
INSPECT FUEL PRESSURE SENSOR
Inspect the fuel pressure sensor.
(See 01-40B-33 FUEL PRESSURE SENSOR
INSPECTION [WL-C, WE-C].)
ACTION
Yes
Replace the common rail, go to Step 9.
No
INSPECT COMMON RAIL

Inspect the common rail.
Yes
No
If DTC pooaa and P0093 are stored together, the possible

cause could be a supply pump internal failure. Replace the
supply pump, then go to the next step.
(See 01-14B-11 SUPPLY PUMP REMOVAU
Go to the next step except for the above case.

COMPLETED
connectors.
Start the engine.
Yes
Replace the PCM, go to the next step.

WE-C].)
No
Yes

No
Troubleshooting completed.
Replace the common rail, go to the next step.

DTC POO93
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 0200001 w07
running. If the fuel pressure is lower than the preprogrammed criteria, the PCM determines that there is
leakage in the fuel system.
Fuel leakage or clogged fuel line
Fuel injector malfunction
Fuel pipe improper connection on fuel tank
PCM malfunction
STEP
1
INSPECTION
RECORDED

AVAILABILITY
Verify related Service Information availability.

Start the engine.
IDENTIFY TRIGGER DTC FOR FREEZE FRAME
DATA
Is P0192 or P0193 on FREEZE FRAME DATA?
01-028-24
ACTION
Yes
No
No


Yes
No

TROUBLESHOOTING".
Yes

No

STEP
5
10
INSPECTION
INSPECT FUEL PIPE CONNECTION ON FUEL
TANK
Inspect the fuel pipes for supply and return
connection at fuel tank.
Are fuel pipes connected properly?
INSPECT FUEL LINE
Inspect for fuel leakage or clogging in the
following fuel lines for each cylinder:
- Supply pump and Common rail.
- Common rail and fuel injector.
INSPECT FUEL INJECTOR
Inspect the fuel injector.
(See 01-14B-16 FUEL INJECTOR
VERIFY TROUBLESHOOTING OF DTC P0093

COMPLETED
connectors.
Start the engine.
ACTION
Yes
No

Reconnect fuel pipes properly, then go to Step 9.
Yes
Repair or replace the suspected fuel line, go to Step 9.
No
Yes
Replace the common rail, go to Step 9.
No
Yes
Replace the fuel injector, go to the next step.

(See 01-14B-15 FUEL INJECTOR REMOVAU
No
If DTC P0088 and P0093 are stored together, the possible

cause could be a supply pump internal failure. Replace the
supply pump, then go to the next step.
Go to the next step except for the above case.
Yes Replace the PCM, go to the next step.
WE-C].)
Yes

No

DTC P0097
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 0200001 wOS

The PCM monitors the input signal from intake air temperature sensor No.2. If the voltage from intake air
temperature sensor No.2 is less than 0.1 V for 2 s, the PCM determines that there is a malfunction in the
IAT sensor No.2 malfunction

Short to ground in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
PCM malfunction
01-028-25

DTC P0097
IAT SENSOR NO.2
PCM
MAF SENSOR/IAT SENSOR NO.2

~EIDfflBIA~
I~~
PCM
lnlnl~I~I~I~I~IM1Ml~laI6
lN1El~I~I~I~IOOI~IMl~IM
INSPECTION
STEP
ACTION

RECORDED

Yes
AVAILABILITY
availability.
No
TROUBLESHOOTING".
Start the engine.
INSPECT MAF SENSORIIAT SENSOR NO.2
Yes Repair or replace the terminal, then go to Step 8.
CONNECTOR FOR POOR CONNECTION
Disconnect the MAF sensor/IAT sensor No.2
connector.
INSPECT IAT SENSOR NO.2 SIGNAL CIRCUIT

FOR SHORT TO GROUND
Inspect for continuity between IAT sensor No.2
terminal 0 (wiring harness-side) and body
ground.
01-028-26
Yes
No
Yes
No

repair information.
Repair or replace the wiring harness for a possible short to

ground, then go to Step 8.

STEP
INSPECTION
Ves
6
INSPECT IAT SENSOR NO.2
Inspect the IAT sensor No.2.
No
(See 01-40B-23 MASS AIR FLOW (MAF)
SENSOR/INTAKE AIR TEMPERATURE (IAT)
SENSOR NO.2 INSPECTION [WL-C, WE-C].)
Ves
7
CONNECTION
No
Ves
8
VERIFV TROUBLESHOOTING OF DTC P0097
COMPLETED
No
connectors.
(Engine off).
Ves
9
No
PROCEDURE [WL-C, WE-C).}
ACTION
Replace the IAT sensor No.2, then go to Step 8.


WE-C].)

dcf01 0200001 wOg

The PCM monitors the input signal from intake air temperature sensor No.2. If the voltage from intake air
DETECTION
temperature sensor No.2 is more than 4.6 V for 1 s, the PCM determines that there is a malfunction in the
CONDITION
POSSIBLE
Open circuit in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
CAUSE
Short to power supply in wiring harness between IAT sensor No.2 terminal D and PCM terminal 188
Open circuit in wiring harness between IAT sensor No.2 terminal E and PCM terminal 154
PCM malfunction
DTC POO98
01-028-27

DTC P0098

IAT SENSOR NO.2
PCM
.---~
~----------------~
~--4
~----------------~
MAF SENSORJIAT SENSOR NO.2

ofITs 1 I)
I~~ I
PCM
124123122121 120119118117116115114113112111 110109 108107106
191Q1%1%11a1g1M1~1~1~1D1~1E1M
INSPECTION
STEP
1
ACTION

RECORDED
Yes
No


AVAILABILITY
availability.
Yes

repair information.
No

FOR SHORT TO POWER SUPPLY
(Engine off).
Measure the voltage between IAT sensor No.2
terminal D (wiring harness-side) and body
ground.
Is the voltage B+?
Yes

power supply, then go to Step 9.
No

TROUBLESHOOTING" .
(See01-03B-60 INTERMITTENT CONCERN
Start the engine.
INSPECT MAF SENSORIIAT SENSOR NO.2
connector.
01-028-28
\.'

STEP
10
INSPECTION
Yes
No

Yes
CONNECTION
No
INSPECT IAT SENSOR NO.2 CIRCUIT FOR
Yes
OPEN CIRCUIT
No
Inspect for continuity between the following
terminals:
- IAT sensor No.2 terminal E (wiring harnessside) and PCM terminal 154 (wiring
harness-side)
- IAT sensor No.2 terminal D (wiring harnessside) and PCM terminal 188 (wiring
harness-side)
COMPLETED
connectors.
(Engine off).
ACTION


.
Yes

WE-C].)
No
Yes

No

DTC P0102
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02001 00w07
amount is below 0.44 9/S {0.OS8 Ib/min} for 2.0 s while the engine is running, the PCM determines that
the airflow sensor signal input is low.

Open circuit in wiring harness between main relay terminal D and MAF sensor terminal A
Open circuit in wiring harness between MAF sensor terminal C and PCM terminal 190
Short to ground in wiring harness between MAF sensor terminal C and PCM terminal 190
PCM malfunction
01-028-29

DTC P0102
IMass airflow (MAF) sensor circuit low input

MAF SENSOR
(J)
~
kS
~
--"
I~~
~E lofcrBI
I~~
n
P
MAIN RELAY
WIRING HARNESS-SIDE
WIRING HARNESS-SIDE
CONNECTOR
CONNECTOR
tffij
oB
PCM
MAIN RELAY
TERMINAL 0
-0
PCM
m;tr
1241123112211211120 119 118 117 116115 114 113112 111 110 109 108 107 106 105 104 103 102 101
4 143 142 141 140 139 138 137136 135 134 133 132 131 130 129 128 127 126 125
1
168 167 166 165 164 163 162 161160 159 158 157 156 155 154 153 152 151 150 149
196195 19411931192 191 190 189 188 187 186 185184 183 182 181 180 179 178 177 176 175 174 173
I~~
INSPECTION
STEP
1

RECORDED
ACTION
Yes
No

repair information.

Yes
AVAILABILITY
availability.
TROUBLESHOOTING".
Start the engine.
INSPECT MAF SENSOR/IAT SENSOR NO.2
connector.
INSPECT MAF SENSOR POWER CIRCUIT FOR Yes Go to the next step.
OPEN CIRCUIT
No Repair or replace the wiring harness for a possible open
circuit or short to ground, then go to Step 10.
(Engine off).
Measure the voltage between MAF sensor
terminal A (wiring harness-side) and body
ground.
Is the voltage B+?
01-028-30

Yes
10
11

No
Inspect for continuity between MAF sensor
terminal C (wiring harness-side) and body
ground.
Yes
INSPECT MAF SENSOR
Inspect the MAF sensor.
No
CONNECTION
INSPECT MAF SENSOR
OPEN CIRCUIT
Inspect for continuity between MAF sensor
terminal C (wiring harness-side) and PCM
terminal 190 (wiring harness-side).
TROUBLESHOOTING OF DTC P0102
Yes
VE
COMPLETED
No
connectors.
(Engine off).
Yes
No
Repair or replace the wiring

for a possible short to
Replace the MAF sensor, then go to Step 10.



WE-C].)
to the applicable DTC inspection.

01-02B-11 DTC TABLE [WL-C, WE-C].)
dcf01 02001 OOwOS

amount is above 170 g/s {22 Ib/min} for 1.5 s while driving other than under a fully open throttle condition,
DETECTION
and the fuel injection quantity based on the engine speed is below the specification, the PCM determines
CONDITION
that the airflow sensor signal input is high.
POSSIBLE
Short to power supply in wiring harness between MAF sensor terminal C and PCM terminal 190
CAUSE
Open circuit in wiring harness between MAF sensor terminal Band PCM terminal 169
PCM malfunction
DTC P0103
01-028-31

DTC P0103
IMass airflow (MAF) sensor circuit high input

MAF SENSOR
-'c,
fA'
~
-
f8'
\J
rJ)
I~,,I
~ I /mBIA~
E
I~~
-0
P
@
rJ)
MAIN RELAY
WIRING HARNESS-SIDE
WIRING HARNESS-SIDE
CONNECTOR
CONNECTOR
tffij
PCM
MAIN RELAY
TERMINAL 0
PCM
"'' " mil!
124 123 122 121 120 119 11B 117 116 115 114 113 112 111 110 109 10B 107 106 105 104 103 10211011111
1.1Q1%1~11g1a1M1W1~1U1D1.1M1M1a1.1~1W
1n1n1ro1~1.1~1.1.1M1.1~1~1M1W1W1~1~1~1M
1.1.1M1a1.1~1W1.1.1~1.1U1M1a1.1~1001n1n
I~~
153152151 1
177 176 175 1
STEP
ACTION
INSPECTION

RECORDED

AVAILABILITY
availability.
TROUBLESHOOTING".
Start the engine.
INSPECT MAF SENSOR/IAT SENSOR NO.2
connector.
INSPECT MAF SENSOR SIGNAL CIRCUIT FOR Yes Repair or replace the wiring harness for a possible short to
SHORT TO POWER SUPPLY
(Engine off).
Measure the voltage between MAF sensor
I
ground.
Is
the
voltage
more
than
4.9
V?
Yes
No

repair information.
01-028-32

STEP
6
10
INSPECTION
INSPECT MAF SENSOR
Yes
Inspect the MAF sensor.
No
SENSOR NO.2 INSPECTION [WL-C, WE-Gj.)
Yes
CONNECTION
No
INSPECT MAF SENSOR GROUND CIRCUIT
Yes
FOR OPEN CIRCUIT
No
Inspect for continuity between MAF sensor/IAT
sensor No.2 terminal B (wiring harness-side)
and PCM terminal 169 (wiring harness-side).
Yes
COMPLETED
No
connectors.
(Engine off).
Yes
No

DTC P0106
DETECTION
CONDITION
ACTION
Replace the MAF sensor, then go to Step 9.


WE-Gj.)

dcf01 02001 00w09

The PCM monitors and compares the intake manifold internal pressure via the boost sensor with the
atmospheric pressure via the barometric pressure sensor (built into PCM) while the engine is not running. If
the difference of these pressure is above 11 kPa {0.11 bar, 1.6 psi}, the PCM determines that there is a
boost sensor characteristic malfunction.
Note
POSSIBLE
CAUSE
If DTCs P01 06 and P2227 are recorded simultaneously, the PCM determines that there is a boost
sensor and barometric pressure sensor characteristic malfunction.
Boost sensor malfunction
PCM malfunction
01-028-33

DTC P0106

PCM
BOOST SENSOR
~--------~
o ~--------~189r----~~J
A 1-77----------*l111

WIRING HARNESS-SIDE
CONNECTOR
frill}
I~~
PCM

124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175
I~
INSPECTION
STEP
1
ACTION

RECORDED
Yes
No

AVAILABILITY
availability.
Yes

Start the engine.
INSPECT BOOST SENSOR
Inspect the boost sensor.
(See 01-40B-27 BOOST SENSOR
COMPLETED
connectors.
(Engine off).
01-028-34
No

repair information.
Yes
No

TROUBLESHOOTING".
Yes
Replace the boost sensor, then go to Step 7.
No
Yes

WE-C].)
No

STEP
INSPECTION
Yes
No
ACTION

DTC P0107
DETECTION
CONDITION
POSSIBLE
CAUSE

The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is less than
0.24 V for 2.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.

Short to ground in wiring harness between boost sensor terminal C and PCM terminal 133
Short to ground in wiring harness between boost sensor terminal D and PCM terminal 189
Open circuit in wiring harness between boost sensor terminal. C and PCM terminal 133
Open circuit in wiring harness between boost sensor terminal D and PCM terminal 189
PCM malfunction
BOOST SENSORIIAT SENSOR NO.1

WIRING HARNESS-SIDE
CONNECTOR
mfYi}
PCM
124123122121120119118117116115114113112111110 109108107106
'II
129 128 127 126
lnlnlml~1~1~1~1.lMl~1~1~lW1Wl~1~1~1.1~
'"
""ro 150
153152151
l"l"lMl.l~l~l~l~lMl~l.l.lMl.l~l~lMl~ln
177 176 175 174
lU1Q1Ul~1"lalQ1Ml~1.1.lD1Ml.1Mlal.l~1~
[~~I
STEP
1
INSPECTION
RECORDED
AVAILABILITY
Verity related service repair information
availability.
Yes
No
Yes
No
ACTION
repair information.
01-028-35

INSPECTION
STEP
3

CONCERN INTERMITIENT OR CONSTANT?
Start the engine.
CLASSIFY 5V CONSTANT VOLTAGE CIRCUIT
OR OTHER RELATED MALFUNCTION
(Engine off).
Measure the voltage between the boost
sensor/IAT sensor No.1 terminal C (wiring
harness-side) and body ground.
Is the voltage 5 V constant voltage?

OR BOOST SENSOR/IAT SENSOR NO.1
RELATED MALFUNCTION
sensor No.1
Disconnect the boost sensor/IAT
,
connector.
(Engine off).
Measure the voltage between the boost sensor
ground.
ACTION
Yes
No

TROUBLESHOOTING".
Yes
Go to Step 11.
No
Yes
No
Go to Step 9.
Yes

10
INSPECT BOOST SENSOR 5V CONSTANT

VOLTAGE CIRCUIT FOR SHORT TO GROUND
Inspect for continuity between the boost
harness-side) and body ground
No

Yes
CONNECTION
No
INSPECT BOOST SENSOR 5V CONSTANT
Yes
VOLTAGE CIRCUIT FOR OPEN
No
harness-side) and PCM terminal 133 (wiring
harness-side).
INSPECT BOOST SENSOR/IAT SENSOR NO.1
Yes
No
Disconnect the boost sensor/I AT sensor No.1
connector.
Inspect the boost sensor/IAT sensor No.1.
01-028-36
Yes
No

Repair or replace the wiring harness for an open circuit,

then go to Step 17.
Go to Step 17.

Replace the boost sensor/IAT sensor No.1, then go to Step

17.
Go to Step 17.
12
13
14
15
16
17
18

(Engine off).
sensor/IAT sensor No.1 terminal D (wiring
Is the voltage more than 0.24 V ?
INSPECT BOOST SENSOR SIGNAL CIRCUIT
FOR SHORT TO GROUND
CONNECTION
INSPECT BOOST SENSOR SIGNAL CIRCUIT
FOR OPEN
harness-side) .
INSPECT BOOST SENSORIIAT SENSOR NO.1
Disconnect the boost sensor/I AT sensor No.1
connector.
COMPLETED
connectors.
(Engine off).
Are any DTCs
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No

Go to Step 15.

then go to Step 17.
Go to Step 17.
Replace
boost sensor/IAT sensor No.1, then go to the
next step.
WE-C).)

01-028-37

DTC P0108
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02001 00w11

The PCM monitors the input signal from the boost sensor. If the voltage from the boost sensor is more
than 4.9 V for 1.0 s, the PCM determines that there is a malfunction in the boost sensor circuit.

Short to power supply in wiring harness between boost sensor terminal 0 and PCM terminal 189
Short to power supply in wiring harness between boost sensor terminal C and PCM terminal 133
Open circuit in wiring harness between boost sensor terminal A and PCM terminal 111
PCM malfunction

WIRING HARNESS-SIDE
CONNECTOR
PCM
DfYi)
I~~I
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.
ACTION
repair information.
Yes
No
Yes
No

TROUBLESHOOTING".
Yes
No
Go to Step 9.
2.

Start the engine.
(Engine off).
sensor/lAT sensor No.1 terminal C (wiring
01-028-38

STEP
10
11
12
INSPECTION
OR BOOST SENSORIIAT SENSOR NO.1
RELATED MALFUNCTION
Disconnect the boost sensor/IAT sensor No.1
connector.
(Engine off).
ground.
CONNECTION
connector.
connector.
INSPECT BOOST SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
Inspect for continuity between boost sensor
terminal A and body ground.
CONNECTION
CLASSIFY SIGNAL CIRCUIT OR OTHER
RELATED MALFUNCTION
(Engine off).
Is the voltage less than 4.9 V ?
ACTION
Yes
No
Go to Step 17.
Yes
No

Yes
No

Yes
Replace the boost sensor/IAT sensor No.1, then go to Step

17.
Go to Step 17.
No
Yes
No
Yes
No
Go to Step 12.
Yes
No

then go to the Step 17.
Yes
No
Go to Step 17.
01-028-39

INSPECTION
STEP
CLASSIFY SIGNAL CIRCUIT OR BOOST
13
SENSOR/IAT SENSOR NO.1 RELATED
MALFUNCTION
Disconnect the boost sensor/lAT sensor No.1
connector.
Turn
the engine switch to the ON position
(Engine off).
terminal D (wiring harness-side) and body
ground.
14
15
16
17
18
ACTION
Yes
Go to Step 15.
No

Yes
CONNECTION
No
Yes
No
connector.

INSPECT BOOSTIIAT SENSOR NO.1 SENSOR

Is there any maifunction?
Replace the boost sensor/IAT sensor No.1, then go to the

step.
Go to the step.

COMPLETED
connectors.
(Engine off).
PROCEDURE [WL-C, WE-Gj.)
Yes
No

Yes

WE-C].)
No
Yes

(Se.e 01-02B-11 DTC TABLE [WL-C, WE-C].)
No
( ..
01-028-40

DlC P0111 [WL-C, WE-C]
DTC P0111
DETECTION
CONDITION
POSSIBLE
CAUSE
id010204803600
Intake air temperature (IAT) sensor No.1 range/performance malfunction

The PCM monitors the input signal from the IAT sensor No.1. If the difference between the maximum and
minimum value of the IAT sensor No.1 is less than 0.3 C {32.6 OF}, the PCM determines that there is a
malfunction in the IAT sensor No.1.
Diagnostic support note
The MIL illuminates if the PCM detects the above malfunction condition in two consecutive drive cycles or
in one drive cycle while the DTC for the same malfunction has been stored in the PCM.
PENDING CODE is available if the PCM detects the above malfunction condition during the first drive
cycle.
FREEZE FRAME DATA is available.
The DTC is stored in the PCM memory.
PCM malfunction
PCM
IAT SENSOR NO.1
,---~
@
B ~----------------~~
L -_ _~
@
H&----------------~~

WIRING HARNESS-SIDE
CONNECTOR
tumtl
I
Gt~
PCM
124 123122 121 120 119118 117116 115 114113 112 111 110 109 108107 106 105 104 103 102101
37136 135 134133 132131 130 129 128 127 126125
172 171 170 169 168 167 166 165 164 163 162161 160 159158 157156 155 154 153152 151 150149
196 195194 193 192191 190 189188 187 186 185 184 183182 181 180 179 178 177 176 175 174173
01-028-40a

INSPECTION
STEP
1
ACTION

RECORDED
Yes
VERIFY RELATED SERVICE INFORMATION

AVAILABILITY
Verify related service information availability.
Is any related service information available?
Yes

service information.
No

No


Yes
Connect the current diagnostic tool to the DLCPerform the "INTERMITTENT CONCERN
2.
TROUBLESHOOTING".
Start the engine.
Is the PENDING CODE for this DTC present?
INSPECT MAFIIAT SENSOR CONNECTOR FOR Yes Repair or replace the terminal, then go to Step 7.
POOR CONNECTION
Disconnect the MAF/IAT sensor connector.
Yes Replace the MAF/IAT sensor, then go to Step 7.
Yes Repair or replace the terminal, then go to the next step.
CONNECTION
Yes Replace the PCM, then go to the next step.
COMPLETED
connectors.
Start the engine and warm it up completely.
Perform the Repair Verification Drive Mode.
01-02B-40b
Yes

(See 01-02C-6 DTC TABLE[WL-C, WE-C].)
No

dcf01 02001 00w12
DTC P0112 Intake air temperature (IAT) sensor No.1 circuit low input
DETECTION The PCM monitors the input signal from IAT sensor No.1. If the voltage from IAT sensor No.1 is less than
CONDITION
0.14 V for 2.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
POSSIBLE
CAUSE
Short to ground in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
PCM malfunction
PCM
IAT SENSOR NO.1

WIRING HARNESS-SIDE
CONNECTOR
krmtl
I
Gt~
PCM
STEP
INSPECTION
1
RECORDED

AVAILABILITY
availability.
2.
ACTION
repair information.
Yes
No
Yes
No

Start the engine.
Yes
No
connector.

TROUBLESHOOTING".

01-028-41

STEP
INSPECTION
FOR SHORT TO GROUND
Inspect for continuity between IAT sensor No.1
terminal B (wiring harness-side) and body
ground.
(See 01-40B-26 INTAKE AIR TEMPERATURE
(IAT) SENSOR NO.1 INSPECTION [WL-C,
WE-C).)
ACTION
Yes

No
Yes

No

Yes
CONNECTION
No
Yes
COMPLETED
No
connectors.
(Engine off).

DTC P0113
DETECTION
CONDITION

WE-C].)
Yes

No
dcf01 02001 00w13

The PCM monitors the input signal from IAT sensor No.1. If the voltage from IAT sensor No.1 is more than
4.90 V for 1.0 s, the PCM determines that there is a malfunction in the IAT sensor No.1 circuit.
POSSIBLE
CAUSE
01-028-42

Open circuit in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
Short to power supply in wiring harness between IAT sensor No.1 terminal Band PCM terminal 141
Open circuit in wiring harness between IAT sensor No.1 terminal A and PCM terminal 111
PCM malfunction

DTC POl13

PCM
IAT SENSOR NO.1
@@
r---~
~--------------~H
~--~
~----------------~

WIRING HARNESS-SIDE
CONNECTOR
IYmtJ]
PCM
61~IMl.l~I~I00I~I~I~I~IU1M1Hl~I~I~lg
01.1~1~IMl~IMl.l~l~
l00I~lnlnlnl~IMln
I~~I
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.

Yes
No
ACTION
repair information.
If the vehicle is not repaired, go to the. next step.
Yes
No
2.

TROUBLESHOOTING".
TROUBLESHOOTING [WL-C, WE-C).)

Start the engine.
connector.
. Is there any malfunction?
Ves Repair or replace the wiring harness for a possible short to
(Engine off).
Measure the voltage between IAT sensor No.1
ground.
Is the voltage more than 4.90 V?
01-028-43

STEP
6
10
INSPECTION
(See 01-40B-26 INTAKE AIR TEMPERATURE
(IAT) SENSOR NO.1 INSPECTION [WL-C,
WE-C].)
ACTION
Yes

No

CONNECTION
INSPECT IAT SENSOR NO.1 CIRCUIT FOR
OPEN CIRCUIT
terminals:
- IAT sensor No.1 terminal B (wiring harnessside) and PCM terminal 141 (wiring
harness-side)
- IAT sensor No.1 terminal A (wiring harnessside) and PCM terminal 111 (wiring
harness-side)
COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No

Yes

No

DTC P0117
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200100w14

The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is less than
0.20 V for 2.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
ECT sensor malfunction
Short to ground in wiring harness between ECT sensor terminal Band PCM terminal 167
PCM malfunction
01-028-44

DTC P0117

ECTSENSOR
PCM
ECT SENSORIWATER TEMPERATURE

SENDER UNIT
PCM
111-1241123112211211120 119 118 117 116 115 114 113112 111 110 109 108 107 106 105 104 103 1021
143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 1261
Iliiir
68 167 166 165 164 163 162 161160 159 158 157 156155 154 153 152 151 1501
196195 194 1931192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 1741
STEP
INSPECTION

RECORDED
Yes
No

AVAILABILITY
availability.
Yes
No
Yes
No
2.

Start the engine.
INSPECT ECT SENSORIWATER
Yes
TEMPERATURE SENDER UNIT CONNECTOR
No
FOR POOR CONNECTION
Disconnect the ECT sensor/water temperature
sender unit connector.
INSPECT ECT SENSOR SIGNAL CIRCUIT FOR
SHORT TO GROUND
Disconnect the ECT sensor connector.
Inspect for continuity between ECT sensor
ground.
ACTION
repair information.
TROUBLESHOOTING".

Yes

No
01-028-45

STEP
6
INSPECTION
INSPECT ECT SENSOR
Inspect the ECT sensor.
(See 01-40B-35 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
CONNECTION
COMPLETED
connectors.
(Engine off).

DTC P0118
DETECTION
CONDITION
POSSIBLE
CAUSE
No
ACTION
Replace the ECT sensor, then go to Step 8.
Yes
No

Yes

WE-C].)
No
Yes

Yes
No
dcf01 02001 00w15
Engine coolant temperature (ECT) sensor circuit high input

The PCM monitors the input signal from the ECT sensor. If the voltage from the ECT sensor is more than
4.91 V for 1.0 s, the PCM determines that there is a malfunction in the ECT sensor circuit.
ECT sensor malfunction
Open circuit in wiring harness between ECT sensor terminal Band PCM terminal 167
Short to power supply in wiring harness between ECT sensor terminal Band PCM terminal 167
Open circuit in wiring harness between ECT sensor terminal A and PCM terminal 156
PCM malfunction
01-028-46
ECT SENSOR
PCM
@@
ECT SENSORIWATER TEMPERATURE

SENDER UNIT
PCM
124 123 122 121 120119 118 117 116 115 114 113112 111 110109 108 107 106 105 104 103 102 101
148 147 146 145 144143 142 141 140 139 138 137136 135 134133 132131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158157 156155 154 153 152 151 150 149
196 195 194 193 192191 190 189 188 187 186 185184 183 182181 180179 178 177 176 175 174 173
STEP
1
INSPECTION
RECORDED
No

Yes
AVAILABILITY
availability.
No
Yes
No
ACTION
Yes
2.

Start the engine.
INSPECT ECT SENSOR! WATER

Yes
TEMPERATURE SENDER UNIT CONNECTOR
No
FOR POOR CONNECTION
Disconnect the ECT sensor/ water temperature
sender unit connector.
INSPECT ECT SENSOR SIGNAL CIRCUIT FOR
(Engine off).
Measure the voltage between ECT sensor
ground.

repair information.

TROUBLESHOOTING".

Yes

No
01-028-47

INSPECTION
STEP
6
INSPECT ECT SENSOR

Inspect the ECT sensor.
(See 01-40B-35 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
ACTION
Yes
Replace the ECT sensor, then go to Step 9.
No

Yes
CONNECTION
No

INSPECT ECT SENSOR CIRCUIT FOR OPEN

CIRCUIT
terminals:
- ECT sensor terminal B (wiring harness-side)
and PCM terminal 167 (wiring harness-side)
- ECT sensor terminal A (wiring harness-side)
Yes
No

COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No
Yes

No
10


DTC P0122
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200100w16
01-028-48
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is less
than 0.29 V for 0.5 s when the APP sensor No.1 power supply voltage is normal, the PCM determines that
there is a malfunction in the APP sensor No.1 circuit.
APP sensor No.1 malfunction
Open circuit in wiring harness between APP sensor No.1 terminal A and PCM terminal 213
Short to ground in wiring harness between APP sensor No.1 terminal A and PCM terminal 213
Open circuit in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
Short to ground in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
PCM malfunction

DTC P0122
APP SENSOR NO.1
PCM -
(j)
(j)
(j)
APPSENSOR
PCM
STEP
1
INSPECTION
RECORDED

Yes
AVAILABILITY
availability.
No
Yes
No
ACTION
Yes
No
2.

Start the engine.
INSPECT APP SENSOR CONNECTOR FOR

Yes
POOR CONNECTION
No
Disconnect the APP sensor connector.

repair information.

TROUBLESHOOTING".

01-028-49

STEP
10
INSPECTION
INSPECT APP SENSOR NO.1 CIRCUIT FOR
SHORT TO GROUND
terminals and body ground:
- APP sensor No.1 terminal A (wiring
- APP sensor No.1 terminal B (wiring
INSPECT APP SENSOR NO.1
Inspect the APP sensor No.1.
(See 01-40B-28 ACCELERATOR PEDAL
POSITION (APP) SENSOR INSPECTION
[WL-C, WE-C].)
ACTION
Yes

No
Yes
Replace the APP sensor, then go to Step 9.
No

Yes
CONNECTION
No
INSPECT APP SENSOR NO.1 CIRCUIT FOR
OPEN CIRCUIT
terminals:
- APP sensor No.1 terminal A (wiring
harness-side)
- APP sensor No.1 terminal B (wiring
harness-side)
Is
there
continuity?

COMPLETED
connectors.
(Engine off).
(See 01-02B-1 0 AFTER REPAIR
Yes
No


Yes

WE-C].)
No
Yes

No

DTC P0123
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02001 00w17
The PCM monitors the input signal from APP sensor No.1. If the voltage from APP sensor No.1 is more

Short to power supply in wiring harness between APP sensor No.1 terminal Band PCM terminal 222
Open circuit in wiring harness between APP sensor No.1 terminal D and PCM terminal 212
PCM malfunction
01-028-50

DTC P0123
APP SENSOR NO.1
PCM
(J)
@
B
@
0
(J)
(J)
APP SENSOR
222
PCM
232 231 230 229 228 22

245 244 243 242 241 24
STEP
INSPECTION
1
RECORDED

AVAILABILITY
availability.
2.
ACTION
repair information.
Yes
No
Yes
No

Start the engine.
Yes
POOR CONNECTION
No
INSPECT APP SENSOR NO.1 SIGNAL CIRCUIT Yes
No
(Engine off).
Measure the voltage between APP sensor
ground.

TROUBLESHOOTING".


01-028-51

STEP
10
INSPECTION
INSPECT APP SENSOR NO.1
Inspect the APP sensor No.1.
[WL-C, WE-C].)
ACTION
Yes
No

Yes
CONNECTION
No
INSPECT APP SENSOR NO.1 GROUND
Tum the engine switch off.
Inspect for continuity between APP sensor
No.1 terminal D (wiring harness-side) and
COMPLETED
connectors.
(Engine off).
OTC P0182 [WL-C, WE-C]

DTC P0182
DETECTION
CONDITION
POSSIBLE
CAUSE
Yes
No


Yes

WE-C].)
No
Yes

(See 01-02B-11 DTC TABLE [WL-C, WE-C).}
No
dcf01 02001 00w18
The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel
temperature sensor is less than 0.2 V, the PCM determines that there is a malfunction in the fuel
temperature sensor circuit.
Fuel temperature sensor malfunction

Short to ground in wiring harness between fuel temperature sensor terminal A and PCM terminal 115
PCM malfunction
01-028-52

DTC P0182

PCM

PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 1021
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 1261
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 1501
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 1741
STEP
INSPECTION
1
RECORDED
2
ACTION
Yes

No Record the FREEZE FRAME DATA on the repair order,
repair information.

AVAILABILITY
availability.
Yes
No
Start the engine.
INSPECT FUEL TEMPERATURE SENSOR
Yes
No
Disconnect the fuel temperature sensor
connector.
Yes
SIGNAL CIRCUIT FOR SHORT TO GROUND
No
connector.
Inspect for continuity between fuel temperature
sensor terminal A (wiring harness-side) and
body ground.
Inspect the fuel temperature sensor.
(See 01-40B-32 FUEL TEMPERATURE
SENSOR INSPECTION [WL-C, WE-C].)
Yes
No

TROUBLESHOOTING".


Replace the fuel temperature sensor, then go to Step 8.

01-028-53

STEP
INSPECTION

Yes
CONNECTION
No
ACTION

COMPLETED
connectors.
(Engine off).
DTC P0183
[WL-C~
DTC P0183
DETECTION
CONDITION
POSSIBLE
CAUSE

Yes

WE-C].)
No
Yes

No
WE-C]
dcf01 02001 00w19

The PCM monitors the input signal from the fuel temperature sensor. If the voltage from the fuel
temperature sensor is more than 4.9 V, the PCM determines that there is a malfunction in the fuel
temperature sensor circuit.
Fuel temperature sensor malfunction
Open circuit in wiring harness between fuel temperature sensor terminal A and PCM terminal 115
Short to power supply in wiring harness between fuel temperature sensor terminal A and PCM terminal
115
.
Open circuit in wiring harness between fuel temperature sensor terminal Band PCM terminal 170
PCM malfunction
PCM
@@
A ~----------------~
~--~
(J)
~----------------~

PCM
124123122121 120119118117116115114113
1~lQ1~lE1la1g1~1~1~lA1D
1n1n
1~1~1~1~1~1.lM1~1~1~
1001%lM1~1~1~100lM1M1~1001.
01-028-54

STEP
INSPECTION
RECORDED
AVAILABILITY
availability.
ACTION
Yes
No

Yes

repair information.
No
Yes
No

TROUBLESHOOTING".
2.

Start the engine.
connector.
SIGNAL CIRCUIT FOR SHORT TO POWER
SUPPLY
(Engine off).
Measure the voltage between fuel temperature
sensor terminal A (wiring harness-side) and
body ground.
Inspect the fuel temperature sensor.
(See 01-408-32 FUEL TEMPERATURE
SENSOR INSPECTION [WL-C, WE-C).}
CONNECTION
terminals:
- Fuel temperature sensor terminal A (wiring
harness-side)
- Fuel temperature sensor terminal 8 (wiring
harness-side)
Yes
No
Yes

No
Yes
Replace the fuel temperature sensor, then go to Step 9.
No
Yes
No

Yes
No

01-028-55

STEP
9
10
INSPECTION
COMPLETED
connectors.
(Engine off).
Yes
ACTION
WE-C].)
No
Yes

No

DTC P0191
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02001 00w20
Fuel pressure sensor range/performance malfunction
The PCM monitors the fuel pressure in the common rail via the fuel pressure sensor when the engine
switch is turned to the ON position after the engine has not been run for several hours. If the fuel pressure
is not 0 MPa {O bar, 0 psi}, the PCM determines that there is a fuel pressure sensor malfunction.
PCM malfunction
STEP
1
INSPECTION
RECORDED
ACTION
Yes
No


AVAILABILITY
Verify related service repair Information
availability.
Yes

repair information.
No

Yes

TROUBLESHOOTING".
CLASSIFY FUEL PRESSURE SENSOR

MALFUNCTION OR PCM MALFUNCTION
Access FRP PID.
(Engine off).
Monitor the FRP PID.
Is the FRP PID value 0 MPa {O Bar, 0 psi}
[ECT: below 20 C{68 OF}]
Yes
No

Yes
Replace the common rail, go to the next step.
No
01-028-56
No
Go to Step 6.

Yes

connectors.
(Engine off).
VE
No
Yes
No

WE-C].)
Go to the applicable
inspection.

DTC P0192
DETECTION
CONDITION
POSSIBLE
CAUSE

The PCM monitors the input voltage from the fuel pressure sensor while the engine is running. If the. input
voltage from the fuel pressure sensor is less than 0.2 V, the PCM determines that there is a malfunction in
the fuel pressure sensor circuit.
Short to ground in wiring harness between fuel pressure sensor terminal C and PCM terminal 109
Open circuit in wiring harness between fuel pressure sensor terminal C and PCM terminal 109
Short to ground in wiring harness between fuel pressure sensor terminal Band PCM terminal 140
Fuel pressure sensor signal and ground circuits are shorted each other.
PCM malfunction
PCM
CV
CV

@)
191
PCM
01-028-57

STEP
1
INSPECTION
ACTION

RECORDED
Yes
No

AVAILABILITY
Yes

No
Yes
No
2.

Start the engine.

Yes
No
pulled-out terminals, corrosion).
INSPECT FUEL PRESSURE SENSOR SIGNAL
- Fuel pressure sensor terminal C
- Fuel pressure sensor terminal B
INSPECT FUEL PRESSURE SENSOR POWER
Turn the engine switch to the ON position.
(Engine off)
Inspect the voltage at fuel pressure sensor
terminal C (wiring harness side).
Is the voltage less than 0.2 V?
INSPECT FUEL PRESSURE SENSOR CIRCUIT

FOR SHORT
Inspect for continuity between fuel pressure
sensor terminals 8 and A.

Yes
No

TROUBLESHOOTING".
(See 01-038-60 INTERMITTENT CONCERN
Repair or replace the suspected terminal, go to Step 11.

Repair or replace the wiring harness for a short to ground,

go to Step 11.
Yes
Repair or replace the wiring harness for an open circuit, go

to Step 11.
No
Yes
Repair or replace wiring harness for a short, go to Step 11.

No
Yes
Repair the supply pump, go to Step 11.

No

Yes
CONNECTION
No


FOR OPEN
sensor terminal Band PCM terminal 140.
Repair or replace suspected terminal, go to the next step.

10
01-028-58
Yes
No

STEP
INSPECTION
11
COMPLETED
connectors.
(Engine off).
12
Yes
ACTION
WE-C].)
No
Yes

No

DTC P0193
DETECTION
CONDITION
POSSIBLE
CAUSE

voltage from the fuel pressure sensor is more than 4.8 V, the PCM determines that there is a malfunction
in the fuel pressure sensor circuit.

Fuel pressure sensor power and signal circuits are shorted to each other.
Short to power supply in wiring between fuel pressure sensor terminal Band PCM terminal 140
Open circuit in wiring between fuel pressure sensor terminal A and PCM terminal 191
PCM malfunction
PCM
(J)
(J)

hW
(J)
PCM
21120119118117116115114113112111110109108107106105
%1lalG1Ml~I.I.IDl.l~IMl~I.I~IMla
~1~1~1~1~IMl~I~I~I.I~I~I~I~I~IM1M
~1~1~1001~1~IUl~I~IMl~I~I~IM1Nlnln
I~,I
01-028-59

STEP
1
10
INSPECTION
RECORDED
ACTION
Yes
No


AVAILABILITY
Yes
No

Start the engine.
Yes

Perform the "INTERMITIENT CONCERN
TROUBLESHOOTING".
No

Yes
No
INSPECT FUEL PRESSURE SENSOR SIGNAL
Yes
No
(Engine off).
Measure the voltage between fuel pressure
sensor terminal B (wiring harness-side) and
body ground
Is the voltage more than 4.8 V
Yes
Inspect
the
fuel
pressure
sensor.

No
Yes
CONNECTION
No
INSPECT FUEL PRESSURE SENSOR FOR
OPEN CIRCUIT
sensor terminal A and PCM terminal 191.

COMPLETED
connectors.
(Engine off).
01-028-60

Repair or replace harness for short with each other, go to

Step 9.

Yes
No

to the next step.
Yes

WE-C].)
No
Yes

No

DTC P0201
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200200w02

detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that
the fuel injector at No.1 cylinder has an open or short circuit.

Fuel injector No.1 malfunction
Short to ground in wiring between fuel injector No.1 terminal Band PCM terminal 174
Open circuit in wiring between fuel injector No.1 terminal Band PCM terminal 174
Open circuit in wiring between fuel injector No.1 terminal A and PCM terminal 125
PCM malfunction
PCM
FUEL INJECTOR NO.1
FUEL INJECTOR NO.1

PCM
STEP
INSPECTION
1
RECORDED
2
Yes
No

Yes
AVAILABILITY
availability.
No
Yes
No
Clear the DTC from the PCM memory using _
Start the engine.
DATA
Is DTC P0201 on FREEZE FRAME DATA?
ACTION
repair information.
Perform the "INTERMITIENT CONCERN
TROUBLESHOOTING".
Yes
No
Go to troubleshooting procedures for the DTC in FREEZE

FRAME DATA.
01-028-61

STEP
INSPECTION
INSPECT FUEL INJECTOR NO.1 CONNECTOR

Yes
FOR POOR CONNECTION
No
INSPECT FUEL INJECTOR ,NO.1 FOR SHORT

TO GROUND
Disconnect fuel injector No.1 connector.
Inspect for continuity between the following fuel
injector No.1 connector terminals and body
ground.
- Terminal A (wiring harness-side)
- Terminal 8 (wiring harness-side)
INSPECT FUEL INJECTOR NO.1
Inspect the fuel injector No.1.
Yes

then go to Step 10.
No
Yes
Replace fuel injector No.1, then go to Step 10.

(See 01-148-15 FUEL INJECTOR REMOVAU
No
Yes
CONNECTION
No
INSPECT FOR OPEN CIRCUIT BETWEEN FUEL

INJECTOR NO.1 AND PCM
PCM and fuel injector No.1 connector
disconnected.
Inspect for continuity between fuel injector No.1
and PCM at following wiring harness-side
connector:
- PCM terminal 174 and fuel injector No.1
terminal 8
terminal A
COMPLETED
connectors.
Clear the DTC using the current diagnostic
tool.
Start the engine.
ACTION
Repair or replace the suspected terminal, then go to Step
10.

10.
Yes
No

10
11

(See 01-028-10 AFTER REPAIR

DTC P0202
DETECTION
CONDITION
POSSIBLE
CAUSE
<I>
Yes

(See 01-408-9 PCM REMOVAUINSTALLATION [WL-C,
WE-C].)
No
Yes
Go to the applicable DTC troubleshooting.

(See 01-028-11 DTC TA8LE [WL-C, WE-C].)
No
dcf010200200w03
01-028-62
detects a control signal current of more or less than the preprogrammed criteria, the PCM determine that
Short to ground in wiring between fuel injector No.2 terminal 8 and PCM terminal 149
Open circuit in wiring between fuel injector No.2 terminal 8 and PCM terminal 149
PCM malfunction
PCM
FUEL INJECTOR NO.2
~~------~=---------~
FUEL INJECTOR NO.2

102
PCM
124123122121 120119118117 116115114113112

1~1Q1.1e11g1a1M1~1~1M1~1M
1n1n1ro1~1~1~1~1.1M1~1~1~1M
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.

Start the engine.
DATA
ACTION
Yes
No

repair information.
Yes
No

TROUBLESHOOTING".
Yes
No

Go to the troubleshooting procedures for the DTC in the
FREEZE FRAME DATA.
10.
Yes
FOR POOR CONNECTION
No
01-028-63

INSPECTION
STEP
10
11
INSPECT FUEL INJECTOR NO.2 FOR SHORT

TO GROUND
injector No.2 terminals and body ground.
- Terminal B (wiring harness-side)
ACTION
Yes

then go to Step 10.
No
Yes

No
Yes
CONNECTION
No
disconnected.
and PCM at following harness-side connector.
terminal B
terminal A

COMPLETED
connectors.
tool.
Start the engine.
PROCEDURE [WL-C, WE-C).}

DTC P0203
DETECTION
CONDITION
POSSIBLE
CAUSE
Yes
No
Yes
No

10.


WE-C].)
Yes

No
dcf010200200w04
01-028-64
detects a control signal current of more or less than the preprogrammedcriteria, the PCM determines that
the fuel injector at NO.3 cylinder has an open or short circuit.
Open circuit in wiring between fuel injector NO.3 terminal A and PCM terminal 101
peM malfunction

DTC P0203

PCM
FUEL INJECTOR NO.3
FUEL INJECTOR NO.3

PCM
148147 146 145 144 143 142 1

172171 170169 168 167 166 1
196195 194193192191 1901
\.
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.
ACTION
Yes
No

Yes

repair information.
No

TROUBLESHOOTING".
Start the engine.
IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA
No Go to the troubleshooting procedures for the DTC in the
FREEZE FRAME DATA.
Is DTC P0203 on the FREEZE FRAME DATA?
Yes
FOR POOR CONNECTION
No

10.
01-028-65

INSPECTION
STEP
6
10
11

TO GROUND
injector No.3 terminals and body ground:
ACTION
Yes
No
Yes
No
Yes
CONNECTION
No
disconnected.
Inspect for continuity between fuel injector NO.3
and PCM at following wiring harness-side
connector:
terminal B
terminal A

COMPLETED
connectors.
tool.
Start the engine.

DTC P0204
DETECTION
CONDITION
POSSIBLE
CAUSE

then go to Step 10.

10.
Yes
No

Yes

WE-C].)
No
Yes

No
dcf010200200w05
01-028-66
detects a control signal current of more or less than the preprogrammed criteria, the PCM determines that
PCM malfunction

DTC P0204
PCM
FUEL INJECTOR NO.4
FUEL INJECTOR NO.4

PCM
lnlnl~I~I~I~IMl~I.I~I~I~I00I.I~I~I~I~IMl
1%1%1~1~1~1~1001~1~IUl~I~IMl~I~I~IOOIMlnl
STEP
1
INSPECTION
ACTION

RECORDED
Yes
No

AVAILABILITY
availability.
Yes

Start the engine.
DATA
No
Yes
No

repair information.

TROUBLESHOOTING".
Yes
No
Go to the troubleshooting procedures for the DTC in the

FREEZE FRAME DATA.

Yes
FOR POOR CONNECTION
No

10.
01-028-67

STEP
6
10
11
INSPECTION
TO GROUND
injector No.4 terminals and body ground.
Yes
ACTION
then go to Step 10.
No
Yes


Yes Repair or replace the suspected terminal, then go to Step
10.
CONNECTION
INSPECT FOR OPEN CIRCUIT BETWEEN FUEL Yes Go to the next step.
No Repair or replace the wiring harness for an open circuit,
disconnected.
(wiring harness-side) and PCM at following
wiring harness-side connector.
terminal B
terminal A
COMPLETED
connectors.
tool.
Start the engine.
Yes
No

WE-C].)
Yes

. (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
No

DTC P0222
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200200w06
01-028-68
The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is less
Open circuit in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
Short to ground in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
Open circuit in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
Short to ground in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
PCM malfunction

DTC P0222

APP SENSOR NO.2
@)@)
0
PCM
@@
@@
@
@@
@@
@@
CD@
CD@
APPSENSOR
209
212
PCM
108107106105104 103 1
132131 130129128 127 1
STEP
INSPECTION
1
VERIFY FREEZE FRAME OAT!, HAS BEEN
RECORDED

AVAILABILITY
availability.
ACTION
repair information.
Yes
No
Yes
No

TROUBLESHOOTING".
Yes
No
Go to Step 11.
Yes
No
Go to Step 9.
2.

Start the engine.
(Engine off).
Measure the voltage between the APP sensor
ground.
OR APP SENSOR RELATED MALFUNCTION
(Engine off).
ground.
01-028-69

STEP
10
11
12
13
14
INSPECTION
ACTION
INSPECT APP SENSOR 5V CONSTANT
Yes Repair or replace the wiring harness for a possible short to
VOLTAGE CIRCUIT FOR SHORT TO GROUND
Inspect for continuity between the APP sensor
ground
CONNECTION
INSPECT APP SENSOR 5V CONSTANT
Yes Go to step 17.
VOLTAGE CIRCUIT FOR OPEN
then go to Step 17.
terminal A (wiring harness-side) and PCM
Yes
POOR CONNECTION
No
INSPECT APP SENSOR
Yes
No
Inspect the APP sensor.
[WL-C, WE-C).)
RELATED MALFUNCTION
,(Engine off).
ground.
Is the voltage more than 0.29 V ?
Yes
No
INSPECT APP SENSOR SIGNAL CIRCUIT FOR Yes

SHORT TO GROUND
No
ground
Yes
CONNECTION
No
INSPECT APP SENSOR SIGNAL CIRCUIT FOR
OPEN
terminal C (wiring harness-side) and PCM
01-028-70
Yes
No


Go to step 17.
Go to Step 13.

Go to Step 15.

Go to Step 17.
then go to Step 17.
16
17
18
No
INSPECT APP SENSOR
[WL-C, WE-Gj.)
Is there
malfunction?
Yes
COMPLETED
No
connectors.
(Engine off).
Yes
No
Are
DTCs nra,,,ant?

WE-C].)

(See 01-02B-11 DTC TABLE [WL-C, WE-Gj.)
dcf01020020Ow07

The PCM monitors the input signal from APP sensor No.2. If the voltage from APP sensor No.2 is more
DETECTION
than 4.80 V for 0.5 s when the APP sensor no.2 power supply voltage is normal, the PCM determines that
CONDITION
DTC P0223
POSSIBLE
CAUSE

Short to power supply in wiring harness between APP sensor No.2 terminal A and PCM terminal 213
Short to power supply in wiring harness between APP sensor No.2 terminal C and PCM terminal 209
Open circuit in wiring harness between APP sensor No.2 terminal D and PCM terminal 212
PCM malfunction
01-028-71

DTC P0223

APP SENSOR NO.2
PCM
@@)
~--~
~--------------~H
APPSENSOR
PCM
0ffi0
I~~
INSPECTION
STEP
1
RECORDED

AVAILABILITY
availabil ity.
Yes
No
Yes
No
Yes
No

TROUBLESHOOTING".
Yes
No
Go to Step 9.
Yes
No
Go to Step 15.
2.

Start the engine.
(Engine off).
ground.
OR APP SENSOR RELATED MALFUNCTION
(Engine off).
ground.
01-028-72
ACTION
repair information.
10
11
12
13
14

CONNECTION
No
POOR CONNECTION
PECT APP SENSOR
(See 01-408-28 ACCELERATOR PEDAL
[WL-C, WE-C].)
POOR CONNECTION
No
INSPECT APP SENSOR GROUND CIRCUIT
FOR OPEN CIRCUIT
terminal D and body ground.
CONNECTION
Is there
malfunction?
RELATED MALFUNCTION
(Engine off).
ground.
CLASSIFY SIGNAL CIRCUIT OR APP SENSOR
RELATED MALFUNCTION
Turn the engine switch to the ON positioll
(Engine off).
ground.
CONNECTION
No


then go to the Step 17.

01-028-73

INSPECTION
STEP
15
16
17
18

POOR CONNECTION
INSPECT APP SENSOR

[WL-C, WE-C].)
COMPLETED
connectors.
(Engine off).
PROCEDURE [WL-C, WE-C).)
ACTION
Yes
No
Yes
No
Go to the step.
Replace the APP sensor, then go to the step.
Yes

(See
01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C].)
No
Yes

No
DTC P0227 [WL-C, WE-C)

DTC P0227
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020020Ow08

The PCM monitors the input voltage from APP sensor No.1 when the idle switch is off. If the input voltage is
less than 0.86 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
01-028-74
Idle switch malfunction.

Accelerator pedal misadjustment.
Open circuit in wiring harness between Idle switch terminal A and PCM terminal 161
Open circuit in wiring harness between Idle switch terminal B and body ground.
PCM malfunction

DTC P0227

PCM
IDELSWITCH
-r-
~-0---0
(j)
Q
'7
:~
PCM
WIRING HARNESS-SIDE
CONNECTOR
IDELSWITCH
WIRING HARNESS-SIDE
CONNECTOR
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
STEP
1
INSPECTION
VERIFY FREEZE FRAME DATA AND
DIAGNOSTIC MONITORING TEST RESULTS
HAS BEEN RECORDED
AVAILABILITY
Is any related Service Information available?
Start the engine.
VERIFY RELATED PENDING CODE OR
STORED DTC
Is DTC P0122 present?
ACTION
Yes
No
Yes
No

Service information.
Yes
No

TROUBLESHOOTING".
Yes
No

Go to appropriate DTC troubleshooting procedure.
(See 01-02B-48 DTC P0122 [WL-C, WE-C].)
INSPECT IDLE SWITCH CONNECTOR FOR

Yes
POOR CONNECTION
No
Disconnect the idle switch connector.
INSPECT IDLE SWITCH POWER CIRCUIT FOR
OPEN CIRCUIT
(Engine off).
Measure the voltage between the idle switch
ground.
Is the voltage B+ ?

Record the FREEZE FRAME on the repair order, then go to
the next step.
Yes
No

Go to go to step 8.
Go to the next Step.
01-028-75

STEP
10
11
INSPECTION
ACTION
Yes Repair or replace the terminal, then go to step 10.
CONNECTION
then go to Step 10.
pulled-out pins, corrosion)
INSPECT IDLE SWITCH GROUND CIRCUIT
FOR OPEN CIRCUIT
terminal B and body ground.
INSPECT IDLE SWITCH
Inspect idle switch.
(See 01-40B-30 IDLE SWITCH INSPECTION
[WL-C, WE-C].)
COMPLETED
connectors.
(Engine off).
(See 01-02B-1 0 AFTER REPAI R

DTC P0228
DETECTION
CONDITION
POSSIBLE
CAUSE
Yes
No

then go to Step 10.
Yes
Replace the idle switch, then go to the next step.

(See 01-13B-11 ACCELERATOR PEDAL COMPONENT
REMOVAUINSTALLATION [WL-C, WE-C].)
No
Adjust the accelerator pedal, then go to the next step.

(See 01-13B-12 ACCELERATOR PEDAL ADJUSTMENT
[WL-C, WE-C].)
Yes

WE-C].)
No
Yes

No
dcf010200200w09
The PCM monitors the input voltage from APP sensor No.1 when the idle switch is on. If the input voltage is
more than 1.35 V for 1.5 s, the PCM determines that the idle switch circuit has a malfunction.
Idle switch malfunction.
Short to ground in wiring harness between idle switch terminal A and PCM terminal 161
PCM malfunction
01-028-76

DTC P0228

PCM
IDELSWITCH
0-0-0-0
(J)
~
p
--:!::
PCM
WIRING HARNESS-SIDE
CONNECTOR
IDELSWITCH
WIRING HARNESS-SIDE
CONNECTOR
124123122121 12011911811711611511411
1n1n1ro1~1~1~1001E1M1.1~1~1W1~1~1~1~1~1M1A1.
1001.1M1.1~1~1001~1M1~1001.1M1.1~1~
1W1m1n1n1n
INSPECTION
STEP
1
HAS BEEN RECORDED
2
AVAILABILITY
3

Start the engine.
STORED DTC
Is DTC P0123 present?
ACTION
Yes
No

the next step.
Yes

No

Yes
No
Yes
No

TROUBLESHOOTING".

(See 01-02B-50 DTC P0123 [WL-C, WE-C].)
INSPECT IDLE SWITCH CONNECTOR FOR

POOR CONNECTION
Disconnect the idle switch connector.
INSPECT IDLE SWITCH POWER CIRCUIT FOR
Yes Go to next the step.
SHORT TO GROUND
No Go to Step 8.
Inspect for continuity between idle switch
terminal A and body ground.
01-028-77

STEP
INSPECTION

Yes
CONNECTION
No
10
ACTION
Repair or replace the wiring harness for a short to ground
INSPECT IDLE SWITCH

[WL-C, WE-C].)
Yes

No

[WL-C, WE-C].)

COMPLETED
connectors.
(Engine off).
Perform the "AFTER REPAIR PROCEDURE".
Is any DTC present?
Yes

WE-C].)
No
Yes

No

DTC P0300
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020030Ow02

The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the
interval time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the
PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts the
number of misfires and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the
preprogrammed criteria, the PCM determines that a misfire, which can affect emission performance, has
occurred.
01-028-78

Fuel line clogged
Fuel filter clogged
Fuel leakage in fuel line
Fuel run out
Poor quality fuel
EGR valve malfunction
Related connector arid terminal malfunction
Related wiring harness malfunction
Insufficient compression

HAVE BEEN RECORDED
Have FREEZE FRAME DATA and
been recorded?
Record the FREEZE FRAME DATA and DIAGNOSTIC

MONITORING TEST RESULTS on the repair order, then
go to the next step.
VERI
RELATED REPAIR INFORMATION
AVAILABILITY
availability.
STORED DTC
Turn the engine switch off, then ON position
(Engine off).
Verify the related PENDING CODE or stored
DTCs using current diagnostic tool.
Is other DTC present?
VERIFY CURRENT INPUT SIGNAL STATUS
UNDER TROUBLESHOOTING CONDITION
Access the BOO, ECT, IAT, MAF, RPM, APp,
SEGRP and VSS PIDs using the current
diagnostic tool.
Is any signal that is far out of specification
when the engine switch is at the ON position
and the engine idles?
Yes

UNDER TROUBLE CONDITION
Inspect the same PIDs as in Step 4 while
simulating the FREEZE FRAME DATA
condition.
Is there any signal which cause drastic
changes?
INSPECT CKP SENSOR

Inspect the CKP sensor and the pulse wheel.
INSPECT CMP SENSOR

INSPECT OPERATION OF EGR VALVE

Remove the EGR valve.
Visually inspect if the EGR valve is stuck open.
Is the EGR valve stuck open?
INSPECT FUEL LINE

Inspect the fuel lines for fuel leakage or
clogging.
No

repair information. If the vehicle is not repaired, go to the
next step.
Yes

No
Yes
Inspect the suspected circuit or part or both according to

the inspection results.
Then go to Step 12
No
Yes
Inspect the suspected circuit or part or both according to

Then go to Step 12
No
Yes
No
Repair or replace the suspected fuel line, then go to Step

12
10
INSPECT ENGINE COOLANT PASSAGE FOR

Yes Repair or replace the malfunctioning part according to the
ENGINE COOLANT LEAKAGE
inspection results.
Perform the engine coolant leakage inspection. f--:-.,.--+T_h_e_n...:g:...o_t_o_S-,-te-'p.,.--12_ _ _ _ _ _ _ _ _ _ _ _ _-l
11
INSPECT ENGINE COMPRESSION

Inspect the engine compression for the
suspected cylinder.
Is the engine compression normal?
VERIFY TROUBLESHOOTING OF MISFIRE DTC
COMPLETED
connectors.
Start the engine.
12
Yes
Replace
PCM, then go to the next step.
WE-C).)
No
01-028-79

STEP
INSPECTION
13
Perform "After Repair Procedure".
PROCEDURE [WL-C, WE-Gj.)
Yes
No
DTC P0301, P0302, P0303, P0304 [WL-C, WE-C]

DTC
DTC
DTC
DTC
ACTION
dcf010200300w03
P0301
P0302
P0303
P0304

The PCM monitors the CKP sensor input signal interval time. The PCM calculates the deviation of the
interval time for each cylinder. If the deviation of the interval time exceeds the preprogrammed criteria, the
DETECTION
PCM detects a misfire in the corresponding cylinder. While the engine is running, the PCM counts the
CONDITION
number of misfires and calculates the misfire ratio for each crankshaft revolution. If the ratio exceeds the
preprogrammed criteria, the PCM determines that a misfire, which can affect emission performance, has
occurred.
POSSIBLE
CAUSE
Inadequate engine compression due to engine internal malfunction
Related connector or terminal malfunction
STEP
INSPECTION
1
RECORDED
2
ACTION
repair information.
Yes
No

AVAILABILITY
availability.
TROUBLESHOOTING".
Start the engine.
IDENTIFY TRIGGER DTC FOR FREEZE FRAME Yes Go to the next step.
DATA
No Go to troubleshooting procedures for the DTC on the
FREEZE FRAME DATA.
Is DTC P0301, P0302, P0303 or P0304 on
FREEZE FRAME DATA?
INSPECT FUEL LINE
Yes Repair or replace the suspected fuel line, then go to Step
13.
Inspect
the
fuel
lines
of
the
suspected
cylinder

for fuel leakage or clogging.
Yes Inspect the suspected circuit or part or both according to
UNDER TROUBLESHOOTING CONDITION
Then
go to Step 13.
Access
the
BOO,
ECT,
IAT,
MAF,
RPM,
APP,
SEGRP and VSS PIDs using the current

diagnostic tool.
Is any signal that is far out of specification
when the engine switch is at the ON position
and the engine idles?
01-028-80

ACTION
INSPECTION
STEP

UNDER TROUBLE CONDITION
Inspect the same PIDs as in Step 6 while
simulating the FREEZE FRAME DATA
condition.
Is there any signal which cause drastic
changes?
Yes
Inspect suspected circuit or part or both according to the

inspection results.
Then go to Step 13.
No
INSPECT CKP SENSOR

Inspect the CKP sensor and the pulse wheel.
Yes
Repair or replace the suspected part according to the

inspection results, then go to Step 13.
No
INSPECT CMP SENSOR

Yes

inspection results, then go to Step 13.
No
10
INSPECT ENGINE COOLANT PASSAGE FOR

Perform the engine coolant leakage inspection.
Yes

Repair or replace the malfunctioning part according to the
inspection results.
Then go to Step 13.
No
11
INSPECT ENGINE COMPRESSION

Inspect the engine compression for the
suspected cylinder.
Is the engine compression normal?
Inspect the fuel injector and the related circuit
for the suspected cylinder.
VERIFY TROUBLESHOOTING OF MISFIRE DTC
COMPLETED
connectors.
Start the engine.
Access the ECT PID using the current
diagnostic tool.
Warm-up the engine until the ECT PID is above
40C {104 OF}.
Idle engine for 5s or more.
Repeat the above mentioned for twice.
.Is the same DTC present?
Yes
No

Overhaul the engine, then go to Step 13.
Yes

inspection results, then go to the next step.
12
13
14
No
Yes

WE-C].)
No
Yes

No
Troubleshooti ng completed.

DTC P0335
DETECTION
CONDITION
Crankshaft position (CKP) sensor circuit malfunction
The PCM monitors the input signal from the CKP sensor while the engine is running. If the following
conditions are detected, the PCM determines that the CKP circuit has a malfunction.
- The PCM receives no pulse from the CKP sensor
- The PCM receives an improper pulse number from the CKP sensor

Short to power supply between CKP sensor terminal Band PCM terminal 193
Short to power supply between CKP sensor terminal A and PCM terminal 192
Short to ground between CKP sensor terminal C and PCM terminal 194
Short to ground between CKP sensor terminal Band PCM terminal 193
Open circuit between CKP sensor terminal Band PCM terminal 193
Open circuit between CKP sensor terminal A and PCM terminal 192
Loose CKP sensor installation bole
CKP sensor pulse wheel malfunction
PCM malfunction
POSSIBLE
CAUSE
dcf01020030Ow04
01-028-81

DTC P0335
I Crankshaft
position (CKP) sensor circuit malfunction

PCM
CKP SENSOR
@r:--
(j)
""
~ D (j)
0s
\.J
"
"
,, -..- .......................... ';" ..,,

,,
,
,, \., ,/
,,
,
,,
,,
,
,
,
,
j~ ,
,
, ,
, ,
..
.
.
.
.... ---------------
(j)
CS ""
I~~
B
B
~/
8
//
'"
@
-//
'"
'"
PCM WIRING HARNESS-SIDE

CONNECTOR
CKP SENSOR WIRING HARNESS-SIDE

CONNECTOR
6lfBID
.
.
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
I~~
INSPECTION
STEP
1

RECORDED
recorded?
AVAILABILITY
availability.
INSPECT CKP CIRCUIT FOR SHORT TO
POWER SUPPLY
Disconnect the CKP sensor connector.
(Engine off).
Measure the voltage between the following
terminals (wiring harness-side):
- CKP sensor terminal A and body ground
- CKP sensor terminal B and body ground
Is the voltage B+?
01-028-82
ACTION
Yes
No
Record FREEZE FRAME DATA on repair order, then go to

the next step.
Yes
Perform repair or diagnosis according to available repair

information.
If vehicle is not repaired, go to the next step.
No
Yes
No

TROUBLESHOOTING".
Yes
Repair or replace the wiring harness, then go to Step 12.

No

STEP
INSPECTION
ACTION
VERIFY CKP SENSOR INSTALLATION

CONDITION
Inspect for CKP sensor looseness.
Is CKP sensor loosen?
Yes
Retighten the CKP sensor installation bolt, then go to Step

12.
(See 01-408-38 CRANKSHAFT POSITION (CKP)
No
INSPECT CKP SENSOR

(See 01-408-39 CRANKSHAFT POSITION
INSPECT CKP SENSOR CONNECTOR FOR
POOR CONNECTION
Verify that the CKP sensor connector is
connected securely.
Is the connector normal?
INSPECT CKP CIRCUIT FOR SHORT TO
GROUND
Inspect for continuity the between the following
terminals:
- CKP sensor connector terminal A (wiring
- CKP sensor connector terminal 8 (wiring
Yes
No

10
11
12
INSPECT CKP CIRCUIT FOR OPEN CIRCUIT

terminals:
- CKP sensor terminal A (wiring harnessside) and PCM terminal 192 (wiring
harness-side)
- CKP sensor terminal 8 (wiring harnessside) and PCM terminal 193 (wiring
harness-side)
Replace the CKP sensor, then go to Step 12.

Yes
No
Reconnect the connector, then go to Step 12.
Yes
No
Yes
No

INSPECT DUAL-MASS FLYWHEEL

Yes
Inspect
the
dual-mass
flywheel
for
damage
and/or cracks.
No
Yes
CONNECTION
No
VERIFY THAT DTC P0335 TROUBLESHOOTING Yes
IS COMPLETED
No
connectors.
(Engine off).
Replace the dual-mass flywheel, then go to Step 12.

(See 05-10-12 CLUTCH UNIT REMOVAUINSTALLATION.)
Repair the terminal, then go to the next step.

WE-C].)
01-028-83

INSPECTION
STEP
13
Yes
No
ACTION

DTC P0340
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200300wOS
Camshaft position (CMP) sensor circuit malfunction

The PCM monitors the input signal from the CMP sensor while the engine is running. If the following
conditions are detected, the PCM determines that the CMP circuit has a malfunction.
- The PCM receives no pulse from the CMP sensor
- The PCM receives an improper pulse number from the CMP sensor

Short to power supply between CMP sensor terminal C and PCM terminal 129
Short to power supply between CMP sensor terminal Band PCM terminal 160
Short to power supply between CMP sensor terminal A and PCM terminal 114
Short to ground between CMP sensor terminal C and PCM terminal 129
Short to ground between CM P sensor terminal Band PCM terminal 160
Open circuit between CMP sensor terminal C and PCM terminal 129
Open circuit between CMP sensor terminal Band PCM terminal 160
Open circuit between CMP sensor terminal A and PCM terminal 114
Loose CMP sensor installation bolt
CMP sensor pulse wheel malfunction
PCM malfunction
PCM
CMP
@
@
CMP SENSOR WIRING HARNESS-SIDE

CONNECTOR
01-028-84

CONNECTOR

RECORDED
recorded?
Yes
AVAILABILITY
availability.
No
Is any related
information available?
2.

INSPECT CMP CIRCUIT FOR SHORT TO
POWER SUPPLY
(Engine off).
- CMP sensor terminal A and body ground
- CMP sensor terminal B and body ground
- CMP sensor terminal C and body ground
Is the voltage B+?
VERIFY CMP SENSOR INSTALLATION
CONDITION
Inspect for CMP sensor looseness.
Is CMP sensor loosen?
INSPECT CMP SENSOR
(See 01-40B-37 CAMSHAFT POSITION
(CMP) SENSOR INSPECTION [WL-C, WEC).)
Is the CMP sensor normal?
POOR CONNECTION
Verify that the CMP sensor connector is
connected securely.
Is the connector normal?
CMP CIRCUIT FOR SHORT TO
GROUND
Inspect for continuity the between the following
terminals:
- CMP sensor connector terminal C (wiring
- CMP sensor connector terminal B (wiring
Yes

information.

Perform the "INTERMllTENT CONCERNS
TROUBLESHOOTING".
(See 01-03B-60 INTERMllTENT CONCERN
Retighten the CMP sensor installation bolt, then go the

Step 12.
(See 01-40B-36 CAMSHAFT POSITION (CMP) SENSOR
Replace the CMP sensor, then go to Step 12.

(See 01-40B-38 CRANKSHAFT POSITION (CKP)
01-028-85

INSPECTION
STEP
INSPECT CMP CIRCUIT FOR OPEN CIRCUIT
9
terminals:
- CMP sensor terminal C (wiring harnessside) and PCM terminal 129 (wiring
harness-side)
- CMP sensor terminal 8 (wiring harnessside) and PCM terminal 160 (wiring
harness-side)
- CMP sensor terminal A (wiring harnessside) and PCM terminal 114 (wiring
harness-side)
INSPECT CMP SENSOR PULSE WHEEL
10
Inspect the CMP sensor pulse wheel for
damage and/or cracks.
11
12
13
ACTION
Yes
Go to Step the next step.
No
Yes
Replace the camshaft pulley, then go to Step 12.

(See 01-108-9 CYLINDER HEAD GASKET
No Go to the riext step.

Yes Repair the terminal, then go to the next step.
CONNECTION
VERIFY THAT DTC P0340 TROUBLESHOOTING Yes Replace the PCM, then go to the next step.
IS COMPLETED
WE-C].)
connectors.
(Engine off).
Clear
the DTC from the memory using the


DTC P0380
The PCM monitors the glow plug relay control signal. If the following conditions are detected, the PCM
determines that the glow plug relay circuit has a malfunction.
- The PCM turns the glow plug relay off but the voltage remains low
- The PCM turns the glow plug relay on but the voltage remains high
- The PCM internal driver IC temperature is more than 150 C {320 OF} when the glow plug relay is on
Glow plug relay malfunction

Glow plug malfunction
Open circuit in wiring harness between glow plug relay terminal 2A and battery
Open circuit in wiring harness between glow plug relay terminal 18 and main relay
Open circuit in wiring harness between glow plug relay terminal1A and PCM terminal 182
Open circuit in wiring harness between glow plug relay terminal3A and PCM terminal 227
Open circuit in wiring harness between glow plug relay terminal 3A and glow plug terminals
Short to ground circuit in wiring harness between glow plug relay terminal 1A and PCM terminal 182
Short to ground circuit in wiring harness between glow plug relay terminal 3A and PCM terminal 227
Short to ground circuit in wiring harness between glow plug relay terminal 3A and glow plug terminals
Short to power supply between glow plug relay terminal 1A and PCM terminal 182
Short to power supply between glow plug relay terminal 3A and PCM terminal 227
PCM malfunction
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200300w06
01-028-86

DTC P0380
MAIN RELAY
GLOW PLUG RELAY
PCM
@@
GLOW PLUG
GLOW PLUG WIRING

HARNESS-SIDE
CONNECTOR
GLOW PLUG RELAY

WIRING HARNESS-SIDE
CONNECTOR
r1Al
@

CONNECTOR
218217216215214213212211210209208207
231 230 229 228 227 226 225 224 223 222 221 220
244 243 242 241 240 239 238 237 236 235 234 233
257 256 255 254 253 252 251 250 249 248 247 246
STEP
1
INSPECTION
ACTION
RECORDED
recorded?
repair information.
AVAILABILITY
availability.
TROUBLESHOOTING".
INSPECT GLOW PLUG RELAY CONNECTOR
FOR POOR CONNECTION
Disconnect the glow plug relay connector.
01-028-87

INSPECTION
STEP
5
10
11
12
13
ACTION
INSPECT GLOW PLUG RELAY POWER SUPPLY

FOR OPEN CIRCUIT
Measure the voltage between glow plug relay
terminal 18 and body ground.
terminal2A and body ground.
Is the voltage B+?
Yes
No

then go to Step 15.
INSPECT GLOW PLUG RELAY

Inspect the glow plug relay.
Yes

Replace the glow plug, then go to Step 15.
INSPECT GLOW PLUG RELAY CIRCUIT FOR

SHORT TO GROUND
Inspect for continuity between glow plug relay
terminal 3A and ground.
OPEN CIRCUIT
terminals and glow plug terminals.
Yes
No
INSPECT GLOW PLUG CONNECTOR FOR

Yes
POOR CONNECTION
No
No
Yes
No

15.

then go to Step 15.
Go to the next step

then go to Step 15.
INSPECT GLOW PLUG

Inspect
the
glow
plug.
No Replace the glow plug, then go to Step 15.
(See 01-138-9 GLOW PLUG INSPECTION

[WL-C, WE-C].)
15.
CONNECTION
Turn
the
engine
switch
off.

Yes Repair or replace the wiring harness for a short to ground,
then go to Step 15.
SHORT TO GROUND
terminal1A and body ground.
Yes Repair or replace the wiring harness for a short to power
supply, go to Step 15.
Disconnect the glow plug relay connector and No Go to the next step.
PCM connector.
(Engine off.)
Inspected the voltage between the following
- Glow plug relay terminal 1A (wiring harnessside) and body ground.
- Glow plug relay terminal 3A (wiring harnessside) and body ground.
Is the voltage B+
01-028-88
15
16

terminals:
- Glow plug relay terminal1A and PCM
terminal 182
- Glow plug relay terminal 3A and PCM
terminal 227
IS COMPLETED
connectors.
(Engine off).
Are any DTCs nrc'"cnt',

Yes
No
Yes
No

WE-C).)


DTC P0403
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020040Ow02
The PCM monitors the EGR solenoid valve control signal. If the following conditions are detected, the PCM
determines that the EGR solenoid valve circuit has a malfunction (open circuit).
- The PCM turns the EGR solenoid valve off but the voltage remains low
- The PCM internal driver IC temperature is more than 150C {320 OF} when the EGR solenoid valve is
on
EGR solenoid valve malfunction

Open circuit in wiring harness between main relay and EGR solenoid valve terminal A
Open circuit in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
PCM malfunction
PCM
EGR SOLENOID VALVE

MAIN RELAY
~r*p___
EGR SOLENOID VALVE

@_8_ _ _
(f)*,.
PCM
lWl~I~IWl~IMl~I~I~I00I~I~I~I~I~IMlg
1.1.1~1~1~IWl~IW1U1Ml~I.I~I00lnlnln
01-028-89

INSPECTION
STEP
1
Yes
No

AVAILABILITY
availability?
Yes

ACTION

RECORDED
INSPECT EGR SOLENOID VALVE CONTROL

Inspect for continuity between EGR solenoid

COMPLETED
connectors.
(Engine off).
Start the engine.
Retrieve DTCs using the current diagnostic
tool.
01-028-90

the next step.
repair information.
No
Yes
No
2.

INSPECT EGR SOLENOID VALVE CONNECTOR
FOR POOR CONNECTION
Disconnect the EGR solenoid valve connector.
pulled-out pins, and corrosion).
(Engine off).
Measure the voltage between EGR solenoid
body ground.
Is the voltage B+?
INSPECT EGR SOLENOID VALVE
Inspect the EGR solenoid valve.
(See 01-16B-5 EGR SOLENOID VALVE
Is the EGR solenoid valve normal?
CONNECTION
Yes
No
Yes
No
Yes
No
Yes
No

TROUBLESHOOTING".
Repair or replace terminal, then go to Step 9.



Replace the EGR solenoid valve, then go to Step 9.
(See 01-16B-4 EGR SYSTEM REMOVAUINSTALLATION
[WL-C, WE-C].)
Repair or replace terminal, then go to the next step.
Yes
No

Yes

WE-C].)
No

STEP
INSPECTION
10
Yes
No
ACTION

DTC P0405

The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the
DETECTION
input voltage is less than 0.1 V, the PCM determines that the EGR valve position sensor circuit has a
CONDITION
malfunction.
EGR valve position sensor malfunction
Short to ground circuit between EGR valve position sensor terminal C and PCM terminal 116.
POSSIBLE
Short to ground circuit between EGR valve position sensor terminal Band PCM terminal 116.
CAUSE
Open circuit between EGR valve position sensor terminal C and PCM terminal 116.
Open circuit between EGR valve position sensor terminal Band PCM terminal 106.
PCM malfunction
EGRVALVE
POSITION SENSOR
PCM
@@
(j)
@@
(j)
(j)

I~~
PCM
STEP
INSPECTION
1
RECORDED
2

AVAILABILITY
Check for related service repair information
availability?
ACTION
then go to the next step .
repair information.
Yes
No
01-028-91

STEP
3
10
ACTION
INSPECTION
Perform the "INTERMITIENT CONCERNS
TROUBLESHOOTING".
(See 01-03B-60 INTERMITIENT CONCERN
INSPECT EGR VALVE POSITION SENSOR
Yes Repair or replace the terminal, then go to Step9.
Disconnect the EGR valve position sensor
connector.
terminals:
- EGR valve position sensor terminal B
(wiring harness-side) and body ground
- EGR valve position sensor terminal C
(wiring harness-side) and body ground
Is the EGR valve position sensor normal?
Inspect the EGR valve position sensor.
(See 01-40B-40 EGR VALVE POSITION
Yes
Replace the EGR valve, then go to Step 9.

[WL-C, WE-C].)
No

Yes
CONNECTION
No
- EGR valve position sensor terminal B
(wiring harness-side) and PCM terminal 106
(wiring harness-side)
- EGR valve position sensor terminal C
(wiring harness-side) and PCM terminal 116
Is
there
continuity?
VERIFY TROUBLESHOOTING OF DTC P040S

COMPLETED
connectors.
(Engine off).
01-028-92
Repair or replace the terminal, then go to step9.

Yes
No

Yes

WE-C].)
No
Yes

No

DTC P0406
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200400w04

The PCM monitors the input voltage from the EGR valve position sensor while the engine is running. If the
input voltage is more than 4.9 V, the PCM determines that the EGR valve position sensor circuit has a
malfunction.
EGR valve position sensor malfunction

Open circuit between EGR valve position sensor terminal A and PCM terminal 110
Short to constant voltage supply between EGR valve position sensor terminal C and PCM terminal 116
EGRVALVE
POSITION SENSOR
PCM
@@
@)
@@
CV@)
@@

~
I~~ I
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
INSPECTION
STEP
1

RECORDED

AVAILABILITY
availability?

ACTION
Yes
No

repair information.
No
Yes

No

TROUBLESHOOTING".
Yes
No

Connect the connector securely, then go to Step 11.
2.

CONNECTOR
Turn the engine switch to off.
Verify that the EGR valve position sensor
connector is connected securely.
Is connector normal?
01-028-93

5
10
11
12
ACTION
INSPECTION
STEP

Disconnect the EGR valve position sensor
connector.
Inspect for poor connection (such as damaged,
Perform EGR valve position sensor inspection.
Is the EGR valve position sensor normal?
SIGNAL FOR SHORT TO POWER SUPPLY
Turn the engine switch to ON (engine off).
Measure voltage between EGR valve position
ground.
Is voltage more than 4.9V?
VERIFY EGR VALVE POSITION SENSOR
GROUND CIRCUIT FOR OPEN CIRCUIT
inspect for continuity at wiring harness-side
connector between EGR valve position sensor
terminal A and PCM terminal 110.
Is there any continuity?
Yes
Repair or replace suspected terminal, then go to Step 11.
No
Yes
No
Yes
Repair or replace for short to power supply, then go to Step

11.
No
Yes
No
Yes
INSPECT PCM CONNECTORS FOR POOR
CONNECTION
No
VERIFY EGR POSITION SIGNAL CIRCUIT FOR
SHORT TO CONSTANT VOLTAGE CIRCUIT
inspect for continuity at EGR valve position
sensor wiring harness side connector between
terminal Band C.
COMPLETED
connectors.
(Engine off).
01-028-94
Yes
No
Replace the EGR valve position sensor, then go to Step 11.

[WL-C, WE-C].)

Repair or replace for open circuit.
Then go to Step 11.

Repair or replace for short circuit, then go to the next step.

Yes

WE-C].)
No
Yes

No

DTC P0489
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200400w05

The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve off but
the voltage remains low, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit
short to ground).

Short to ground in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
PCM malfunction
PCM
EGR SOLENOID VALVE
~
'--------~
EGR SOLENOID VALVE

PCM
124123122121120119118117116115114113112111110 1091081071061
19lQl%lgllalalMl~1.1.lTI1.1U1Ml~1~1~lWl
lnln
lrolWl~l~l~l~lMl~l~l~lMl~l~l~l~l~lMl
l%l%lMl~l~l~l~l~l~l~l~l~lMl~l~lMl~l~lnl
STEP
1
INSPECTION
RECORDED
No


Yes
AVAILABILITY
availability.
No
Yes
No
ACTION
Yes
2.

DATA stored condition .
INSPECT EGRSOLENOID VALVE CONNECTOR
FOR POOR CONNECTION
Inspect for poor connection (damaged/pulledout pins, corrosion, etc.).
Is there malfunction?
MALFUNCTION
Perform EGR solenoid valve inspection.
Is EGR solenoid valve normal?

repair information.

TROUBLESHOOTING".
Yes
No

Yes
No
Replace the EGR solenoid valve, then go to step 8.
01-028-95

INSPECTION
STEP
6

Disconnect the EGR solenoid valve connector
and PCM connector.
Inspect for continuity between EGR solenoid
body ground.
CONNECTION
Inspect for poor connection at terminal 176.
(damaged/pulled-out pins, corrosion, etc.).

COMPLETED
connectors.
(Engine off).
Start the engine.
tool.
Are any DTC present?
Yes
No
Yes
No
DETECTION
CONDITION
POSSIBLE
- CAUSE

Yes

WE-C].)
No
Yes

No

DTC P0490
ACTION
Repair or replace the wiring harness for short to ground,
then go to Step 9.
dcf010200400w06
01-028-96
The PCM monitors the EGR solenoid valve control signal. If the PCM turns the EGR solenoid valve on but
the voltage remains high, the PCM determines that EGR solenoid valve circuit has a malfunction (circuit
short to power supply).
Short to power supply in wiring harness between EGR solenoid valve terminal Band PCM terminal 176
PCM malfunction

DTC P0490

MAIN RELAY
PCM
EGR SOLENOID VALVE
(J)'@
EGR SOLENOID VALVE

PCM
STEP
INSPECTION
1
RECORDED

Yes
AVAILABILITY
availability.
No
Yes
CONCERN INTERMITTENT OR CONSTANT? ,.
No
ACTION
Yes
No
2.

INSPECT EGR SOLENOID VALVE CONNECTOR
FOR POOR CONNECTION
MALFUNCTION
Perform EGR solenoid valve inspection.
INSPECTION [WL-C, WE-C).)
Is the EGR solenoid valve normal?

CONNECTION
(such as damaged/pulled-out pins, corrosion).
Go to the next step,

repair information.
TROUBLESHOOTING".
Yes
No
Yes
No

Replace the EGR solenoid valve, then go to Step 8.
Yes
Repair the terminal, then go to Step 8.
No
01-028-97

STEP
INSPECTION
CIRCUIT SHORT TO POWER SUPPLY
(Engine off).
Measure the voltage between EGR solenoid
body ground.
Is the voltage B+?
COMPLETED
connectors.
(Engine off).
Start the engine.
tool.
Yes
No
ACTION
Repair or replace the wiring harness for short to power
supply, then go to the next step.
Yes

WE-C].)
No
Yes

No
DTC POSOO [WL-C, WE-C]

DTC P0500
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020050Ow03

The PCM monitors the input signal from the instrument cluster during set conditions. If the input signal is
less than 0 km/h {O mph} for 25 s, the PCM determines that there is a VSS circuit malfunction.
PCM malfunction
Instrument cluster malfunction
Open circuit in wiring harness between PCM terminal 184 and instrument cluster terminal 2F
Short to ground in wiring harness between PCM terminal 184 and instrument cluster terminal 2F
INSTRUMENT CLUSTER
PCM
cv@
INSTRUMENT CLUSTER
01-028-98
PCM

STEP
INSPECTION
ACTION
RECORDED
No Record the FREEZE FRAME PID DATA on the repair order,
Has FREEZE FRAME PID DATA been
recorded?
service repair Information.
AVAILABILITY
Verify related service repair Information
availability.
VERIFY CURRENT INPUT SIGNAL STATUS: IS
Yes Intermittent concern exists.
CONCERN INTERMITTENT OR CONSTANT
TROUBLESHOOTING".
Connect the current diagnostic tool to the DLC(See 01-03B-60 INTERMITTENT CONCERN
2.
Start engine.
Access VSS PID.
Read the VSS PID when the vehicle is driving.
Is the VSS PID normal?
CHECK INPUT/OUTPUT CHECK MODE
Yes DTC 10 and/or 12 displayed: Inspect instrument cluster.
(See 09-22-4 INSTRUMENT CLUSTER INPUT/OUTPUT
Turn the ignition switch to the ON position
CHECK MODE.)
(Engine off).
Is instrument cluster DTCs 10 or 12 detected?
(See 09-22-4 INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE.)
INSPECT INSTRUMENT CLUSTER
No Repair or replace terminals, then go to Step 10.
Turn the ignition switch off.
Disconnect instrument cluster connector.
Inspect for poor connections (damaged/pulledout terminals, corrosion, etc.).
Are terminals normal?
INSPECT VOLTAGE
Yes Replace instrument cluster, then go to Step 10.
(See 09-22-2 INSTRUMENT CLUSTER REMOVAU
INSTALLATION.)
(Engine off).
Measure voltage at instrument cluster terminal No Go to the next step.
2F (wiring harness-side).
Is there 5 V at instrument cluster terminal 2F
(wiring harness-side)?
INSPECT VSS CIRCUIT FOR SHORT TO
Yes Repair or replace harness, then go to Step 10.
GROUND
Inspect for continuity between instrument
cluster terminal 2F (wiring harness-side) and
body ground.
CONNECTION
No Repair or replace pin or connector, then go to Step 10.
Disconnect PCM connector.
Inspect for poor connection (damaged/pulledout terminals, corrosion, etc.).
Are terminals normal?
INSPECT VSS CIRCUIT FOR OPEN CIRCUIT
Yes Replace instrument cluster then go to the next step.
No Repair or replace harness, then go to the next step.
(Engine off).
cluster terminal 2F (wiring harness-side) and
01-028-99

INSPECTION
STEP
10
11

COMPLETED
connectors.
(Engine off).
Start the engine.
tool.
Yes
ACTION
Replace PCM, then go to the next step.
WE-C].)
No
Yes

No

DTC P0563
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200500w04

The PCM monitors the battery voltage. If the battery voltage is more than 16 V, the PCM determines that
there is a malfunction in the battery charging system.
Generator malfunction
Battery malfunction
Open circuit in wiring harness between generator terminal S and battery positive terminal
PCM malfunction
GENERATOR
PCM
@
@
ENGINE
SWITCH
BATTERY
GENERATOR
01-028-100
PCM

"n,..
",1',',.
nrnt"Ot'lure

RECORDED
a Has FREEZE FRAME DATA been recorded?

AVAILABILITY
a Verify related service repair information
availability.
a Is any related repair information available?
a Connect the current diagnostic tool to the DLC-
Yes

repair information.
a If the vehicle is not repaired, go to the next step.
No

TROUBLESHOOTING".
2.

a Start the engine.
a Is the same DTC nroc>ont,
INSPECT GENERATOR TERMINAL FOR POOR

INSTALLATION
a Turn the engine switch off.
a Inspect generator terminal B for looseness.
a Is there any malfunction?
INSPECT GENERATOR
a Inspect the generator.
(See 01-17-5 GENERATOR INSPECTION.)
INSPECT BATTERY POSITIVE TERMINAL FOR
POOR INSTALLATION
a Turn the engine switch off.
Inspect the battery positive terminal for
looseness.
INSPECT BATTERY
Inspect the battery.
(See 01-17-2 BATTERY INSPECTION.)
10
11

CONNECTION
INSPECT GENERATOR CIRCUIT SHORT
CIRCUIT
Inspect for continuity between generator
terminal S (wiring harness-side) and battery
plus terminal.
COMPLETED
connectors.
(Engine off).
a Clear the DTC from the memory using the
a Run the vehicle under the FREEZE FRAME
Yes
No
Yes
No
Replace the generator, then go to Step 10.

(See 01-17-4 GENERATOR REMOVAUINSTALLATION.)
Connect the battery positive terminal correctly, then go to
Step 10.
Yes
Replace the battery, then go to Step 10.

(See 01-17-2 BATTERY REMOVAUINSTALLATION.)
No
Repair or replace the wiring harness for short, then go to

the next step.
Yes

WE-C].)
No
Yes

(See 01-02B-11 DTC TABLE [WL-C,
No
01-028-101

DTC P0602
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w02
No configuration data in the PCM

Note
When the configuration is completed, DTC P0602 is cleared.
Complete configuration has not been completed

PCM malfunction
INSPECTION
STEP
1
ACTION

RECORDED
Yes
No


AVAILABILITY
availability.
COMPLETED
connectors.
(Engine off).
Clear
the DTC from the PCM memory using

Start the engine.
Yes

repair information.
No
Yes

WE-C].)
No
Yes

No
DTC P0606, P2530 [WL-C, WE-C]

DTC P0606
DTC P2530
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020060Ow03
PCM malfunction
PCM malfunction
INSPECTION
STEP
1

DTC P0607
DETECTION
CONDITION
POSSIBLE
CAUSE
01-028-102
ACTION
Replace the PCM.
WE-C].)
dcf010200600w04

STEP
INSPECTION
RECORDED
AVAILABILITY
availability.
VERIFY TROUBLESHOOTING OF P0607
COMPLETED
connectors.
Clear DTC from PCM memory using the
Start the engine.
Is same DTC present?
Yes
No
ACTION
the next step.
Yes

information.
No
Yes

WE-C].)
No
Yes
Go to applicable DTC inspection.

No

DTC P0610
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w05

PCM data configuration error
Configuration procedure has not been completed
PCM malfunction
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.
COMPLETED
connectors.
(Engine off).
Start the engine.
ACTION
repair information.
Yes
No
Yes

WE-C].)
No
Yes

No
01-028-103

DTC P0627
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020060OW06

The PCM monitors the fuel metering valve driver IC temperature in the PCM and the control voltage while
the engine is running. If either of the following conditions is met, the PCM determines that there is a
malfunction in the fuel metering valve range/performance.
- The PCM monitors the fuel metering valve driver IC temperature in the PCM. If the fuel metering valve
driver IC temperature is more than 150 C {320 OF} during the fuel metering valve operation, the PCM
determines that the fuel metering valve has a malfunction
- The PCM monitors the fuel metering valve control voltage at the PCM terminals. If fuel metering valve
control voltage is less than 5 V when fuel metering valve is not operating, the PCM determines that the
fuel metering valve has a malfunction (open circuit)
Fuel metering valve malfunction

Open circuit in wiring harness between fuel metering valve terminal A and main relay
Open circuit in wiring harness between fuel metering valve terminal Band PCM terminal 179
PCM malfunction
PCM
MAIN RELAY
FUEL METERING VALVE
FUEL METERING VALVE

(J)
PCM
INSPECTION
STEP
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED

AVAILABILITY
availability.
2.

01-028-104
ACTION
Yes

repair information.
No
No
Yes
No

TROUBLESHOOTING".

STEP
4
10
INSPECTION
INSPECT FUEL METERING VALVE
Yes
No
Disconnect the fuel metering valve connector.
INSPECT FUEL METERING VALVE CONTROL
(Engine off).
Measure the voltage between fuel metering
body ground
Is the voltage B+?
Inspect the fuel metering valve.
(See 01-14B-13 FUEL METERING VALVE
ACTION
Yes
No
Yes
Repair the supply pump, then go to Step 9.

No

Yes
CONNECTION
No
INSPECT FUEL METERING VALVE CONTROL
Yes
No
Inspect for continuity between fuel metering
PCM terminal 179 (wiring harness-side)
Yes
COMPLETED
No
connectors.
(Engine off).
Yes
Perform
the
"After
Repair
Procedure".

No




WE-C].)

01-028-105

DTC P0628
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w07
The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects
that the circuit voltage is low when the fuel metering valve is off, the PCM determines that there is a
malfunction in the fuel metering valve circuit (circuit short to ground).
Short to ground in wiring harness between fuel metering valve terminal Band PCM terminal 179
PCM malfunction
PCM
MAIN RELAY
FUEL METERING VALVE
@
A
//
@
B
\\
(J)
//
",
//
FUEL METERING VALVE

PCM
(LiW)
124123 122121 120 119118 117 116 115 114113 112 111 110 109 lOB 107 106 105104 103 102101
14B 147 146145 144 143 142141 140 139 13B 137 136 135 134 133132 131 130 129128 127 126125
Gt~
172 171 170 169 16B 167166 165 164 163 162161 160 159 15B 157 156155 154 153152 151 150 149
196 195 194 193 192 191 190 189 lBB lB7 lB6 lB5 lB4 lB3 lB2 181 lBO 179 17B 177 176 175 174 173
Gt~
STEP
INSPECTION
ACTION

RECORDED
Yes
No

AVAILABILITY
Yes

Yes
No
No
2.

Start the engine.
INSPECT POOR CONNECTION OF FUEL

Yes
METERING VALVE CONNECTOR
No
01-028-106

TROUBLESHOOTING".


INSPECTION
STEP
INSPECT FUEL METERING VALVE CIRCUIT

FOR A SHORT TO GROUND
Disconnect the fuel metering valve connector
and PCM connector.
Inspect for continuity between fuel metering
valve terminal 8 (wiring harness-side) and
body ground.
Inspect the fuel metering valve.
(See 01-148-13 FUEL METERING VALVE
CONNECTION
COMPLETED
connectors.
(Engine off).
ACTION
Yes

go to Step 8.
No
Yes

(See 01-148-11 SUPPLY PUMP REMOVAU
No
Yes
Repair or replace the suspected terminal, go to the next

step.
No
Yes

WE-C].)
No
Yes

No

DTC P0629
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w08

The PCM monitors the fuel metering valve circuit voltage while the engine is running. If the PCM detects
that the circuit voltage is high when the fuel metering valve is on, the PCM determines that there is a
malfunction in the fuel metering valve circuit (circuit short to power supply).

Short to power supply in wiring harness between fuel metering valve terminal 8 and PCM terminal 179
PCM malfunction
01-028-107

DTC P0629

PCM
FUEL METERING VALVE
MAIN RELAY
FUEL METERING VALVE

PCM
INSPECTION
STEP
1
RECORDED
ACTION
Yes
No


AVAILABILITY
Yes

Yes
No
No
2.

Start the engine.

Yes
No
INSPECT FUEL METERING VALVE CIRCUIT
Disconnect the fuel metering valve connector
and PCM connector.
(Engine off).
Inspected the voltage between fuel metering
body ground.
Is the voltage B+?
01-028-108


TROUBLESHOOTING".

Yes

supply, go to Step 8.
No

STEP
INSPECTION

Yes
Inspect
the
fuel
metering
valve.
(See 01-14B-13 FUEL METERING VALVE

No
Yes
CONNECTION
No
Yes
COMPLETED
No
connectors.
(Engine off).
. Clear the DTC from the memory using the
Yes
No
ACTION
Repair or replace the suspected terminal, go to the next
step.

WE-C].)


DTC P0642
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020060Ow09
The PCM monitors the fuel pressure sensor and the boost sensor 5 V circuit. If the fuel pressure sensor
and boost sensor power voltage is lower than 4.9 V, the PCM determines that there is a fuel pressure
sensor and boost sensor 5 V circuit malfunction.
Short to ground circuit between circuit in wiring between boost sensor terminal C and PCM terminal 133
Short to ground circuit between circuit in wiring between fuel pressure sensor terminal C and PCM terminal
109
PCM malfunction
01-028-109

DTC P0642

PCM
5V

WIRING HARNESS-SIDE
CONNEOTOR
1-*-----@----~(J)~1331----4
o

~--------------------~~
~--------------------~~109~------+-~J
~--------------------~~1401---~O
PCM
;'~ ,~'" ,~'"
105 104 103 102 101
""" """ '" """ '" """' ,.,., '00 129 128 127 126 125
lQl~lUllalG1Ml~1.1.1~1.1.lMlal.l~lW
lnlrol~1~lDl~1~lMl~1~1~1~1~lAl~1~lY1M
lM1Ml~1~1~1~lM1Ml~lMl~lMl~1~1~1~1~ln
153 152 151 150 149

177 176 175 174 173
INSPECTION
STEP
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED
recorded?
2
AVAILABILITY
availability.
3
Yes
No
Yes
No
01-028-110

repair information.
Yes
No

TROUBLESHOOTING".
Yes
No

Go to Step 10.
2.

CLASSIFY BOOST SENSORIIAT SENSOR NO.1
OR FUEL PRESSURE SENSOR RELATED
MALFUNCTION
(Engine off).
Is the voltage 4.9 V or less?
ACTION

STEP
10
11
12
INSPECTION
ACTION
connector.
CLASSIFY BOOST SENSORIIAT SENSOR NO.1 Yes Go to the next step.
OR HARNESS RELATED MALFUNCTION
I-:-N:-o+G:::-o--:t--:o-=S::-te-p-:g:-.- - ' - - - - - - - - - - - - - - - /
connector.
(Engine off).
Measure the voltage between the Boost sensor
ground.
CONNECTION
No Go to Step 15.
Inspect for continuity between the boost sensor
ground.
Yes Replace the boost sensor/IAT sensor No.1, then go to Step
15.
No Go to Step 15.
Disconnect the fuel pressure sensor connector.
CLASSIFY FUEL PRESSURE SENSOR OR
HARNESS RELATED MALFUNCTION
No Go to Step 14.
(Engine off).
Measure the voltage between the fuel pressure
sensor terminal C (wiring harness-side) and
body ground.
Yes Repair or replace the terminal, then go to the next step.
CONNECTION
01-028-111

STEP
13
14
15
16
INSPECTION
FOR SHORT TO GROUND
Inspect for continuity between the fuel pressure
sensor terminal C (wiring harness-side) and
body ground.
COMPLETED
connectors.
(Engine off).

DTC P0643
DETECTION
CONDITION
POSSIBLE
CAUSE
No
ACTION
Go to Step 15.
Yes
No
Replace the fuel pressure sensor, then go to the next step.

Yes

WE-C].)
Yes
Nb
Yes
No

dcf01 0200600w1 0

The PCM monitors the fuel pressure sensor and boost sensor 5 V circuit. If the fuel pressure sensor and
boost sensor power voltage is higher than 4.9 V, the PCM determines that there is a fuel pressure sensor
and boost sensor 5 V circuit malfunction.
Short to power supply between boost sensor connector terminal C and PCM terminal 133
Short to power supply between fuel sensor connector terminal C and PCM terminal 109
Open circuit in wiring harness between boost sensor connector terminal C and PCM terminal 133
Open circuit in wiring harness between fuel sensor connector terminal C and PCM terminal 109
PCM malfunction
01-028-112

DTC P0643

PCM
BOOST SENSOR!IAT SENSOR NO.1

WIRING HARNESS-SIDE
CONNECTOR
BOOST SENSOR!
IAT SENSOR NO.1
(m91~
I~~ I
CD@
5V
@@@
@)@
@)

EW3JJ
I~~
140
191
PCM
124123122121120119118117116115 114113112111110109108107106
,~ ,~ '"'~l
191Q1g1~11a1.1~1~1~1~1D1.1.1M1.1.1~1W
129128127126
1n1n1m1~1M1~1M1.1M1~1~1~1~1~1~1~1A1.1M
153152 151 150

177 176 175 174
1001%1M1~1.1~1001.1.1~1.1.1M1~1~1~1001n1n
,ro
STEP
INSPECTION
ACTION
VERIFY
FREEZE
FRAME
DATA
HAS
BEEN
Go
to
the
next
step.
1
Yes
RECORDED
recorded?
2
repair information.
AVAILABILITY
availability.
VERIFY
CURRENT SIGNAL STATUS: IS
3
Connect the current diagnostic tool to the DLCPerform the "INTERMITTENT CONCERNS
2.
TROUBLESHOOTING".
CLASSIFY BOOST SENSOR/IAT SENSOR NO.1 Yes Go to step 14
4
OR FUEL PRESSURE SENSOR RELATED
No If the voltage is 1.0 V or less, go to the next step.
MALFUNCTION
If the voltage is 5.1 V or more, go to Step 10.
(Engine off).
sensor/IAT sensor No.1 connector terminal C
and body ground.
01-028-113

INSPECTION
STEP
INSPECT POOR CONNECTION OF BOOST

SENSORIIAT SENSOR NO.1 CONNECTOR
connector.
Inspect for poor connection
(damaged, pulled-out terminals, corrosion,
etc.).
Is there a malfunction?
connector.
(Engine off).
sensor/lAT sensor No.1 connector terminal C
and body ground.
Inspect the boost sensor/lAT sensor No.1.
CONNECTION
etc.).
10
11
12

POWER CIRCUIT FOR OPEN
and PCM terminal 133
INSPECT POOR CONNECTION OF BOOST

SENSORIIAT SENSOR NO.1 CONNECTOR
connector.
etc.).
connector.
(Engine off).
and body ground.
Is the voltage 5.1 V or more?
Inspect the boost sensor/lAT sensor No.1.
01-028-114
ACTION
Yes
Repair or replace the terminals, then go to Step 24.
No
Yes
No
Yes
No
Yes
No
Repair or replace the pins, then go to Step 24.
Yes
No
Yes
No
Yes
Go to step 8
Go to Step 24.
Go to Step 24.
Repair or replace the wiring harness for an open, go to
Step 24.

No
Go to the Step 13.

Yes
No
Go to Step 24.
14
15
16
17
18
19

Inspect for poor connection (damaged, pulled-out terminals, corrosion,
etc.).
CLASSIFY FUEL PRESSURE SENSOR OPEN
CIRCUIT OR SHORT CIRCUIT RELATED
MALFUNCTION
(Engine off).
sensor connector terminal C and body ground.
PRESSURE SENSOR CONNECTOR
etc.).
(Engine off).
(See 01-408-33 FUEL PRESSURE SENSOR
CONNECTION
etc.).
INSPECT FUEL PRESSURE SENSOR POWER
CIRCUIT FOR OPEN
Inspect for continuity between the fuel pressure
sensor connector terminal C and PCM terminal
Repair or replace the wiring harness for a short to power,

go to the Step 24.
If the voltage is 1.0 V or less, go to the next step.

No

Step 24.
No
109
20
PRESSURE SENSOR CONNECTOR
etc.).
01-028-115

STEP
INSPECTION
21
Yes
No
(Engine off).
22
Yes
No
Yes
23
CONNECTION
No
etc.).
24
Yes
COMPLETED
No
connectors.
(Engine off).
Yes
25
Perform
the
"After
Repair
Procedure".

No

DTC P0652
DETECTION
CONDITION
POSSIBLE
CAUSE
ACTION
Go to the Step 23.
i''
Replace the fuel pressure sensor, then go to Step 24.

Go to Step 24.
Repair or replace the pins, then go to the next step.


WE-C].)

dcf010200600w11

voltage is lower than 4.9 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
malfunction.
Short to ground circuit between circuit in wiring between CMP sensor terminal C and PCM terminal 129
Short to ground circuit between circuit in wiring between APP sensor terminal A and PCM terminal 213
APP sensor malfunction
PCM malfunction
01-028-116
,1
PCM
CMP SENSOR
WIRING HARNESS-SIDE
CONNECTOR
fiJTfJ
CMPSENSOR
5V
@@
APPSENSOR
APP SENSOR
WIRING HARNESS-SIDE
CONNECTOR
0ZfE0
iGt'1
PCM
WIRING HARNESS-SIDE
CONNECTOR
STEP
INSPECTION
ACTION

RECORDED
recorded?
Yes
No


AVAILABILITY
availability.
Yes

repair information.

2.

No
Yes
No

TROUBLESHOOTING".
01-028-117

STEP
4
10
11
INSPECTION
Yes
CLASSIFY CMP SENSOR OR APP SENSOR
RELATED MALFUNCTION
No
(Engine off).
Measure the voltage between the CMP sensor
ground.
Yes
POOR CONNECTION
No
CLASSIFY CMP SENSOR OR HARNESS
Yes
RELATED MALFUNCTION
No
(Engine off).
ground.
Yes
CONNECTION
No
INSPECT CMP SENSOR CIRCUIT FOR SHORT
TO GROUND
Inspect for continuity between the CMP sensor
ground.
INSPECT CMP SENSOR
(See 01-408-37 CAMSHAFT POSITION
(CMP) SENSOR INSPECTION [WL-C, WEC].)
POOR CONNECTION
CLASSIFY APP SENSOR OR HARNESS
RELATED MALFUNCTION
(Engine off).
ground.
01-028-118
ACTION
Go to Step 10.


Go to Step 9.

Yes

No
Go to Step 15.
Yes
No
Go to Step 15.
Yes
No

Yes
No
Go to Step 14.
13
14
15
16

INSPECT APP SENSOR CIRCUIT FOR SHORT
TO GROUND
ground.
INSPECT APP
[WL-C, WE-C].)
COMPLETED
connectors.
(Engine off).
Is the same DTC resent?
No
Repair or replace
round, then go to
Go to Step 15.
Yes
No
Yes
No
wiring harness for a possible short to

15.

WE-C].)

dcf010200600w12

DETECTION
voltage is higher than 5.1 V, the PCM determines that there is a CMP sensor and APP sensor 5 V circuit
CONDITION
malfunction.
Short to power supply between CMP sensor connector terminal C and PCM terminal 133
Short to power supply between APP sensor connector terminal A and PCM terminal 213
Open circuit in wiring harness between CMP sensor connector terminal C and PCM terminal 133
POSSIBLE
Open circuit in wiring harness between APP sensor connector terminal A and PCM terminal 213
CAUSE
PCM malfunction
DTC P0653
01-028-119

DTC P0653 . CMP sensor and APP sensor 5 V circuit high input
CMP SENSOR
WIRING HARNESS-SIDE
CONNECTOR
5V
fii!fJ
@@
PCM
APP SENSOR
APP SENSOR
WIRING HARNESS-SIDE
CONNECTOR
@@
0W0
I~~I
PCM
WIRING HARNESS-SIDE
CONNECTOR
INSPECTION
STEP
1
RECORDED
recorded?
2
AVAILABILITY
availability.
3
ACTION
Yes
No

Yes

repair information.
No
Yes
No

TROUBLESHOOTING".
Yes
No
Go to step 14
2.

CLASSIFY CMP SENSOR OR APP SENSOR
RELATED MALFUNCTION
(Engine off).
connector terminal C and body ground.
01-028-120

INSPECTION
STEP
10
11
12
INSPECT POOR CONNECTION OF CMP

SENSOR CONNECTOR
etc.).
RELATED MALFUNCTION
(Engine off).
INSPECT CMP SENSOR
(CMP) SENSOR INSPECTION [WL-C, WE-
13

Yes
No
Go to step 8
Yes
No
Go to Step 24.
Yes

C).}

CONNECTION
etc.).
INSPECT CMP SENSOR POWER CIRCUIT FOR

OPEN
Inspect for continuity between the CMP sensor
connector terminal C and PCM terminal 133
INSPECT POOR CONNECTION OF CMP
SENSOR CONNECTOR
etc.).
RELATED MALFUNCTION
(Engine off).
Measure
the voltage between the CMP sensor

INSPECT CMP SENSOR
(CMP) SENSOR INSPECTION [WL-C, WE-
ACTION
Yes
No
No
Yes
Go to Step 24.
No

Step 24.
Yes
No
Yes
No
Go to the Step 13.

Yes
No
Go to Step 24.
Yes
No

go to the Step 24.
C).}

CONNECTION
etc.).
01-028-121

STEP
INSPECTION
CLASSIFY APP SENSOR OPEN CIRCUIT OR
14
SHORT CIRCUIT RELATED MALFUNCTION
(Engine off).
connector terminal A and body ground.
15
INSPECT POOR CONNECTION OF APP
SENSOR CONNECTOR
etc.).
16
RELATED MALFUNCTION
(Engine off).
17
INSPECT APP SENSOR
[WL-C, WE-C].)
18
CONNECTION
etc.).
19
20
21
22
INSPECT APP SENSOR POWER CIRCUIT FOR

OPEN
connector terminal A and PCM terminal 213.
INSPECT POOR CONNECTION OF APP
SENSOR CONNECTOR
etc.).
RELATED MALFUNCTION
(Engine off).
INSPECT APP SENSOR
[WL-C, WE-C].)
01-028-122
Yes
No
ACTION
Go to step 24
Yes
No

Yes
No

Go to step 18
Yes
No

Go to Step 24.
Yes
No

Yes
No
Go to Step 24.
Step 24.
Yes
No

Yes
No
Go to the Step 23.

Yes
No

Go to Step 24.
24
25

etc.).
COMPLETED
connectors.
(Engine off).
Is the same DTC n."..:":>lnT,
Yes
No

Yes
No

WE-C].)

dcf01020060Ow13
DTC P0660

The PCM monitors the intake shutter solenoid valve (half) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (half) control circuit has a malfunction.
- The PCM turns the intake shutter solenoid valve (half) off, but the intake shutter solenoid valve (half)
DETECTION
CONDITION
control voltage is less than 5 V for 2 s (open circuit)
- The PCM internal driver IC temperature is more than 150 C {320 OF} when the intake shutter solenoid
valve (half) is on
Intake shutter solenoid valve (half) malfunction
POSSIBLE
Open circuit in wiring harness between intake shutter solenoid valve (half) terminal A and main relay
CAUSE
Open circuit in wiring harness between intake shutter solenoid valve (half) terminal Band PCM terminal
152
PCM malfunction
VALVE (HALF)
MAINRELAY~
PCM
~~

~mTh
I~~I
PCM
124123122121 120119118117116115114113112111 110109108107106

1~lQl~1~1lalgl~1~1~1~lDl.l.1Ml~1~1~1~
lnlnlrol~l~l~l~l.l.l~l.l~l~lWl~l~l~l~lM
iii
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 17711761175117411731111
I~~I
01-028-123

STEP
1
INSPECTION
ACTION

RECORDED
Yes

AVAILABILITY
availability.
Yes

No
No

repair information.
Yes
No

TROUBLESHOOTING".
INSPECT INTAKE SHUTTER SOLENOID VALVE Yes

(HALF) CONNECTOR FOR POOR
No
CONNECTION
Disconnect the intake shutter solenoid valve
(half) connector.
(HALF) CONTROL CIRCUIT FOR OPEN
No
CIRCUIT
(Engine off).
Measure the voltage between intake shutter
solenoid valve (half) terminal A (wiring
Is the voltage B+?
(HALF)
Inspect the intake shutter solenoid valve (half).
(See 01-16B-6INTAKE SHUTTER SOLENOID
VALVE (HALF) INSPECTION [WL-C, WE-C].)
No


Repair or replace the wiring harness for a pos:,?ible open
Replace the intake shutter solenoid valve (half), then go to

Step 9.

CONNECTION
INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Go to the next step.
(HALF) CONTROL CIRCUIT FOR OPEN
CIRCUIT
Inspect for continuity between intake shutter
solenoid valve (half) terminal B (wiring
harness-side)
01-028-124
10

connectors.
(Engine off).
Are
DTCs 'Vc":",,n'"
Yes

WE-C].)
No
Yes

No

DTC P0661
DETECTION
CONDITION
The PCM monitors the intake shutter solenoid valve (half) control signal at PCM terminal 152. If the PCM
turns the intake shutter solenoid valve (half) off but the voltage at PCM terminal 152 remains low, the PCM
determines that intake shutter solenoid valve (half) circuit has a malfunction (circuit short to ground).
POSSIBLE
CAUSE
Intake shutter solenoid valve malfunction

Short to ground in wiring harness between intake shutter solenoid valve (half) terminal Band PCM terminal
152
PCM malfunction
PCM
MAIN RELAY
INTAKE SHUTTER
SOLENOID VALVE (HALF)

PCM
120119118117116115114113112111 110109108107106105104103102101
1~lMl~1~1~lMl~1~1~1~1.1~lDl~1.lMlglgl~1~10
1~1.1~1001~lMl~1~1~lMl~1~1~lM1MlnlnlnlnlMln
01-028-125

STEP
1
INSPECTION
ACTION

RECORDED
Yes
No

AVAILABILITY
availability.
INSPECT INTAKE SHUTTER SOLENOID VALVE
CONNECTION
(half).
Yes

(HALF) MALFUNCTION
Perform intake shutter solenoid valve (half)
inspection.
(See 01-16B-6 INTAKE SHUTTER
SOLENOID VALVE (HALF) INSPECTION [WLC, WE-C].)
Is intake shutter solenoid valve normal?
CONTROL CIRCUIT FOR SHORT TO GROUND
solenoid valve (half) valve terminal B (wiring
CONNECTION

COMPLETED
connectors.
(Engine off).

01-028-126
No

repair information.
Yes
No

TROUBLESHOOTING".
Yes
No

Yes
No

step 8.
Yes

then go to Step 8.
No
Yes
No

Yes

WE-C].)
No
Yes

No

DTC P0662
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020060Ow15

The PCM monitors the intake shutter solenoid valve (half) control signal at PCM terminal 152. If the PCM
turns the intake shutter solenoid valve (half) on but the voltage at PCM terminal 152 remains high, the
PCM determines that the intake shutter solenoid valve (half) circuit has a malfunction (circuit short to power
supply).
Intake shutter solenoid valve (half) malfunction
Short to power supply in wiring harness between intake shutter solenoid valve (half) terminal Band PCM
terminal 152
Shorted intake shutter solenoid valve (half) or PCM connector
PCM malfunction
PCM
MAIN RELAY
PCM

124 123 122 121 120 119 118 117 116 115 114113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
STEP
1
INSPECTION
RECORDED
ACTION
Yes
No


AVAILABILITY
availability.
Yes

repair information.
Yes
No


(HALF) MALFUNCTION
Perform intake shutter solenoid valve (half)
inspection.
(See 01-16B-6INTAKE SHUTTER
SOLENOID VALVE (HALF) INSPECTION [WLC, WE-C].)
Is the intake shutter solenoid valve (half)
normal?
Yes
No

Step 7.

CONNECTION
(half) connector.
No
01-028-127

5
ACTION
INSPECTION
STEP
Yes
No
Yes

No

COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No

Yes

No

CONNECTION

(HALF) CONTROL CIRCUIT SHORT TO POWER
SUPPLY
(Engine off).
solenoid valve (half) terminal B (wiring
Is the voltage B+?
dcf010200600w16

The PCM monitors the intake shutter solenoid valve (full) control signal. If the following conditions are
detected, the PCM determines that the intake shutter solenoid valve (full) control circuit has a malfunction.
- The PCM turns the intake shutter solenoid valve (full) off, but the intake shutter solenoid valve (full)
DETECTION
control voltage is less than 5 V for 2 s (open circuit)
CONDITION
- The PCM internal driver IC temperature is more than 150C {320 OF} when the intake shutter solenoid
valve (full) is on
DTC P0663
POSSIBLE
CAUSE
Intake shutter solenoid valve (full) malfunction

Open circuit in wiring harness between intake shutter solenoid valve (full) terminal A and main relay
Open circuit in wiring harness between intake shutter solenoid valve (full) terminal Band PCM terminal 155
PCM malfunction
01-028-128
PCM
MAIN RELAY
INTAKE SHUTTER
SOLENOID VALVE (FULL)
PCM

'N'~ '" '" ,,, "" " .." " .." ". """ '" "",00 '00 ""00 .... 00 ""~I
l~lQl~lglMlalal~l~l~l~l~l.l.lMlal~l~l~lnl~lVl~
172171 170169168 167 166 165 164163 162 161160 159 158 157 156155154153152151 150
l00l~lMl~l.l~l00l~lMl~lMl~lMl.l~l~l00l~lnlnlNlnlM
STEP
INSPECTION
RECORDED
Yes
No

repair information.

AVAILABILITY
availability.
No
Is any related ~epair information available?
Yes
No
ACTION
2.

TROUBLESHOOTING".

INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Repair or replace the terminal, then go to Step 9.
(FULL) CONNECTOR FOR POOR
CONNECTION
(full) connector.
INSPECT INTAKE SHUTTER SOLENOID VALVE Yes Go to the next step.
(FULL) CONTROL CIRCUIT FOR OPEN
CIRCUIT
(Engine off).
Measure the voltage between Intake shutter
solenoid valve (full) terminal A (wiring harnessside) and body ground
Is the voltage B+?
01-028-129

INSPECTION
STEP
6
10

(FULL)
Inspect the intake shutter solenoid valve (full).
(See 01-16B-7 INTAKE SHUTTER SOLENOID
VALVE (FULL) INSPECTION [WL-C, WE-C].)

CONNECTION
(FULL) CONTROL CIRCUIT FOR OPEN
CIRCUIT
solenoid valve (full) terminal B (wiring harnessside) and PCM terminal 155 (wiring harnessside)
COMPLETED
connectors.
(Engine off).
current diagnostic. tool.
(See 01-02B-1 0 AFTER REPAIR
ACTION
Yes
Replace the intake shutter solenoid valve (full), then go to

Step 9.
No
Yes

No
Yes
No
Yes
No


WE-C].)
Yes

No

DTC P0664
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w17
The PCM monitors the intake shutter solenoid valve (full) control signal at PCM terminal 155. If the PCM
turns the intake shutter solenoid valve (full) off, but the voltage at PCM terminal 155 remains low, the PCM
determines that intake shutter solenoid valve (full) circuit has a malfunction (circuit short to ground).

Short to ground in wiring harness between intake shutter solenoid valve (full) terminal Band PCM terminal
155
PCM malfunction
01-028-130
PCM
MAIN RELAY
INTAKE SHUTTER
SOLENOID VALVE (FULL)
PCM

124123122121 120119118117116115114113112111 110109108107106

1~1Q1g1U11a1a1~1~1~1~1~1~1.1M1a1.1~1M
1n1n1ro1~1M1~1~1E1M1~1~1~1001~1~1~1~1~1M
1001001M1~1~1~1~1~1M1~1~1E1M1~1~1~1001~1n
'""""li
129128127
153152151
177 176 175
STEP
INSPECTION
RECORDED
ACTION
Yes
No

repair information.

Yes
AVAILABILITY
availability.
No
Yes
No
2.


Perform the "INTERMITIENT CONCERNS
TROUBLESHOOTING".

CONNECTION
(full) connector.
Yes
No

(FULL) MALFUNCTION
Perform intake shutter solenoid valve (full)
inspection.
(See 01-16B-7INTAKE SHUTIER
SOLENOID VALVE (FULL) INSPECTION [WLC, WE-C).)
Is intake shutter solenoid valve (full) normal?
Yes

step 8.
No
01-028-131

STEP
INSPECTION
(FULL) CONTROL CIRCUIT FOR SHORT TO
GROUND
(full) connector and PCM connector.
Inspect
for continuity between intake shutter
solenoid valve (full) terminal B (wiring harnessside) and body ground.


CONNECTION
ACTION
Yes Repair or replace the wiring harness for short to ground,
then go to Step 8.
Yes
No


COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No

Yes

No

DTC P0665
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010200600w18

The PCM monitors the intake shutter solenoid valve (full) control signal at PCM terminal 155. If the PCM
turns the intake shutter solenoid valve (full) on, but the voltage at PCM terminal 155 remains high, the PCM
determines that the intake shutter solenoid valve (full) circuit has a malfunction (circuit short to power
supply).
Short to power supply in wiring harness between intake shutter solenoid valve (full) terminal Band PCM
terminal 155
Shorted intake shutter solenoid valve (full) or PCM connector
PCM malfunction
" "".
01-028-132
PCM
MAIN RELAY
PCM
INTAKE SHUTIER SOLENOID VALVE (FULL)

124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172 171 170 169 168167 166165 164 163 162 161160 159 158 157 156155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
STEP
1
INSPECTION
RECORDED
ACTION
Yes
No


AVAILABILITY
availability.
INSPECT INTAKE SHUTIER SOLENOID VALVE
CONNECTION
(full) connector.
Yes
No

INSPECT INTAKE SHUTIER SOLENOID VALVE

(FULL) MALFUNCTION
Perform intake shutter solenoid valve (full)
inspection.
(See 01-16B-7INTAKE SHUTIER
SOLENOID VALVE (FULL) INSPECTION [WLC, WE-C].)
Is the intake shutter solenoid valve (full)
normal?
Yes
No

Step 7.

CONNECTION
Yes

No
Yes
No

repair information.
01-028-133

STEP
INSPECTION
(FULL) CONTROL CIRCUIT SHORT TO POWER
SUPPLY
(Engine off).
solenoid valve (full) terminal B (wiring harnessside) and body ground.
Is the voltage B+?
VERIFY TROUBLESHOOTING OF DTC POGGS
COMPLETED
connectors.
(Engine off).

DTC POG8S
DETECTION
CONDITION

No
Yes

WE-GJ.)
No
Yes
No

dcf010200600w19
POSSIBLE
CAUSE
ACTION
Yes
The PCM monitors the power supply to the PCM. If the power supply is shut down several times when the
engine switch is turned to the ON position, the PCM determines that there is a power circuit malfunction
(open circuit).
Open circuit in wiring harness between main relay terminal Band PCM terminal 219
Open circuit in wiring harness betwee:n main relay terminal 0 and PCM terminal 201, 203, or 205
Main relay malfunction
Open circuit in wiring between main relay terminal A, terminal C and battery
PCM malfunction
01-028-134
BATTERY
PCM
MAIN RELAY
MAIN RELAY WIRING

HARNESS-SIDE
CONNECTOR
(j)
(j)
(j)
(j)

CONNECTOR
rc1Al
[Eli]
1

RECORDED
. recorded?
Yes
No

Yes
AVAILABILITY
availability.
No
Yes
No
ACTION
INSPECTION
STEP
2.

INSPECT MAIN RELAY CONNECTOR FOR
POOR CONNECTION
Disconnect the generator connector.
Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).

repair information.
Go to the next step. .
TROUBLESHOOTING".
TROUBLESHOOTING [WL-C, WE-C).}
Yes
No
01-028-135

INSPECTION
STEP
5
10
INSPECT MAIN RELAY POWER CIRCUIT FOR

OPEN CIRCUIT
terminal:
- Main relay terminal A and body ground.
- Main relay terminal C and body ground.
Is the voltage B+?
INSPECT MAIN RELAY
Inspect the main relay.

CONNECTION
Turn the engine switch ott.
Inspect for poor connection (damaged, pulledout terminals, corrosion, etc.).
INSPECT MAIN RELAY CONTROL CIRCUIT
FOR OPEN CIRCUIT
terminal:
- Main relay terminal Band PCM terminal 219
- Main relay terminal D and PCM terminal
201,203,or205
IS COMPLETED
connectors.
(Engine ott).
ACTION
Yes
No
Repair or replace the wiring harness for open circuit, then

go to Step 9.
Yes
Replace the main relay, then go to Step 9.
No
Yes
Repair terminals, then go to Step 9.
No

,
Yes
No

Repair or replace the wiring harness for open circuit, then
go to Step 9.
Yes

WE-C].)
No
Yes

No
DTC P069S [WL-C, WE-C]
dcf010200600w20
DTC P0698
DETECTION
CONDITION
The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is lower
Short to ground circuit between circuit in wiring between EGR position sensor terminal Band PCM terminal
108
EGR position sensor malfunction
PCM malfunction
POSSIBLE
CAUSE
01-028-136

DTC P0698

EGRVALVE
POSITION SENSOR
----~
PCM
@@
~~--------------~
A ~~--------------~

PCM
STEP
INSPECTION
1
RECORDED
recorded?
2
AVAILABILITY
availability.
3

2.
Yes
No
Yes
No
Yes
No

INSPECT EGR POSITION SENSOR
Yes
No
Disconnect the EGR position sensor
connector.
ACTION
repair information.
TROUBLESHOOTING".

01-028-137

STEP
10
INSPECTION
CLASSIFY EGR POSITION SENSOR OR
connector.
(Engine off).
Measure the voltage between the EGR position
sensor terminal B (wiring harness-side) and
body ground.
CONNECTION
INSPECT EGR POSITION SENSOR CIRCUIT
FOR SHORT TO GROUND
Inspect for continuity between the EGR
position sensor terminal B (wiring harnessside) and body ground.
Inspect the EGR position sensor.
SENSOR INSPECTION [WL-C, WE-C).)
COMPLETED
connectors.
(Engine off).

DTC P0699
DETECTION
CONDITION
POSSIBLE
CAUSE
ACTION
Yes
No

Go to Step 8.
Yes
No

Yes
No

Go to Step 9.
Yes
No
Replace the EGR position sensor, then go to the next step.

Yes

WE-C).)
No
Yes
No

dcf010200600w21

The PCM monitors the EGR position sensor 5 V circuit. If the EGR position sensor power voltage is higher
Short to power supply between EGR position sensor connector terminal Band PCM terminal 108
Open circuit in wiring harness between EGR position sensor connector terminal Band PCM terminal 108
EGR position sensor malfunction
PCM malfunction
01-028-138

DTC P0699

EGRVALVE
POSITION SENSOR
PCM
@@
@@@
r---~
~----------------~
~.~~
~----------------~

PCM
124123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108 107 106 105 104 103 102 101
148147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132131 130 129 128 127 126125
172171 170 169 168 167 166 165 164 163 162161 160 159 158 157 156155 154 153 152 151 150149
196195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180179 178 177 176 175 174173
INSPECTION
STEP
1
RECORDED
recorded?
2
AVAILABILITY
availability.
3

ACTION
Yes

repair information.
No
Yes
No
2.

CLASSIFY EGR POSITION SENSOR OPEN
CIRCUIT OR SHORT CIRCUIT RELATED
MALFUNCTION
(Engine off).
sensor connector terminal B and body ground.
INSPECT POOR CONNECTION OF EGR
POSITION SENSOR CONNECTOR
connector.
etc.).
Yes
No


TROUBLESHOOTING".
Yes
Go to step 10
No
Yes
No
01-028-139

INSPECTION
STEP
10
11
12
13

connector.
(Engine off).
sensor connector terminal 8 and body ground.
(See 01-408-40 EGR VALVE POSITION
CONNECTION
etc.).
INSPECT EGR POSITION SENSOR POWER
CIRCUIT FOR OPEN
Inspect for continuity between the EGR
position sensor position sensor connector
terminal 8 and PCM terminal 108.
INSPECT POOR CONNECTION OF EGR
POSITION SENSOR CONNECTOR
connector.
etc.).
connector.
(Engine off).
sensor connector terminal 8 and body ground.
(See 01-408-40 EGR VALVE POSITION
SENSOR INSPECTION [WL-C, WE-C).}
CONNECTION
etc.).
01-028-140
ACTION
Yes
No
Go to step 8
Yes
No
Go to Step 14.
Yes
No
Yes
Go to Step 14.
No

Step 14.
Yes
No

Yes
No
Go to the Step 13.

Yes
Replace the EGR position sensor, then go to Step 14.
No
Go to Step 14.
Yes
Repair or replace the pins, then go to the next step.
No

Replace the EGR position sensor, then go to Step 14.

STEP
14
15
INSPECTION
COMPLETED
connectors.
(Engine off).
ACTION
Yes Replace PCM, then go to the next step.
WE-C].) .
No
Yes

No

DTC P1196
DETECTION
CONDITION
The PCM monitors whether the main relay opens after 2 5 when the engine switch is turned to the off
position. If the main relay does not open after 2 5, the PCM determines that there is malfunction in the
main relay circuit.
POSSIBLE
CAUSE

Short to power supply between main relay terminal D and PCM terminal 201, 203, and 205
PCM malfunction
BATTERY
PCM
MAIN RELAY
@
l*::--~~---<H201
}----o
~~H205}----n
MAIN RELAY
PCM
icTAl
~
01-028-141

INSPECTION
STEP
1
RECORDED
2
5
6

AVAILABILITY
availability.

DATA
ACTION
Yes
No
Yes
No

Yes
No
Go to troubleshooting procedures for DTC in FREEZE

FRAME DATA.
INSPECT MAIN RELAY CONNECTOR FOR

Yes
POOR CONNECTION
No
Disconnect the main relay connector.
INSPECT MAIN RELAY

Inspect the main relay.
Is it normal?
INSPECT MAIN RELAY CIRCUIT FOR SHORT
TO POWER SUPPLY
Measure voltage between main relay terminal
D (wiring harness-side) and body ground.
Is the voltage B+?
COMPLETED
connectors.
(Engine off).

repair information.
Yes
No

Install the sensor securely, then go to the Step 7.
Yes
Repair or replace for short to power supply.

Then, go to the next step.
No
Yes

WE-C].)
No
Yes

No

DTC P1259
DETECTION
CONDITION
POSSIBLE
CAUSE

The PCM does not complete target ID transfer.

Communication error between immobilizer unit and PCM
PCM malfunction
01-028-142
dcf010201200w02

nr(l~""nure
FREEZE FRAME DATA AND

HAVE BEEN RECORDED
been recorded?

Yes
AVAILABILITY
No
availability.
Yes
INSPECT IMMOBILIZER UNIT CONNECTOR
FOR POOR CONNECTION
Turn engine switch off.
No
Disconnect the IMMOBILIZER UNIT connector.
INSPECT COMMUNICATION LINE FOR SHORT Yes
TO GROUND
No
-IMOBILIZER unit connector terminal A
PECT COMMUNICATION LINE FOR SHORT Yes
TO POWER SUPPLY
Measure the voltage between following
No
-IMMOBILIZER unit connector terminal A
Is the voltage B+?
Yes
CONNECTION
Turn engine switch off.
No
(See 01-40B-9 PCM REMOVAU
INSPECT COMMUNICATION LINE FOR OPEN
CIRCUIT
terminals:
-IMMOBILIZER UNIT connector terminal A
(wiring harness-side) and PCM connector
terminal 230 (wiring harness-side)
VERIFY THAT DTC P1259
IS COMPLETED
connectors.
No
Start the engine and warm-up to normal
operating temperature.
Retrieve the DTC using the current diagnostic
tool.
Is the PENDING CODE same DTC present?
No


(See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
8.
Repair or replace the suspected wiring harness, then go to

Step 8.
r or replace the suspected wiring harness, then go to
8.
8.
Repair or replace the suspected wiring harness, then go to

the next step.
Replace
WE-C].)
o to the applicable DTC inspection.

01-028-143

dcf010201200w03
DTC P1260 Theft detected Vehicle immobilizer

DETECTION
CONDITION
POSSIBLE
CAUSE
PCM malfunction
1
ACTION
INSPECTION
STEP

HAVE BEEN RECORDED
been recorded?
Yes

AVAILABILITY
availability.
Yes
VERIFY STORED DTC IN IMMOBILIZER

SYSTEM
(Engine off).
Verify stored DTC in IMMOBILIZER SYSTEM.
(See 09-02A-2 DTC TABLE [IMMOBILIZER
SYSTEM].)
Are DTCs stored?
IS COMPLETED
connectors.
tool.
Perform "After Repair Procedure".
Is there any DTC present?
No
No


repair information.
Yes

No
Yes

WE-C].)
No
Yes

No

DTC P1391
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010201300w03

The PCM monitors the output signal to the glow plug relay when the glow plug relay is on. If the glow plug
relay voltage is less than 2 V for 1 s when the glow plug relay is operating, The PCM determines that there
is a malfunction in the glow plug relay circuit.

Melt or burnt glow fuse
PCM malfunction
Open circuit in wiring harness between glow plug
Short to ground circuit in wiring harness between
01-028-144
relay terminal 3A and PCM terminal 227

relay terminal1A and PCM terminal 182
relay terminal 1B and main relay
relay terminal 2A and battery
glow plug relay terminal 3A and PCM terminal 227
PCM
BATTERY
GLOW
FUSE
GLOW PLUG RELAY
L-..:::~--"@~ 2A
1
!-7r'=@=-----=-,----"'----(@-=
-*l227J----.----()
GLOW
PLUG
MAIN RELAY
GLOW PLUG RELAY

PCM
DB
GLOW PLUG
4 243 242 241 240 239 238 237 236 235 234 233
7256 255 254 253 252251 250249248 247 246
INSPECTION
STEP
1
RECORDED

Yes
AVAILABILITY
availability.
No
Yes
No
ACTION
Yes
No
2.

Start the engine.
GLOW PLUG CONNECTOR FOR POOR
Yes
CONNECTION
No
pulled- out terminals, corrosion).

repair information.
TROUBLESHOOTING".

01-028-145
ON-BOARD DIAGNOSTIC IWL-C, WE-C]

STEP
INSPECTION

Yes
FOR POOR CONNECTION
No
10
11
12
13
ACTION

INSPECT GLOW PLUG RELAY POWER SUPPLY

FOR OPEN CIRCUIT
terminal 2A and body ground.
Is the voltage B+?
Yes
No

to Step 13.
INSPECT GLOW PLUG RELAY CONTROL

POWER FOR OPEN CIRCUIT
Remove the glow plug relay.
terminal 18 and ground.
INSPECT GLOW PLUG RELAY SIGNAL FOR
OPEN CIRCUIT
(Engine off).
terminal 1A.
Is voltage less than 2 V?
(See 01-138-9 GLOW PLUG RELAY
INSPECT POOR CONNECTION OF PCM
CONNECTOR
Yes

to Step 13.
No
Yes

to Step 13.
No
Yes
No
Replace the glow plug relay, go to Step 13.
Yes

INSPECT GLOW PLUG RELAY SIGNAL

Remove the glow plug relay connector.
terminal 3A and PCM terminal 227.

COMPLETED
connectors.
(Engine off).
01-028-146
No
Yes
No

then go to Step 13.
Go to the next step
Yes
Go to the next step
No

Yes

WE-C).}
No

STEP
INSPECTION
14 VERIFY AFTER REPAIR PROCEDURE
Yes
No
ACTION

DTC P1392
DETECTION
CONDITION
POSSIBLE
CAUSE
The PCM monitors the output signal to the glow plug relay when the glow plug relay is off. If the glow plug
relay voltage is more than 2 V for 1 s when the glow plug relay is off, The PCM determines that there is a
malfunction in the glow plug relay control circuit.

PCM malfunction
Short to power supply in wiring harness between glow plug relay terminal 3A and PCM terminal 227
Short to ground in wiring harness between glow plug relay terminal 1A and PCM terminal 182
PCM
BATTERY
GLOW
FUSE
GLOW PLUG RELAY
@
' - - - - - - * I 2A
227 )----.--0
GLOW
PLUG
MAIN RELAY
GLOW PLUG RELAY

PCM
GLOW PLUG
01-028-147

STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.

ACTION
Yes
No

repair information.
Yes
No
Yes
No

TROUBLESHOOTING".
2.

Start the engine.
Yes
FOR POOR CONNECTION
No
(See 01-13B-9 GLOW PLUG RELAY
CIRCUIT FOR SHORT TO POWER
(Engine off).
Measure the voltage between glow plug
Is the voltage more than 2 V?

Yes
No
Replace the glow plug relay, go to Step 10.

Yes

supply, then go to Step 10.
No
Go to the next step
INSPECT GLOW PLUG

Yes Replace the glow plug, go to Step 10.
Inspect glow plug.
(See 01-13B-9 GLOW PLUG INSPECTION
[WL-C, WE-C].)
INSPECT POOR CONNECTION OF PCM
Yes Repair or replace the suspected terminal, go to the Step
10.
CONNECTOR
INSPECT GLOW PLUG RELAY CONTROL
Yes Repair or replace the wiring harness for a short to power
POWER CIRCUIT FOR SHORT TO GROUND
No Go to the next step
01-028-148
11

COMPLETED
connectors.
(Engine off).
VER
AFTER REPAIR
RE
Yes

WE-C].)
No
Yes
No
to the applicable DTC inspection.

01-02B-11 DTC TABLE [WL-C, WE-C].

DTC P1602
DETECTION
CONDITION
POSSIBLE
CAUSE
PCM malfunction
INSPECTION
STEP
1

Yes
No
ACTION
WE-C].)
dcf010201600w03
DTC P1603 ID Number Unregistered

DETECTION
CONDITION
POSSIBLE
PCM malfunction
CAUSE
STEP
1
INSPECTION
ACTION
WE-C].)

Yes

No
01-028-149

dcf01020160OW04
DTC P1604 Code word unregistered

DETECTION
CONDITION
POSSIBLE
PCM malfunction
CAUSE
STEP
1
INSPECTION
ACTION
WE-C).)

Yes

No
DTC P1621, P1622, P1623, P1624 [WL-C, WE-C]

DTC P1621
DTC P1622
DTC P1623
DTC P1624
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01020160OW05

Immobilizer ID does not match
Immobilizer code word/lD number write failure
Anti-theft system
ID number stored in immobilizer system and PCM does not to match.
PCM malfunction
INSPECTION
STEP
1
HAVE BEEN RECORDED
been recorded?
2
AVAILABILITY
availability.
VERIFY STORED DTC IN IMMOBILIZER
3
SYSTEM
(Engine off).
Verify stored DTC in IMMOBILIZER SYSTEM.
(See 09-02A-2 DTC TABLE [IMMOBILIZER
SYSTEM].)
Are DTCs stored?
VERIFY THAT DTC P1621/P16221P1623/P1624
4
TROUBLESHOOTING IS COMPLETED
connectors.
tool.
01-028-150
ACTION
Yes
No

Yes

repair information.
No
Yes

No
Yes

WE-C].)
No

RE
No

DTC P1675
DETECTION
CONDITION
POSSIBLE
CAUSE

The fuel injector compensation data configuration has not been completed.
Fuel injector compensation data input procedure does not been completed.
PCM malfunction
STEP
INSPECTION
RECORDED
AVAILABILITY
availability.
VERIFY FUEL INJECTOR COMPENSATION
DATA INPUT PROCEDURE
Does the fuel injector compensation data input
procedure properly?
COMPLETED
connectors.
Turn the engine switch to ON position (engine
off).
Clear the DTC from PCM memory using the
Start the engine.
ACTION
Yes

repair information.
No
No
Yes
No

Perform the fuel injector compensation data input
procedure.
INSTALLATION [WL-C, WE-C).)
Yes Replace the PCM, go to the next step.
WE-C].)
No
Yes

No
01-028-151

DTC P1676
dcf01020160OW07
DETECTION
CONDITION
The fuel injector compensation data check sum error.
POSSIBLE
CAUSE
Fuel injector compensation data reprogramming error.
STEP
1
INSPECTION
RECORDED
ACTION
Yes
No

AVAILABILITY
availability.
VERIFY FUEL INJECTOR COMPENSATION
DATA INPUTTED PROPERLY
Perform the fuel injector compensation data
input procedure.
Does the inputted fuel injector compensation
data properly?
Yes

repair information.
No
Yes

Clear the learning data on PCM. Perform the fuel injector
compensation data input procedure again.

COMPLETED
connectors.
Turn the engine switch to ON position (engine
off).
Clear the DTC from PCM memory using the
Start the engine.
Yes

WE-C].)
No
Yes

No
No

DTC P2135
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010202100w01
Accelerator pedal position (APP) sensor No.1/No.2 voltage correlation problem
The PCM monitors the input signals from accelerator pedal position sensor No.1 and accelerator pedal
position sensor No.2. If the difference between accelerator pedal position sensor No.1 and accelerator
pedal position sensor No.2 is more than 0.9 V for 0.5 s, the PCM determines that there is a malfunction in
the accelerator pedal position sensor characteristic.
PCM malfunction
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.
01-028-152
ACTION
Yes
No
Yes
No

repair information.

Start the engine.
PECT APP S""."",...,"
[WL-C, WE-C).)
COMPLETED
connectors.
(Engine off).
Are any DTCs nroc>on,t"

TROUBLESHOOTING" .
Yes
No
Yes
No

WE-C].)

dcf01 02021 00w02
Accelerator pedal position (APP) sensor No.1/idle switch voltage correlation problem
The PCM compares the input voltage from APP sensor No.1 with the input voltage from the idle switch
DETECTION
when the accelerator pedal is released (idle switch is on). If the difference is more than 1.35 V for 0.5 s,
CONDITION
the PCM determines that there is an APP sensor No.1/idle switch angle correlation problem.
DTC P2136
POSSIBLE
CAUSE

Idle switch malfunction
PCM malfunction
STEP
INSPECTION
1
HAS BEEN RECORDED
2
AVAILABILITY
3

Start the engine.
Yes
No
Yes
No
Yes
No
ACTION
the next step.
TROUBLESHOOTING".
01-028-153

STEP
4
INSPECTION
STORED DTC
Is DTC P0122, P0123, P0227 or P0228
present?
ACTION
Yes
No

Yes

REMOVAUINSTALLATION [WL-C, WE-C).)
No
INSPECT IDLE SWITCH

[WL-C, WE-C].)
Yes

No

[WL-C, WE-C).)

COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No
Yes

INSPECT APP SENSOR

[WL-C, WE-C].)

DTC P2143
DETECTION
CONDITION
POSSIBLE
CAUSE
No
dcf01 02021 00w03

The PCM monitors the EGR control solenoid valve control signal. If the following conditions are detected,
the PCM determines that the EGR control solenoid valve circuit has a malfunction.
- The PCM turns the EGR control solenoid valve off but the voltage remains low (open circuit).
- The PCM internal driver IC temperature is more than 150 C {320 OF} when the EGR control solenoid
valve is on.
EGR
control solenoid valve malfunction

Open circuit in wiring harness between EGR control solenoid valve (vent) terminal A and main relay
Open circuit in wiring harness between EGR control solenoid valve (vent) terminal Band PCM terminal 177
PCM malfunction
01-028-154
PCM
MAIN RELAY
EGRCONTROL
SOLENOID VALVE (VENT)
PCM
EGR CONTROL SOLENOID VALVE (VENT)

g.:D)
I~~I
INSPECTION
STEP
1

RECORDED
2.

repair information.
No

AVAILABILITY
availability.
No
Yes
No
ACTION
Yes

TROUBLESHOOTING".
TROUBLESHOOTING [WL-C, WE-C).}

INSPECT EGR CONTROL SOLENOID VALVE
Disconnect the EGR control solenoid valve
connector.
CONTROL CIRCUIT FOR OPEN CIRCUIT
(Engine off).
Measure the voltage between EGR control
solenoid valve terminal A (wiring harness-side)
and body ground
Is the voltage B+?
01-028-155

INSPECTION
STEP
6
10

Inspect the EGR control solenoid valve.
(See 01-16B-6 EGR CONTROL SOLENOID
VALVE INSPECTION [WL-C, WE-C].)
Yes
ACTION
Replace the EGR control solenoid valve, then go to Step 9.
No

CONNECTION
CONTROL CIRCUIT FOR OPEN CIRCUIT
Inspect for continuity between EGR control
solenoid valve terminal B (wiring harness-side)
Yes Replace the PCM, then go to the next step.
COMPLETED
WE-C].)
Turn
the
engine
switch
off.

connectors.
(Engine off).
Clear
the DTC from the memory using the

Start the engine.
tool.
Yes Go to the applicable DTC troubleshooting.
No Troubleshooting completed.
OTC P2144 [WL-C, WE-C)

DTC P2144
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02021 00w04
The PCM monitors the EGR control solenoid valve control signal. If the PCM turns the EGR control
solenoid valve off but the voltage remains low, the PCM determines that the EGR control solenoid valve
circuit has a malfunction (circuit short to ground).
EGR control solenoid valve malfunction

Short to ground in wiring harness between EGR control solenoid valve terminal Band PCM terminal 177
PCM malfunction
01-028-156
peM
MAIN RELAY
EGR CONTROL
SOLENOID VALVE
(j)
PCM

~B~~
I~~
STEP
1
INSPECTION
RECORDED
2.

-,
repair information.
If
the
vehicle
is
not
repaired,
go
to
the
next
step.

No

AVAILABILITY
availability.
Yes
No
ACTION
Yes

Yes
No
connector.
Yes
MALFUNCTION
No
Perform EGR control solenoid valve inspection.
(See 01-168-6 EGR CONTROL SOLENOID
Is EGR control solenoid valve normal?
Yes
CONTROL CIRCUIT FOR SHORT TO GROUND
No
Inspect for continuity between EGR control
solenoid valve terminal 8 (wiring harness-side)
and body ground.

TROUBLESHOOTING".


Replace the EGR control solenoid valve, then go to step 8.

then go to Step 8.
01-028-157

7
ACTION
INSPECTION
STEP

CONNECTION

COMPLETED
connectors.
(Engine off).
Start the engine.
tool.
Yes
No
Yes

WE-C].)
No
Yes

No

DTC P2145
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02021 OOwOS
"
The PCM monitors the EGR control solenoid valve control signal. If the peM turns the EGR control
solenoid valve on but the voltage still remains high, the PCM determines that the EGR control solenoid
valve circuit has a malfunction (circuit short to power supply).
EGR control solenoid valve malfunction

Short to power supply in wiring harness between EGR control solenoid valve terminal Band PCM terminal
177
PCM malfunction
PCM
MAIN RELAY
-< I-
EGR CONTROL
SOLENOID VALVE
---- ~
@

a:nn
I~~I
01-.028-158
I"
1//
(J)
@
//
"
8
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180 179 178 177 176 175 174 173
I~~I

Yes
AVAILABILITY
availability.
No
connector.
MALFUNCTION
Perform EGR control solenoid valve inspection.
(See 01-16B-6 EGR CONTROL SOLENOID
Is the EGR solenoid valve (vent) normal?
CONNECTION
Yes
CONTROL CIRCUIT SHORT TO POWER
SUPPLY
No
(Engine off).
Measure the voltage between EGR control
solenoid valve terminal B (wiring harness-side)
and body ground.
Is the voltage B+?
Yes
COMPLETED
No
connectors.
(Engine off).
Start the engine.
tool.
Yes
Perform
the
"After
Repair
Procedure".

No

repair information.
concern exists.
TROUBLESHOOTING".

to the next step.

WE-C].)

01-028-159

DTC P2146
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010202100w06

The PCM monitors the fuel injector No.1 and No.4 power supply voltage when the engine is running. If the
- Fuel injector No.1 and No.4 power supply voltage is less than 43 V
- Fuel injector No.1 and No.4 power supply voltage is 53 V or above
PCM malfunction
INSPECTION
STEP
1
RECORDED
2

AVAILABILITY
availability.
Start the engine.
COMPLETED
Make sure to reconneCt all disconnected
connectors.
(Engine off).
Yes
No
Yes
No
ACTION
repair information.
Yes
No

TROUBLESHOOTING".
Yes

WE-C].)
No
Yes
No


DTC P2147
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010202100w07
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or
above, the PCM determines that the fuel injector No.1 and No.4 power supply current is too high.
Short to ground in the wiring harness between the fuel injector No.1 terminal Band PCM terminal 174
Short to ground in the wiring harness between the fuel injector No.4 terminal Band PCM terminal 150
PCM malfunction
01-028-160

DTC P2147
FUEL INJECTOR
PCM
@
NO.1
(j)
.----~@
NO.4
FUEL INJECTOR NO.1, NO.4

PCM
24123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
48147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
72171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
96195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180179 178 177 176 175 174 173
INSPECTION
STEP
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED
ACTION
Yes

Yes Perform the repair or diagnosis according to the available
repair information.
AVAILABILITY
Is
any
related
repair
information
available?

TROUBLESHOOTING".
Start the engine.
INSPECT FUEL INJECTOR CONNECTOR FOR
8.
POOR CONNECTION
INSPECT FUEL INJECTOR CIRCUIT FOR A
Yes Repair or replace the wiring harness for a short to ground,
then go to Step 8.
SHORT TO GROUND
terminals (wiring harness-side) and body
ground.
- Fuel injector No.1 terminal B
No
01-028-161

INSPECTION
STEP
6
7
CONNECTION
Inspect for poor connection. (such as
damaged/pulled-out terminals, corrosion).
8
COMPLETED
connectors.
(Engine off).
9
Perform the "After Repair. Procedure".
PROCEDURE [WL-C, WE-GJ.)

DTC P2148
DETECTION
CONDITION
POSSIBLE
CAUSE
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Replace the fuel injector, then go to Step 8.
Repair or replace the suspected terminal, then go to the
next step.

WE-C].)

dcf01 02021 00w08
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.1 and No.4
power supply current is too high.
Short to power in the wiring harness between the fuel injector No.1 terminal Band PCM terminal 174
Short to power in the wiring harness between the fuel injector No.1 terminal A and PCM terminal 125
Short to power in the wiring harness between the fuel injector No.4 terminal A and PCM terminal 126
PCM malfunction
01-028-162
PCM
FUEL INJECTOR
@
NO.1
NO.4
(j)
(j)
(j)
(j)
174
125
FUEL INJECTOR NO.1. NO.4

PCM
"""1
124123122121120119118117116115114113112111110 109 108107106 105

191Q1.1g11g1g1M1~1.1~1~1.1.1M1.1.1~1~ 129 1281271
1n1n1~1~1~1~1~1E1M1.1~1~1W1W1~1~1~1Y1M
1~1M1M1.1~1~1~1~1W1~1E1E1M1.1~1M1001~1n
153 152151 1
177 1761751
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.
No

Yes

repair information.
No

Yes
No
ACTION
Yes
2.

Start the engine.
POOR CONNECTION
Inspect for poor connection fuel injector for
each cylinder (such as damaged/pulled-out
terminals, corrosion).
Yes
No

TROUBLESHOOTING".
8.
01-028-163

INSPECTION
STEP
5
INSPECT FUEL INJECTORS CIRCUIT FOR

(Engine off).
Inspect the voltage between following terminals
(wiring harness-side) and body ground:
- Fuel injector No.1 terminal 8
- Fuel injector No.4 terminal 8
- Fuel injector No.1 terminal A
- Fuel injector No.4 terminal A
Is the voltage B+?
(See 01-148-16 FUEL INJECTOR
ACTION
Yes

supply for the suspected cylinder, then go to Step 8.
No
Yes

No

CONNECTION
Yes
Repair or replace the suspected terminal, then go the to

Step.
No

COMPLETED
connectors.
(Engine off).
Yes

WE-C].)
No
Yes

No

DTC P2149
The PCM monitors the fuel injector No.2 and NO.3 power supply voltage when the engine is running. If the
- Fuel injector No.2 and NO.3 power supply voltage is less than 43 V
- Fuel injector No.2 and NO.3 power supply voltage is 53 V or above
PCM malfunction
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf01 02021 OOW09
INSPECTION
STEP
ACTION

RECORDED
Yes
No


AVAILABILITY
availability.
Yes

repair information.
01-028-164
No

Start the engine.
VERI
TROUBLESHOOTING OF
P2149
COMPLETED
connectors.
(Engine off).

TROUBLESHOOTING".
Yes

WE-C].
No
Yes

No ' Troubleshooting completed.
dcf01 02021 00w1 0
DTC P2150
DETECTION
power supply current is 25 A or above 3 times while other fuel injector power supply current is 25 A or
CONDITION
above, the PCM determines that the fuel injector No.2 and NO.3 power supply current is too high.
POSSIBLE
Short to ground in the wiring harness between the fuel injector No.2 terminal A and PCM terminal 102
CAUSE
Short to ground in the wiring harness between the fuel injector No.3 terminal A and PCM terminal 101
PCM malfunction
01-028-165

DTC P2150 I Fuel injector No.2 and No.3 power supply circuit low input
FUEL INJECTOR
PCM
DQ@
B
NO.2
"
(J)
~@
NO.3
(J)
,-
J -8
~
(J)
"
(J)
I~~
(3
PCM

8
8
124 123 122 121 120 119 118 117 116 115 114 113112 111 110 109 108107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137136 135 134 133 132131 130 129 128 127 126 125
172171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156155 154 153 152 151 150 149
196195 194 193 192 191 190 189 188 187 186 185184 183 182 181 180179 178 177 176 175 174 173
I~~
STEP
INSPECTION
RECORDED.
ACTION
Yes
No


AVAILABILITY
availability.
Yes

repair information.
No
Yes
No

TROUBLESHOOTING".

POOR CONNECTION
Yes
No

SHORT TO GROUND
terminals and body ground.
Yes

then go to Step 8.

Start the engine.
01-028-166
No

STEP
INSPECTION
6
7
CONNECTION
8
COMPLETED
connectors.
(Engine off).
9

DTC P2151
DETECTION
CONDITION
POSSIBLE
CAUSE
No
ACTION
Yes
No

Yes

.
WE-C].)
No
Yes

Yes
No
dcf010202100w11
power supply current is 50 A or above 3 times, the PCM determines that the fuel injector No.2 and NO.3
power supply current is too high.
Short to power circuit in the wiring harness between the fuel injector No.2 terminal A and PCM terminal 102
Short to power circuit in the wiring harness between the fuel injector No.3 terminal A and PCM terminal 101
PCM malfunction
01-028-167

DTC P2151
PCM
FUEL INJECTOR
NO.2
NO.3
(j)
(j)
(j)
(j)

PCM
115114113112111 1101
139 138 137136 135 134 1
01-028-168

STEP
INSPECTION
RECORDED
ACTION
Yes
No


Yes
AVAILABILITY
availability.
No
Yes
No
Start the engine.
Yes
POOR CONNECTION
No
Inspect for poor connection fuel injector for
each cylinder (such as damaged/pulled-out
terminals, corrosion).
Yes
No
(Engine off).
Inspect the voltage between following terminals
(wiring harness-side) and body ground:
- Fuel injectors No.2 terminal A
- Fuel injectors No.2 terminal B
- Fuel injectors No.3 terminal A
- Fuel injectors No.3 terminal B
Is the voltage B+?
Yes
No
Yes
CONNECTION
No
Yes
COMPLETED
No
connectors.
(Engine off).

repair information.
TROUBLESHOOTING".

9.

supply for the suspected cylinder, then go to Step 8.

Repair or replace the suspected terminal, then go to the

next step.

WE-C].)
Yes

No
01-028-169

DTC P2227
DETECTION
CONDITION

The PCM monitors the input signal from the barometric pressure sensor. If the difference between the
barometric pressure input from the barometric pressure sensor and the boost pressure is more than 11
kPa {O.11 bar, 1.6 psi}, the PCM determines that there is a malfunction in the barometric pressure sensor.
Note
POSSIBLE
CAUSE
dcf010202200w01
If DTCs P2227 and P0106 are recorded simultaneously, the PCM determines that there is a boost
sensor and barometric pressure sensor characteristic malfunction.
BARO sensor (integrated in PCM) malfunction
STEP
INSPECTION
1
RECORDED
2

AVAILABILITY
availability.
Start the engine.
COMPLETED
connectors.
(Engine off).
ACTION
Yes
No

repair information.
Yes
No

TROUBLESHOOTING".
Yes

WE-C].)
No concern is detected. Go to the next step.
No
Yes
No

DTC P2228
DETECTION
CONDITION
POSSIBLE
CAUSE

dcf010202200w02
sensor is less than 2.2 V for 1 s, the PCM determines that there is a malfunction in the barometric
pressure sensor signal system.
01-028-170
VERIFY FREEZE FRAME DATA

RECORDED
2

Yes
AVAILABILITY
availability.
No
No
Start the engine.
Yes
COMPLETED
No
connectors.
(Engine off).
Yes
No

repair information.

TROUBLESHOOTING".

WE-C].)


DTC P2229
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf010202200w03

sensor is more than 4.8 V for 1 s, the PCM determines that there is a malfunction in the barometric
pressure sensor signal system.
STEP
1
INSPECTION
RECORDED
AVAILABILITY
availability.

Start the engine.
ACTION
Yes
No
Yes
No
Yes
No

repair information.
TROUBLESHOOTING".
01-028-171

INSPECTION
STEP
4

COMPLETED.
connectors.
(Engine off).
01-028-172
ACTION
Yes

WE-C).)
No
Yes

No
SYMPTOM TROUBLESHOOTING [WL-C, WE-C]
01-03B SYMPTOM TROUBLESHOOTING [WL-C, WE-C]

SYMPTOM TROU8LESHOOTING
WIRING DIAGRAM [WL-C, WE-C] ....
SYMPTOM DIAGNOSTIC INDEX
[WL-C, WE-C] ...............
SYMPTOM QUICK DIAGNOSIS CHART
[WL-C, WE-C] .............
NO.1 MELTING OF MAIN OR OTHER
FUSES [WL-C, WE-C] ............
NO.2 ENGINE CHECK LAMP
ILLUMINATES [WL-C, WE-C] .....
NO.3 WILL NOT CRANK [WL-C, WE-C]
NO.4 HARD START/LONG CRANK/
ERRATIC START/ERRATIC
CRANK [WL-C, WE-C] .......
NO.5 ENGINE STALLS-AFTER START/
AT IDLE [WL-C, WE-C] ........
NO.6 CRANKS NORMALLY BUT
WILL NOT START [WL-C, WE-C] .....
NO.7 SLOW RETURN TO IDLE
[WL-C, WE-C] ..............
NO.8 ENGINE RUNS ROUGH/
ROLLING IDLE [WL-C, WE-C] .......
NO.9 FAST IDLE/RUNS ON
[WL-C, WE-C] ..............
NO.10 LOW IDLE/STALLS DURING
DECELERATION [WL-C, WE-C] ...
NO.11 ENGINE STALLS/QUITS,
ENGINE RUNS ROUGH, MISSES,
8UCK/JERK, HESITATION/STUM8LE,
SURGES [WL-C, WE-C] .........
NO.12 LACK/LOSS OF
POWER-ACCELERATION/CRUISE
[WL-C, WE-C] .................
01-038-2
NO.13 KNOCKING/PINGING
[WL-C, WE-C] ................ 01-038-38
N~14POORFUELECONOMY
01-038-6
01-038-8
01-038-14
01-038-15
01-038-15
01-038-17
01-038-19
01-038-22
01-038-24
01-038-26
01-038-28
01-038-30
01-038-32
01-038-35
[WL-C, WE-C] ............ 01-038-41

NO.15 EMISSION COMPLIANCE
[WL-C, WE-C] ................ 01-038-44
NO.16 HIGH OIL CONSUMPTION/
LEAKAGE [WL-C, WE-C] ......... 01-038-47
NO.17 COOLING SYSTEM CONCERNSOVERHEATING [WL-C, WE-C] ....... 01-038-48
NO.18 COOLING SYSTEM
CONCERNS-RUNS COLD
[WL-C, WE-C] ................ 01-038-50
NO.19 EXCESSIVE 8LACKSMOKE
[WL-C, WE-C] ................... 01-038-50
NO.20 FUEL ODOR (IN ENGINE
COMPARTMENT) [WL-C, WE-C] .... 01-038-53
NO.21 ENGINE NOISE [WL-C, WE-C] .. 01-038-54
NO.22 VI8RATION CONCERNS
(ENGINE) [WL-C, WE-C] .......... 01-038-56
NO.23 AlC DOES NOT WORK
SUFFICIENTLY [WL-C, WE-C] ...... 01-038-57
NO.24 AlC ALWAYS ON OR AlC
COMPRESSOR RUNS
CONTINUOUSLY
[WL-C, WE-C] .................. 01-038-59
NO.25 AlC DOES NOT CUT OFF
UNDER WIDE OPEN THROTTLE
CONDITIONS [WL-C, WE-C] ........ 01-038-59
INTERMITTENT CONCERN
TROU8LESHOOTING
[WL-C, WE-C] ................ 01-038-60
ENGINE CONTROL SYSTEM OPERATION
INSPECTION [WL-C, WE-C] ...... 01-038-62
01-038-1

SYMPTOM TROUBLESHOOTING WIRING DIAGRAM [WL-C, WE-C]
dcf010300000w27

r-----~Y'~------~D
.j--f---{E
STA
DLC
IG-
FEN
KLN
TEN
DLC-2
KLN
' - - - - - I TEN
GLOW INDICATOR
LIGHT
~-+------I-----------{
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG 102BWBY01
01-038-2

C
j- -------
APP
SENSOR
-------WITH RFW-
)--+-+.1'
RFWLOCK
SOLENOID
VALVE
)-_-+.1'
RFW FREE
SOLENOID
VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR LL-1-1----\.
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
11---+--0 o---+--+-... GLOW

BLOWER
MOTOR
L...-_-I
REFRIGERANT
PRESSURE
SWITCH (LOW)
~~-;-~ o-~~~
AlC
COMPRESSOR
PLUG
RELAY
- ---------------------------.
VARIABLE SWIRL:
CONTROL
,
SOLENOID VALVE :
AlC RELAY
AlC
:SWITCH
THERMO SWITCH
'- - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - - ~
DBG102BWBY02
01-038-3

~-+------(E
DLC
IG-
FEN
KLN
TEN
DLC-2
'-----;KLN
'-----lTEN
GLOW INDICATOR
LIGHT
~-+------I---------{
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-038-4
RFWLOCK
SOLENOID
I--+-I-.r' VALVE
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
ECT
SENSOR ~I--__--(
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
I1-+--o
o--+-+-....
BLOWER L...-_----'
MOTOR
REFRIGERANT
PRESSURE
SWITCH (LOW)
~~--~ O--~~~
AlC
COMPRESSOR
GLOW
PLUG
RELAY
EGR CONTROL
SOLENOID VALVE
- ---------------------------1
VARIABLE SWIRL:
CONTROL
,
SOLENOID VALVE :
AlC RELAY
AlC
:SWITCH
THERMO SWITCH
'- - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - -
DBG102BWBY02
01-038-5

SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C]
No.
dcf010300000w28
DESCRIPTION
PAGE
(See 01-038-14 NO.1
MELTING OF MAIN OR
OTHER FUSES [WL-C, WEC).)
Engine check lamp illuminates
Engine check lamp is illuminated incorrectly.
(See 01-038-15 NO.2 ENGINE

CHECK LAMP ILLUMINATES
[WL-C, WE-C).)
Will not crank
(See 01-038-15 NO.3 WILL

NOT CRANK [WL-C, WE-C).)
Hard start!long crank/erratic start!

erratic crank
Starter cranks engine at normal speed but

engine requires excessive cranking time
before starting.
(See 01-038-17 NO.4 HARD

START/LONG CRANK/
CRANK [WL-C, WE-C].)
Engine stalls
Engine stops unexpectedly at idle and/or

after start.
Starter cranks engine at normal speed but

engine will not run.
Slow return to idle
Engine takes more time than normal to

return to idle speed.
Engine runs rough/rolling idle
Fast idle/runs on
10
After start!at idle
Engine stalls/quits
Acceleration/
cruise
Engine runs rough
Acceleration/
cruise
Misses
11
8uck/jerk
Acceleration/
cruise
Acceleration/
cruise/
deceleration
Hesitation/stumble Acceleration
Surges
Acceleration/
cruise
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 engine switch is turned to
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.

STALLS-AFTER START/AT
IDLE [WL-C, WE-C).)
(See 01-038-22 NO.6
CRANKS NORMALLY BUT
WILL NOT START [WL-C, WEC).)
(See 01-038-24 NO.7 SLOW
RETURN TO IDLE [WL-C, WEC).)
RUNS ROUGH/ROLLING
IDLE [WL-C, WE-C].)
(See 01-038-28 NO.9 FAST
IDLE/RUNS ON [WL-C, WEC).)
(See 01-038-30 NO.10 LOW
IDLE/STALLS DURING
DECELERATION [WL-C, WEC).)
(See 01-038-32 NO.11

ENGINE STALLS/QUITS,
ENGINE RUNS ROUGH,
MISSES, 8UCK/JERK,
HESITATION/STUM8LE,
SURGES [WL-C, WE-C].)
Momentary pause at beginning of

acceleration or during acceleration.
Momentary minor irregularity in engine
output.
12
Acceleration/
Lack/loss of power
cruise
Performance is poor under load (e.g. power

down when climbing hills).
(See 01-038-35 NO.12 LACK/

LOSS OF POWERACCELERATION/CRUISE
[WL-C, WE-C).)
13
Knocking/pinging
Excessive shrilly knocking sound from

engine.
(See 01-038-38 NO.13

KNOCKING/PINGING [WL-C,
WE-C].)
14
Poor fuel economy
Fuel economy is unsatisfactory.
15
Emissions compliance
Fails emissions test.
01-038-6
(See 01-038-41 NO.14 POOR

FUEL ECONOMY [WL-C, WEC).)
(See 01-038-44 NO.15
EMISSION COMPLIANCE
[WL-C, WE-C].)

No.
DESCRIPTION
PAGE
(See 01-03B-47 NO.16 HIGH
OIL CONSUMPTION/
LEAKAGE [WL-C, WE-C].)
16
Oil consumption is excessive.
17
Cooling system
concerns
Overheating
Engine runs at higher than normal

temperature/overheats.
(See 01-03B-48 NO.17

COOLING SYSTEM
CONCERNS-OVERHEATING
[WL-C, WE-C].)
18
Cooling system
concerns
Runs cold
Engine does not reach normal operating

temperature.
(See 01-03B-50 NO.18

COOLING SYSTEM
CONCERNS-RUNS COLD
[WL-C, WE-C].)
19
Excessive black smoke
Excessive black smoke is observed in

exhaust gas.
(See 01-03B-50 NO.19

EXCESSIVE BLACK SMOKE
[WL-C, WE-C].)
20
Fuel odor (in engine compartment)
Fuel smell or visible leakage.
21
Engine noise
Engine noise from under hood.
22
Vibration concerns (engine)
Vibration from under hood or driveline.
23
AlC does not work sufficiently
AlC compressor magnetic clutch does not

engage when AlC is turned on.
(See 01-03B-53 NO.20 FUEL

ODOR (IN ENGINE
COMPARTMENT) [WL-C, WEC].)
(See 01-03B-54 NO.21
ENGINE NOISE [WL-C, WEC].)
(See 01-03B-56 NO.22
VIBRATION CONCERNS
(ENGINE) [WL-C, WE-C).)
(See 01-03B-57 NO.23 AlC
DOES NOT WORK
SUFFICIENTLY [WL-C, WEC).)
24
AlC always on or AlC compressor runs

continuously

disengage.
(See 01-03B-59 NO.24 AlC

ALWAYS ON OR AlC
COMPRESSOR RUNS
CONTINUOUSLY [WL-C, WEC).)
25
AlC does not cut off under wide open

throttle conditions

disengage under wide open throttle.
(See 01-03B-59 NO.25 AlC

DOES NOT CUT OFF UNDER
WIDE OPEN THROTTLE
CONDITIONS [WL-C, WE-C].)
01-038-7

SYMPTOM QUICK DIAGNOSIS CHART [WL-C, WE-C]
dcf010300000w29
x: Applicable
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23
24
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Will not crank
Hard start/long crank/erratic start/erratic crank
x
x

Acceleration/cruise
Acceleration/cruise
Acceleration/cruise
Acceleration/cruise/deceleration
Acceleration
Acceleration/cruise
Acceleration/cruise
After start/at idle

Engine stalls
Slow return to idle
Fast idle/runs on
Engine stalls/quits
Engine runs rough
11
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Q)
.c
~
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Misses
Buck/jerk
Hesitation/stumble
Surges
Lack/loss of power
Knocking/pinging
Poor fuel economy

Cooling system concerns Overheating
x
x
x
x
Cooling system concerns Runs cold

Engine noise

AlC always on or AlC compressor runs continuously
AlC does not cut off under wide open throttle conditions
01-038-8
x
x

x Applicable
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Engine stalls
After start/at idle
Slow return to idle
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Misses
Buck/jerk
Lack/loss of power
Knocking/pinging
Poor fuel economy
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x
x
x
x
x
x
x
Acceleration/cruise
Acceleration/cruise
Acceleration
Acceleration/cruise
Acceleration/cruise
x
x
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Cooling system concerns
Overheating
Runs cold
x
x
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Engine noise
Fast idlelruns on
Acceleration/cruise
Engine stalls/quits
Hesitation/stumble
Surges
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Gl
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Will not crank
Engine runs rough
11
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01-038-9

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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
::::J
::::J

Will not crank
x
x
x
Engine stalls
After start/at idle
Slow return to idle
Fast idle/runs on

Engine stalls/quits
Acceleration/cruise
Engine runs rough
Acceleration/cruise
Misses
Acceleration/cruise
Acceleration/cruise/
deceleration
Buck/jerk
Hesitation/stumble
12
13
14
15
16
17
18
19
20
21
22
23
24
25
t5c:
rn
Ol
-0
-0
Surges
Lack/loss of power
Knocking/pinging
Acceleration
Acceleration/cruise
Acceleration/cruise
Poor fuel economy

Overheating
Runs cold


01-038-10
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
Engine noise
x
x
x
x
x

x: Applicable
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20
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24
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Will not crank
Engine stalls
After start/at idle
Slow return to idle
Fast idle/runs on
Acceleration/cruise
Engine stalls/quits
Acceleration/cruise
Engine runs rough
Misses
Buck/jerk
Hesitation/stumble
Surges
Lack/loss of power
Knocking/pinging
Acceleration/cruise
Acceleration
Acceleration/cruise
Acceleration/cruise
Poor fuel economy

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
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x

Cooling system concerns Overheating
Cooling system concerns Runs cold
Engine noise
x
x
x
x
x
x
x
x
x

01-038-11

x: Applicable
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Will not crank

Engine stalls
After start/at idle
Slow return to idle

Fast idle/runs on
x
x
Engine stalls/quits
Engine runs rough
Acceleration/cruise
Acceleration/cruise
Misses
Acceleration/cruise
Buck/jerk
Hesitation/stumble
Acceleration
Surges
Lack/loss of power
Acceleration/cruise
Acceleration/cruise
Knocking/pinging
Poor fuel economy

Overheating
Runs cold

Engine noise
x
x
x
x
x
x
01-038-12

x:
c
0
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01-038-13

NO.1 MELTING OF MAIN OR OTHER FUSES [WL-C, WE-C]
dcf010300000w30
MELTING OF MAIN OR OTHER FUSES

[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
Deterioration
Shorted wiring harness
.n.
Repair shorted wiring harness and replace fuse
Damaged fuse
MAIN
IGKEY1
IGKEY2
BTN1
INJ/FIP
ROOM
ENGINE
METER
01-038-14
Fuse
Related wiring harness

MAIN fuse
BTN1 fuse
- Room fuse
-DLC-2
IGKEY2fuse
- Engine switch
-PCM
- Starter
Generator
IGKEY1 fuse
Engine switch
METER fuse
ENGINE fuse
-DLC
-PCM
IGN 2 fuse
Engine switch
-PCM
- Starter
BTN1 fuse
ROOM fuse
-DLC-2
INJ/FIP fuse
Generator
Main relay
-PCM
- Glow plug relay
- MAF sensor/lAT sensor No.2
- Intake shutter solenoid valve (full)
- Intake shutter solenoid valve (half)
- Fuel metering valve
- Variable swirl control solenoid valve *1
- EGR solenoid valve
- EGR control solenoid valve
- VBC solenoid valve
- Lock solenoid
ROOM fuse
DLC-2
ENGINE fuse
DLC
PCM
METER fuse
DLC
.fi.
Replace fuse

Damaged fuse
GLOW
*1
Related wiring harness

GLOW fuse
Glow plug relay
-Glow plug
: With variable swirl system
NO.2 ENGINE CHECK LAMP ILLUMINATES [WL-C, WE-C]

2
DESCRIPTION
POSSIBLE
CAUSE
ENGINE CHECK LAMP ILLUMINATES

Engine check lamp illuminates incorrectly.
PCM illuminates for emission-related concern (DTC is stored in PCM).
Instrument cluster malfunction.
STEP
INSPECTION
2.
RESULTS
ACTION
Yes
DTC is displayed:
Go to the appropriate DTC test.
No
No DTC is displayed:
Inspect the instrument cluster operation.

(Engine off).
Retrieve any DTCs.
Are any DTCs displayed?
If normal, return to the diagnostic index to service any additional symptoms.
(See 01-03B-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
- If the vehicle is repaired, troubleshooting completed.
- If the vehicle is not repaired or additional diagnostic information is not available, reprogram the PCM if later
calibration is available. Retest.
NO.3 WILL NOT CRANK [WL-C, WE-C]

3
DESCRIPTION
POSSIBLE
CAUSE
dcf01030000Ow32
WILL NOT CRANK

Open starter circuit between engine switch and starter
Starter malfunction
Seized/hydrolocked engine, dual-mass flywheel
Immobilizer system and/or circuit malfunction (if equipped)
Immobilizer system operating properly (engine key is not registered)
Low or dead battery
Charging system malfunction
STEP
1
INSPECTION
Note
The following test should be perform for
vehicles with immobilizer system. Go to
Step 10 for vehicles without immobilizer
system.

Do following conditions appear?
Engine is not completely started.
DTC P1260 is displayed.
Is the coil connector securely connected to coil?
Does the security light illuminate?
RESULTS
ACTION
Yes
Both conditions appear:
Go to Step 4.
Either or other condition appears:
No
Yes
No
Yes
No

Connect the coil connector securely.
Return to Step 1.
Inspect the instrument cluster and wiring harness.
01-038-15

STEP
INSPECTION
RESULTS
Connect the current diagnostic tool to the DLC-2

and retrieve the any DTCs.
Yes
No
DTC
ACTION
P1259, P1260, P1602, P1603, P1621, P1622,

P1623,P1624
5
Is there continuity between PCM ground

terminals 202, 204, 206 and ground?
Yes
No

(Engine off).
Access the VPWR PID.
Is the VPWR PID normal?
Specification
Battery voltage
Yes
Repair or replace wiring harness.

No
Inspect the following wiring harnesses and

connectors.
Between immobilizer unit terminal F and coil
terminal A
Between immobilizer unit terminal D and coil
terminal C
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
Yes
No
Repair or replace malfunctioning part.

Inspect the following:

Battery connection
Battery condition
Fuses
Are all items normal?
Yes
No
Service if necessary.
Repeat Step 12.
Is the clicking sound heard from starter when

engine switch is turned to START?
Yes
No
Go to Step 11.
10
Inspect the starting system.

Is the starting system normal?
Yes
Inspect for seized/hydro locked engine, dual-mass

flywheel.
No
Yes
Repair or replace components as required.
11
12
Do any other electrical accessories work?

(Engine off).
Retrieve the any DTCs.
Are any DTC displayed?
No
Yes
No
13

Inspect the charging system.
DTC is displayed:
Communication error message is displayed:
inspect the following:
Open circuit between main relay and PCM terminal
201,203,205
Open circuit main relay and PCM terminal 219
Main relay stuck open
Open or poor ground circuit (PCM terminal 202,
204,206)
Poor connection vehicle body ground
START circuit in engine switch
Open circuit between engine switch and starter

- If the vehicle is repaired, the troubleshooting completed.
01-038-16

NO.4 HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK [WL-C, WE-C]
4
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w33
HARD START/LONG CRANK/ERRATIC START/ERRATIC CRANK

Starter cranks engine at the normal speed but the engine requires excessive cranking time before
starting.
Battery is in normal condition.
Poor fuel quality

Intake-air system restriction or clogging
Starting system malfunction
Inadequate fuel pressure
Fuel pressure limiter malfunction (built-in common rail)
Engine overheating
Glow system malfunction
Fuel filter clogging or restriction
Fuel line clogging or restriction
Fuel leakage
Exhaust system and/or oxidation catalytic converter restriction or clogging
Incorrect fuel injection timing
Erratic signal from CKP sensor
Erratic signal from CMP sensor
ECT sensor or related circuit malfunction
Accelerator pedal position (APP) sensor or related circuit malfunction
MAF sensor/IAT sensor No.2 or related circuit malfunction
Fuel pressure sensor or related circuit malfunction
Low engine compression
EGR system malfunction
Warning
The following troubleshooting flow chart contains the fuel system diagnosis and repair
procedures. Read the following warnings before performing the fuel system services:
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 injury 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.
Diagnostic Procedure
STEP
INSPECTION
1
Fuel quality (e.g.: include water
contamination, winter/summer blend)
Fuel line/fuel filter clogging
Intake-air system restriction
2
Is the engine overheating?

(Engine off).
Retrieve any DTCs.
RESULTS
ACTION
Yes
No
Repeat Step 1.
Yes
No
Yes
No
Go to the symptom troubleshooting "NO.17 COOLING

SYSTEM CONCERNS-OVERHEATING [WL-C, WEC]".
DTC is displayed:
201,203,205
204,206)
Poor connection to vehicle body ground
01-038-17

INSPECTION
STEP
4
Does the engine start normally after warm-up?
Is there any restriction in the exhaust system or

oxidation catalytic converter?
Inspect for fuel leakage from the fuel pipe.

Is any fuel leakage found on the fuel pipe?
RESULTS
Yes
ACTION
Inspect the glow system operation.
(See 01-138-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
Replace any malfunctioning part if necessary.
If the glow system is normal, go to the next step.
No
Yes
Repair or replace if necessary.
No
Yes
No


POSITION (APP) SENSOR INSPECTION [WLC, WE-C].)
Is the APP sensor normal?
Yes

(CKP) SENSOR REMOVAUINSTALLATION
[WL-C, WE-C].)
Yes
No

Replace the CKP sensor.
Then go to the next step.
Visually inspect the CMP sensor and teeth of

pulse wheel.
Are CMP sensor and teeth of pulse wheel
normal?
Yes
Inspect following PIDs:

(See 01-408-10 PCM INSPECTION [WL-C, WE-C].)
ECT
IAT
MAF
RPM
If the PID value is not as specified, repair or replace
the malfunctioning parts.
If the PID value is normal, go to the next step.
10
Inspect fuel pressure sensor.

Is fuel pressure normal?
11
12
13
14
15
No
No
Yes
No
Is engine compression correct?

(See 01-108-6 COMPRESSION INSPECTION
[WL-C, WE-C].)
Yes
Inspect fuel injector.

(See 01-148-16 FUEL INJECTOR INSPECTION
[WL-C, WE-C).)
Is fuel injector normal?
Yes
No
Inspect the EGR system operation.

Is the EGR system operation normal?
Yes
No
Inspect starting system.

Is the starting system normal?
Yes
No

Replace the accelerator pedal component.
Replace malfunctioning parts.

Replace common rail.
Damaged valve seat
Worn valve stem and valve guide
Worn or stuck piston ring
Worn piston, piston ring or cylinder
Repair or replace the malfunctioning part according to
the EGR system operation results.
Inspect for loose connectors or poor terminal contact.
If normal, remove and inspect supply pump and
common rail.
Repair or replace components as required.

No
If normal, return to the diagnostic index to service any additional symptoms .
(See 01-038-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
If the malfunction remains, inspect the related Service Information and perform repair or diagnosis .
01-038-18
io"
'

NO.5 ENGINE STALLS-AFTER START/AT IDLE [WL-C, WE-C]
5
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w34
ENGINE STALLS-AFTER START/AT IDLE

Engine stops unexpectedly.
Poor fuel quality
Engine overheating
AlC system improper operation
Fuel pressure sensor related circuit malfunction
Fuel leakage
Exhaust system and/or catalyst converter restriction or clogging
V-reference voltage supply circuit malfunction
Warning
.
STEP
1
INSPECTION
Note
system.

Engine is not completely started .
DTC P1260 is displayed .
Connect the current diagnostic tool to the DLC-2

and retrieve the any DTCs.
Yes
No
Yes
No

Return to Step 1.
P1259,P1260,P1602, P1603,P1621, P1622,

P1623,P1624
Yes
No

DTC
RESULTS
ACTION
Yes
Go to Step 4.
No
Yes
No
01-038-19

STEP
INSPECTION
6
(Engine off).
Access the VPWR PID.
Is the VPWR PID normal?
RESULTS
ACTION
Yes
No
Yes
No
Specification
Battery voltage
7
10
Inspect the following wiring harnesses and

connectors.
Between immobilizer unit terminal F and coil
terminal A
Between immobilizer unit terminal 0 and coil
terminal C
Is there any malfunction (open or short circuit,
terminal corrosion, etc.)?
Note
Ignore DTC P0122, P0123, P0222 or
P0223 while performing this test.
Yes
No
Repeat Step 8.
Yes
Go to symptom troubleshooting "NO.17 COOLING

No
Yes

No
Inspect the open or short circuit for wiring harness.

Between PCM terminal 213 and APP sensor
terminal A
Yes
DTC is displayed:
201,203,205
204,206)
Poor connection vehicle body ground
No
.Go to the next step.

Measure the voltage at the APP sensor
connector the VREF terminal (terminal A) with
the engine switch to the ON position.
Specification
4.5-5.5 V
Is the voltage normal?

11

(Engine off).
Retrieve the any DTCs.
Are any DTC displayed?
12
Does the engine start normally after warm-up?
Yes

(See 01-13B-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
No
13
Is there any restriction in the exhaust system or

the catalyst converter?
Yes
No
Access the RPM PID.

Is the RPM PID indicating engine speed during
cranking engine?
Yes
No

Go to Step 17.
14
01-038-20

STEP
15
16
17
INSPECTION
Note
The following test should be performed on
the vehicles with AlC system. If the
following test cannot be performed due to
engine stalling, go to the next step.
Go to the next step for the vehicle without
AlC system.
Connect the pressure gauge to the AlC line.

Turn the blower and the AlC switches on.
Is the pressure within specifications?
Inspect the adjustment of the APP sensor.
Are APP sensor adjusted correctly?
Depress the accelerator pedal slightly.
Crank engine.
Does the engine start now?
18
Inspect for fuel leakage from fuel pipe.

Is any fuel leakage found on fuel pipe?
19

[WL-C, WE-C].)
Visually inspect the CMP sensor and teeth of the
pulse wheel.
Are the CMP sensor and teeth of pulse wheel
normal?
20
21
22
23
24
25

Is the fuel pressure normal?
Is the engine compression correct?
(See 01-10B-6 COMPRESSION INSPECTION
[WL-C, WE-C].)

(See 01-14B-16 FUEL INJECTOR INSPECTION
[WL-C, WE-C].)
Is the fuel injector normal?
RESULTS
ACTION
Yes
AlC is always on:
No
Go to symptom troubleshpoting "NO.24 AlC ALWAYS
ON OR AlC COMPRESSOR RUNS CONTINUOUSLY
[WL-C, WE-C]".
Other symptoms:
Inspect following:
Refrigerant charging amount
Cooling fan No.1 and/or cooling fan No.2 operation
Yes
No

Adjust APP sensor correctly.
Yes
Inspect the idle speed.

(See 01-10B-22 Idle Speed Inspection.)
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No

(See 01-40B-10 PCM INSPECTION [WL-C, WE-C].)
ECT
IAT
MAF
RPM
malfunctioning parts.
Damaged valve seat
Repair or replace malfunctioning part according to
EGR system operation results.

01-038-21

NO.6 CRANKS NORMALLY BUT WILL NOT START [WL-C, WE-C]
6
DESCRIPTION
POSSIBLE
CAUSE
dcfO 10300000w35
CRANKS NORMALLY BUT WILL NOT START

Starter cranks engine at normal speed but engine will not run.
Refer to symptom troubleshooting "NO.5 Engine stalls" if this symptom appears after engine stall.
Fuel is in fuel tank.
Battery is in normal condition.
Poor fuel quality
Fuel line restriction
Fuel leakage
Fuel filter clogging
V-reference supply circuit malfunction
Main repay malfunction
Warning
STEP
1
INSPECTION
Note
system.
Connect the current diagnostic tool to the OLC2.

Engine is not completely started .
OTC P1260 is displayed .
Connect the current diagnostic tool to the OLC-2

and retrieve the any OTCs.
Yes
No
Yes
No

Return to Step 1.
Go to the appropriate OTC test.
P1259, P1260, P1602, P1603, P1621, P1622,

P1623,P1624
Yes
No

DTC
ACTION
RESULTS
Yes
Go to Step 4.
No
01-038-22
Yes
No

STEP
15
16
17
18
INSPECTION
[WL-C, WE-CJ.)

[WL-C, WE-CJ.)
RESULTS
ACTION
Yes
No
Replace the common rail.
Yes
No
Yes
No
Yes
No
19

Damaged valve seat
Remove and inspect the supply pump and common
rail.
Repair or replace malfunctioning part according to

(See 01-038-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-CJ.)
If malfunction remains, inspect the related Service Information and perform repair or diagnosis .
NO.7 SLOW RETURN TO IDLE [WL-C, WE-C]

7
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w36
SLOW RETURN TO IDLE

Engine takes more time than normal to return to idle speed.
Engine speed continues at fast idle after warm-up.
Thermostat is stuck open
Fuel injection timing is incorrect
MAF sensor/lAT sensor No.2 or related circuit malfunction
Incorrect idle speed
Excessive fuel pressure
Fuel injector malfunction (incorrect fuel regulate pressure)
AlC system malfunction
Warning
01-038-24

STEP
1
INSPECTION
2.
RESULTS
Yes

(Engine off).
Retrieve any DTCs.
No
2
Access ECT PID.

Start and warm-up the engine to normal
Is the ECT PID reading between 82-112 C
{180-233 OF}?
Yes
No
ACTION
OTC is displayed:
.
201,203,205
204,206)
No OTC is displayed:
ECT PIO is higher than 112C {233 OF}:
SYSTEM CONCERNS-OVERHEATING [WL-C, WE-
C]".
ECT PIO is less than 82C {180 OF}:

SYSTEM CONCERNS-RUNS COLD [WL-C, WE-C]".
3

(See 01-108-21 ENGINE TUNE-UP [WL-C, WEC].)
Is the idle speed correct?
Inspect the AlC system operation
Are AlC operation normal?
Yes
No
Repair or replace malfunctioning part according to idle

speed inspection results.
Yes
No
Go to the symptom trouble shooting "No.23 AlC DOES

NOT WORK SUFFICIENTLY [WL-C, WE-C]" and
"No.24 AlC ALWAYS ON OR AlC COMPRESSOR
RUNS CONTINUOUSLY [WL-C, WE-C]".
Inspect the cooling fan control system operation.
Yes
Does the cooling fan control operate properly? I----::N-=-o---!-=R:-e-p-ai:-r-o-rr-e-p:-Ia-ce---'-:-th-e-m-a-:lf:-u-n-ct:-io-n:-in-g-p-a-:rt-a-c-co-r-:d:-in-g"'-to--1
cooling fan No.2 control system operation inspection
results.

[WL-C, WE-C].)
Yes.
No
Yes
No

Visually inspect the CMP sensor and the teeth of

the pulse wheel.
Are the CMP sensor and the teeth of the pulse
wheel normal?
Yes
Inspect the following PIDs:

ECT
IAT
MAF
RPM
No
Remove the thermostat and inspect the

operation.
(See 01-128-7 THERMOSTAT REMOVAU
(See 01-128-8 THERMOSTAT INSPECTION
[WL-C, WE-C].)
Is the thermostat normal?
Yes
No
Replace thermostat.
01-038-25

STEP
10
11
INSPECTION
Inspect the fuel injector relief pressure.
Is the fuel injector relief pressure normal?
RESULTS
ACTION
Yes
Remove and inspect the supply pump and the
common rail.
No
Replace the fuel injector.

NO.8 ENGINE RUNS ROUGH/ROLLING IDLE [WL-C, WE-C]

8
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w37
ENGINE RUNS ROUGH/ROLLING IDLE

Engine the speed fluctuates between specified idle speed and a lower speed and the engine shakes
excessively.
Idle speed is too slow and the engine shakes excessively.
Poor fuel quality
Air leakage from intake-air system
Engine overheating
Cooling fan system malfunction
EGR system improper operation
EGR cooler malfunction
Fuel leakage
Fuel filter clogging
Fuel line restriction
APP sensor or related circuit malfunction
MAF sensor/lAT sensor No.2 malfunction
Neutral switch or related circuit malfunction
Engine compression excessive unbalance for each cylinder
Unbalanced fuel injection amount for each cylinder
Fuel injection learning improper
Warning
01-038-26

STEP
INSPECTION
Fuel quality (e.g.: including water
Loose bands on intake-air system
Cracks on intake-air system parts
Vacuum leakage
Cooling fan system operation
2.
RESULTS
Yes
No
Service if necessary
Repeat Step 1.
Yes
No
Yes

(Engine off).
Retrieve any DTCs.
No
?
8
Note
vehicles with the AlC system. If the
Go to the next step for vehicles without an
AlC system.
Turn the blower and the AlC switches on.
Depress the accelerator pedal slightly.
Crank the engine.
Does the engine start now?
POSITION (APP) SENSOR INSPECTION [WLC, WE-C).)
Inspect for fuel leakage from the fuel pipe.
Is any fuel leakage found on the fuel pipe?
[WL-C, WE-C).)
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Go to symptom troubleshooting "NO.1? COOLING

SYSTEM CONCERNS-OVERHEATING [WL-C, WEC)."
DTC is displayed:
201,203,205
204,206)
AlC is always on:
Go to the symptom troubleshooting "NO.24 AlC
ALWAYS ON OR AlC COMPRESSOR RUNS
CONTINUOUSLY [WL-C, WE-Cr.
Other symptoms:
Cooling fan operation
(See 01-108-21 ENGINE TUNE-UP [WL-C, WE-C).)

01-038-27

INSPECTION
STEP
9
the pulse wheel.
wheel normal?
10
11

[WL-C, WE-C].)
RESULTS
ACTION
Yes
ECT
IAT
MAF
RPM
No
Yes
No
Yes
No

Damaged valve seat
rail.
12

[WL-C, WE-C].)
Yes
No
13

Yes
No
14
Inspect the EGR cooler for the following:

Yes
Coolant passage clogging/restriction
Exhaust gas clogging/restriction
No
Is EGR cooler normal?
15
NO.9 FAST IDLE/RUNS ON [WL-C, WE-C]

9
DESCRIPTION
POSSIBLE
CAUSE
01-038-28
dcf010300000w38
RUNS IDLE/RUNS ON
Engine speed continues at fast idle after warm-up.
Engine runs after the engine switch is turned off.
Vacuum leakage
Improper engine oil level
Warning

STEP
INSPECTION
Verify the following:
- Proper dipstick
- Engine oil level
Are all item normal?
2.
Access the ECT PID.

Start and warm-up the engine to normal
Is the ECT PID reading between 82-112 C
{180-233 OF}?
3
Perform the self-test function using the current

diagnostic tool.
(Engine off).
Retrieve any DTCs.
RESULTS
ACTION
Yes
No
Repeat Step 1.
Yes
No
Yes
No
Yes
No

ECT PID is higher than 112 C{233 OF}:
Go to the symptom troubleshooting "NO.1? COOLING
ECT PID is less than 82 C{180 OF}:
DTC is displayed:
201,203,205
204,206)
Replace the fuel injector.
Inspect the vacuum leakage.
Replace the accelerator component.

[WL-C, WE-C).)

Yes
No
01-038-29

NO.10 LOW IDLE/STALLS DURING DECELERATION [WL-C, WE-C]
10
DESCRIPTION
LOW IDLE/STALLS DURING DECELERATION
POSSIBLE
CAUSE
dcf010300000w39
Engine stops unexpectedly at the beginning of deceleration or recovery from deceleration.

Poor fuel quality
Fuel leakage
Fuel line restriction or clogging
Fuel filter restriction or clogging
Warning
INSPECTION
STEP
RESULTS
ACTION
Does the engine idle roughly?
Yes
Go to the symptom troubleshooting "NO.8 ENGINE

RUNS ROUGH/ROLLING IDLE [WL-C, WE-Cr.
No

Fuel line/fuel filter clogging or restriction
Yes
No
Repeat Step 2.

diagnostic tool.
(Engine off).
Retrieve any DTCs.
Yes
DTC is displayed:
201,203,205
204,206)
No
Inspect idle speed.

(See 01-10B-21 ENGINE TUNE-UP [WL-C, WEC].)
01-038-30
Yes
No

the idle speed inspection results.

STEP
INSPECTION
5
6
[WL-C, WE-C).)
7
the pulse wheel.
wheel normal?

[WL-C, WE-C].)
RESULTS
ACTION
Yes
No
Yes
No

Yes

ECT
IAT
MAF
RPM
No
Yes
No
Yes
No
10
Inspect fuel injector:

[WL-C, WE-C].)
Yes
No
11
Note
vehicles with an AlC system. If the
Go to the next step for vehicles without an
AlC system.
Yes
No
12
13
14
Connect the pressure gauge to AlC line.

Turn the blower and AlC switches on.

Damaged valve seat
AlC is always on:
Other symptoms:
Yes
No

Yes
ai_1.- : - - - ; : - - - - - - - - - - - - - - - 1
1----:-:--_t-:r::No

Is glow system operation normal?
01-038-31

NO.11 ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,
SURGES [WL-C, WE-C]
dcf010300000w40
11
DESCRIPTION
POSSIBLE
CAUSE
ENGINE STALLS/QUITS, ENGINE RUNS ROUGH, MISSES, BUCK/JERK, HESITATION/STUMBLE,

SURGES
Engine stops unexpectedly at beginning of acceleration or during cruise.
Engine stops unexpectedly while cruising.
Engine speed fluctuates during acceleration or cruising.
Engine misses during acceleration or cruising.
Vehicle bucks/jerks during acceleration, during or deceleration.
Momentary pause at beginning of acceleration or during acceleration.
Momentary minor irregularity in engine output.
Poor fuel quality
Engine overheating
Turbocharger malfunction
Cooling fan No.1 or cooling fan No.2 seat are improper
Fuel line restriction or clogging
Fuel filter restriction or clogging
Fuel inlet-filter restriction or clogging
Boost sensor or related circuit malfunction
IAT sensor No.1 or related circuit malfunction
VSS or related circuit malfunction
Exhaust system and/or oxidation catalytic converter restriction
Clutch slippage
Warning
STEP
1
INSPECTION
Is the idle speed stable?
01-038-32
ACTION
RESULTS
Yes
Go to symptom troubleshooting "NO.8 ENGINE RUNS
No
ROUGH/ROLLING IDLE [WL-C, WE-C]".
Yes
Go to symptom troubleshooting "NO.1? COOLING
No

STEP
3
INSPECTION
diagnostic tool.
(Engine-off) .
Retrieve any DTCs.
RESULTS
Yes
No
4

Fuel line/fuel filter clogging and/or restriction
Fuel inlet-filter clogging and/or restriction
Exhaust system and/or oxidation catalytic
converter restriction
Cooling fan seat
Does the engine run normal after warm-up?
Yes
Note
vehicles with an AlC system. If the
Go to the next step for the vehicles an
without AlC system.
Yes
No

AlC is always on:
CONTINUITY [WL-C, WE-C]".
Other symptoms:
Inspect the hose bands between the following

parts:
Turbocharger compressor housing and air
cleaner
Turbocharger compressor housing and
charge air cooler
Are the hose bands loose?
Yes
Retighten the hose bands.

If the concern is resolved, the inspection is complete.
If the concern still exists, go to the next step.
Inspect for improper operation, kinks, clogging or

disconnection on the guide blade actuator.
Is the guide blade actuator normal?
Yes
Turbocharger is normal.
No
Perform the EGR system inspection.

Is the EGR system normal?
Yes

If concern is resolved, the inspection is complete.
If concern still exists, the turbocharger is normal.
No

The EGR system operation results.

(See 01-10B-21 ENGINE TUNE-UP [WL-C, WE-
Yes
No

idle speed inspection results.
Yes
No

No
Yes
No
6
Connect the pressure gauge to AlC line.

10
C].)
No

11
ACTION
DTC is displayed:
201,203,205
204,206)
Repeat Step 4.


(See 01-13B-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
01-038-33

STEP
12
INSPECTION
Inspect the adjustment of the neutral switch.
(See 01-408-43 NEUTRAL SWITCH
Is the neutral switch adjusted correctly?
RESULTS
ACTION
Yes
No
Adjust the neutral switch correctly.

[WL-C, WE-C].)
Yes
No
14

the pulse wheel.
wheel normal?
Yes
No
15

Yes
No


[WL-C, WE-C).)
Yes
No

Damaged valve seat
Inspect fuel injector.

[WL-C, WE-C].)
Yes

Inspect the timing belt for the following:

Chipping of gear teeth
Low tension
8reakage damage or cracks
Is the timing belt normal?
Yes

Clutch slippage
CKP sensor
VSS
If normal, remove and inspect the supply pump and
common rail.
No
If the timing is incorrect, adjust the valve timing.

If the timing belt is not normal, replace the timing belt.
13
16
17
18
19
No


ECT
IAT
MAF
RPM

01-038-34

NO.12 LACK/LOSS OF POWER-ACCELERATION/CRUISE [WL-C, WE-C]
12
DESCRIPTION
POSSIBLE
CAUSE
defO 10300000w41
LACK/LOSS OF POWER-ACCELERATION CRUISE

Performance is poor under load (e.g., power down when climbing hills).
Poor fuel quality

Engine overheating
Improper operation of AlC cut-off control
Variable boost control (VBC) system malfunction
Vacuum leakage
Clutch slippage
Fuel line or clogging or restriction
Fuel inlet-filter clogging or restriction
Cooling fan seat is improper
Charge air cooler malfunction
Brake system dragging
Intake shutter valve malfunction
Guide blade valve malfunction
Warning
INSPECTION
STEP
Is the idle speed stable?
1
RESULTS
ACTION
Yes
No
Go to the symptom troubleshooting "NO.8 ENGINE
RUNS ROUGH/ROLLING IDLE [WL-C, WE-C]".
Yes
Go to the symptom troubleshooting "NO.1? COOLING
SYSTEM CONCERNS-OVERHEATING [WL-C, WE-
Cl"
No
01-038-35

INSPECTION
STEP
3
10
11
12

diagnostic tool.
(Engine off).
Retrieve any DTCs.
RESULTS
ACTION
Yes
DTC is displayed:
(See 01-028-11 DTC TA8LE [WL-C, WE-C).)
201,203,205
204,206)
No

Charge air cooler condition (restriction or
damaged)
Vacuum leakage
Cooling fan seat
Yes

Repeat Step 5.
Inspect the intake shutter valve operation.

(See 01-038-62 ENGINE CONTROL SYSTEM
OPERATION INSPECTION [WL-C, WE-C].)
Yes
No
Inspect the guide blade valve operation.

Yes
No
Inspect the AlC cut-off operation.

Does the AlC cut-off work properly?
Yes

AlC cut-off system inspection results.

parts:
cleaner
charge air cooler
disconnection on guide blade actuator.
Is actuator normal?
Yes

No
Yes
No
No
No

If the concern still exists, the turbocharger is normal.
Remove parts necessary to inspect the

turbocharger.
Do not remove the turbocharger.
Inspect if the turbocharger compressor wheel is
bent, damaged, or interfering with the housing
on vehicle.
Inspect if the turbocharger compressor wheel
locknut is loose or has fallen down inside the
turbocharger.
Yes
Replace the turbocharger.
No
Yes
No
Inspect if turbocharger compressor wheel by

hand.
Does wheel turn easily and smoothly?
Yes
No
01-038-36
I:" . "

STEP
INSPECTION
RESULTS
13
Inspect if turbocharger turbine wheel is

damaged, cracked or interfering with the housing
on the vehicle.
Yes
No

ACTION
Excessive amount of oil is found:

Small amount of oil is found:
Wipe oil off of the vehicle, then go to the next step.
Note
Inspect all fins on each turbine wheel.

14
Is any engine oil found inside the turbocharger

turbine housing?
Yes
15

compressor housing?
Yes
No
16
17
18
19
20
21
22
23
No
Wipe oil off of vehicle and install all removed parts in

Step 11. Then, go to the next step.
Install all the parts removed in Step11.

Yes
No
Inspect idle speed.

(See 01-108-21 ENGINE TUNE-UP [WL-C, WEC].)
Yes

No

the idle speed inspection results.

Visually inspect the CKP sensor and the teeth of
the pulse wheel.
Are the CKP sensor and the teeth of the pulse
wheel normal?
Yes
No
Yes
No
Replace the malfunctioning parts.

[WL-C, WE-C].)
the pulse wheel.
wheel normal?
Yes
No

Yes

ECT
IAT
MAF
MAP
RPM
No
Yes

No
Yes
No

Damaged valve seat

[WL-C, WE-C].)
01-038-37

STEP
24
INSPECTION
[WL-C, WE-C].)
RESULTS
ACTION
Yes
No
Yes
Clutch slippage
CKP sensor
Boost sensor and related circuit
Brake system for dragging
common rail.
No
If the valve timing is incorrect, adjust the valve timing.
25

Low tension
Breakage damage or cracks
26

NO.13 KNOCKING/PINGING [WL-C, WE-C]

13
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w42
KNOCKING/PINGING
Excessive shrilly knocking sound from engine.
Poor fuel quality
Intake shutter valve stuck close
Low coolant temperature
Boost sensor or related malfunction
Fuel return line clogging or restriction
Warning
01-038-38

STEP
INSPECTION
Does the engine run cold?

Fuel return line clogging and/or restriction
converter restriction or clogging
damaged)
Access ECT PID.
Verify that the ECT PID is above 80C {176
RESULTS
ACTION
Yes
Go to symptom troubleshooting "NO.18 COOLING
SYSTEM CONCERNS-RUNS COLD [WL-C, WE-Cr.
No
Yes
No
Repeat Step 2.
Yes
No

Inspect the ECT PID.
Yes
DTC is displayed:
201,203,205
204,206)
OF}?

diagnostic tool.
(Engine off).
Retrieve any DTCs.
No
5
10
Yes
No
Yes
Go
to the next step.
No
Retighten hose bands.
Yes
parts:
cleaner
No
charge air cooler
Yes
t----:N-=-o--f-:R=-e-p-a-=-ir-o-r-re-p-:I-ac-e-':-:-if-n-ec-e-s-s-a-ry-.- - - - - - - - - 1
disconnection on the guide blade actuator.
OPERATION INSPECTION [WL-C, WE-C).)
If the concern still exists, the turbocharger is normal.
Is the actuator normal?
turbocharger.
bent, damaged, or interfering with housing on
vehicle.
(See 01-138-5 TUR80CHARGER
Inspect if turbocharger compressor wheel
turbocharger.
Yes
No
Replace turbocharger.
Yes
No
01-038-39

STEP
11
12
INSPECTION
Inspect the turbocharger compressor wheel by
hand.
Does the wheel turn easily and smoothly?
Inspect if the turbocharger turbine wheel is
damaged, cracked or interfering with housing on
vehicle.
RESULTS
Yes
ACTION
No
Yes

No
Note

Wipe oil off of vehicle, then go to the next step.
13

turbine housing?
Yes
No
14

compressor housing?
Yes
No
Wipe oil off of the vehicle and install all removed parts
in Step 10. Then, go to the next step.
Install all parts removed in Step10.

Yes
No

Is the glow system operation normal?
[WL-C, WE-C].)
Yes

15
16
17
No

glow system operation results.
Yes
No

Inspect the following PI Os:

ECT
IAT
MAF
MAP
RPM
18

the pulse wheel.
wheel normal?
Yes
No
19

[WL-C, WE-C].)
Yes
No

Damaged valve seat
20
Inspect the supply pump.

Is the supply pump normal?
Yes

800st sensor
IAT sensor No.1
APP sensor
Replace the supply pump.
No
01-038-40

INSPECTION
ACTION
STEP
21
If normal, return to the diagnostic index to service any additional symptoms ..
(See 01-03B-6 SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C).)
NO.14 POOR FUEL ECONOMY [WL-C, WE-C]

14
DESCRIPTION
POSSIBLE
CAUSE
POOR FUEL ECONOMY

Fuel economy is unsatisfactory.
Intake -air system clogging or restriction
Engine cooling system malfunction
Poor fuel quality
Improper coolant level
Exhaust system and/or oxidation catalytic converter clogging
Fuelleakage
Fuel inlet-filter clogging or restriction
Brake dragging
Vacuum leakage
Clutch slippage
Coolant heater system malfunction
Warning
01-038-41

STEP
INSPECTION
RESULTS

Fuel line leakage
damaged)
Vacuum leakage
Is the brake system functioning properly?
Yes
No
2
3
ACTION
Repeat Step 1.
Yes
No
Inspect for cause.
Yes
DTC is displayed:
201,203,205
204,206)
No
Yes
No

AlC is always on:
Other symptoms:
Yes
No
Inspect for coolant leakage, cooling fan operation or

thermostat operation.

(See 01-10B-21 ENGINE TUNE-UP [WL-C, WEC).)
Is the idle speed normal?
Yes
No

Go to symptom troubleshooting "NO.7 SLOW
RETURN TO IDLE [WL-C, WE-Cr.

Yes
No

Yes

No

[WL-C, WE-C).)
Yes
No

Damaged valve seat

diagnostic tool.
(Engine off).
Retrieve any DTCs.
Note
the vehicles with an AlC system. If the
Go to the next step for vehicles without n
AlC system

Is the pressure within the specifications?
Access the ECT PID.
Drive the vehicle while monitoring the PID.
Is the PID within the specification?
01-038-42

STEP
INSPECTION
10
(See01-14B-16 FUEL INJECTOR INSPECTION
[WL-C, WE-C].)
11
12
13
14
15
Perform the turbocharger inspection.

(See 01-13B-5 TURBOCHARGER
Is the turbocharger normal?
(See 01-03B-62 ENGINE CONTROL SYSTEM
Is the there any malfunction?
[WL-C, WE-C].)
the pulse wheel.
wheel normal?

Low tension
RESULTS
ACTION
Yes
No
Yes
No
Yes
No

Yes
No

Yes

ECT
IAT
MAF
MAP
RPM
VSS
Clutch slippage
CKP sensor
Boost sensor and related circuit
Brake system for dragging
Coolant heater system
Glow system
If normal, remove and inspect supply pump.
If the timing is incorrect, adjust the valve timing.
No
Yes
No
16

01-038-43

NO.15 EMISSION COMPLIANCE [WL-C, WE-C]
15
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w44
EMISSION COMPLIANCE
Fails emissions test.
Poor fuel quality
Vacuum leakage
Intake shutter valve stuck close
Guide blade valve malfunction
EGR cooler malfunction
Low coolant temperature
Engine overheating
MAF sensor/IAT sensor No.2 related circuit malfunction
APP sensor or related circuit malfunction
Base engine malfunction
Oxidation catalytic converter malfunction
Warning
01-038-44

STEP
INSPECTION
Does the engine run cold?

diagnostic tool.
(Engine off).
Retrieve any DTCs.

Fuel return line clogging and/or restriction
damaged)
Vacuum leakage
Inspect the adjustment of neutral switch.
(See 01-408-43 NEUTRAL SWITCH
Is the neutral switch adjusted correctly?
10
RESULTS
ACTION
Yes
No
Yes
No
Yes
DTC is displayed:
(See 01-028-11 DTC TA8LE [WL-C, WE-C).)
201,203,205
204,206)
No
Yes
No
Repeat Step 4.
Yes
No

Yes

Adjust the neutral switch correctly.
No

Yes
No

Yes
No

parts:
cleaner
charge air cooler
Yes

No

Yes
No

If the concern still exists, turbocharger is normal.
01-038-45

STEP
11
12
13
14
INSPECTION
RESULTS
ACTION

turbocharger.
vehicle.
(See 01-138-5 TUR80CHARGER
Yes
No

turbocharger.
Yes
No


hand.
Yes
No

on vehicle.
Yes
No

Note

15

turbine housing?
Yes
16

compressor hosing?
Yes
No
Install all parts removed in Step10.
No
17

Yes
No
18
Inspect the EGR cooler for the following:

Coolant passage clogging/restriction
Exhaust gas clogging/restriction
Is the EGR cooler normal?
Yes
No

Is the glow system operation normal?
Yes
No

glow system operation results.

[WL-C, WE-C).)
Yes
No


the pulse wheel.
wheel normal?
Yes

ECT
IAT
MAF
MAP
RPM
VSS
No
19
20
21
01-038-46

STEP
22
23
INSPECTION
[WL-C, WE-C).)
RESULTS
ACTION
Yes
No
Yes
No
24

[WL-C, WE-C].)
Yes
No
25

Low tension
Yes
No
26

Damaged valve seat
ECT sensor
Boost sensor
common rail.
If the timing is incorrect, adjust the valve the timing.

NO.16 HIGH OIL CONSUMPTION/LEAKAGE [WL-C, WE-C]

16
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w45
HIGH OIL CONSUMPTION/LEAKAGE

Oil consumption is excessive.
Improper engine oil level
Improper dipstick
Improper engine oil viscosity
Engine internal parts malfunction
Oil leakage
INSPECTION
STEP
Verify the following:
1
Proper dipstick
Proper engine viscosity
Engine oil level
Remove if necessary to inspect the
2
turbocharger.
RESULTS
Yes
No
ACTION
Repeat Step 1.
Yes
No

Yes
No

Note

vehicle.
locknut is loose or has fallen down inside
turbocharger.
01-038-47

STEP
INSPECTION
Turn the turbocharger compressor wheel by
hand.
on the vehicle.
RESULTS
Yes
ACTION
No
Yes

No
Note

6

turbine housing?
Yes

compressor housing?
Yes
No
No
Yes
Is any engine oil found around oil pipes attached

on turbocharger center housing?
Is any engine oil found inside air intake pipes or

hoses?
Yes
No

[WL-C, WE-C].)
Yes
No
10
11
No

Wipe oil off of vehicle, then go to the next step.
If oil leaks from a damaged pipe, replace the oil pipe.
Wipe engine oil off.
Install all parts removed in Step 2.
Inspect for oil leakage from outside of engine.
Damaged valve seat

NO.17 COOLING SYSTEM CONCERNS-OVERHEATING [WL-C, WE-C]

17
DESCRIPTION
POSSI8LE
CAUSE
COOLING SYSTEM CONCERNS-OVERHEATING
01-038-48
Engine runs at higher than normal temperature/overheats.

Cooling fan malfunction
Low drive belt tension
Drive belt damage
Improper coolant level
Thermostat malfunction
Radiator clogging
Improper water/anti-freeze mixture
Improper or damaged radiator cap
Radiator hose damage
Coolant leakage (engine internal, turbocharger, external)
Ale system malfunction
dcf010300000w46

... nn~i'i,.
Procedure

Engine coolant level
Coolant leakage (around heater unit in
passenger compartment, coolant hoses and/
or radiator, and around coolant heater unit.)
Water and anti-freeze mixture
Radiator condition
Collapsed or restricted radiator hoses
Radiator pressure cap
Drive belt tension
Drive belt
Fan rotational direction
diagnostic tool.
(Engine off).
Retrieve any DTCs.
Repeat Step 1.
Yes
No
Note
the vehicles with an AlC system. Go to the
next step for vehicles without an AlC
system
DTC is displayed:
201,203,205
204,206)
Start the engine and run it at idle speed.

Turn the AlC switch off.
Does the AlC compressor disengage?
Is the drive belt normal?
Is there any leakage around heater unit in

passenger compartment?
Is there any leakage at coolant hoses and/or

radiator?

Perform the coolant heater system inspection.

(See 01-12B-8 THERMOSTAT INSPECTION
[WL-C, WE-C].)
the coolant heater system operation results.
'
Is the coolant heater system normal?
Thermostat is normal.
Yes
Cool down engine.
Inspect the cylinder block for leakage or blockage.
operation.
No
Replace thermostat.
,.
10
01-038-49

NO.18 COOLING SYSTEM CONCERNS-RUNS COLD [WL-C, WE-C]
18
DESCRIPTION
POSSIBLE
CAUSE
dcf01030000OW47
COOLING SYSTEM CONCERNS-RUNS COLD
Engine takes excessive period of time to reach normal operating temperature.
Thermostat malfunction
Cooling fan system malfunction
INSPECTION
STEP
ACTION
RESULTS
Is the customer complaint "Lack of passenger

compartment heat"?
Yes
Inspect the AlC heater system.
No
Does the engine speed continue at fast idle?
Yes

Go to the symptom troubleshooting "NO.7 SLOW
RETURN TO IDLE [WL-C, WE-Cr.

operation.
(See 01-12B-7 THERMOSTAT REMOVAU
(See 01-12B-8 THERMOSTAT INSPECTION
[WL-C, WE-C].)
Yes

No
Replace the thermostat.
No

NO.19 EXCESSIVE BLACK SMOKE [WL-C, WE-C]

19
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w48
EXCESSIVE BLACK SMOKE

Excessive black smoke is observed in exhaust gas.
Intake-air system clogging or restriction
Air leakage from Intake-air system
Base engine malfunction
Vacuum leakage
Intake shutter valve malfunction
Exhaust system and/or oxidation catalytic converter restriction or clogging
Mass airflow sensor malfunction
Warning
01-038-50

Intake-air system clogging or restriction
converter restriction or clogging
damaged)
diagnostic tool.
(Engine off).
Retrieve any OTCs.
Are any OTCs displayed?
Ooes any other symptom exist?
Inspect the air cleaner element for clogging.

Is the air cleaner element normal?
Inspect intake shutter valve operation.


[WL-C, WE-C].)
the pulse wheel.
wheel normal?
10
11
Repeat Step 1.
Yes
DTC is displayed:
(See 01-02B-11 OTC TABLE [WL-C, WE-C].)
201,203,205
204,206)
No
No
Go to
Yes
Inspect the following PIOs:

IAT
MAP
RPM
MAF
If the PIO value is not as specified, repair or replace
If the PIO value is normal, go to the next step.

Inspect the hose bands between following parts:
cleaner
charge air cooler
displayed:
next step.
Yes

If the concern still exists, go to the next
No

If the concern still exists, turbocharger is normal.
01-038-51

STEP
12
13
14
15
INSPECTION
turbocharger.
vehicle.
RESULTS
ACTION
Yes
No

turbocharger.
Yes
No


hand.
Does wheel turn easily and smoothly?
Yes
No

on vehicle.
Yes

No
Note

16

compressor housing?
Yes
No
17
18

[WL-C, WE-C].)
Yes
No

[WL-C, WE-C].)
Yes
No
19
Install all parts removed is Step 15. Then, go to the
next step.
Damaged valve seat
800st sensor
Fuel pressure limiter (built-in common rail)
Fuel return line restriction or clogging

Ifthe malfunction remains, inspect the related Service Information and perform repair or diagnosis .
01-038-52

NO.20 FUEL ODOR (IN ENGINE COMPARTMENT) [WL-C, WE-C]
20
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w49
FUEL ODOR (IN ENGINE COMPARTMENT)

Fuel smell or visible leakage.
Fuel leakage
Warning
STEP
INSPECTION
Visually inspect for fuel leakage at the fuel
injector and fuel line.
Is there any fuel leakage?
Visually inspect for a damaged or cracked fuel
filter.
Is the fuel filter normal?
diagnostic tool.
(Engine off).
Retrieve any DTCs.
RESULTS
Yes
No
Yes
No

Replace the fuel filter.
Yes
No

Yes
DTC is displayed:
201,203,205
204,206)
Remove and inspect common rail.
No
5
ACTION

01-038-53

NO.21 ENGINE NOISE [WL-C, WE-C]
21
DESCRIPTION
ENGINE NOISE
Engine noise under hood.
POSSIBLE
CAUSE
dcf010300000w50
Engine internal damage

Timing belt displacement
Loose attaching bolts or worn parts
Improper drive belt tension
Incorrect injection timing
EGR system or malfunction
Vacuum leakage
Air in power steering fluid line
Turbocharger operating noise
Solenoid valve operating noise
Warning
INSPECTION
STEP
Is there a squeal, click or chirp sound present?
1
RESULTS
Yes
No
ACTION
Inspect the engine oil level, solenoid valve installation
or the drive belt.
Inspect the drive belt tension or the power steering
system fluid level.
If normal, perform power steering fluid line air bleed.
Is there a rumble or grind sound present?
Yes
Is there a rattle sound present?
Yes
Is there a hiss sound present?
No
Yes

Inspect for vacuum leakage and intake-air system
leakage.
No
No

Inspect the location of the rattle for loose parts.
Is there a rap or roar sound present?
Yes
No
Inspect the exhaust system for loose parts.


diagnostic tool.
(Engine off).
Retrieve any OTCs.
Are any OTCs displayed?
Yes
DTC is displayed:
201,203,205
204,206)
No
01-038-54

INSPECTION
STEP
ACTION
RESULTS
Yes
Inspect the ECT sensor and the related wiring
No
harnesses.
Access the ECT PID.

Inspect the ECT PID while warming up the
engine.
Is the PID value correct?
Access the IAT PID.

Inspect the IAT PID while running the engine.
Is the PID value correct?
Yes

(CKP) SENSOR INSPECTION [WL-C, WE-C).)
[WL-C, WE-C].)
the pulse wheel.
wheel normal?
Yes
No
10
11
12

turbocharger.
No
Yes
No
Yes
No
Yes
No

Inspect the IAT sensor No.1 and the related wiring
harnesses.

(See 01-408-10 PCM INSPECTION [WL-C, WE-C).)
ECT
IAT
MAF
MAP
RPM
Note
13
14
15

vehicle.
turbocharger.
Yes
No
Turn the turbocharger compressor wheel by

hand.
Yes
No


on vehicle.
Yes
No

Yes

No
Note
16
17
18

turbine housing?

compressor housing?
Yes

No
Is any exhaust gas leakage found around the

location where the turbocharger is attached to
the exhaust manifold?
Yes
Remove the turbocharger.

Inspect for cracks on the center housing inlet surface.
If cracks are found, replace the turbocharger.
No
01-038-55

INSPECTION
STEP
Are any center housing and turbine housing
19
attaching bolts loose?
RESULTS
ACTION
Retighten the loose bolts.
Yes
If a bolt is found to be missing, attach appropriate new
bolts.
No
Install all parts removed in Step 12.
Yes
Metal flow
Bent connecting rod
Damaged valve seat
Incorrect valve clearance
No
20
Inspect the fuel injector and fuel injector gasket.

[WL-C, WE-C].)
21

NO.22 VIBRATION CONCERNS (ENGINE) [WL-C, WE-C]

22
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w51
VIBRATION CONCERNS (ENGINE)
Vibration from the under hood or driveline.

Loose attaching bolts or worn parts
Cooling fan seat are improper
Engine or transaxle mounts are improperly installed
Components malfunction such as worn parts
MAF sensor/lAT sensor No.2 or related circuit malfunction
Vacuum leakage
Improper tension or damaged drive belts
Improper balance of wheels or tires
Driveline malfunction
Suspension malfunction
Warning
STEP
1
INSPECTION
Inspect the following components for loose
attaching bolts or worn parts:
Cooling fan
Cooling fan seat
Drive belt and pulley
Engine mounts
Exhaust system
Inspect the vacuum leakage.
Are the vacuum hoses normal?
01-038-56
RESULTS
Yes
No
Yes
No
ACTION
Readjust or retighten the engine mount installation
position.
Service if necessary for other parts.

Repeat Step 2.

2.

(Engine off).
Retrieve any DTCs.
No
4

the pulse wheel.
wheel normal?
Yes

ECT
IAT
MAF
RPM
If the PID value is normal, 0 to the next step.
Inspect the following systems:
Wheels
Transaxle and mounts
Driveline
Suspension

[WL-C, WE-C].)
No
displayed:
Inspect following:
201,203,205
204,206)

Verity test results.

NO.23 AlC DOES NOT WORK SUFFICIENTLY [WL-C, WE-C]

23
DESCRIPTION
dcf010300000w52
AlC DOES NOT WORK SUFFICIENTLY

. AlC compressor magnetic clutch does not engage when the AlC switch is turned on.
Improper refrigerant charge amount
Open AlC switch magnetic clutch
Open circuit between AlC relay and AlC magnetic clutch
Poor ground of AlC magnetic clutch
Improper AlC magnetic clutch clearance
Refrigerant pressure switch is stuck open
AlC relay is stuck open
Improper AlC cut-off control
Open circuit between AlC switch and PCM through both refrigerant pressure switch and AlC amplifier
POSSIBLE
CAUSE
01-038-57

INSPECTION
STEP
RESULTS
ACTION
Yes
DTC is displayed:
201,203,205
204,206)
Yes

diagnostic tool.
(Engine off).
Retrieve any DTCs.
Disconnect the AlC compressor connector.

Start the engine and turn the AlC switch to the
ON position.
Is there correct voltage at the terminal of the AlC
compressor magnetic clutch connector?
Specification
More than 10.5 V
Yes
Disconnect the refrigerant pressure switch

connector.
Connect jumper wire between terminals of
refrigerant pressure switch connector.
Start the engine and turn the AlC switch to the
ON position.
Is there correct voltage at the terminal of the AlC
compressor magnetic clutch connector?
Specification
More than 10.5 V
Yes
Inspect refrigerant pressure switch operation.

If switch is normal, go to the next step.
No

AlC switch is stuck open
Open circuit between refrigerant pressure switch
and AlC relay
Open circuit of blower motor fan switch and
resistor (if blower motor does not operate)
Evaporator temperature sensor and AlC amplifier
Inspect the AlC cut-off operation.

Does the AlC cut-off work properly?
Yes
No

the AlC cut-off system inspection results.
Remove the jumper wire from the switch

connector.
Reconnect the connector to the refrigerant
pressure switch.
Start the engine and turn the AlC switch on.
Does the AlC operate?
Yes
Inspect for a stuck open AlC relay.

Replace if necessary.
Inspect following and repair or replace if necessary:
Seized AlC compressor
No
No
Inspect for ground condition of the magnetic clutch on

the AlC compressor.
If ground condition is normal, inspect the magnetic
clutch coil for an open circuit.

(See 01-03B-6SYMPTOM DIAGNOSTIC INDEX [WL-C, WE-C].)
01-038-58

NO.24 AlC ALWAYS ON OR AIC COMPRESSOR RUNS CONTINUOUSLY [WL-C, WE-C]
24
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w53
AlC ALWAYS ON OR AlC COMPRESSOR RUNS CONTINUOUSLY

AlC compressor magnetic clutch does not disengage.
AlC compressor magnetic clutch stuck engagement
AlC relay is stuck closed
Improper AlC compressor magnetic clutch clearance
Short to ground circuit between AlC switch and PCM
Short to ground circuit between AlC relay and PCM
AlC relay to magnetic clutch circuit shorts to battery power
STEP
INSPECTION
diagnostic tool.
(Engine off).
Retrieve any DTCs.
RESULTS
ACTION
Yes
DTC is displayed:
201,203,205
204,206)
No
Yes
AlC relay is stuck closed
Short to ground circuit between AlC relay and
PCM terminal 128
If both items are normal, go to the next step.
No
Inspect if circuit between AlC relay and magnetic
clutch shorts to battery power circuit.
If circuit is normal, inspect magnetic clutch stuck
engagement or clearance or inspect for a stuck closed
AlC switch.
Start the engine and run it at idle.

Turn the AlC switch on.
Remove the AlC relay.
Does the AlC magnetic clutch disengage?

NO.25 AlC DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS [WL-C, WE-C]
25
DESCRIPTION
POSSIBLE
CAUSE
dcf010300000w54
AlC DOES NOT CUT OFF UNDER WIDE OPEN THROTTLE CONDITIONS
AlC compressor magnetic clutch does not disengage under a wide open throttle.
Accelerator pedal position (APP) sensor malfunction
Loosely installed APP sensor
INSPECTION
STEP
Does the AlC compressor disengage when the
1
AlC switch is turned off?
RESULTS
ACTION
Yes
Go to symptom troubleshooting "NO.24 AlC ALWAYS
No
ON OR AlC COMPRESSOR RUNS
CONTINUOUSLY".
01-038-59

STEP
2
INSPECTION
diagnostic tool.
(Engine off).
Retrieve any DTCs.
ACTION
RESULTS
Yes
DTC is displayed:
201,203,205
Main relay stuck open.
204,206)
No
Inspect APP sensor.
(See 01-40B-28 ACCELERATOR PEDAL POSITION
(APP) SENSOR INSPECTION [WL-C, WE-C].)

INTERMITTENT CONCERN TROUBLESHOOTING [WL-C, WE-C]
dcf010300000w55
Vibration Method
1. If a malfunction occurs or becomes worse while driving on a rough road, or due to engine vibration, perform the
steps below.
Note
There are several reasons why the vehicle or engine vibration could cause an electrical malfunction.
Some of the things to check for are:
Connectors not fully seated.
- Wire harnesses not having full play.
- Wires laying across brackets or moving parts.
- Wires routed too close to hot parts.
An improperly routed, improperly clamped, or loose wiring harness can cause the wiring to become
pinched between parts.
The connector joints, points of vibration, and places where wire harnesses pass through the fire wall, body
panels, etc. are the major areas to be checked.
Inspection Method for Switch Connectors or Wires
1. Connect the current diagnostic tool to the DLC-2.
2. Turn the engine switch to the ON position (Engine off).
Note
If the engine starts and runs, perform the following steps at idle.
3. Access the PIDs for the switch you are inspecting.
4. Turn the switch on manually.
5. Shake each connector or wiring harness a bit
vertically and horizontally while monitoring the
PID.
If the PID value is unstable, check for a poor
connection.
,
1///,./
'//
I --'
I
"I
...
I
\~
,, ,
\
'\..~ \
"
A6E40802001
01-038-60

Inspection Method for Sensor Connectors or Wires
Note
3. Access the PIDs for the switch you are inspecting.
4. Shake each connector or wiring harness a bit
PID.
If the PID value is unstable, check for a poor
connection.
Inspection Method for Sensors

Note
3. Access PIDs for the switch you are inspecting.
4. Shake the sensor slightly with your finger.
If the PID value is unstable or a malfunction occurs, check for a poor connection and/or poorly mounted
sensor.
Inspection Method for Actuators or Relays
Note
3. Prepare the Output State Control for the actuators or relays that you are inspecting.
4. Shake the actuator or relay with your finger for 3 seconds after the Output State Control is activated.
If a variable click sound is heard, check for a poor connection and/or poorly mounted actuator or relay.
Note
Shaking the relays too strongly may result in
open relays.
A6E40802003
01-038-61
. SYMPTOM TROUBLESHOOTING [WL-C, WE-C]

Water Sprinkling Method
Caution
Indirectly change the temperature and humidity by spraying water onto the front of the radiator.
If a vehicle is subject to water leakage, the leakage may damage the control module. When testing
a vehicle with a water leakage malfunction, special caution must be used.
If a malfunction occurs only during high humidity or rainy/snowy weather, perform the following steps.
1. Connect the current diagnostic tool to the DLC-2 if you are inspecting sensors or switches.
Note
3. Access the PIDs for sensor or switch if you are inspecting sensors or switches.
4. If you are inspecting a switch, turn it on manually.
5. Spray water onto the vehicle or run it through a
car wash.
If the PID value is unstable or a malfunction
occurs, repair or replace the part if necessary.
A6E40B02004
ENGINE CONTROL SYSTEM OPERATION INSPECTION [WL-C, WE-C]
dcf010300000w56
Guide Blade Actuator Operation Inspection

1. Connect current diagnostic tool to DLC-2.
2. Start the engine and run it at idle.
3. Access the VBCV PID.
4. Verify that the guide blade actuator rod moves when the VBCV PID from 0 to 100 % using simulation function.
If the rod movement cannot be verified inspect the followings;
Guide blade actuator (See 01-13B-6 GUIDE BLADE ACTUATOR INSPECTION [WL-C, WE-C].)
Vacuum hose conn~ction between the vacuum chamber and the guide blade actuator through the VBC
solenoid valve (See 01-13B-2INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [WL-C,
WE-C].)
VBC solenoid valve (See 01-13B-6 VARIABLE BOOST CONTROL (VB C) SOLENOID VALVE
Glow Plug Control Operation Inspection
1. Verify that the battery is charged fully.
2. If not, charge the battery.
3. Connect the current diagnostic tool to the DLC.
5. Access and monitor the VPWR and GPL PIDs.
6. Verify that the VPWR PID drops 0.3 V or more while the GPL is turned on from off using the simulation
function.
If it cannot be verified, inspect the followings;
Glow plug relay
Glow plug
Wiring harness for battery positive post-glow plug relay-glow plug
Wiring harness for PCM terminal 182-glow plug relay-ground
01-038-62

Intake Shutter Valve Operation Inspection
2. Start the engine and run it at idle.
3. Access the IASV and IASV2 PID.
4. Verify that the Intake Shutter Valve actuator rod moves to half open when the IASV PID from OFF to ON and,
full open when the IASV2 PID from OFF to ON using simulation function.
If the rod movement cannot be verified inspect the followings;
Intake Shutter Valve actuator
Vacuum hose connection between the vacuum chamber and the Intake Shutter Valve actuator through
the ISV solenoid valve
ISV solenoid valve and related harness
Fuel Injector Operation Inspection
2. Start the engine and warm it up to normal operating temperature.
3. Perform the KOER self-test. (See 01-02B-10 KOEO/KOER SELF TEST [WL-C, WE-C].)
4. Verify that DTCs P0200, P0201, P0202, P0203 and/or P0204 are not shown using the KOER self-test.
If DTC P0200, P0201, P0202, P0203 and/or P0204 are shown, perform the DTC troubleshooting
procedure. (See 01-02B-11 DTC TABLE [WL-C, WE-C].)
5. Verify that the engine speed drops or stalls when each cylinder fuel injector turns to off from on using the
simulation function.
If it cannot be verified, inspect the following for the suspected cylinder;
Fuel injector (See 01-14B-16 FUEL INJECTOR INSPECTION [WL-C, WE-C].)
- Wiring harness for PCM-fuel injector
01-038-63
01-108 MECHANICAL [WL-C, WE-C]

MECHANICAL LOCATION
INDEX [WL-C, WE-C] ............
DRIVE BELT INSPECTION
[WL-C, WE-C] .............
DRIVE BELT ADJUSTMENT
[WL-C, WE-C] ..............
[WL-C, WE-C] ................
VALVE CLEARANCE
ADJUSTMENT [WL-C, WE-C] ....
COMPRESSION INSPECTION
[WL-C, WE-C] ...............
TIMING BELT REMOVAU
INSTALLATION [WL-C, WE-C] ....
01-10B-2
01-10B-3
01-10B-4
01-10B-5
01-10B-5
01-10B-6
01-10B-7

REPLACEMENT [WL-C, WE-C] ..... 01-10B-9
ROCKER ARM REMOVAU
INSTALLATION [WL-C, WE-C] ....... 01-10B-16
FRONT OIL SEAL
REPLACEMENT [WL-C, WE-C] ....... 01-10B-16
REAR OIL SEAL
REPLACEMENT [WL-C, WE-C] ..... 01-10B-18
ENGINE REMOVAU
INSTALLATION [WL-C, WE-C] ...... 01-10B-19
ENGINE DISASSEMBLY/
ASSEMBLY [WL-C, WE-C] ........ 01-10B-21
ENGINE TUNE-UP [WL-C, WE-C] ...... 01-10B-21
01-108-1

MECHANICAL LOCATION INDEX [WL-C, WE-C]
dcf01100000Ow04
DBG110BWB87
;' ......
'
01-108-2
Engine
(See 01-10B-5 VALVE CLEARANCE INSPECTION
[WL-C, WE-C].)
(See 01-10B-5 VALVE CLEARANCE
ADJUSTMENT [WL-C, WE-C].)
(See 01-10B-6 COMPRESSION INSPECTION [WLC, WE-C].)
(See 01-10B-19 ENGINE REMOVAU
(See 01-10B-21 ENGINE DISASSEMBLY/
ASSEMBLY [WL-C, WE-C].)
Drive belt
(See 01-10B-3 DRIVE BELT INSPECTION [WL-C,
WE-C].)
(See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C,
WE-C].)
Timing belt
(See 01-10B-7 TIMING BELT REMOVAU
Rocker arm
(See 01-10B-16 ROCKER ARM REMOVAU
(See 01-10B-9 CYLINDER HEAD GASKET
Front oil seal
(See 01-10B-16 FRONT OIL SEAL
Rear oil seal
(See 01-10B-18 REAR OIL SEAL REPLACEMENT
[WL -C, WE-C].)
DRIVE BELT INSPECTION [WL-C, WE-C]

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.
GENERATOR
MEASURING
NC
DBG110AWB301

Drive Belt
Generator
a
AlC
b
*
(mm {in})
New*
Used
7.4-9.4
{0.30-0.37}
6.1-6.9
8.7-10.4
{0.35-0.40}
7.1-8.0
{0.28-0.31}
11.3-12.6
{0.45-0.49}
{0.24-D.27}
10.0-11.0
{0.40-0.43}
Limit
14.3 {0.56} or more
11.3 {0.44} or more
17.4 {0.69} or more
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. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C,
WE-C].)
01-108-3

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.
DBG110AWB302
Drive Belt Tension

Drive Belt
Generator
Ale
New
490-637
{50. 0-64. 9, 111-143}
455-572
{46.4-58.3, 103-128}
(N {kgf, Ibf})
Used
431-539
{44.0-54.9,96.9-121}
353-431
{36.0-43.9, 79.4-96.8}
Limit
225 {22.9, 50.6} or less

156 {15.9, 35.1} or less
: 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. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WEC].)
DRIVE BELT ADJUSTMENT [WL-C, WE-C]
dcf01101580Ow04
Generator
1. Loosen the mounting bolt C and locknut A.
2. Adjust the belt deflection or tension by turning adjusting bolt B. (See 01-1 OB-3 DRIVE BELT INSPECTION [WLC, WE-C].)
3. Tighten the mounting bolt C and locknut A.
4. Tighten the adjust bolt B.
B
A 18.6-25.5
{1.9-2.6,
14-18 }
Tightening torque
7.84-9.80 Nm {80-100 kgfcm, 69.4-86.7
inlbf}
5. Inspect the belt deflection or tension. (See 0110B-3 DRIVE BELT INSPECTION [WL-C, WE-
37.3-51.9
{3.8-5.3,
28-38}
Nm {kgfm, ftlbf}
C].)
DBG110AWB303
AlC
1. Loosen the locknut A.
2. Adjust the belt deflection or tension by turning adjusting bolt B. (See 01-1 OB-3 DRIVE BELT INSPECTION [WLC, WE-C].)
3. Tighten the locknut A.
4. Inspect the belt deflection or tension. (See 0137.3-52.0
10B-3 DRIVE BELT INSPECTION [WL-C, WE{3.8-5.3, A
C].)
28-38 }
Nm {kgfm, ftlbf}
DBG110AWB304
01-108-4

VALVE CLEARANCE INSPECTION [WL-C, WE-C]
dcf011012111w03
1. Remove the engine cover.

2. Remove the following parts to turn the crankshaft.
1. Drive belt. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C).)
2. Cooling fan. (See 01-12B-8 COOLING FAN REMOVAUINSTALLATION [WL-C, WE-C].)
3. Water pump pulley.
3. Remove the fuel injector. (See 01-14B-15 FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
5. Turn the crankshaft and align the timing mark so that the piston of the No.1 or No.4 cylinders is at TDC of
compression.
B
A
B
A
cylinder at TDC of compression, and those of B
EX
recheck the valve clearance. (See 01-1 OB-5
VALVE CLEARANCE ADJUSTMENT [WL-C,
WE-C].)
IN
A
DBG110BEB023

IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
CAMSHAFT
FEELER
GAU\

--~~~
8. Install the cylinder head cover. (See 01-1 OB-9
CYLINDER HEAD GASKET REPLACEMENT
[WL-C, WE-C].)
9. Install the fuel injector. (See 01-14B-15 FUEL
ROCKER ARM
INJECTOR REMOVAUINSTALLATION [WL-C,
WE-C].)
10. Install the water pump pulley, cooling fan and
drive belt.
11. Adjust the drive belt deflection. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
12. Install the engine cover.
VALVE CLEARANCE ADJUSTMENT [WL-C, WE-C]
DBG110BTBRR5
dcf011012111w04
Caution
Loosening the locknut and the adjust screw while the cam lobe is not pressing down the rocker
arm will damage the claw of the rocker arm. When loosening the locknut and the adjust screw,
rotate the crankshaft clockwise and be sure that the cam lobe presses down the rocker arm firmly
2. Remove the following parts to turn the crankshaft.
1. Drive belt. (See 01-1 OB-4 DRIVE BELT
2. Cooling fan. (See 01-12B-8 COOLI NG FAN
REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Water pump pulley.
3. Remove the fuel injector. (See 01-14B-15 FUEL
INJECTOR REMOVAL/INSTALLATION [WL-C,
WE-C].)
TDC of compression.
CAM LOBE
CLAW
ROCKER ARM
DBG110BTBRR6
01-108-5

cylinder at TDC of compression, and those of B
DBG110BEB023

IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
Tightening torque (lock nut)
20-24 Nm {2.1-2.4 kgfm, 15-17 ftlbf}
CAMSHAFT
FEELER
GAU\_E______
~~~~~

8. Install the cylinder head cover. (See 01-1 OB-9
ROCKER ARM
CYLINDER HEAD GASKET REPLACEMENT
[WL-C, WE-C].)
9. Install the fuel injector. (See 01-14B-15 FU EL
INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
10. Install the water pump pulley, cooling fan and drive belt.
11. Adjust the drive belt deflection. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
COMPRESSION INSPECTION [WL-C, WE-C]
DBG110BTBRR5
dcf01100200Ow03
Warning
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. (See 01-17-2 BATTERY INSPECTION.)
2. Warm up the engine to the normal operating temperature.
3. Stop the engine and allow it to cool down for about 10 minutes.
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 following "Fuel
Line Safety Procedure". (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE-C].)
5. Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-CD
6. Remove all the glow plugs. (See 01-13B-8 GLOW PLUG REMOVAUINSTALLATION [WL-C, WE-C].)
01-108-6

7. Install the SSTs into the glow plug hole.
8. Crank the engine and note the maximum gauge
reading.
9. Check each cylinder as above.
Compression (kPa {kgf/cm 2 , psi} [rpm])
Standard: 2,942 {30, 427} [200]
Minimum: 2,648 {27, 384} [200]
10. 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.
(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.
11. Remove the SST.
12. Install the glow plug. (See 01-138-8 GLOW PLUG REMOVAL/INSTALLATION [WL-C, WE-C].)
13. Install the common rail. (See 01-148-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-CD
TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C]
1.
2.
3.
4.
dcf011012040w02
Remove the engine cover.

Disconnect the negative battery cable.
Remove in the order indicated in the table.
Install in the reverse order of removal.
37-52 {3.7-5.3,
27-38}
~~
70-95 inlbf}
Nm {kgfm, ftlbf}
DBG110BWB99
Timing belt cover

(See 01-10B-9 Timing Belt Cover Installation
Note.)
Tensioner
(See 01-10B-8 Tensioner Removal Note.)
(See 01-10B-9 Timing Belt Installation Note.)
3
4
Idler
Timing belt
(See 01-10B-8 Timing Belt Removal Note.)
(See 01-10B-9 Timing Belt Installation Note.)
01-108-7

Tensioner Removal Note
marks as shown.
INTAKE
CAMSHAFT
PULLEY
EXHAUST
CAMSHAFT
PULLEY
DBG110BWB98
2. Turn the auto tensioner counterclockwise using

an Allen wrench. (Rotate the auto tensioner with a
force of 39 Nm {4.0 kgfm, 28.8 ft.lbf} or less.)
3. Insert a fixing pin of approx. Smm {O.24 in}
diameter into hole A to secure the auto tensioner.
4. Remove the bolts in the order of Band C, then
remove the auto tensioner.
Note
If the rod projects suddenly while removing
the auto tensioner, the air flows into the
pressure chamber and the rod could move
slightly. If this occurs, bleed the air from the
pressure chamber using the following
procedure.
39 Nm {4.0 kgfm, 28.8 ftlbf}

MAX.
DBG110BEB033
5. Assemble the auto tensioner to the engine.

6. Turn the auto tensioner with a force of 39 Nm
{4.0 kgf.m, 28.8 ft.lbf} or less using an Allen
wrench, then turn it back slowly. Repeat this
procedure several times.
7. Verify that the rod has resistance when it is in the
most projected position. If there is no resistance,
repeat the above procedure.
39Nm
{4.0 kgfm,
28.8 ftlbf} MAX.
REPEAT
SEVERAL
TIMES
ALLEN
WRENCH
DBG110BWB999
Timing Belt Removal Note

Caution
The following will damage the timing belt and shorten its life; forcefully twisting it, turning it inside
out, or getting oil or grease on it.
.
After removing the timing belt, do not move the crankshaft and/or camshaft pulley from this
position because it can cause the valve and piston to contact and damage them.
reinstallation.
~~""
~OTATION
~I ~
ARROW
30 mm {1.2 in } MIN.
NG
DBG110BWB003
01-108-8

Timing Belt Installation Note
1. Align the timing marks as shown.
2. Verify that the supply pump attaching bolts and
nuts are tightened to the specified torque. This
must be done to prevent over-tensioning of the
timing belt after it has been installed.
INTAKE
CAMSHAFT
PULLEY
EXHAUST
CAMSHAFT
PULLEY
TIMING MARK
TIMING
MARK
~@\-SUPPLY PUMP
~
PULLEY
3. Install the tensioner and hand-tighten the lock bolt

A and B.
5. Install the idler.
6. Tighten the lock bolt A.
7. Tighten the lock bolt B.
8. Remove the set pin from the tensioner.
camshaft pulley timing marks. If they are not
aligned, remove the timing belt and repeat from
Step 1.
DBG110BWB96
Timing Belt Cover Installation Note

shown.
DBG110BEB043
CYLINDER HEAD GASKET REPLACEMENT [WL-C, WE-C]
dcf011010271w02
Warning
Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
speaks 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 Procedures".
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Drain the engine coolant. (See 01-12B-2 COOLING SYSTEM SERVICE WARNINGS [WL-C, WE-C].)
Remove the intake manifold, air intake pipe and breather chamber. (See 01-13B-3 INTAKE-AIR SYSTEM
Remove the fuel injector. (See 01-14B-15 FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C].)
Remove the turbocharger. (See 01-15B-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
Remove the timing belt. (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C].)
Adjust the drive belt deflection. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
Bleed air in the fuel line. (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
01-108-9

12. Start the engine and
(1) Inspect for engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed.
13. Inspect the compression.
i
1
7.8-10.8Nm
{80-110 kgfcm,
70-95 in.lbf}
-:1
~c;o~
~'c;o~
~
29 {3.0, 21}
+ 90_105
7.8-10.8 Nm
{80-110 kgf.cm,
70-95 inlbf}
DBG110BWB95
01-108-10

1
Cylinder head cover

(See 01-108-15 Cylinder Head Cover Installation
Note.)
Camshaft pulley
(See 01-108-11 Camshaft Pulley Removal. Note.)
(See 01-108-14 Camshaft Pulley Installation Note.)
Seal plate
(See 01-108-14 Seal Plate Installation Note.)
Camshaft cap upper
(See 01-108-11 Camshaft Cap Upper Removal
Note.)
(See 01-108-13 Camshaft Cap Upper Installation
Note.)
5
6
Camshaft
Camshaft cap lower
(See 01-108-13 Camshaft Cap Lower Installation
Note.)
Cylinder head
(See 01-108-11 Cylinder Head Removal Note.)
(See 01-108-12 Cylinder Head Installation Note.)
(See 01-108-12 Cylinder Head Gasket Installation
Note.)
Camshaft Pulley Removal Note

1. Hold the camshaft by using a wrench on the cast hexagon.
Caution
damage them.
CAMSHAFT PULLEY
DBG110BEBR17
Camshaft Cap Upper Removal Note

steps in the order shown.
Cylinder Head Removal Note

1. Remove bolts A.
steps in the order shown.
DBG110BEBR09
01-108-11

Cylinder Head Gasket Installation Note
1. Measure the piston topping of all the cylinders.
+TOPPING
CYLINDER
BLOCK
PISTON
DPE110ZE1R02

piston topping.

identification mark
0.080-0.190 {0.004-0.007}
0.135-0.255 {0.006-0.01 O}
.-----J
0.200-0.310 {0.008-0.012}
++-'
IDENTIFICATION MARK
POSITION
DPE110BEBR94

shown.
Thickness
02.0-3.0 mm {0.08-0.11 in}
~+-+
16.0 mm
{0.63 in}
44.0 mm
{1.73 in}
39.5 mm
ENGINE
FRONT
>.-l,d-III-+ {1.56 in}
23.5 mm
{0.93 in}
DBG110BWBR9
Cylinder Head Installation Note

1. Measure the length of each bolt. Replace the bolt
if necessary.
Bolt head mark W
Bolt head mark N
Bolt head mark I
Standard length: 149-150 mm {5.8675.905 in}
I.
),),,)))))))))))))
((
LENGTH
01-108-12
.1
DBG110AEB097
.'J

Tighten torque
{3.0 kgfm, 2.1 ft.lbf}.

by turning each 90-105 in the sequence
shown.
9. Apply adhesive to the thread of bolt A.
10. Tighten bolts A.
Tightening torque
17.6-19.6 Nm {1.80-1.99 kgf.m, 13.0-14.4
ft.lbf}
PAINT MARK
PAINT MARK
DBG110AWB311
Camshaft Cap Lower Installation Note

DBG110BEB105
Camshaft Cap Upper Installation Note

1. Apply adhesive to the front camshaft cap
mounting surfaces as shown.
ADHESIVE
DBG1WBWB86
01-108-13

2. Tighten the camshaft cap bolts gradually in three or four steps in the order shown.
Caution
Because there is little camshaft thrust
applied to the thrust area, causing burr
cylinder head journal: To avoid this, the

oil seal.
5. Tap the oil seal lightly into the cylinder head using
the SST and a hammer.
0.5-1.0 mm {0.02-0.03 in}
1r!~"'"'iIIiIlII
Iii.
CYLINDER
HEAD
0.5-1.0 mm {0.02-0.03 in}
'sMMER
Ii
OIL SEAL
DPE110ZE1R41
Seal Plate Installation Note

in the figure.
SEAL PLATE
DBG110BEB041
Camshaft Pulley Installation Note

1. Install the camshaft pulleys, positioning the knock
pins as shown.
INTAKE
CAMSHAFT
PULLEY
KNOCK PIN
DBG110BWB85
01-108-14

2. Hold the camshaft using a wrench on the cast
hexagon.
CAMSHAFT PULLEY
Caution
damage them.
Cylinder Head Cover Installation Note

shown.
Thickness
02.0-3.0 mm {0.08-0.11 in}
DBG110BWB84

shown.
DBG110BEB005
01-108-15

ROCKER ARM REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011 01201 OW02
Caution
Removing the camshaft under load can break the camshaft. When removing the camshaft, be sure
to prevent the camshaft from pressing down the rocker arm. (See 01-108-5 VALVE CLEARANCE
1.
2.
3.
4.
S.
6.
7.
1

Remove the air intake pipe and breather chamber.
Remove the timing belt. (See 01-108-7 TIMING 8ELT REMOVAUINSTALLATION [WL-C, WE-C].)
Remove the camshaft. (See 01-108-9 CYLINDER HEAD GASKET REPLACEMENT [WL-C, WE-C].)
Remove the order indicated in the table.
Rocker arm
(See 01-108-16 Rocker Arm Installation Note.)
Pivot
(See 01-108-16 Pivot Installation Note.)
11
20-24 {2.1-2.4, 15-17}
~j
o
/,
4
I
15-19 {1.6-1.9, 11-14}
Nm {kgfm, tt.lbf}
DBG110BWB93
Pivot Installation Note

1. Apply adhesive to the thread of the pivot.
Rocker Arm Installation Note
1. If a new rocker arm is used, set dimension A as
follows.
Dimension A
0.0-4.0 mm {0.0-0.115 in}
DBG110BWB92
FRONT OIL SEAL REPLACEMENT [WL-C, WE-C]

1.
2.
3.
4.
S.
6.
7.

Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C].)
Remove the upper radiator hose.
Remove the radiator cowling and cooling fan.
Inspect the engine oil level.
01-108-16
dcf011 01 0602w02

8. Adjust the drive belt deflection. (See 01-1 OB-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
1
Drive belt
Crankshaft pulley
(See 01-108-17 Crankshaft pulley Removal Note.)
(See 01-108-18 Crankshaft pulley Installation Note.)
Front oil seal
(See 01-108-17 Front Oil Seal Removal Note.)
(See 01-108-17 Front Oil Seal Installation Note.)
mim3~
1m2
392-441
{40-44,
291l-'~@)l!&
~9;~y
.v
/~'I~)
~~&
1
N'm {kgfm, ftlbf}
Crankshaft pulley Removal Note

Caution
Turning the crankshaft after the
crankshaft pulley is removed can
dislocate the timing gear.
Removing the key can cause the key
groove to become misaligned.
Front Oil Seal Removal Note

1. Cut the oil seal lip using a razor knife.
with a rag.
DBG110AWB015
Front Oil Seal Installation Note

hammer.
gear case cover and the face of the front oil seal.
GEAR CASE COVER
0.0-0.4 mm
{0.0-0.015 in}
Pushing distance of the front oil seal

0.0-0.4 mm {0.0-0.015 in}
MER
i!ONT OIL SEAL

DBG110BWB006
01-108-17

Crankshaft pulley Installation Note
REAR OIL SEAL REPLACEMENT [WL-C, WE-C]

1.
2.
3.
4.
5.
dcf011011399w02

Remove the dual-mass flywheel. (See 05-10-12 CLUTCH UNIT REMOVAUINSTALLATION.)
Inspect the engine oil level. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
Rear oil seal
(See 01-108-18 Rear 011 Seal Removal Note.)
(See 01-108-19 Rear Oil Seal Installation Note.)
DBG110AWB316
Rear 011 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.
RAG
DBG110AWB317
01-108-18

Rear Oil Seal Installation Note
hammer.
cover and the face of the rear oil seal.
I P'-'iII I. t.SI
REAR COVER
D.O-O.Smm
{D.O-D.Di9 in}
Pushing distance of the rear oil seal

0.0-0.5 mm {0.0-0.019 in}
HAMMER
ilROILSEAL
DBG110BWB007
ENGINE REMOVAUINSTALLATION [WL-C, WE-C]

Warning
1.
2.
3.
4.
5.
Remove the air intake pipe. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
Remove the battery. (See 01-17-2 BATTERY REMOVAL/INSTALLATION.)
Remove the radiator. (See 01-12B-6 RADIATOR REMOVALIINSTALLATION [WL-C, WE-C].)
Remove the front pipe. (See 01-15B-2 EXHAUST SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
Remove the transmission. (See 05-11 B-5 TRANSMISSION REMOVAL/INSTALLATION [S15M-D].) (See 0511 B-1 0 TRANSMISSION AND TRANSFER REMOVAL/INSTALLATION [S15MX-D].)
6. Remove the PIS oil pump with the oil hoses and pipes still connected. (See 06-14-14 POWER STEERING OIL
PUMP REMOVAL/INSTALLATION.)
Note
Position and secure the PIS oil pump out of the way with a rope.
7. Remove the AIC compressor with the pipes still connected. (See 07-11-6 AlC COMPRESSOR REMOVAL/
INSTALLATION.)
Note
Position and secure the AIC compressor out of the way with rope or wire.
8.
9.
10.
11.
12.
Remove the order indicated in the table.

Adjust the drive belt deflection. (See 01-10B-4 DRIVE BELT ADJUSTMENT [WL-C, WE-C].)
Bleed air in the fuel line. (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
Start the engine and
(1) Inspect the engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed.
13. Perform a road test.
01-108-19
J..-_-,3
mil
53.9-76.4 {5.50-7.79, 39.S-56.3}

Nm {kgf.m, ftlbf}
DBG110BWB91
ICooling fan
Engine
(See 01-108-20 Engine Removal/Installation Note.)
Engine Removal/Installation Note

1. Install the SST to the cylinder head by using bolt
(99784 1020 or M1 OX1.2S, ST, length 20mm
{0.79 in}) as shown.
Tightening torque
43.1-60.S Nm {4.40-6.10 kgfm, 31.S-44.S

ft.lbf}
2. Suspend the engine using the SST.
DBG110BWB89
01-108-20

ENGINE DISASSEMBLY/ASSEMBLY [WL-C, WE-C]
dcf011000000w06
1. Remove the intake-air system. (See 01-138-3 INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WEC].)
2. Remove the exhaust system. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
3. Remove the oil cooler. (See 01-118-4 OIL COOLER REMOVAUINSTALLATION [WL-C, WE-C].)
5. Assemble in the reverse order of disassembly.
1
2
3
4
5
Drive belt
Generator
(See 01-17-5 Generator Installation Note.)
Idler
AlC compressor bracket
Engine mount
Oil pressure switch
(See 01-118-2 OIL PRESSURE INSPECTION [WLC, WE-C].)
Water pump pulley
11.8-17.6 {1.2-1.8, 9-13}
6
37.3-S2.0
{3.8-S.3,
28-38}
{3.8-S.3,
28-38}
18.6-2S.S
{1.9-2.6,14-18}
38-S1
{3.9-S.2,
29-37}
Nm {kgfm, ft-lbf}
DBG110BWB88
ENGINE TUNE-UP [WL-C, WE-C]
dcfO 11 002000w04
Engine Tune-up Preparation

1. Start the engine and warm up completely.
2. Verify that the gear is in neutral position.
3. Verify that the accelerator pedal is released.
4. Turn off the AlC switch. (if equipped)
5. Turn off all electrical loads.
6. Verify that no DTC is present.
DBG110BWBA01
01-108-21

Idle Speed Inspection
1. Perform "Engine Tune-up Preparation". (See 01-108-21 Engine Tune-up Preparation.)
Note
Idle speed is not adjustable.
Idle speed verification requires current diagnostic tool.
2. Verify that the idling speed (current diagnostic tool: RPM PID) is within the specification using the current
diagnostic tool function.
Specification
No load: 695-745 rpm
AlC ON: 725-775 rpm
If not as specified, inspect the following parts.
APP sensor
ECT sensor
CMP sensor
CKP sensor
Fuel injector
Supply pump
If the parts are normal, replace the PCM.
Correction Procedure
MAF correction
Using PDS/IDS
Note
Perform this procedure after replacing the MAF/IAT sensor No.2 or at the recommended interval as
described under "E.G.R. system" in "SCHEDULED MAINTENANCE."
2. After the vehicle is identified, select the following items from the initial screen of the PDS/IDS.
1. Select the "Powertrain".
2. Select the "Engine Checks".
1. Select "All Tests and Calibrations".
3. Then, select the "Learning", "MAF Correction" and perform procedures according to directions on the PDS/IDS
screen.
4. Perform the MAF correction according to the directions on the PDS/IDS screen.
UsingWDS
Note
Perform this procedure after replacing the MAF sensor/lAT sensor No.2 or at the recommended interval as
described under "E.G.R. system" in "SCHEDULED MAINTENANCE:'
1.
2.
3.
4.
5.
6.
7.
Perform "Engine Tune-up Preparation". (See 01-108-21 Engine Tune-up Preparation.)

Set up the WDS (including the vehicle recognition).
Select the "Powertrain".
Select the "Engine Checks".
Select the "Learning".
Select the "MAF Correction" and perform procedures according to directions on the WDS screen.
Perform the MAF correction according to the directions on the WDS screen.
01-108-22

Without using current diagnostic tool
Note
completed.
1. Short the DLC-2 terminal TEN to body ground
using a jumper wire.
2. Short circuit the DLC-2 terminal TEN five times

within 5 s.
JUMPER
WIRE
GND1
DBG102BWB301
01-108-23

ENGINE TUNE-UP[WL-C, WE-C (AT)]
idO 11 099800600
Engine Tune-up Preparation

1. Start the engine and warm up completely.
2. Verify that the selector lever is in P position.
3. Verify that the accelerator pedal is released.
4. Turn off the AlC switch. (if equipped)
6. Verify that no DTC is present.
arnffw00001573
01-108-24

Idle Speed Inspection
Note
Idle speed is not adjustable.
Idle speed verification requires PDS/IDS.
2. Verify that the idling speed (PDS/IDS: RPM PID) is within the specification using the PDS/IDS function.
Specification
AlC ON: 725-775 rpm
If not as specified, inspect the following parts.
APP sensor
ECT sensor
CMP sensor
CKP sensor
Fuel injector
Supply pump
If the parts are normal, replace the PCM.
Correction Procedure
MAF correction
Using PDSIIDS
Note
Perform this procedure after replacing the MAF/IAT sensor No.2 or at the recommended interval as
described under "E.G.A. system" in "SCHEDULED MAINTENANCE."
2. After the vehicle is identified, select the following items from the initial screen of the PDS/IDS.
2. Select the "Engine Checks".
3. Then, select the "Learning", "MAF Correction" and perform procedures according to directions on the PDS/IDS
screen.
4. Perform the MAF correction according to the directions on the PDS/IDS screen.
01-108-25

Without using PDS/IDS
Note
completed.
1. Short the OLC terminal TEN to body ground using
a jumper wi're.
arnffw00001558
2. Short circuit the OLC terminal TEN five times

within 5 s.
FEN
JUMPER
WIRE
GND
DLe
BODY GROUND
IG-
arnffw00001559
01-108-26
01-11B LUBRICATION [WL-C, WE-C]

LOCATION INDEX [WL-C, WE-C] .....
OIL PRESSURE INSPECTION
[WL-C, WE-C] ....................
ENGINE OIL LEVEL INSPECTION
[WL-C, WE-C] . . . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT
[WL-C, WE-C] ....................
OIL FILTER REPLACEMENT
[WL-C, WE-C] ....................
01-11B-1
01-11B-2
01-11 B-2
01-11B-3
01-11B-3
OIL COOLER REMOVAU

INSTALLATION [WL-C, WE-C] ...... . 01-11 B-4
OIL COOLER BODY INSPECTION
[WL-C, WE-C] ................... . 01-11B-5
OIL PAN REMOVAUINSTALLATION
[WL-C, WE-C] .................... 01-11 B-5
OIL PUMP REMOVAU
INSTALLATION [WL-C, WE-C] ...... . 01-11B-7
OIL PUMP INSPECTION
[WL-C, WE-C] .................... 01-11 B-1 0
LOCATION INDEX [WL-C, WE-C]
DBG110BWB78
Oil pressure switch

(See 01-118-2 OIL PRESSURE INSPECTION [WLC, WE-C].)
Oil filter
(See 01-118-3 OIL FILTER REPLACEMENT [WL-C,
WE-C).)
Oil level gauge

(See 01-118-2 ENGINE OIL LEVEL INSPECTION
[WL-C, WE-C).)
(See 01-118-3 ENGINE OIL REPLACEMENT [WLC, WE-C].)
Oil cooler
(See 01-118-4 OIL COOLER REMOVAU
(See 01-118-5 OIL COOLER 80DY INSPECTION
[WL-C, WE-C].)
01-118-1

5
Oil pan
(See 01-11 B-5 OIL PAN REMOVAUINSTALLATION
[WL-C, WE-C].)
Oil strainer
(See 01-11B-7 OIL PUMP REMOVAU
INSTALLATION [WL-C, WE-CJ.)
Oil pump component

(See 01-11 B-7 OIL PUMP REMOVAU
(See 01-11B-10 OIL PUMP INSPECTION [WL-C,
WE-C].)
OIL PRESSURE INSPECTION [WL-C, WE-C]
dcf01111400Ow02
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.
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.
3. Warm up the engine to normal operating
temperature.
4. Run the engine at the specified speed, and note
the gauge readings.
Note
The oil pressure can vary with oil viscosity
and temperature.
410-570 kPa {4.19-5.81 kgf/cm 2,59.682.6 psi}
5.
6.
7.
8.
If the pressure is not as specified, inspect for the cause and repair or replace as necessary.
Stop the engine and wait until it becomes cool.
Remove the SST.
Apply silicone sealant to the oil pressure switch
threads as shown.
9. Install the oil pressure switch before the sealant
hardens.
Tightening torque
11.8-17.6 Nm {1.2-1.8 kgf.m, 9-13 ftlbf}
10. Start the engine and inspect for oil leakage.
4.0-6.0 mm
{0.160-0.23 in}
I~I
DBG111AWB102
ENGINE OIL LEVEL INSPECTION [WL-C, WE-C]

1.
2.
3.
4.
dcf011114001w03
Position the vehicle on level ground.

Warm up the engine to normal operating temperature and stop it.
Wait for five minutes.
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.
01-118-2

ENGINE OIL REPLACEMENT [WL-C, WE-C]
dcf011114001w04
Warning
When the engine and the engine oil are hot, they can badly burn. Don't burn yourself with either.
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.
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.
2.
3.
4.

Remove the oil filler cap and the oil pan drain plug.
Drain the oil into a container.
Install the drain plug by using a new washer.
Tightening torque
29.4-41.2 Nm {3.00-4.20 kgf.m, 21.7-30.3 ft.lbf}
5.
6.
7.
8.
Refill the engine oil with the specified type and amount of engine oil.
Refit the oil filler cap.
Run the engine and inspect for oil leakage.
Inspect the oil level and add oil if necessary. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
Note
The actual oil level may very from the specified capacity in some cases.
Item
Grade
Viscosity (SAE)
Specification
API CO/CE/CF-4 or ACEA 81/83/85
5W-30, 1OW-3~

OIL FILTER REPLACEMENT [WL-C, WE-C]
dcf011114300w02
1. Remove the oil filter by using the filter wrench.

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 filter wrench.
4. Start the engine and inspect for oil leakage.
5. Inspect for the oil level and add oil if necessary.
(See 01-118-2 ENGINE OIL LEVEL
INSPECTION [WL-C, WE-C].)(See 01-118-3
ENGINE OIL REPLACEMENT [WL-C, WE-C].)
DBG111AWB1R3
01-118-3

OIL COOLER REMOVAL/INSTALLATION [WL-C, WE-C]
dcf01111470Ow03
1.
2.
3.
4.
5.
6.
7.

Remove the turbocharger. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
Remove the oil filter. (See 01-118-3 OIL FILTER REPLACEMENT [WL-C, WE-C].)
Remove in the order shown in the figure.
Fill the radiator with the specified amount and type of engine coolant. (See 01-128-3 ENGINE COOLANT
8. Inspect the engine oil level. (See 01-118-2 ENGINE OIL LEVEL INSPECTION [WL-C, WE-C].)
9. Start the engine and inspect for engine coolant leakage.
18.6-25.5 {1.9-2.6, 14-18}
-.....,."...
&---191
Nm {kgfm, ft-lbf}
DBG111AWB104
Dipstick pipe
2
3
Radiator hose
Thermostat case
Oil cooler body

(See 01-11 B-4 Oil Cooler Body Installation Note.)
Oil cooler
Oil Cooler Body Installation Note

Tighten the mounting bolts and nuts in the order
shown.
DBG111AWB105
01-118-4

OIL COOLER BODY INSPECTION [WL-C, WE-C]
dcf011114700w04
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}
rnn
BYPASS VALVE SPRING
~ 0
PRESSURE CONTROL VALVE SPRING
rnn~[ID
OIL PAN REMOVAL/INSTALLATION [WL-C, WE-C]
1.
2.
3.
4.

Drain the engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WE-C).)
Remove the under cover.
Remove the front stabilizer. (See 02-13-16 FRONT STABILIZER AND TENSION ROD REMOVAU
INSTALLATION [4x2 (EXCEPT Hi-Rider)].) (See 02-13-17 FRONT STABILIZER REMOVAUINSTALLATION
[Hi-Rider,4x4].)
Disconnect the center link on the left side of the vehicle. (See 06-14-10 STEERING GEAR AND LINKAGE
REMOVAUINSTALLATION.)
Remove in the order shown in the figure.
Fill with the specified amount and type of engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WEC].)
Start the engine and inspect for engine oil leakage.
5.
6.
7.
8.
9.
54.9-80.4
{5.6-8.1,40.5-59.3}
APPLY SCREW LOCK AGENT

94.2-115.7
{9.5-11.8, 68.8-85.3}
7.8-10.8 Nm
{80-110 kgfcm, 70-95 inlbf}
Nm {kgfm, ftlbf}
DBG110BWB76
Front crossmember
Rear crossmember (4x4)
(See 01-118-6 Rear Crossmember Removal Note.)
Oil pan
(See 01-118-6 Oil Pan Removal Note.)
(See 01-118-7 Oil Pan Installation Note.)
01-118-5

Rear Crossmember Removal Note
1. Set the transmission jack on the front differential.
DBG110BWB77
2. Remove the bolts and nuts indicated in the figure.
DBG110BWB83
Oil Pan Removal Note

1. Remove the oil pan mounting bolts.
Caution
Pry tools can easily scratch the cylinder block and oil pan contact surfaces. Prying off the oil pan
can also easily bend the oil pan flange.
2. Use a separate tool to separate the oil pan.
B3E0111W008
01-118-6

Oil Pan Installation Note
Caution
bolt hole damage.
!o'
tv@l=j=E
~
OLD SEALANT
1. Apply silicone sealant to the oil pan along the

inside of the bolt holes and overlap the ends.
..
...____...:::P~
o~
~O~----.;.O
Thickness
02.0-3.0 mm {0.OB-0.11 in}
2. Tighten the oil pan bolts A as indicated in the
figure.
passes.
A
o
DBG110AEBRB7
OIL PUMP REMOVAUINSTALLATION [WL-C, WE-C]
dcf011114100w03
1. Disconnect the negative battery cable.

2. Drain the engine oil. (See 01-11B-3 ENGINE OIL REPLACEMENT [WL-C, WE-C).)
3. Remove the under cover.
4. Remove the oil pan. (See 01-11B-5 OIL PAN REMOVAUINSTALLATION [WL-C, WE-C].)
5. Remove the timing belt. (See 01-10B-7 TIMING BELT REMOVAUINSTALLATION [WL-C, WE-C].)
6. Remove the crankshaft pulley. (See 01-10B-16 FRONT OIL SEAL REPLACEMENT [WL-C, WE-C].)
7. Remove in the order shown in the figure.
9. Fill with the specified amount and type of engine oil. (See 01-11 B-3 ENGINE OIL REPLACEMENT [WL-C, WEC).)
10. Start the engine and inspect for engine oil leakage.
01-118-7

8.8-12.7 Nm
{90-129 kgfcm,
78-112 inlbf}
7.8-10.8 Nm
{81-110 kgfcm,
18.6-25.5
{1.9-2.6,14-18}
7.9-10.8 Nm
{81-110 kgfcm,
70-95 inlbf}
Nm {kgfm, ftlbf}
DBG111BWB99
2
3

Timing gear cover
(8ee 01-118-8 Timing Gear Cover Removal Note)
(8ee01-11 8-9 Timing Gear Cover Installation Note)
Oil strainer
Oil pipe
(8ee01-118-9 Oil Pipe Installation Note)
Oil pump
6
7
8
9
10
11
Oil pump cover

(8ee01-118-9 Oil Pump Cover Installation Note)
Driven gear
Plug
Plunger spring
Control plunger
Oil pump body
Timing Gear Cover Removal Note

1. Remove the timing gear cover by using a
separator tool.
SEPARATOR TOOL
(
DBG110AEB044
01-118-8
"

2. Remove the oil seal by using a screwdriver
protected with a rag,
Oil Pump Cover Installation Note

shown.
Oil Pipe Installation Note

shown.
DBG110AEBR89
Timing Gear Cover Installation Note

shown.
Thickness
~2.0-3.0
mm {O.079-0.118 in}
DBG110BEB071
01-118-9

2. Tithe bolts in two or three steps in the order
shown.
oil seal.

hammer.
0.0-0.40 mm {0.0-0.015 in}
.'
SUPPLY PUMP
OIL SEAL
O.0-0.40mm
{O.O-O.015 in}
IPUWi"MI
FRONT OIL SEAL
IP"i,II'lCt,1I
OIL SEAL

0.0-0.40 mm {0.0-0.015 in}
DBG111BWB98
OIL PUMP INSPECTION [WL-C, WE-C]
dcf01111410Ow04

.
replace the gear and/or pump body.
0.10-0.19 mm {0.0040-0.0074 in}
0.20 mm {0.0079 in}
DBG110AEB101

0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
DBG110AEB102
2. Measure the free length of plunger spring .

replace the plunger spring.
43.8 mm {1.72 in}
DBG110AEB103
01-118-10
01-128 COOLING SYSTEM [WL-C, WE-C]

COOLING SYSTEM
LOCATION INDEX [WL-C, WE-C] ....
COOLING SYSTEM
SERVICE WARNINGS
[WL-C, WE-C] . ...................
ENGINE COOLANT
LEVEL INSPECTION [WL-C, WE-C] ..
ENGINE COOLANT
PROTECTION INSPECTION
[WL-C, WE-C] ..... ...............
ENGINE COOLANT
REPLACEMENT [WL-C, WE-C] ......
INSPECTION [WL-C, WE-C] . ........
COOLING SYSTEM CAP
INSPECTION [WL-C, WE-C] . ........
01-128-1
01-128-2
01-128-2
01-128-2
01-128-3
01-128-5
01-128-5
COOLANT RESERVE TANK

REMOVALIINSTALLATION
[WL-C, WE-C] . ................... . 01-128-6
RADIATOR REMOVALI
INSTALLATION [WL-C, WE-C] ...... . 01-128-6
THERMOSTAT REMOVALI
THERMOSTAT INSPECTION
[WL-C, WE-C] ................... . 01-128-8
COOLING FAN REMOVALI
COOLING FAN INSPECTION
[WL-C, WE-C] ................... . 01-128-8
WATER PUMP REMOVALI
COOLING SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf011200000w03
DBG112BWB702
Coolant reserve tank

(See 01-128-6 COOLANT RESERVE TANK
Thermostat
(See 01-128-7 THERMOSTAT REMOVAU
(See 01-128-8 THERMOSTAT INSPECTION [WLC, WE-C).)
Radiator
(See 01-128-6 RADIATOR REMOVAU
Water pump
(See 01-128-9 WATER PUMP REMOVAU
Cooling fan
(See 01-128-8 COOLING FAN REMOVAU
INSTALLATION [WL-C, WE-C])
(See 01-128-8 COOLING FAN INSPECTION [WLC, WE-C).)
Cooling system cap

(See 01-128-5 COOLING SYSTEM CAP
. 3
01-128-1

COOLING SYSTEM SERVICE WARNINGS [WL-C, WE-C]
dcf01120000Ow04
Warning
Never remove the cooling system cap while the engine is running, or when the engine and radiator
are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage
the engine and cooling system.
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.
When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
ENGINE COOLANT LEVEL INSPECTION [WL-C, WE-C]
1.
2.
3.
4.
dcf011215001w05
Remove the radiator cap.

Verify that the coolant level is near the radiator filler neck.
Verify that the coolant level in the radiator reservoir is between the FULL and LOW marks.
Add coolant if necessary.
ENGINE COOLANT PROTECTION INSPECTION [WL-C, WE-C]
dcf011215001w06
1. Measure the coolant temperature and specific gravity using a thermometer and a hydrometer.
Caution
Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.
FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
IFL22lWi
E5U112ZW5010
01-128-2
"

2. Determine the coolant protection level by referring
to the graph shown.
If the coolant protection level is not correct,
add water or coolant.
SPECIFIC
GRAVITY
COOLANT PROTECTION
(EXCEPT FL22 TYPE ENGINE COOLANT)
1.10
1.09
I-- I"-----
1.08 r--...
-...... ..........
1.07
r- ..........
1.06
I"----- I"-----
t--- t..........
1.05
r--.....
..........
r---- .......... ..........
I"'- t---
1.04
1"-----......
--
55%
I"'- 45%
r-- ............ 35%
1.03
1.02
1.01
1.00
o 5 10 15 20 25 30 35 40 45 50
(32)
(41)
(50)
(59)
(6S)
(77)
(S6)
(95) (104) (113) (122)
COOLANT TEMPERATURE
c {OF}
DDA 112ZW4003
ENGINE COOLANT REPLACEMENT [WL-C, WE-C]
dcf011215001w07
Warning
Never remove the cooling system cap while the engine is running, or when the engine and radiator
are hot. Scalding coolant and steam may shoot out and cause serious injury. It may also damage
the engine and cooling system.
When you are sure all the pressure is gone, press down on the cap using the cloth, turn it, and
remove it.
Caution
Use engine coolant at a concentration that meets the environmental conditions in which the
vehicle is driven, otherwise engine damage could occur.
The engine has aluminum parts and must be protected by an ethylene-glycol-based coolant to
prevent corrosion and freezing.
Do not use coolants containing Alcohol, Methanol, Borate or Silicate. These coolants could
damage the cooling system.
Use only soft (demineralized) water in the coolant mixture. Water that contains minerals will cut
down on the coolant's effectiveness.
Engine coolant damages paint. If engine coolant does get on a painted surface, rinse it off quickly.
Note
If the "FL22" mark is shown on or near the cooling system cap, use FL22 type engine coolant.
FL22 type engine coolant is shipped as a
diluted solution (55% coolant, 45% water).
Use the solution as is when replacing
coolant.
9.4 L{9.9 US qt, 8.3 Imp qt}
1. Remove the coolant reserve tank with the hose
still connected.
2. Remove the coolant reserve tank cap and drain
the engine coolant from the coolant reserve tank.
IFL22Wl
E5U112ZW5010
01-128-3

3. Remove the cooling system cap.
COOLING
SYSTEM CAP
DBGl12AWB702
4. Loosen the radiator drain plug and drain the

engine coolant into a container.
5. Flush the cooling system with water until all traces
of color are gone.
6. Let the system drain completely.
7. Tighten the radiator drain plug.
8. Referring to the following chart, select the correct
volume percentage of the water and coolant.
DRAIN
PLUG
DBGl12AWB101
Antifreeze solution mixture percentage (Except FL22 type engine coolant)

Volume percentage ('Yo)
Engine coolant
protection
Above -16C {3 OF}

Above -26C {-15 OF}
Above -40C {-40 OF}
Water
65
55
45
Coolant
35
45
55
Gravity at 20C {68 OF}

1.057
1.072
1.086
9. Refill the coolant from the cooling system filler neck until it is close to the top of the cooling system filler neck.
10. Refill the coolant into the coolant reserve tank up to the F mark on the tank.
11. Install the cooling system cap.
Caution
If the water temperature gauge rises too high, stop the engine and decrease the water temperature
to prevent overheating. Then, verify the malfunctioning part and repair or replace it.
12. Start the engine and warm up the engine by idling.
13. After the engine warms up, perform the following steps. At this time, be careful of the coolant temperature to
prevent overheating.
(1) Run the engine at approx. 2,500 rpm for 5 min.
(2) Run the engine at approx. 3,000 rpm for 5 s, then idle.
(3) Repeat step (2) 4-5 times.
14. Stop the engine, and inspect the coolant level after the coolant temperature decreases. If it is low, repeat steps
10-14.
15. Inspect for coolant leakage. (See 01-128-5 ENGINE COOLANT LEAKAGE INSPECTION [WL-C, WE-C].)
If the coolant leaks, specify the malfunctioning part and repair or replace it.
01-128-4

ENGINE COOLANT LEAKAGE INSPECTION [WL-C, WE-C]
dcf011215001w08
Warning
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.
When you're sure all the pressure is gone, press down on the cap still using the cloth, turn it, and
remove it.
1.
2.
3.
4.
5.
Inspect the engine coolant level. (See 01-128-2 ENGINE COOLANT LEVEL INSPECTION [WL-C, WE-C).)
Remove the radiator cap.
Clean the installation parts of the cooling system cap.
Connect a radiator cap tester and the SST to the radiator filler neck.
Apply pressure to the radiator.
,------------------------,
Pressure
122 kPa {1.25 kgf/cm 2 , 17.7 psi}
Caution
Applying more than 122 kPa {1.25 kgfl
cm 2 , 17.7 psi} can damage the hoses,
fittings, and other components, and
cause leakage.
6. Verify that the pressure is help. If not, inspect the
system for coolant leakage.
COOLING SYSTEM CAP INSPECTION [WL-C, WE-C]
DBG112BWB001
dcf011215201w02
Warning
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.
When you're sure all the pressure is gone, press down on the cap still using the cloth, turn it, and
remove it.
1. Clean the cooling system cap and the sealed part.
2. Inspect the cooling system cap for cracks or everted seal.
If there is any malfunction, replace the cooling system cap.
3. Attach the cooling system cap to the SST and a
,------------------------,
radiator cap tester.
4. Hold the cooling system cap downward and apply
pressure gradually. Verify that the pressure is held
stable for 10 s.
If the pressure is not held stable, replace the
cooling system cap.

93.2-122.6 kPa {O.95-1.25 kgflcm 2 , 13.517.8 psi}
COOLING SYSTEM CAP

DBG112BWB002
01-128-5

COOLANT RESERVE TANK REMOVAUINSTALLATION [WL-C, WE-C]
dcf01121503Ow02
Warning
Remove and install all parts when the engine is cold, otherwise they can cause severe burns or
serious injury.
IHose
DBG112BWB701
RADIATOR REMOVAUINSTALLATION [WL-C, WE-C]
dcf01121520Ow02
Warning
serious injury.
1.
2.
3.
4.
Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C).)
Fill the radiator with the specified amount and
type of engine coolant.(See 01-128-3 ENGINE
COOLANT REPLACEMENT [WL-C, WE-C].)
1
2
3
4
Radiator upper seal

Radiator hose
Lower radiator cowling
Radiator
Radiator cowling
(lr
Nm {kgfm, ftlbf}
DBG112AWB102
i"
01-128-6

THERMOSTAT REMOVAUINSTALLATION [WL-C, WE-C]
dcf011215171w03
Warning
serious injury.
1.
2.
3.
4.
drain the engine coolant.(See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C].)
type of engine coolant. (See 01-128-3 ENGINE
1
2
3
Dipstick pipe
Lower radiator hose
Thermostat cover
Thermostat
(See 01-128-7 Thermostat Installation Note.)
"",.5
{80-110 kgfcm.
18.6-25.5
{1.90-2.60.
13.8-18.8}
"'.0
Nm {kgfm. ttlbf}
DBG112BWB003
Thermostat Installation Note

Install the thermostat into the thermostat cover,
aligning the projection on the gasket to the
thermostat cover as shown.
GASKET
THERMOSTAT COVER
DBG112AWB104
01-128-7

THERMOSTAT INSPECTION [WL-C, WE-C)
dcf011215171w04
Warning
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.
Open valve in room temperature
Opening temperature and lift of valve

80-84 C {176-183 OF}
95C {203 OF}
Full open life
COOLING FAN REMOVAL/INSTALLATION [WL-C, WE-C)
1.
2.
3.
4.
dcf01121514Ow03
Remove the drive belt.

Remove in the order indication in the table.
Adjust the drive belt (generator) deflection. (See
01-10B-4 DRIVE BELT ADJUSTMENT [WL-C,
WE-C].)
ICooling fan
18.6-25.5 Nm {1.90-2.60 kgfm, 13.8-18.8}

DBG112BWB004
COOLING FAN INSPECTION [WL-C, WE-C)
dcf01121514Ow04
1. Rotate the cooling fan by hand and inspect for

abnormal noise and looseness. Replace the
cooling fan id necessary. (See 01-12A-8
COOLING FAN REMOVAL/INSTALLATION [WL3].)
DBG112AWB107
01-128-8

WATER PUMP REMOVAUINSTALLATION [WL-C, WE-C]
1.
2.
3.
4.
5.
dcf011215010w02
Remove the cooling fan. (See 01-128-8 COOLING FAN REMOVAL/INSTALLATION [WL-C, WE-C].)
Drain the engine coolant. (See 01-128-3 ENGINE COOLANT REPLACEMENT [WL-C, WE-C]
Remove in the reverse order of removal.
type of engine coolant. (See 01-128-3 ENGINE
IWater pump
18.6-25.5 {1.90-2.60,
13.8-18.8}
Nm {kgf.m, ftlbf}
01-128-9
01-138 INTAKE-AIR SYSTEM [WL-C, WE-C]

INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM VACUUM HOSE
ROUTING DIAGRAM [WL-C, WE-C] ..
INTAKE-AIR SYSTEM
REMOVAUINSTALLATION
[WL-C, WE-C] . ...................
AIR CLEANER ELEMENT
INSPECTION [WL-C, WE-C] ........
TURBOCHARGER
GUIDE BLADE ACTUATOR
SOLENOID VALVE INSPECTION
[WL-C, WE-C] . ...................
01-13B-1
01-13B-2
01-13B-3
01-13B-5
01-13B-5
01-13B-6
01-13B-6
VACUUM CHECK VALVE

INSPECTION [WL-C, WE-C] . ....... . 01-13B-8
GLOW PLUG REMOVAU
GLOW PLUG INSPECTION
[WL-C, WE-C] . .................... 01-13B-9
GLOW PLUG RELAY REMOVAU
GLOW PLUG RELAY
INSPECTION [WL-C, WE-C] ......... 01-13B-9
GLOW PLUG CORD
INSPECTION [WL-C, WE-C] ......... 01-13B-11
ACCELERATOR PEDAL
COMPONENT REMOVAU
ACCELERATOR PEDAL
ADJUSTMENT [WL-C, WE-C] ........ 01-13B-12
INTAKE-AIR SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf01130000Ow04
CD
DBG113BWB301
Intake-air system
Turbocharger
(See 01-13B-5 TURBOCHARGER INSPECTION
[WL-C, WE-C].)
Air cleaner
(See 01-13B-5 AIR CLEANER ELEMENT
Fresh-air duct
Guide blade actuator

(See 01-13B-5 TURBOCHARGER INSPECTION
[WL-C, WE-C].)
VBC solenoid valve

(VBC) SOLENOID VALVE INSPECTION [WL-C,
WE-C].)
01-138-1

7
Vacuum check valve

(See 01-138-8 VACUUM CHECK VALVE
11
Charge air cooler

(See 01-138-3 INTAKE-AIR SYSTEM REMOVAU
Glow plug relay

(See 01-138-9 GLOW PLUG RELAY REMOVAU
(See 01-138-9 GLOW PLUG RELAY INSPECTION
[WL-C, WE-C].)
12
Intake manifold
Glow plug cord

(See 01-138-11 GLOW PLUG CORD INSPECTION
[WL-C, WE-C).)
13
10
Glow plug
(See 01-138-8 GLOW PLUG REMOVAU
(See 01-138-9 GLOW PLUG INSPECTION [WL-C,
WE-C).)
Accelerator pedal component

COMPONENT REMOVAUINSTALLATION [WL-C,
WE-C].)
INTAKE-AIR SYSTEM VACUUM HOSE ROUTING DIAGRAM [WL-C, WE-C]
dcf01130000OW05
VACUUM CHECK VALVE

AIR FILTER
VBC SOLENOID VALVE
EGRVALVE
INTAKE SHUTTER
SOLENOID VALVE
(HALF)
INTAKE SHUTTER
SOLENOID VALVE
(FULL)
EGR CONTROL
SOLENOID VALVE
VACUUM PUMP
DBG113BWB305
01-138-2

INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf011300000w06
Warning
A hot engine and intake-air system can cause severe burns. Turn off the engine and wait until they
are cool before removing the intake-air system.
Note
If the MAF sensor is replaced, always perform each adjustment procedure using the following steps.
MAF sensor
STEP
2
3
4
5
6
7
ACTION
Perform mass air flow (MAF) sensor data reset

procedure.
Perform KOEO self-test procedure.
Turn the engine switch to the off position.
Wait for 5 s.
Start the engine.
Perform KOER self-test procedure.
Turn the engine switch to the off position.
PAGE/CONDITION
(See 01-408-22 MASS AIR FLOW (MAF) SENSOR DATA RESET

[WL-C, WE-C].)
(See 01-028-10 KOEO/KOER SELF TEST [WL-C, WE-C].)
(See 01-028-10 KOEO/KOER SELF TEST [WL-C, WE-C].)

01-138-3

19-25Nm
{2.0-2.5 kgfm,
15-1S ftlbf}
6.9-9.S
{71-99,62-S6}
~ ~.\
4.9 {50, 43}
7.S-10.S
{SO-110,70-95}
7.8-10.S
{SO-110, 70-95}
1
7.S-10.S
{SO-11 0, 70-95}
6.9-9.S -----,~
{71-99,62-S6}
6
Nm {kgf.cm, inlbf}
DBG113BWB312
Air intake hose

Air cleaner cover
3
4
5
Air cleaner element

Air cleaner case
01-138-4
Fresh-air duct
(See 01-13B-5 Fresh-Air Duct Removal Note.)
VBC solenoid valve
Vacuum check valve
Turbocharger air outlet hose
10
Turbocharger air outlet pipe

11
12
Charge air cooler inlet hose

Charge air cooler outlet hose
17
18
Intake shutter valve

EGR control solenoid valve bracket
13
Charge air cooler

Charge air cooler air outlet pipe
19
Boost sensor/lAT sensor No.1

Intake manifold
(See 01-13B-5 Intake Manifold Removal Note.)
14
15
Charge air cooler air outlet hose
16
Vacuum pipe
20
Fresh-Air Duct Removal Note

1. Remove the front mud guard. (See 09-10-9 FRONT FENDER PANEL REMOVAUINSTALLATION.)
Intake Manifold Removal Note
1. Set the fuel filter component slightly out of the way. (See 01-14B-9 FUEL FILTER REMOVAUINSTALLATION
[WL-C, WE-C].)
2. Remove the EGR valve and EGR pipe.
3. Remove the injection pipe. (See 01-14B-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
4. Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
AIR CLEANER ELEMENT INSPECTION [WL-C, WE-C]
1. Remove the air cleaner element. (See 01-13B-3 INTAKE-AI R SYSTEM REMOVAL/INSTALLATION [WL-C,
WE-C].)
2. Inspect the following items:
If there is any malfunction, clean or replace the air cleaner element.
If the replacement interval has come, replace the air cleaner element.
Is the air cleaner element soiled, damaged, or bent?
- Are the air cleaner case and the air cleaner element correctly sealed?
Is the correct air cleaner element installed?
TURBOCHARGER INSPECTION [WL-C, WE-C]
dcf011313700w02
Note
Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-5 Troubleshooting Procedure.)
Compressor Wheel Inspection
2. Remove the air intake hose between the air cleaner and the turbocharger. (See 01-13B-3INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Visually inspect the compressor wheel from view A and verify that all fins are free from damage, cracks or
bends.
If there are damaged fins, cracks or bends,
replace the turbocharger. (See 01-15B-2
EXHAUST SYSTEM REMOVAU
Note
To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
If the compressor wheel is interfering with
the compressor housing, it is likely that the
MIRROR
fin edges are cracked, damaged, or bent.
If the compressor wheel is damaged, check
the following before replacing the
turbocharger to avoid reoccurrence of the malfunction.
Foreign material in intake air/exhaust system.
- Oil pipe clogging.
~A"
DBG113BWB306
01-138-5

Turbine Wheel Inspection
2. Remove the jOint pipe. (See 01-158-2 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
3. Visually inspect the turbine wheel from view B and verify that all fins are free from damage, cracks or bends.
If there are damaged fins, cracks or bends,
replace the turbocharger. (See 01-15B-2
EXHAUST SYSTEM REMOVAU
Note
To make the inspection easier, set a small
mirror as shown in the figure and use a
penlight.
If the turbine wheel is interfering with the
turbine housing, it is likely that the fin edges
are cracked, damaged, or bent.
If the turbine wheel is damaged, check the
following before replacing the turbocharger
to avoid reoccurrence of the malfunction.
Foreign material in intake air/exhaust system.
- Oil pipe clogging.
DBG113BWB307
GUIDE BLADE ACTUATOR INSPECTION [WL-C, WE-C]
dcf01131370Ow03
1. Disconnect the vacuum hose from the guide blade actuator.

2. Connect the vacuum pump to the guide blade
.-----------------------,
actuator.
3. Apply vacuum and verify that the rod moves as
specified.
If not as specified, replace the turbocharger.
Specification
Vacuum (kPa {mmHg, inHg})
Rod movement
Below -14.2 {-1 06, -4.19}
Starts to move
Fully pulled
Above -47.3 {-355, -14.0}
VARIABLE BOOST CONTROL (VBC) SOLENOID VALVE INSPECTION [WL-C, WE-C]
dcf011318748w01
Note
Perform the following test only when directed.
Airflow Inspection
2. Remove the VBC solenoid valve. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C,
WE-C].)
3. Inspect airflow between the ports under the following conditions.
If not as specified, replace the VBC solenoid valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAU
If as specified, carry out the "Resistance Inspection".
r----------------------,
0--0 : Continuity
Step
()::=(): Airflow
Terminal
B+
Port
-0
GROUND
,....
,....
DBG113BWB322
01-138-6
DBG113BWB311
'

Resistance Inspection
2. Disconnect the VBC solenoid valve connector. (See 01-13B-3INTAKE-AIR SYSTEM REMOVAU
3. Measure the resistance between the VBC solenoid valve terminals using an ohmmeter.
If not as specified, replace the VBC solenoid valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAU
If VBC solenoid valve is okay, perform the
"Circuit Open/Short Inspection".
VBC solenoid valve resistance
12.6-15.4 ohms [20-30 C {67-a6 OF}]
VBC SOLENOID VALVE

DBG113BWB315
Circuit Open/Short Inspection

1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harness for open or
short circuit (continuity Inspection).
VBC SOLENOID VALVE
WIRING HARNESS-SIDE
CONNECTOR
MAIN RELAY
rc1AI
1m]
DBG113BWB316
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
If there is no continuity, the circuit is open. Repair or replace the wiring harness.
VBC solenoid valve terminal A and main relay terminal D
- VBC solenoid valve terminal Band PCM terminal 178
Short circuit
If there is continuity, the circuit is shorted. Repair or replace the wiring harness.
VBC solenoid valve terminal A and body ground
VBC solenoid valve terminal B and power supply
VBC solenoid valve terminal B and body ground
01-138-7

VACUUM CHECK VALVE INSPECTION [WL-C, WE-C]
dcf011318748w02
1. Remove the vacuum check valve. (See 01-13B-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C,
WE-C].)
2. Blow through port A and verify that the airflows
from port B. "
If not as specified, replace the vacuum check
valve. (See 01-13B-3 INTAKE-AIR SYSTEM
3. Blow through port B and verify that the air does
A
B
not flow from port A.
If not as specified, replace the vacuum check
valve. (See 01-13B-3INTAKE-AIR SYSTEM
A6E40102015
GLOW PLUG REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011318601w03
Warning
Caution
Do not damage the heated section of the glow plug.
Do not reuse a glow plug that has been dropped over a height of 10 cm {3.9 in}, even when there
are no scratches and resistance is normal (approx. 1.4 ohms [20C {58 OF}] (Reference value.
Do not remove the glow plug unless you are replacing it.
1.
2.
3.
4.
1

Remove the common rail. (See 01-14B-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-C].)
Glow plug cord
Glow plug
(See 01-138-8 Glow Plug Removal Note.)
(See 01-138-8 Glow Plug Installation Note.)

15-20
{1.6-2.0,
12-14}
DBG113BWB309
Glow Plug Removal Note

1. When removing the glow plug, first loosen it at least one pitch using a tool, then loosen by hand.
Glow Plug Installation Note
1. Tighten the glow plug it at least one pitch by hand, and continue tightening with a tool.
01-138-8

GLOW PLUG INSPECTION [WL-C, WE-C)
dcf011318601w04
1. Remove the glow plug cord. (See 01-138-8 GLOW PLUG REMOVAUINSTALLATION [WL-C, WE-C].)
2. Measure the resistance between the glow plug terminal and the cylinder head (body ground) using an
ohmmeter.
If not as specified, replace the glow plug. (See 01-138-8 GLOW PLUG REMOVAUINSTALLATION [WL-C,
WE-C].)
Glow plug resistance (Reference value)

Approx. 1.4 ohms [20C {68F}]
DBG113BWB310
GLOW PLUG RELAY REMOVAUINSTALLATION [WL-C, WE-C)

1.
2.
3.
4.

Install the glow plug relay.
Connect the negative battery cable.
DBG113AWB208
GLOW PLUG RELAY INSPECTION [WL-C, WE-C)
dcf011318611w05
Note
System Inspection
1. Carry out the "Glow Plug Control Operation Inspection". (See 01-038-62 Glow Plug Control Operation
Inspection. )
2. If not as specified, perform the further inspection for the glow plug relay.
01-138-9

Continuity Inspection
1. Remove the glow plug relay. (See 01-138-9 GLOW PLUG RELAY REMOVAUINSTALLATION [WL-C, WE-C].)
2. Verify the continuity between the glow plug relay
terminals.
0-0 : Continuity
Step
Terminal
B+
GND
-0
CHU0921W006
If not as indicated in the table, replace the

glow plug relay. (See 01-138-8 GLOW PLUG
If as specified but the "System Inspection" is failed, perform the "Circuit Open/Short Inspection".
DBG113AWB310

1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harnesses for an
open or short circuit. (Continuity inspection)
GLOW PLUG RELAY
W
n
Q:;
MAIN RELAY
rcfA1
I~~I
DBG113AWB311
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
If there is no continuity in the following wiring harnesses, there is an open circuit. Repair or replace the
wiring harness.
Glow plug relay terminal A and PCM terminal 182
Glow plug relay terminal 8 and main relay terminal D
- Glow plug relay terminal C and power supply
- Glow plug relay terminal D and PCM terminal 227
- Glow plug relay terminal D and glow plug cord
Short circuit
If there is continuity in the following wiring harnesses, there is a short circuit. Repair or replace the wiring
harness.
Glow plug relay terminal A and power supply
Glow plug relay terminal A and body ground
Glow plug relay terminal 8 and body ground
Glow plug relay terminal C and body ground
Glow plug relay terminal D and body ground
01-138-10

GLOW PLUG CORD INSPECTION [WL-C, WE-C]
dcf011318611w06
1. Remove the glow plug cord from glow plug. (See 01-13B-8 GLOW PLUG REMOVAUINSTALLATION [WL-C,
WE-C).)
2. Verify that the glow plug cord is not broken or bent.
Note
When inspecting for continuity in the glow plug cord, do not let the uncovered parts (A) come into contact
with other parts and be shorted.
3. Verify there is continuity at both ends of the glow
plug cord.
If there is no continuity, replace the glow plug
cord. (See 01-13B-8 GLOW PLUG
REMOVAL/INSTALLATION [WL-C, WE-C].)
A
DBG113BWB314
ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011341600w03

2. Set the power brake unit slightly out of the way. (See 04-11-10 POWER BRAKE UNIT REMOVAU
INSTALLATION.)
3. Set the clutch master cylinder slightly out of the way. (See 05-10-6 CLUTCH MASTER CYLINDER REMOVAU
INSTALLATION.)
4. Remove the column cover and steering shaft. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAU
INSTALLATION.)
1
Neutral switch connector
Brake switch connector
3
4
Idle switch connector

APP sensor connector
Spring pin
5
6
Clevis pin
Pedal component (See 01-13B-11 Pedal
Component Installation Note.)
18.6-25.5
Nm {kgfm, ftlbf}
DBG113AWB305
Pedal Component Installation Note

Carry out the "BRAKE PEDAL INSPECTION" procedure after installing the pedal component. (See 04-11-6
BRAKE SWITCH INSPECTION.)
Carry out the "CLUTCH PEDAL ADJUSTMENT" procedure after installing the pedal component. (See 05-10-4
CLUTCH PEDAL ADJUSTMENT.)
01-138-11

ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION[WL-C, WE-C (AT)]
id011398807300

2. Remove the 4x4 control module. (4x4) (See 03-18-S 4x4 CONTROL MODULE REMOVAL/INSTALLATION [AT.
(SRSSS)].)
1
2
3
Idle switch connector

APP sensor connector
4
5
Clevis pin
iii
4
Spring pin
Pedal component (See 01-13B-1 Pedal Component
Installation Note.)
18.6-25.5
{1.90-2.60,
13.8-18.8}
Nm {kgfm, ftlbf}
arnffw00001574
Pedal Component Installation Note

1. Carry out the "BRAKE PEDAL INSPECTION" procedure after installing the pedal component.
01-138-11a

ACCELERATOR PEDAL ADJUSTMENT [WL-C, WE-C]
c\
dcf01134160OW04
Caution
Adjusting the APP sensor and idle switch unnecessarily may adversely affect engine control.
Therefore, adjust APP sensor and/or idle switch only when it is replaced.
Note
Perform the following adjustment only when directed.
1. Temporarily install the APP sensor and the idle switch to the pedal assembly and verify that the APP sensor
installation bolts and idle switch locknut are lightly tightened.
2. Connect the APP sensor and the idle switch connector.
4. Verify that the voltage between APP sensor
terminals A and 0 is between 4.9 to 5.1 V (target
APP SENSOR
value 5.0 V).
r=::=l
1:0 1 C 1 B 1 A:IJ
I~~
I
DBG140AWB311
5. Set the current diagnostic tool and monitor APp,

APP2 and IVS PIDs.(See01-02B-8 PID/DATA
Monitor And Record Procedure)
APP SENSOR
PCM
DBG140BWB314
6. Adjust the APP sensor installation position so that

the APP and APP2 PIDs value is between 0.5 to
0.7 V (target value 0.6 V) with the accelerator
pedal fully released, then tighten the APP sensor
installation bolts
APP SENSOR
DBG140AWB332
01-138-12
-,.

7. While fully depressing the accelerator pedal until
it contacts the stopper rubber, adjust the stopper
rubber installation position so that the APP and
APP2 value is between 3.4 to 3.8 V (target value
3.6 V).
8. While slowly depressing the accelerator pedal by
hand, adjust the idle switch installation position so

that the IVS PIO turns from ON to OFF with the
APP and APP2 value is between 1.0 to 1.2 V
(target value 1.1 V), then tighten the idle switch
locknut.
DBGl13AWB701
Tightening torque
13.7-17.6 Nm {1.40-1.79 kgfm, 10.2-12.9
ftlbf}
9. Verify that the IVS PIO turns from OFF to ON
when the accelerator pedal is full released.
10. While depressing the accelerator pedal again,
verify that the IVS PIO turns from ON to OFF with
the APP and APP2 PIOs value is between 1.0 to
1.2 V (target value 1.1 V).
IDLE SWITCH
LOCKNUT
DBG113AWB702
01-138-13
01-148 FUEL SYSTEM [WL-C, WE-C]
CI
FUEL SYSTEM
FUEL SYSTEM
DIAGRAM [WL-C, WE-C] ...........
8EFORE REPAIR
PROCEDURE [WL-C, WE-C] ........
AFTER REPAIR
PROCEDURE [WL-C, WE-C] ........
FUEL TANK REMOVAU
INSTALLATION [WL-C, WE-C] .......
FUEL TANK
FUEL FILTER REMOVAU
SEDIMENTOR
WATER DRAINING [WL-C, WE-C] ....
01-148-1
01-148-3
01-148-3
01-148-4
01-148-4
01-148-8
01-148-9
01-148-9
SEDIMENTOR SWITCH
INSPECTION [WL-C, WE-C] ......... 01-148-10
SUPPLY PUMP REMOVAU
SUPPLY PUMP
INSPECTION [WL-C, WE-C] . ....... . 01-148-13
FUEL METERING
VALVE INSPECTION [WL-C, WE-C] ... 01-148-13
FUEL-INLET FILTER
REMOVAUINSTALLATION
[WL-C, WE-C] ..................... 01-148-14
COMMON RAIL
INSPECTION [WL-C, WE-C] ........ . 01-148-14
FUEL INJECTOR REMOVAU
FUEL INJECTOR
FUEL SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf011400000w05
Engine Room Side
DBG114BWB301
Fuel filter
(See 01-148-9 FUEL FILTER REMOVAU
(See 01-148-9 SEDIMENTOR WATER DRAINING
[WL-C, WE-C).)
Supply pump
(See 01-148-13 SUPPLY PUMP INSPECTION [WLC, WE-C].)
Sedimentor switch
(See 01-148-10 SEDIMENTOR SWITCH
Fuel metering valve

(See 01-148-13 FUEL METERING VALVE
01-148-1

5
Fuel-inlet filter
(See 01-14B-14 FUEL-INLET FILTER REMOVAU
Common rail
(See 01-14B-14 COMMON RAIL INSPECTION
[WL-C, WE-C].)
Fuel injector
[WL-C, WE-C].)
Check valve
Fuel Tank Side

Double cab 4x2(except Hi-Rider), Stretch cab 4x2 (with rear access system (except Hi-Rider))
DBG114BWB331
Regular cab, Double cab 4x4, stretch cab 4x4 (with rear access system), Hi-Rider
DBG114BWB330
Fuel tank
(See 01-14B-4 FUEL TANK REMOVAU
(See 01-14B-8 FUEL TANK INSPECTION [WL-C,
WE-C].)
01-148-2
IFuel gauge sender unit
I..
/

FUEL SYSTEM DIAGRAM [WL-C, WE-C]
dcf011400000w06
*:TOPCM
-----.. : FUEL FLOW
BEFORE REPAIR PROCEDURE [WL-C, WE-C]
dcf011400000w07
Warning
Fuel line spills and leads 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".
A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before performing work on the fuel system, discharge static electricity by touching
the vehicle body.
Fuel Line Safety Procedures
1. 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 line hose, wrap a rag around it to protect against fuel leakage.
(3) Plug the hose after removal.
01-148-3

AFTER REPAIR PROCEDURE [WL-C, WE-C]
dcf01140000Dw08
Warning
damage. When installing the fuel hose, observe "Fuel Hose Installation" described below.
Caution
If fuel does not pass through the fuel filter, foreign material may have penetrated in the supply
pump, and this may cause a malfunction resulting in damage to the supply pump. Therefore, do
not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always
follow the Fuel Hose Installation Note in the Workshop Manual and perform the procedure. (See
01-14B-13 Fuel Hose Installation Note.)
Fuel Line Air Bleeding
Caution
Continuously cranking the engine for over 30 s can damage the battery and the starter.
1. Continue cranking the engine for 30 s and stop for 5-10 s until the engine starts.
Fuel Hose Installation
1. Verify that there is no damage or deformation on the fuel hose and fuel pipe when installing.
2. When installing the fuel hose connected to the supply pump, verify each side (main and return), and install at
the specified position. (See 01-14B-13 Fuel Hose Installation Note.)
FUEL TANK REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011442110w03
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.
A person charged with static electricity could cause a fire or explosion, resulting in death or
serious injury. Before draining fuel, make sure to discharge static electricity by touching the
vehicle body.
2. Complete the "BEFORE REPAIR PROCEDURE" (See01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE3.
4.
5.
6.
7.
C].)
Remove the drain plug and drain the fuel from the fuel tank.
Remove the rear flap.
Remove in the reverse order indicated in the table.
Install in the reverse order indicated of removal.
Complete the "AFTER REPAIR PROCEDURE". (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
01-148-4

1.1-2.1 Nm {11-22 kgfcm,

10-19 inlbf}
7.9-10.7 Nm {80-110 kgfcm,
69.5-95.4 inlbf}
L~
-~
~(Q)
9-+A
~1
fftJi~~
2.5-3.5 Nm
{25-36 kgf.cm,
22-26 inlbf}
}m
26-32 {2.6-3.3,
19-23}
32-46 {3.2-4.7, 24-33}
Nm {kgf.m, ttlbf}
DBG114BWB332
01-148-5

1.1-2.1 N'm {11-22 kgfcm.
10-19 inlbf}
1.1-2.1 Nm
{11-22 kgfcm.
10-19 inlbf}
7.9-10.7 Nm {80-110 kgfcm.

69.5-95.4 inlbf}
~1
fQ'~~
2.5-3.5 Nm
{25-36 kgf.cm.
22-26 inlbf}
1
2.5-4.6 Nm
{25-47 kgfcm.
22-40 inlbf}
10
11.8-16.6 Nm
32-46 {3.2-4.7.
24-33}
32-46 {3.2-4.7. 24-33}
Nm {kgfm. ft.lbf}
DBG114BWB333
Joint hose (See 01-14B-7 Joint Hose Installation

Note.)
Breather hose (See 01-14B-7 Breather Hose
Installation Note.)
Under guard
Fuel hose
Fuel tank
01-148-6
Evaporative hose (See 01-14B-7 Evaporative Hose

Installation Note.)

Rollover valve
8
9
Fuel-filler pipe
10
Dust cover
11
Fuel inlet pipe

Evaporative Hose Installation Note
Fit each hose onto the respective fittings within the specification, and install clamps as shown.
Length
Evaporative hose: 25 mm {O.98 in}
(~:~~m;"
;'l
BREATHER HOSE
Fuel Hose Installation Note

Fit each onto the respective fittings within the specification, and install camp as shown.
Length
Fuel hose: 25mm {O.98 in}
'\
1,10 mm {0.39 in}
ptfl~~l
FUEL HOSE
DBG114AWB015
Breather Hose Installation Note

Fit each hose onto the respective fittings within the specification, and install clamp as shown.
Length
Breather hose: 25 mm {O.98 in}
'\
1,10 mm {0.39 in}
ptfl~~l
EVAPORATIVE HOSE
DBG114AWB016
Joint Hose Installation Note

Fit the joint hose onto the respective fittings within the specification, and install clamps as shown.
Length
Joint hose: 35 {1.4 in]
912 mm
{0.3S 0.47 in}
VIEWA
912 mm
{0.3S 0.47 in}
VIEWS
DBG114AWB017
01-148-7

FUEL TANK INSPECTION [WL-C, WE-C]
dcf011442110w04
Note
This inspection is for the two rollover valves and the check valve (two-way) which is integrated in the fuel
hose.
1. Follow "BEFORE REPAIR PROCEDURE" before performing any work operations to prevent fuel from spilling
from the fuel system. (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C, WE-C).)
3. Remove the fuel tank. (See 01-14B-4 FUEL TANK REMOVAUINSTALLATION [WL-C, WE-C].)
4. Plug the fuel pipe of the fuel gauge sender unit.
.
5. Plug port C.
6. Connect the pump to port B.
7. Level the fuel tank.
CHECK VALVE
(TWO-WAY)
DBG114AWB060
8. Apply pressure of 5-6 kPa {38-45 mmHg,

1.5-1.7 inHg} to port B.
(1) Verify there is airflow from port A.
If there is no airflow, replace the two
rollover valves and the three fuel hoses
indicated in the figure.
ROLLOVER VALVE
FUEL HOSE
ROLLOVER VALVE
CHECK VALVE
(TWO-WAY)
DBG114AWB303
9. Apply pressure of -5- -6 kPa {-38- -45

mmHg, -1.5--1.7 inHg} to port B.
If there is no airflow, replace the two rollover
valves and the three fuel hoses indicated in
the figure.
ROLLOVER VALVE
FUEL HOSE
ROLLOVER VALVE
CHECK VALVE
(TWO-WAY)
DBG114AWB303
If there is airflow, turn the fuel tank upsidedown and proceed to next step.
FUEL GAUGE
SENDER UNIT
ROLLOVER VALVE
C
DBG 114AWB061
01-148-8

10. Apply pressure of 5-6 kPa {38-45 mmHg,
1.5-1.7 inHg} to port B.
(1) Verify there is no airflow from port A.
If there is airflow, replace the two rollover
valves and the three fuel hoses indicated
in the figure.
ROLLOVER VALVE
FUEL HOSE
ROLLOVER VALVE
CHECK VALVE
(TWO-WAY)
DBG114AWB303
FUEL FILTER REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011420490w02

2. Complete the "BEFORE REPAIR PROCEDURE". (See 01-14B-3 BEFORE REPAIR PROCEDURE [WL-C,
WE-C].)
4. Assemble in the reverse order of removal.
5. Complete the "AFTER REPAIR PROCEDURE". (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
6. Bleed air from the fuel filter.
7. Start the engine and verify that fuel does not leak from the fuel system.
8. If fuel leaks, reassemble the fuel filter.
,---------------------,
1
2
3
4
5
6
~~
Connector
Fuel hose
Priming pump
Fuel filter
(See 01-148-9 Fuel Filter Assembly Note.)
Sedimentor switch
(See 01-148-9 Sedimentor Switch Assembly
Note.)
Drain plug
14.7-19.6
{1.5D-1.99,
10.9-14.4}
4.4-5.4 Nm
{45-55 kgfcm,
39-47 inlbf}
N'm {kgfm, ttlbf}

DBG114AWB038
Sedimentor Switch Assembly Note

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
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.
SEDIMENTOR WATER DRAINING [WL-C, WE-C]
dcf011413080w02

WE-C].)
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". (See 01-14B-4 AFTER REPAIR PROCEDURE [WL-C, WE-C].)
7. Reconnect the negative battery cable.
01-148-9

SEDIMENTOR SWITCH INSPECTION [WL-C, WE-C]
dcf011413081w02
Note
1.
2.
3.
4.

Drain fuel from the fuel filter. (See 01-14B-9 SEDIMENTOR WATER DRAINING [WL-C, WE-C].)
Remove the sedimentor switch.
Inspect continuity of the sedimentor switch by
using an ohmmeter.
Float
Continuity
Up
Down
Yes
No
DBG114AWB019
5. If not as specified, replace the sedimentor switch.

If as specified, inspect following:
Open circuit
Ground circuit (Sedimentor switch connector
terminal B and body ground)
Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C)
SEDIMENTOR SWITCH

(VIEW FROM TERMINAL SIDE)
DBG114AWB020
6.
7.
8.
9.
Short circuit
Ground circuit (Sedimentor switch connector
terminal B and body ground to power circuit)
Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C to ground)
Repair or replace faulty areas.
Install the sedimentor switch.
Reconnect the negative battery cable.
Bleed air from the fuel filter.
ENGINE SWITCH
IArBI
tffij
(VIEW FROM TERMINAL SIDE)
DBG 114AWB021
01-148-10

SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C]
dcf011413350w01
Caution
Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
To prevent the fuel injection pipe from clogging, be careful that foreigo material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system
components to prevent foreign matter ingress to the components.
If fuel does not pass through the fuel filter, foreign material may have penetrated in the supply
pump, and this may cause a malfunction resulting in damage to the supply pump. Therefore, do
not install the fuel hoses (main and return side) in reverse. When installing the fuel hose, always
follow the Fuel Hose Installation Note in the Workshop Manual and perform the procedure. (See
01-14B-13 Fuel Hose Installation Note.)
WE-C].)
3. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAL/INSTALLATION.)
4. Remove the battery carrier.
\. ~
5. Set the fuel filter component slightly out of the
'----"'F>-'way. (See 01-14B-9 FUEL FILTER REMOVAL/
6.9-9.8 Nm
{71-99 kgfcm,
62-86 inlbf}
8. Complete the "AFTER REPAIR PROCEDURE".
(See 01-14B-4 AFTER REPAIR PROCEDURE
15.7-22.5 -~IIoG/'~
[WL-C, WE-C].)
{1.61-2.29,
11.6-16.5}
Nm {kgfm, ttlbf}
DBG114BWB705
9. Start the engine and verify that fuel does not leak
from the fuel system.
1
2
3
4
5
6
Injection pipe
(See 01-148-12 Injection Pipe Removal Note.)
Common real
Fuel hose
(See 01-148-13 FuelHose Installation Note.)
Connector
Timing belt cover (See 01-108-9 Timing 8elt Cover
Installation Note.)
7.8-10.8 Nm
Supply pump
(See 01-148-12 Supply Pump Pulley Removal
Note.)
{1.90-2.60,
13.8-18.8}
Nm {kgfm, Itlbf}
DBG114BWB002
01-148-11

Injection Pipe Removal Note
Caution
If the fuel injector inlet connector is not locked against rotation when removing the injection pipe,
it may loosen and cause fuel leakage.
1. Lock the fuel injector inlet connector against

rotation.
2. Loosen the flare nut on the injection pipe while
being careful not to allow the inlet connector to
rotate.
FLARE NUT
FUEL INJECTOR
DBG114BWB304
Supply Pump Pulley Removal Note

1. Removal the two supply pump pulley mounting bolts.
2. Loosen the fuel injection pump pulley locknut.
3. Remove the pulley with the SST.
\(~(
t:JJ
0'-'
FUEL INJECTION
PUMP PULLY
~OCKNUT
DBG114BWB023
01-148-12

Fuel Hose Installation Note
Install the fuel main hose and fuel return hose as shown in the figure.
CHECK VALVE
FUEL INJECTOR
COMMON RAIL
SEDIMENTOR SWITCH
SUPPLY PUMP
DBG114BWB787
SUPPLY PUMP INSPECTION [WL-C, WE-C]
dcf011413350w02
Caution
The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
Consult authorized parts distributor for repair if any of the injection pump inner parts are possibly
malfunctioning.
1. Supply pump inner parts
2. Fuel metering valve
3. Fuel temperature sensor
FUEL METERING VALVE INSPECTION [WL-C, WE-C]
dcf011413350w03
Caution
The supply pump is sealed to maintain proper function. Special tools and testers are required
when disassembling the supply pump. Disassembling the supply pump without special tools and
testers will cause a malfunction.
01-148-13

2. Disconnect the fuel metering valve connector.
3. Measure the resistance between the fuel
metering valve terminals using an ohmmeter.
If not as specified, repair the supply pump.
(See 01-14B-13 SUPPLY PUMP
If as specified, carry out the "Circuit Open/
Short Inspection".
Specification
Ambient temperature (OC eF})
Resistance (ohm)
20 {68}
2.6-3.15
FUEL METERING
VALVE
DBG114BWB012

1. Inspect for an open or short circuit in the following wiring harnesses.
If there is an open or short circuit, repair or replace wiring harnesses.
Open circuit
Power circuit (fuel metering valve terminal A and main relay terminal D)
Ground circuit (fuel metering valve terminal Band PCM terminal 179)
Short circuit
Fuel metering valve terminal A and main relay terminal D to ground
FUEL-INLET FILTER REMOVAUINSTALLATION [WL-C, WE-C]
dcf01141335Ow04

2. Disconnect the fuel hose connecting to the fuel-inlet pipe.
3. Remove in the eye bolt.
,-----------------------,
Note
The fuel-inlet filter cannot be removed as it is
crimped to the eye bolt.
GASKET
iii
4. If there is any malfunction, clean the fuel-inlet

filter.
23-27Nm
{2.4-2.7 kgfm,
17-19 ftlbf}
DBG114BWB004
COMMON RAIL INSPECTION [WL-C, WE-C]
dcf011413151w01
Caution
Do not remove the fuel pressure sensor nor the fuel pressure limiter from the common rail. Since
fuel pressure in the common rail is extremely high, the fuel pressure sensor, fuel pressure limiter,
or the common rail can be damaged, leading to fuel leakage if any of them are removed.
1. Visually inspect the common rail for damage and cracks. Also verify that there is no extreme rust which will
cause fuel leakage.
If either is observed, replace the common rail.
01-148-14

FUEL INJECTOR REMOVAUINSTALLATION [WL-C, WE-C]
dcf011413250w01
Caution
Fuel line spills and leakage on the parts are dangerous. Fuel can ignite and also deteriorate the
parts. To prevent this, always cover the mouths of the removed parts in the fuel system with rags
to soak up the fuel.
To prevent the fuel injection pipe from clogging, be careful that foreign material has not entered
the pipe. Also, be sure to tighten the bolts with the specified tightening torque when installing the
fuel injection pipe.
To prevent fuel leakage, follow the procedure indicated in the workshop manual when removing
and installing the fuel injector.
The fuel injection pipe can be removed and reinstalled up to five times. Be sure to record in the
service record when removing and installing the fuel injection pipe. If removing it for the sixth
time, be sure to replace it with a new one.
Always carry out the cleaning process before carrying out any repairs to the fuel injection system
components to prevent foreign matter ingress to the components.
Note
Perform "FUEL INJECTOR CODE PROGRAM" after replacing fuel injector. (See 01-40B-21 FUEL
INJECTOR CODE PROGRAM [WL-C, WE-C].)
WE-C].)
3. Disconnect the CMP sensor connector.
4. Disconnect the ECT sensor connector.
5. Disconnect the fuel presser sensor connector.
6. Disconnect the fuel injector connector.
9. Complete the "AFTER REPAIR PROCEDURE".
21.0-26.0
(See 01-14B-4 AFTER REPAIR PROCEDURE
{2.15-2.65,
21.0-26.0
[WL-C, WE-C].)
1
2
3
4
Fuel return hose

Fuel injection pipe
Injector bracket
Fuel injector
~4
I
~
~25_29
f?
{2.5-2.9,
=~~ll~~~~~~19-21}
-'-N"-D.T=
9''''==\
..F __ ,...r=r . ...F~
~_
~Cl
-=---
(tr
~I
Nm {kgfm, ftlbf}
DBG114BWB001
01-148-15

FUEL INJECTOR INSPECTION [WL-C, WE-C]
dcf01141325OW02
Note

2. Disconnect the fuel injector connectors.
3. Measure the resistance of the fuel injector using
an ohmmeter.
If not as specified, replace the fuel injector.
(See 01-148-15 FUEL INJECTOR
Short Inspection".
Resistance
Approx. 0.225 ohms
DBG114BWB010

1. Disconnect the PCM connector.
2. Inspect the following wiring harnesses for open or
short (continuity check).
FUEL INIJECTOR
DBG114BWB011
PCM
DBG114BWB009
01-148-16

Open circuit
If there is no continuity, the circuit is open. Repair or replace the wiring harness.
No.1 cylinder fuel injector terminal Band peM terminal 174.
No.1 cylinder fuel injector terminal A and peM terminal 125.
NO.3 cylinder fuel injector terminal A and peM terminal 101.
Short circuit
If there is continuity, the circuit is short. Repair or replace the wiring harness.
No.1 cylinder fuel injector terminal B and body ground.
No.1 cylinder fuel injector terminal A and body ground.
NO.3 cylinder fuel injector terminal A and body ground.
No.1 cylinder fuel injector terminal B and power supply.
No.1 cylinder fuel injector terminal A and power supply.
01-148-17
01~15B
EXHAUST SYSTEM
INSPECTION [WL-C, WE-C] . ........ 01-158-1
EXHAUST SYSTEM
REMOVAUINSTALLATION
[WL-C, WE-C] ................... . 01-158-2
EXHAUST SYSTEM INSPECTION [WL-C, WE-C]
dcf011500000w03
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
If leakage is found, repair or replace if necessary.
01-158-1

EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf01150000Ow04
Warning
When the engine and exhaust system are hot, they can cause severe burns or injury. Turn off the
engine and wait until they are cool before removing the exhaust system.
1.
2.
3.
4.
5.
6.
7.

Remove the air cleaner. (See 01-138-3 INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WL-C, WE-C].)
Remove the EGR cooler. (See 01-168-4 EGR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
Start the engine and:
(1) Inspect the exhaust gas leakage.
(2) If any servicing around the turbocharger is performed, inspect around the turbocharger for oil or engine
coolant leakage.
37-52 {3.8-5.3, 28-38}

19-25 {2.0-2.5, 15-18}
22-27 {2.3-2.7, 17-19}
Nm {kgfm, ttlbf}
DBG115BWB001
2
3
4
5
Main silencer
Front pipe
(See 01-158-3 Front Pipe Installation Note.)
Exhaust manifold insulator
Turbocharger insulator
01-158-2
Water pipe
(See 01-158-3 Water Pipe Removal Note.)
(See 01-158-3 Water Pipe Installation Note.)
Oil pipe
Oil hose (supply)
(See 01~158-3 Oil Hose (Supply) Installation Note.)

9 .1 Turbocharger
10 Joint pipe
11
IExhaust manifold
Water Pipe Removal Note

1. Drain the engine coolant before removing the water pipe. (See 01-12B-3 ENGINE COOLANT REPLACEMENT
[WL-C, WE-C].)
Oil Hose (Supply) Installation Note
1. Secure section A using a spanner.
2. Tighten the nut at B.
Tightening torque:
B, D: 14.7-20.6 Nm {150-210 kg.em, 131182 in.lbf}
3. Hold section C using pliers.
4. Tighten the nut at D.
Water Pipe Installation Note

1. Refill the engine coolant after Installing the water pipe. (See 01-12B-3 ENGINE COOLANT REPLACEMENT
[WL-C, WE-C].)
Front Pipe Installation Note
1. Temporarily tighten the nuts A.
Tightening torque:
A, B: 37-52 Nm {3.8-5.3 kgm, 28-38
ftlbf}
C: 19-25 Nm {2.0-2.5 kgm, 15-18 ftlbf}
2. Temporarily tighten the bolts Band C.
3. Completely tighten the nuts A.
4. Completely tighten the bolts Band C.
DBG115BWB002
01-158-3
01-168 EMISSION SYSTEM [WL-C, WE-C]

EMISSION SYSTEM
EMISSION SYSTEM
DIAGRAM [WL-C, WE-C] ...........
EGR SYSTEM REMOVAL!
EGR VALVE INSPECTION
[WL-C, WE-C] . ...................
EGR SOLENOID VALVE
01-168-1
01-168-3
01-168-4
01-168-5
01-168-5

(HALF) INSPECTION [WL-C, WE-C] .. 01-168-6
(FULL) INSPECTION [WL-C, WE-C] .. 01-168-7
ROLLOVER VALVE INSPECTION
[WL-C, WE-C] ................... . 01-168-8
EMISSION SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf01160000Ow03
Engine Room Side
arnffw00000460
2
3
EGR valve
(See 01-168-4 EGR SYSTEM REMOVAU
(See 01-168-5 EGR VALVE INSPECTION [WL-C,
WE-C].)
EGR cooler
(See 01-168-4 EGR SYSTEM REMOVAU
Intake shutter valve
(See 01-168-7 INTAKE SHUTTER VALVE
EGR solenoid valve

(See 01-168-5 EGR SOLENOID VALVE
EGR control solenoid valve

(See 01-168-6 EGR CONTROL SOLENOID VALVE
Air filter
6
7

(See 01-168-6 INTAKE SHUTTER SOLENOID
VALVE (HALF) INSPECTION [WL-C, WE-C].)

(See 01-168-7 INTAKE SHUTTER SOLENOID
VALVE (FULL) INSPECTION [WL-C, WE-C].)
01-168-1

9

(See 01-158-2 EXHAUST SYSTEM REMOVAU
Fuel Tank Side

DBG116BWB330
DBG116BWB331
Roliover valve
(See 01-168-8 ROLLOVER VALVE INSPECTION
[WL-C, WE-C].)
01-168-2

EMISSION SYSTEM DIAGRAM [WL-C, WE-C]
dcf01160000Ow04
EGR CONTORL SOLENOID VALVE

EGR SOLENOID VALVE
INTAKE SHUTTER SOLENOI

VALVE (HALF OPEN)
J---lI-\YIO~

VALVE (FULL CLOSE)
-*:TOPCM
DBG116BWB332
01-168-3

EGR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C]
dcf01160002Ow02

3; Install in the reverse order of removal.
19-25 {2.Q-2.5, 15-18}
Nm {kgfm, ftlbf}
DBG116BWB702
IEGR pipe
EGR cooler
EGR system installation note

1. Temporarily tighten bolts and nuts in order of A to F.
01-168-4
IEGR valve

2. Tighten the bolts and nuts in order of A to F.
TO FRONT
TO FRONT
DBG116BWB703
EGR VALVE INSPECTION [WL-C, WE-C]
dcf011620300w02
1. Inspect for airflow between 1 and 2 when vacuum is applied using a vacuum pump as shown in the figure.
If not as specified, replace the EGR valve.
Specification
Vacuum
kPa {mmHg, inHg}
Below -30.0- -36.6

{-226- -274,-8.90 - -10.8}
Except above
Airflow
Yes
No
DBG116AWB002
EGR SOLENOID VALVE INSPECTION [WL-C, WE-C]

2. Monitor the following signals using the PID/data
monitor.
EGR solenoid
Mass air flow (MAF)
3. Using the "SEGRP" simulation function, verify that
the mass intake airflow amount changes.
If the mass airflow amount does not change,
EGR solenoid valve
Wiring harness and connector open
circuit (main relay-EGR solenoid valvePCM)
Vacuum hose disconnection or damage
4. Clear all DTCs stored in the PCM referring to the "AFTER REPAIR PROCEDURE".
dcf011618741w04
DBG110BWBA01
01-168-5

EGR CONTROL SOLENOID VALVE INSPECTION [WL-C, WE-C]
dcf011618741w05

If not as specified, replace the EGR control solenoid valve.
If as specified, carry out the "Circuit Open/Short Inspection."
.-------------------------------------,
0=0 : Airflow
Step
1
2
Port
Terminal
B
r-..
B+
GND
()
~B:fTh
C
~
:()
A '---C::;:lJl~---.-.1
I ~~I
YTA4114Wl05
DBGl16BWB705

Open circuit
Power circuit (EGR control solenoid valve terminal A and main relay terminal D)
Ground circuit (EGR control solenoid valve terminal Band PCM terminal 177)
Short circuit
EGR control solenoid valve terminal A and main relay terminal D to ground
INTAKE SHUTTER SOLENOID VALVE (HALF) INSPECTION [WL-C, WE-C]
dcf01160000Ow05

If not as specified, replace the intake shutter valve (half).
If as specified, carry out the "Circuit Open/Short Inspection:'
0=0 : Airflow
Step
1
2
B
()
B+
GND
Port
Terminal
,,
YTA4114Wl05
,,,
,
,,
L __________________________________________________________ 1
DBG116BWB704

Open circuit
. Power circuit (intake shutter solenoid valve (half) terminal A and main relay terminal D)
Ground circuit (intake shutter solenoid valve (half) terminal Band PCM terminal 152)
Short circuit
Intake shutter solenoid valve (half) terminal A and main relay terminal D to ground
to,
01-168-6

INTAKE SHUTTER SOLENOID VALVE (FULL) INSPECTION [WL-C, WE-C]
dcf011600000w06

If not as specified, replace the intake shutter valve (full).
If as specified, carry out the "Circuit Open/Short Inspection."
0=0 : Airflow
Step
Terminal
A
B+
Port
~
GND
,,,
,,
,,
,,
,
YTA4114W105
L __________________________________________________________ 1
DBG116BWB704

Open circuit
Power circuit (intake shutter solenoid valve (full) terminal A and main relay terminal D)
Ground circuit (intake shutter solenoid valve (full) terminal Band PCM terminal 155)
Short circuit
Intake shutter valve (full) terminal A and main relay terminal D to ground
INTAKE SHUTTER VALVE INSPECTION [WL-C, WE-C]
dcf011600000w07
1. Disconnect the vacuum hose from the intake shutter valve.

2. Connect a vacuum pump to port A.
.-----------------------,
3. Apply vacuum and verify that the rod moves.
If the rod does not move, replace the intake
shutter valve.
Specification (WL-C)
r----------Vacuurn----------:----------------------------:
kPa {mmHg, inHg}
Rod movement
'
f----Seiow:::4 1:"3"0::"1~2} ----: --------Startto move -------:
: -Above-~25~3-f~ 190~ -~7 ~47} -: ---------Fully-pulle-ci --------:

L ____________________________ ~ ____________________________ ~
Specification (WE-C)
:----------Vac-uurn----------:----------------------------:
,
:
kPa {mmHg, inHg}
,
:
Rod movement
DBG116BWB706
'
:
r---Below :::3.-6 1:"2T:"1~ 1}---: --------Start-to move -------:

:L -Above
____________________________
-~2i9-f~209~ -~8~24} -: ---------Fully
____________________________
-pulled --------:
~
4. Connect a vacuum pump to port A and B.

5. Apply vacuum and verify that the rod moves.
If the rod does not move, replace the intake
shutter valve.
Specification (WL-C)
----------------------------,'
,r---------------------------Vacuum
~:
:L ________________________________________________________
kPa {mmHg, inHg}
Rod movement
~
:L ________________________________________________________
Above -40 {-300, -11.8}
Fully pulled
:
Specification (WE-C)
,r---------------------------Vacuum
:
kPa {mmHg, inHg}
----------------------------,'
Rod movement
DBG116BWB707
~-------------------------------------------------------~~
L ________________________________________________________
: Above -44 {-330, -13.0}
Fully pulled
01-168-7

ROLLOVER VALVE INSPECTION [WL-C, WE-C]
Note
The rollover valve cannot be disassembled and inspected as it is integrated in the fuel tank.
1. Perform the fuel tank inspection. (See 01-148-8 FUEL TANK INSPECTION [WL-C, WE-C].)
01-168-8
dcfO 1164272OW02
CHARGING SYSTEM
01-17
CHARGING SYSTEM
CHARGING SYSTEM
LOCATION INDEX . ................
BATTERY REMOVAUINSTALLATION ..
BATTERY INSPECTION .............
BATTERY RECHARGING . ...........
01-17-1
01-17-2
01-17-2
01-17-4
GENERATOR
REMOVAUINSTALLATION ......... . 01-17-4
GENERATOR INSPECTION . ......... . 01-17-5
GENERATOR
DISASSEMBLY/ASSEMBLY .. ...... . 01-17-8
CHARGING SYSTEM LOCATION INDEX
DBGl17ZWB004
Battery
(See 01-17-2 BATTERY REMOVAU
INSTALLATION.)
(See 01-17-4 BATTERY RECHARGING.)
Generator
(See 01-17-4 GENERATOR REMOVAU
INSTALLATION.)
(See 01-17-8 GENERATOR DISASSEMBLY/
ASSEMBLY.)
01-17-1
CHARGING SYSTEM
BATTERY REMOVAL/INSTALLATION
dcf01171852OW01

Negative battery cable
Positive battery cable
(See 01-17-2 Positive Battery Cable Installation
Note.)
Battery clamp
Battery
Battery tray
1
2
3
4
Nm {kgf.cm, inlbf}
DBG117ZWB002
Positive Battery Cable Installation Note

Note
Secure the positive battery cable to the battery clamp with the band.
BATTERY INSPECTION
dcf01171852OW02
Warning
Since battery acid is toxic, be careful when handling the battery.
Since battery acid is highly corrosive, be careful not to allow it to contact clothing or the vehicle.
In case battery acid contacts skin, eyes, or clothing, flush it immediately with running water.
EspeCially if the acid gets in the eyes, flush with water for more than 15 min and get prompt
medical attention.
'
Electrolyte specific gravity
1. Measure the electrolyte specific gravity using a hydrometer.
If it is less than the specification, recharge the battery. (See 01-17-4 BATTERY RECHARGING.)
1.22-1.29
Battery voltage
1. Inspect the battery as follows:
Step
1
Inspection
Measure the battery
positive voltage.
Quick charge for 30

min and recheck
voltage.
01-17-2
12.4 Vor
more
Less
than
12.4 V
12.4 Vor
more
Less
than
12.4 V
Action
Go to Step
3.
Go to the
next step.
Go to the
next step.
Replace the
battery.
CHARGING SYSTEM
Step
Inspection
Using the battery load
tester, apply load
current (see battery
load test current) and
record battery voltage
after 15 s. Is voltage
more than
specification?
Yes
No
Action
Normal
Replace the
battery.
65031 R (56): 165 A

75026R (52): 195 A
75026L (52): 195 A
95031 R (64): 250 A
Standard specification
Battery temp. (Oe eF})
4 {39}
10 {50}
16 {61}
21 {70}
Minimum voltage (V)

9.3
9.4
9.5
9.6
Back-up current
1. Verify that the engine switch is off (key has been removed) and that all doors are closed.
3. Connect the tester between the negative battery terminal and negative battery cable, leave the battery
undisturbed for 15 min., and then measure the back-up current.
If not within the specification, measure the back-up current while removing the fuses one by one from the
inside of the main fuse block and the inside of the fuse block.
Note
If the battery is not left undisturbed for 15 min., the tester will indicate a high value (approx. 200 mA).
If the key or any electrical accessory is operated within approx. 15 min. after the tester is connected, the
battery must be left undisturbed for approx. 15 min. from that point.
Caution
Operating electrical loads while the back-up current is being measured can damage the tester.
Note
For the vehicles with the immobilizer system, periodically shifts synchronization of the security light
flashing. Therefore, 25 rnA (0.1 s) current is supplied when the security light is illuminated, and 5 mA (2 s)
current is supplied when the security light is not illuminated. In addition, the measuring instrument, which
shows the average value, indicates around 10 rnA.
4. Inspect and repair wiring harnesses and connectors of the fuse where the current has decreased.
01-17-3
CHARGING SYSTEM
BATTERY RECHARGING
dcf01171852Ow03
Warning
Keep all flames away from the battery, otherwise evaporated gas from the battery fluid may catch
fire, and cause serious injury.
Remove the battery filler caps when recharging to prevent battery deformation or damage.
Caution
Do not quick charge for more than 30 min. It will damage the battery.
1. Remove the battery and then place it in a pan of
water.
2. Remove the battery filler caps.
3. Connect a battery charger to the battery and
adjust the charging current as follows.
65031 R (56): 4.0-5.0 A
75026R (52): 5.0-6.0 A
75026L (52): 5.0-6.0 A
95031 R (64): 6.5-8.0 A
Battery quick charge current [30 min]
650~1 R (56): 30 A
75026R (52): 35 A
75026L (52): 35 A
95031 R (64): 40 A
BATTERY
CHARGER
CHU0117W004
4. After the battery is recharged, verify that the

voltage is within the specification and remains at
the same value for 1 h or more after the recharging was completed.
If not within the specification, replace the battery.
Standard voltage
12.4 V or more
GENERATOR REMOVAUINSTALLATION
dcf01171830Ow01
Warning
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 negative cable before performing the following operation.
1.
2.
3.
4.

Inspect the drive belt deflection/tension. (See 0110A-3 DRIVE BELT INSPECTION [WL-3].) (See
01-10B-3 DRIVE BELT INSPECTION [WL-C,
WE-C].)
B terminal cable
Generator connector
3
4
Drive belt
Generator
(See 01-17-5 Generator Installation Note.)
N?m {kgf?m, ft?lb
01-17-4
DBG117ZWB003
CHARGING SYSTEM
Generator Installation Note
1. Tighten locknut A by hand.
2. Tighten mounting nut B.
Tightening torque:
12-25 Nm {123-254 kgf.cm, 107-221 inlbf}
3. Adjust the drive belt deflection or tension by turning adjusting bolt C. (See 01-1 OA-3 DRIVE BELT
INSPECTION [WL-3].) (See 01-10B-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
4. Tighten mounting nut B and locknut A.
GENERATOR INSPECTION
dcf011718300w02
Generator Warning Light

1. Verify that the battery is fully charged.
Charge if necessary.
2. Verify that the drive belt deflection/tension is within the specification. (See 01-10A-3 DRIVE BELT
3. Turn the engine switch on and verify that the generator warning light illuminates.
If not as specified, inspect the generator warning light, and wiring harnesses between the battery and the
generator warning light.
4. Verify that the generator warning light goes out after the engine is started.
If not as specified, inspect the generator.
Generator
Voltage
2. Verify that the drive belt deflection/tension is within the specification. (See 01-1 OA-3 DRIVE BELT
4. Turn the engine switch to start the engine and verify that the generator rotates smoothly without any noise while
the engine is running.
5. Measure the voltage at each terminal using a
tester.
GENERATOR
If not as specified, repair or replace the
generator if necessary.
Generator standard voltage [Engine switch
ON]
Terminal B: B+
Terminal S: B+
Generator standard voltage [Idle, 20C {S8
OF}]
Terminal B: 14.1-14.7 V
DBG117ZWB850
01-17-5
CHARGING SYSTEM
Current
Note
Since the charging current decreases rapidly after starting the engine, perform the following procedure
quickly, and read the maximum current value.
2. Verify that the drive belt deflection/tension is within the specification. (See 01-1 OA-3 DRIVE BELT
INSPECTION [WL-3].) (See 01-1 OB-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
4. Connect a tester, which can read 120 A or more, between generator terminal B and the wiring harness.
6. Start the engine and increase the engine speed to 2,000-2,500 rpm.
7. Turn the following electrical loads on and verify that the current reading increases.
(1) Headlights
(2) Blower motor
(3) Rear window defroster
If generator terminal B current does not increase, repair or replace the generator if necessary.
Note
Current required for generating power varies with the electrical loads applied.
13.5 V, Engine hot
Engine speed (rpm)
1,000
2,000

0-55 A
0-70 A
Generator Inner Parts

Rotor
1. Measure the resistance between the slip rings
using a tester.
If not as specified, replace the rotor.
Generator rotor resistance (between slip
rings) [20C {68 OF}]
2.3-2.7 ohms
CHU0117W005
2. Verify that there is no continuity between the Slip

ring and core using a tester.
If there is continuity, replace the rotor.
3. Inspect the slip ring surface condition.
If the slip ring surface is rough, use a lathe or
fine sandpaper to repair it.
CHU0117W006
01-17-6
CHARGING SYSTEM
Stator coil
1. Inspect for continuity between the stator coil leads
using a tester.
If there is no continuity, replace the stator.
2. Verify that there is no continuity between the

stator coil leads and the core using a tester.
If there is continuity, replace the stator coil.
CHU0117W008
Brush
1. Inspect brushes for wear.
If any brush is worn almost to or beyond the
limit, replace all of the brushes.
fE
t
S"[ANDARD
CHU0117W009
Brush spring
1. Measure the force of the brush spring using a spring pressure gauge.
2. Read the spring pressure gauge at the brush tip
,-----------;-------;----------,
projection of 2 mm {0.079 in}.
Replace the brush spring if necessary.
Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.081.34Ibf}
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
01-17-7
CHARGING SYSTEM
Rectifier
1. Inspect for continuity of the diodes using a tester.
If not as specified, replace the rectifier.
Specification
Tester
Negative
Positive
E
B
P1, P2, P3
P1, P2, P3
E
B
P1
Continuity
P2
Yes
No
No
Yes
P3
DPE117BW1003
P1
B
DPE117BW1004
Bearing
1. Inspect for abnormal noise, looseness, and
sticking.
Replace the bearing if necessary.
CHU0117W015
GENERATOR DISASSEMBLY/ASSEMBLY
dcf01171830Ow03
Caution
Melt the solder quickly, otherwise the diodes (rectifier) and regulator will be damaged by excessive
heat.

01-17-8
CHARGING SYSTEM
3
127-18.6
{13Q-189,113-164}
3.4-5.4
{3!C-55~
2.9-4.9~
{30-49,
26-43}
~
r~
98-137 Nm
{10.Q-13.9 kgfm,
73-101 ftlbf}
2.9-4.9
{30-49,
26-43}
{30-49,
26-43}
5
Nm {kgfcm, inlbf}
DBG117ZWB001
2
3
4
Front cover
Pulley
Rotor
Bearing
5 . Stator coil
6
7
8
Rectifier
Brush holder
Rear bracket
01-17-9
STARTING SYSTEM
01-19
STARTING SYSTEM
STARTING SYSTEM
LOCATION INDEX ................. 01-19-1
STARTER
REMOVAL/INSTALLATION [WL-3] .... 01-19-2
STARTER REMOVAL/
STARTER INSPECTION . ............ . 01-19-3
STARTER
DISASSEMBLy/ASSEMBLy ......... 01-19-8
STARTING SYSTEM LOCATION INDEX
DBG119ZWB003
Starter
(See 01-19-2 STARTER REMOVAUINSTALLATION
[WL-3].)
(See 01-19-2 STARTER REMOVAUINSTALLATION
[WL-C, WE-C].)
(See 01-19-3 STARTER INSPECTION.)
(See 01-19-8 STARTER DISASSEMBLY/
ASSEMBLY.)
01-19-1
STARTING SYSTEM
STARTER REMOVAUINSTALLATION [WL-3]
dcf01191840Ow01
Warning
When the battery cables are connected, touching the vehicle body with starter terminal B will
Always disconnect the negative battery cable before performing the following operation.
1. Remove the battery. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
1
Terminal B cable
Terminal S connector
Starter
(See 01-19-2 Starter Installation Note.)
38-51 {3.9-5.2,29-37}
3
Nm {kgfm, ftlbf}
DBG119ZWB002
Starter Installation Note

1. Temporarily tighten the installation bolts.
2. Tighten the installation bolts.
STARTER REMOVAUINSTALLATION [WL-C, WE-C]
dcf01191840Ow02
Warning
When the battery cables are connected, touching the vehicle body with starter terminal B will
Always disconnect the negative battery cable before performing the following operation.
2. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
3. Set the fuel filter component slightly out of the way. (See 01-14B-9 FUEL FILTER REMOVAUINSTALLATION
[WL-C, WE-C].)
4. Set the bracket that secure the intake shutter solenoid valve out of the way.
1
2
Terminal B cable
Terminal S connector
Starter
(See 01-19-3 Starter Installation Note.)
38-51 {3.9-5.2, 29-37}
9.8-11.7 Nm
{100_119 kgf.cm,
J~~71b'
~
~
3
Nm {kgfm, ftlbf}
DBG119ZWB002
01-19-2
i .'
STARTING SYSTEM
Starter Installation Note
1. Temporarily tighten the installation bolts.
2. Tighten the installation bolts.
STARTER INSPECTION
On-vehicle Inspection
2. The starter is normal if it rotates smoothly and without any noise when the engine is cranked.
If the starter does not operate, inspect the following:
Remove the starter, and inspect the starter unit.
Inspect the related wiring harnesses and the engine switch.
No-load test
2. Connect the starter, battery, and a tester as
3. Operate the starter and verify that it rotates
smoothly.
If the starter does not rotate smoothly, inspect
the starter unit.
4. Measure the voltage and current while the starter
is operating.
starter.
11 V
ENGINE SWITCH
TESTER
r---~~----~~A
TESTER T
V
: BATTERY
..L
DPEl19BW1003

130 A or less
Magnetic Switch Operation Inspection
Pull-out test
Note
Depending on the battery charge condition, the starter motor pinion may rotate while in a protracted state.
This is due to current flowing to the starter motor through the pull-in coil to turn the starter motor, and does
not indicate an abnormality.
1. Verify that the starter motor pinion is protracted
while battery positive voltage is connected to
terminal S and the starter body is grounded.
If flot pulled out, repair or replace the starter.
CHUOl19W023
Return test
1. Disconnect the motor wire from terminal M.
01-19-3
STARTING SYSTEM
2. Connect battery positive voltage to terminal M
and ground the starter body.
3. Pull out the drive pinion with a screwdriver. Verify
that it returns to its original position when
released.
If it does not return, repair or replace the
starter.
CHU0119W022
Pinion Gap Inspection

1. Pull out the drive pinion with the battery positive
voltage connected to terminal S and the starter
body grounded.
Caution
Applying power for more than 10 scan
damage the starter. Do not apply power
for more than 10 s.
CHU0119W023
2. Measure the pinion gap while the drive pinion is

pulled.
If not as specified, adjust with an adjustment
washer (between drive housing front cover
and magnetic switch).
Starter pinion gap
o mm {O in}
PINION GAP
"'
DPE119BW1005
Starter Inner Parts Inspection

Armature
1. Verify that there is no conductivity between the
commutator and the core at each segment using
a tester.
If there is conductivity, replace the armature.
01-19-4
STARTING SYSTEM
2. Verify that there is no conductivity between the
commutator and the shaft using a tester.
If there is conductivity, replace the armature.
3. Place the armature on V-blocks, and measure the

runout using a dial indicator.
0.1 mm {0.039 in} max.
CHU0119W018
4. Measure the commutator diameter.

If not within the minimum specification,
replace the armature.
CHU0119W019
5. Measure the segment groove depth of the

commutator.
undercut the grooves to the standard depth.
CHU0119W020
01-19-5
STARTING SYSTEM
Magnetic switch
1. Inspect for conductivity between terminals Sand
M using a tester.
If there is no conductivity, replace the
magnetic switch.
2. Inspect for conductivity between terminal Sand

the body using a tester.
If there is no conductivity, replace the
magnetic switch.
CHU0119W008
3. Verify that there is no conductivity between

terminals M and B using a tester.
If there is conductivity, replace the magnetic
switch.
TERMINAL M
TERMINAL B
CHU0119W009
Brush and brush holder

1. Verify that there is no conductivity between each
insulated brush and plate using a tester.
If there is conductivity, replace the brush
holder.
CHU0119W012
01-19-6
STARTING SYSTEM
2. Measure the brush length.
If any brush is worn almost to or beyond the
minimum specification, replace all the
brushes.

MINIMUM
BRUSH
LENGTH
CONTACT FACE WITH COMMUTATOR
3. Measure the brush spring force using a spring

balance.
replace the brush spring.

Standard: 26.7-36.1 N {2.73-3.68 kgf,
6.01-8.11 Ibf}
Minimum: 14.7 N {1.5 kgf, 3.3Ibf}
CHU0119W014
01-19-7
STARTING SYSTEM
STARTER DISASSEMBLY/ASSEMBLY
dcf01191840Ow04

6.9-12.7
{71-129,
62-112}
Nm {kgf.cm, inlbf}
DBG119ZWB001
1
2
3
4
5
6
7
8
Magnetic switch
Rear housing
Brush and brush holder
Armature
Yoke
Planetary gear
Front cover
Lever
01-19-8
10
11
Drive pinion
Internal gear
Gear shaft
01-408 CONTROL SYSTEM [WL-C, WE-C]

CONTROL SYSTEM
LOCATION INDEX [WL-C, WE-C] ...
CONTROL SYSTEM
WIRING DIAGRAM [WL-C, WE-C] ....
CONTROL SYSTEM
DIAGRAM [WL-C, WE-C] .........
PCM REMOVAL/INSTALLATION
[WL-C, WE-C] . . . . . . . . . . . . . . . .
PCM INSPECTION [WL-C, WE-C] ....
PCM CONFIGURATION
[WL-C, WE-C] .............
FUEL INJECTOR CODE PROGRAM
[WL-C, WE-C] .............
PCM DATA RESET [WL-C, WE-C] .....
DATA RESET [WL-C, WE-C] .....
MAIN RELAY INSPECTION
[WL-C, WE-C] ...............
MASS AIR FLOW (MAF) SENSOR!
SENSOR NO.2 INSPECTION
[WL-C, WE-C] . . . . . . . . . . . . . . . . .
[WL-C, WE-C] ....................
800ST SENSOR INSPECTION
[WL-C, WE-C] ...............
(APP) SENSOR INSPECTION
[WL-C, WE-C]. . . . . . . . . . . . . . . .
01-408-2
01-408-4
01-408-8
01-408-9
01-408-10
01-408-20
01-408-21
01-408-22
01-408-22
01-408-23
01-408-23
01-408-26
01-408-27
01-408-28
IDLE SWITCH INSPECTION

[WL-C, WE-C] ................ 01-408-30
(ECT) SENSOR REMOVAL/
INSTALLATION [WL-C, WE-C] ....... 01-408-34
(ECT) SENSOR INSPECTION
[WL-C, WE-C] ............... 01-408-35
CAMSHAFT POSITION (CMP)
SENSOR REMOVAL/
INSTALLATION [WL-C, WE-C] .... 01-408-36
INSPECTION [WL-C, WE-C] ..... 01-408-37
SENSOR REMOVAL/INSTALLATION
[WL-C, WE-C] .............. 01-408-38
SENSOR INSPECTION
[WL-C, WE-C] ................... 01-408-39
SWITCH INSPECTION
[WL-C, WE-C] ............. 01-408-42
NEUTRAL SWITCH INSPECTION
[WL-C, WE-C] ............... 01-408-43
01-408-1

CONTROL SYSTEM LOCATION INDEX [WL-C, WE-C]
dcf014000000w05
DBG140BWB107
PCM (8uilt into 8ARO sensor)

(See 01-408-9 PCM REMOVAUINSTALLATION
[WL-C, WE-C].)
MAF sensor/IAT sensor No.2

(See 01-408-23 MASS AIR FLOW (MAF) SENSOR/
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.2
800st sensor/IAT sensor No.1

(See 01-408-27 800ST SENSOR INSPECTION
[WL-C, WE-C].)
(See 01-408-26 INTAKE AIR TEMPERATURE (IAT)
01-408-2
ECT sensor
(See 01-408-34 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR REMOVAU
(See 01-408-35 ENGINE COOLANT
TEMPERATURE (ECT) SENSOR INSPECTION
[WL-C, WE-C].)
CKP sensor
SENSOR REMOVAUINSTALLATION [WL-C, WEC).)

CMP sensor
(See 01-408-36 CAMSHAFT POSITION (CMP)
SENSOR REMOVAUINSTALLATION [WL-C, WEC).)
(See 01-408-37 CAMSHAFT POSITION (CMP)
SENSOR INSPECTION [WL-C, WE-C).)
10
CPP sensor
(See 01-408-42 CLUTCH PEDAL POSITION (CPP)
SWITCH INSPECTION [WL-C, WE-C).)
11

12
Idle switch
(See 01-408-30 IDLE SWITCH INSPECTION [WLC, WE-C].)
main relay
(See 01-408-23 MAIN RELAY INSPECTION [WL-C,
WE-C].)

(See 01-408-40 EGR VALVE POSITION SENSOR
13

(See 01-408-32 FUEL TEMPERATURE SENSOR
APP sensor
POSITION (APP) SENSOR INSPECTION [WL-C,
WE-C].)
14
Neutral switch
(See 01-408-43 NEUTRAL SWITCH INSPECTION
[WL-C, WE-C].)
01-408-3

CONTROL SYSTEM WIRING DIAGRAM [WL-C, WE-C]
dcf014000000w06
.J:-+----{E
DLC
r---------r~-----++-~------------+_----------------~IG-
FEN
KLN
TEN
DLC-2
KLN
'-------I TEN
GLOW INDICATOR
LIGHT
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.4
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
FUEL
INJECTOR
NO.1
DBG 102BWBY01
01-408-4
RFWLOCK
SOLENOID
il---;-+...r VALVE
APP
SENSOR
RFWFREE
SOLENOID
VALVE
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMPSENSOR
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
Il--t--o 0--+--+-.... GLOW

BLOWER '-------'
MOTOR
.----------------------------------------,,,
REFRIGERANT
,,
PRESSURE
,,
SWITCH (LOW)
,,
~r--~~ ~-+~~
,,
,
AlC
,,,
COMPRESSOR
,,
,,
,
AlC RELAY
,,,
,,
PLUG
RELAY
- ---------------------------,
VARIABLE SWIRL :
CONTROL
,
SOLENOID VALVE :
:AlC
:SWITCH
,,
THERMO SWITCH
'- - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - -
DBG102BWBY02
01-408-5

-I:-+----{E
DLC
IG-
FEN
KLN
TEN
DLC-2
L...----1KLN
L-----1TEN
GLOW INDICATOR
LIGHT
~-+-------1r----------{
PCM
(BUILT INTO
BARO SENSOR)
VEHICLE
SPEED SIGNAL
FUEL
INJECTOR
NO.4
INSTRUMENT CLUSTER
FUEL
INJECTOR
NO.3
FUEL
INJECTOR
NO.2
IAT
SENSOR
NO.2
FUEL
INJECTOR
NO.1
DBG102BWBY03
01-408-6

C
- - - - - - - - - - - - - - - -WITH RFW -.
RFWLOCK
SOLENOID
:}---+--t:""J VALVE
APP
SENSOR
FUEL PRESSURE
SENSOR
BOOST
SENSOR
CMP SENSOR
ECT
SENSOR LJ.!-I----{
FUEL
TEMPERATURE
SENSOR
EGRVALVE
POSITION
SENSOR
CKPSENSOR
PCM
D
F
n---+--o
0--+--1-... GLOW
BLOWER '-------'
MOTOR
PLUG
RELAY
------- ---------------------------------
REFRIGERANT
:
PRESSURE
:
SWITCH (LOW) ,-----,:
O--~.~~
AlC
COMPRESSOR
- ---------------------------.
VARIABLE SWIRL:
CONTROL
:
SOLENOID VALVE :
'-------':
AlC RELAY'
:AlC
:SWITCH
THERMO SWITCH
'- - - - - - - - - - - - - - - WITH AlC - - - - - - - - - - - - - - DBG102BWBY02
01-408-7

CONTROL SYSTEM DIAGRAM [WL-C, WE-C]
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-----.. : FUEL FLOW
GLOW INDICATOR LIGHT -j
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---- CPP SWITCH

---- AlC RELAY
EGRVALVE
APP
IDLE
SENS~CH
ACCELERATOR
PEDAL
VARIABLE SWIRL CONTROL VALVE

TO VACUUM RESERVER TANK
FOR BRAKE SYSTEM
DBG140BTB002
01-408-8

PCM REMOVAUINSTALLATION [WL-C, WE-C]
dcf014018880w09
Note
If the PCM is replaced, always perform each adjustment procedure using the following steps.
1. Disconnect the battery negative cable.

2. Remove the passenger's side front side trim.
1
2
3
PCM Connector
PCM
Bracket
7.8-10.8 Nm
7.8-10.8 Nm
{80-110 kgf.cm,
69.0-95.5 inlbf}
DBG140BWB850
01-408-9

PCM INSPECTION [WL-C, WE-C]
dcf014018880w10
Without Using the current diagnostic tool

Note
The PCM terminal voltage can vary with the conditions when measuring and changes due to aged
deterioration on the vehicle, causing false diagnosis. Therefore determine comprehensively where the
malfunction occurs among the input systems, output systems, and the PCM.
PCM
219218217216215214213212211210209208207
232 231 230 229 228 227 226 225 224 223 222 221 220
245 244 243 242 241 240 239 238 237 236 235 234 233
258 257 256 255 254 253 252251 250 249 248 247246
DBG140BWB001
Terminal voltage table (Reference)

Terminal
Signal
Connected to
101
Fuel injector (#3)
Fuel injector No.3
102
Fuel injector (#2)
Fuel injector No.2
103
104
105
106
Constant voltage
107
108
Test condition
Approx.5
Constant voltage
Fuel pressure
sensor
Engine switch ON
Approx.5
110
Ground
EGR valve position

sensor
Under any condition
Below 1.0
Ground
BoosVIAT sensor
No.1
112
113
114
115
Ground
Fuel temp
01-408-10
Below 1.0
Fuel temperature
sensor
Under any condition
Engine switch
ON
Below 1.0
Fuel
temperature
40C {1 04 OF}
Approx.
2.5
Fuel
temperature
45C {113 OF}
Approx.
2.3
Inspect related
wiring harness
EGR valve position
sensor
CMP sensor
Under any condition
Engine switch ON
Inspect related
wiring harness
Fuel injector No.3
Inspect related
wiring harness
Fuel injector No.2
109
111
Inspection item
Inspect using the wave profile.

(See 01-40B-16 Inspection Using An
Oscilloscope (Reference).)
EGR valve position

sensor
Voltage
(V)
Inspect related
wiring harness
Fuel pressure
sensor
Inspect related
wiring harness
EGR valve position
sensor
Inspect related
wiring harness
BoosVIAT sensor
No.1
-
Inspect related
wiring harness
CMP sensor
Inspect related
wiring harness
Fuel temperature
sensor

Terminal
116
Signal
EGR position
117
118
Engine switch ON
Voltage
(V)
Below 1.0
EGR valve opening angle 40%
Approx.2
Test condition
Connected to
EGR valve
Inspection item
Inspect related
wiring harness
EGR valve
119
120
121
122
123
124
125
Fuel injector (#1)
Fuel injector No.1
126
Fuel injector (#4)
Fuel injector No.4
127

-
AlC
AlC relay
129
Constant voltage
CMP sensor
AlC not operating
B+
Engine switch ON
Approx.5
130
131
132
133
Constant voltage
134
135
neutral switch
136
137
BoostilAT sensor
No.1
4x4 indicator switch 4x4 indicator switch

-
139
141
Fuel pressure
Fuel pressure
sensor
BoostilAT sensor
No.1
IAT
142
143
144
145
146
147
148
Approx.5
Except above
-
Except above
Inspect related
wiring harness
BoostilAT sensor
No.1
-
Below 1.0
B+
Inspect related
wiring harness
Transfer neutral
switch
-
B+
Below 1.0
Inspect related
wiring harness
AlC relay
Inspect related
wiring harness
CMP sensor
Transfer shift lever 2H position
Inspect related
wiring harness
Fuel injector No.4
Transfer shift lever neutral

position
138
140
Transfer neutral
switch
Engine switch ON
Inspect related
wiring harness
Fuel injector No.1
Below 1.0
AlC operating
128
Inspect related
wiring harness
-
Engine speed is 2,800 rpm
Approx.
1.2
Approx.
2.5 .
IAT 30C
{86 OF}
Approx.
1.9
IAT 50C
{122 OF}
Approx.
1.2
Inspect related
wiring harness
BoostilAT sensor
No.1
Idle
Engine switch
ON
Inspect related
wiring harness
Fuel pressure
sensor
01-408-11

Signal
Terminal
149
150
Fuel injector (#2)
Fuel injector (#4)
151
Connected to
Test condition
Voltage
(V)
Fuel injector No.2

Fuel injector No.4

Intake shutter
Intake shutter
solenoid valve (half) solenoid valve (half) Idle
153
155
Intake shutter
solenoid valve (full)
Engine switch ON
156
Ground
ECT sensor
Under any condition
159
160
161
CMP
CMP sensor
Idle switch
162
163
164
165
166
167
Under any condition
Inspect related
wiring harness
Intake shutter
Inspect related
wiring harness
ECT sensor
B+
Below 1.0
Idle
Inspect related
wiring harness
CMP sensor
Inspect related
wiring harness
Idle switch
-
ECT sensor
MAF/IAT sensor
No.2
170
Ground
Fuel temperature
sensor
171
CAN (L)
Fuel injector (#3)
01-408-12
Inspect related
wiring harness
MAF/IAT sensor
No.2
Ground
173
Inspect related
wiring harness
Intake shutter
solenoid valve (half)
172

-"".-
Engine switch
ON
ECT 30C
{86 OF}
Approx.
2.6
ECT 40C
{104 OF}
Approx.
2.1
ECT 50C
{122 OF}
Approx.
1.8
Approx.
1.4
ECT 60C
{140 OF}
169
Below 1.0
Inspect related
wiring harness
Fuel injector No.4
B+
Inspect related
wiring harness
Fuel injector No.2
ECT
168
Below 1.0
Engine switch On
Idle
Intake shutter
MAF/IAT sensor
No.2
B+
B+
(WL-C)
Ground
Below 1.0
(WE-C)
154
157
158
Engine switch ON
152
Inspection item
Fuel injector No.3
Under any condition
Below 1.0
Under any condition
Below 1.0
Because this terminal is for CAN, no valid

determination of terminal voltage is possible

Inspect related
wiring harness
ECT sensor
Inspect related
wiring harness
MAF/IAT sensor
No.2
Inspect related
wiring harness
Fuel temperature
sensor
Inspect related
wiring harness
-
Inspect related
wiring harness
Fuel injector NO.3

Terminal
174
Signal
Fuel injector (#1)
Connected to
Fuel injector No.1
175
Test condition
EGR solenoid valve EGR solenoid valve
177
EGR control
solenoid valve
178
VBC solenoid valve VBC solenoid valve
179
182
Variable swirl
control solenoid
valve
Glow
185
Idle
B+
Approx.
3.5
Idle
Variable swirl
control solenoid
valve
Glow plug relay
Vehicle speed
B+
Below 1.0
RFW switch
186
187
Engine switch ON
Approx.
3.3
13 s from when engine switch is

turned to ON position with ECT at
20C {68 OF} or less
RFW Switch
Idle (2m or more after engine is

started)
Below 1.0
RFW"LOCK"
Below 1.0
RFW"FREE"
B+
Approx.
1.2
MAP
BoosVIAT sensor
No.1
Engine switch ON
Approx.
1.6
Engine switch ON
Below 1.0
Idle
Approx.
1.8
MAF
MAF/IAT sensor
No.2
191
Ground
Fuel pressure
sensor
Under any condition
192
CKP
CKP sensor

CKP sensor

Ground
CKP sensor
Under any condition .
Below 1.0
Below 1.0
Inspect related
wiring harness
EGR solenoid valve
Inspect related
wiring harness
EGR control
solenoid valve
Inspect related
wiring harness
VBC solenoid valve
Inspect related
wiring harness
Fuel Metering Valve
Inspect related
wiring harness
Variable swirl
control solenoid
valve
Inspect related
wiring harness
Glow plug relay
Inspect related
wiring harness
VSS
Inspect related
wiring harness
RFW switch
IAT 50C
{122 OF}
189
Engine switch
ON
194
MAF/IAT sensor
No.2
CKP
Approx.
1.9
IAT
193
IAT 30C
{86 OF}
188
190
B+

Inspect related
wiring harness
Fuel injector No.1
VSS
Engine switch ON
183
184

Fuel Metering Valve Fuel Metering Valve (See 01-40B-16 Inspection Using An
180
181
EGR control
solenoid valve
Inspection item

Engine switch ON
176
Voltage
(V)
Inspect related
wiring harness
MAF/IAT sensor
No.2
Inspect related
wiring harness
Boost sensor
Inspect related
wiring harness
MAF/IAT sensor
No.2
Inspect related
wiring harness
Fuel pressure
sensor
Inspect related
wiring harness
CKP sensor
Inspect related
wiring harness
CKP sensor
Inspect related
wiring harness
CKP sensor
01-408-13

Signal
Terminal
195
CAN (H)
196
Connected to .
Test condition
Because this terminal is for CAN, no valid

determination of terminal
201
B+
Main relay
202
Ground
Body ground
203
B+
Main relay
204
Ground
Body ground
205
B+
Main relay
206
Ground
Body ground
Under any condition
Below 1.0
Main relay ON
B+
Main relay OFF
Below 1.0
Under any condition
Below 1.0
Main relay ON
B+
Main relay OFF
Below 1.0
Under any condition
Below 1.0
Accelerator pedal released

Accelerator pedal depressed
210
211
Below 1.0
Approx.
3.6
212
Ground
APP sensor
Under any condition
Below 1.0
213
Constant voltage
APP sensor
Engine switch ON
Approx.5
216
217
218
Inspect related
wiring harness
APP sensor
-
Inspect related
wiring harness
APP sensor
Inspect related
wiring harness
APP sensor
-
APP
Main relay
APP sensor
Engine switch ON
Below 1.0
Engine switch OFF
B+
Accelerator pedal released
Below 1.0
Accelerator pedal depressed
Approx.
3.6
Inspect related
wiring harness
Main relay
Inspect related
wiring harness
APP sensor
IG 1
Diagnostic test
mode
01-408-14
226
Inspect related
wiring harness
Inspect related
wiring harness
Main relay
Inspect related
wiring harness
220
221
225
Inspect related
wiring harness
Main relay
Main relay control
223
224
Inspect related
wiring harness
219
222
Below 1.0
215
Inspect related
wiring harness
Main relay
Main relay OFF
214
Inspect related
wiring harness
APP sensor
B+
208
APP
Inspection item
Main relay ON
207
209
Voltage
(V)
Engine switch
Data link connector
(DLC) (Terminal
TEN)
Engine switch is ON and Start

position
B+
Engine switch is other position
Below 1.0
Engine switch
ON
Open terminal
TEN
B+
Short terminal
TEN
Below 1.0
Inspect related
wiring harness
Inspect related
wiring harness

Terminal
Signal
Connected to
Test condition
For less than

approx.13
seconds after
B+
turning engine
switch ON.
Over approx. 13
seconds after
Below 1.0
turning engine
switch dN.
For less than 2
minutes starting
B+
engine.
ECTis below
60C {140 OF}
227
Glow system
Over 2 minutes
after starting
engine.
Glow relay
While cranking
For less than
approx.4
seconds after
turning engine
switch ON.
Over approx. 4
seconds after
turning engine
switch ON.
While cranking
ECT is above
60C {140 OF}
228
Clutch
CPP switch
229
Clutch pedal released

Clutch pedal depressed
Voltage
(V)
Below 1.0
Inspection item
Inspect related
wiring harness
Glow relay
B+
B+
Below 1.0
Below 1.0
B+
Below 1.0
Inspect related
wiring harness
CPP switch
-
230
Coil
(Immobilizer
system)
Immobilizer-related
information
No valid determination of terminal voltage is

possible
Inspect related
wiring harness
DTC output
Data link connector

(DLC) (Terminal
TEN)
No DTC output
231
Inspect related
wiring harness
Inspect related
wiring harness
Instrument cluster
(4x4 indicator light)
232
233
4x4 indicator light
234
235
IG 1
236
237
238
4x4 indicator light
4x4 indicator light OFF
Below 1.0
4x4 indicator light ON
B+
Below 1.0
Engine switch OFF

Engine switch is ON and within
approx. 0.5 sec. (25C {77 OF})
Over 0.5 seconds (25C {77 OF})
after turning engine switch ON
-
Engine switch ON
B+
B+
Brake light
Brake light
Thermo switch
240
Neutral
Neutral switch
brake pedal released

brake pedal depressed
AlC operating
Shift lever neutral position

Except shift lever neutral position
B+
Below 1.0
B+
Inspect related
wiring harness
Engine fuse
B+
Inspect related
wiring harness
Below 1.0
Below 1.0
AlC not operating
Thermo
242
Below 1.0
239
241
DTC output
Engine fuse
B+
Inspect related
wiring harness
Brake light
Inspect related
wiring harness
Thermo switch
Inspect related
wiring harness
Neutral switch
01-408-15

Terminal
Signal
-
243
Connected to
Voltage
(V)
Test condition
-
RFW indicator light
245
246
247
248
249
250
251
252
253
LOCK indicator light
Below 1.0
Free solenoid valve
Free solenoid valve
255
258
Inspect related
wiring harness
Instrument cluster
(LOCK indicator
light)
Lock solenoid valve Lock solenoid valve
Malfunction
indicator light
MIL
257
LOCK indicator light ON
254
256
B+
LOCK indicator light OFF

244
Inspection item
RFW main switch
Lock solenoid valve operating
B+
Lock solenoid valve not operating

Free solenoid valve operating
Below 1.0
Free solenoid valve not operating
B+
Below 1.0
Malfunction indicator light OFF
B+
Inspect related
wiring harness
Malfunction
indicator light
RFW main switch released (OFF)

B+
RFW main switch depressed
Below 1.0
(ON)
Inspection Using An Oscilloscope (Reference)

Fuel injector signal
PCM terminals
Fuel injection (#1): 125, 174 (+)-body ground
Fuel injection (#3): 101,173 (+)-body ground
Oscilloscope setting
20 V/DIV (Y), 20 ms/DIV (X), DC range
Vehicle condition
Idle after warm up
Inspect related
wiring harness
Lock solenoid valve
Inspect related
wiring harness
Free solenoid valve
-
Malfunction indicator light ON
RFW main switch
Below 1.0
Inspect related
wiring harness
RFW main switch
(-)
(-)
(-)
(-)
1
,
1
1
- -I- - -1- - " 1 - -
1
1
,
1
1
1
- -I- - -1- - -1- - -I - - .. - I

I
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- -r - -,- -.,--
- -r- - -1- - . , - - , - - T - -
1
- -r1 - -1-1 -"1--
- -r -
1
1
,
- _1- __ , ___I __
1
I
I
I
1
I
I
I
I
I
I
-1- - ., - - , - - 1 - I
I
I
I
--:- --:- --:- - ~ --+-I
DBG140BWB105
CMP signal
PCM terminals
160 (+)-body ground (-)
Vehicle condition
Idle after warm up
1
1
1
1
1
1
- -1- --1- - , - -
__ I ___ I __
_ _ 1___ I__
J __
J
,...----,
_ _1
I.. __ 1, __ ..I1
ov ..
1
1
1
1
,
,
-->---1---<
1
1
1
1
1
1
- -t- - -11
-"'1--
1
1
1
--r--,--,-1
1
1
1
1
,
1
,
1
1
- -r - -,- - -.-- _1- __ 1___, __
I
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__ 1___ 1__
I
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I
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__ L __ I__
--1---1--
_-1 __ .... __
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I
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"i -
DBG140BWB101
01-408-16

VBC solenoid valve signal
PCM terminals
178 (+)-body ground H
Vehicle condition
Idle after warm up
I
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I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
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I
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I
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I
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I _ I __
__
I
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1
I
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- -r - -,- - , - - , -
I
I
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I
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I
I
-"T - - T - - i - - , - -,- - . . , - - , - -"T - I
I
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t i l
- -,- - -,- - -,- -,- -, - - r - - r - -.- - -,- -1-- 1
- -, --
--:- --:- --:- - ~ --4 -- +-- t --:- --:- --:- --{- -4--
Fuel Metering Valve signal

PCM terminals
Vehicle condition
Idle after warm up, AlC ON
I
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I
I
I
I
I
I
I
I
I
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,
,
I
,
I
,
I
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I
,
,
I
,
I
I
,
I
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I
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I
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I
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1
~_
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I
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ov" -"
I
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__ L
__1I__ J , __ J1 __ l1 __
--~-~--~--~--+--~--~--~-~--~--~--+-I
I
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1
1
I
I
I
1
I
1
I
1
l i t
1
I
I
- -r - -,- - ,- -, - -
'T - -
- -.- - -,- -"1- - , - - i - -
til
r - - r - -r -
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-r --
r -- r --.- --,- -,- -, -- i
--
- -:- - -:- - -:- - -i -- t -- t - - ~ - -:- - -:- - -:- -,- -1-DBG140BWB103

PCM terminals
1 V/DIV (Y), 2.5 ms/DIV (X), DC range
Vehicle condition
Vehicle speed is 32 km/h {20 mph}.
l i t
t + ~ ~! -~
--r-'--'--'--T--r--r--r-'--,--'--T-r
4
I
-t
~ ~:- ~ ~;~ ~ !~+- ~ t~ ti- ~

I
,
1
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ov .. ~:
,
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1
1
,
,
.J _ _ _ _ ..L
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1
1
1
1
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- -r - -,- -.,- -"1 -
1
1
1
,
- 'T - - T - -
- -.- - -,- -1- - , - - i - - T - -
'1
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--1- ~ ,--i ~ ~--:~

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1
1
H I
~-1
r - -, - -,- -.,- -, - -
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i --
1
I
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,
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I
I
1
I
,
- -:- - -:- - -:- -,- - t - - t - - ~ --:- - -:- - -:- -,- - t -I
DBG140AWB184
CKP signal
PCM terminals
192, 193 (+)-body ground (-)
Vehicle condition
Idle after warm up
,
I
I
I
t i l
1
I
1
I
I
t
I
I
1
1
1
1
1
r
,
--r--r--'--'--T--r--r--r--I--,--'--T---:-r - -:- --:-, - ~ -~:
- -. - -(- - -:- - -:- -,- - -i - - +-i-:
~ - - +- - t 1- 1
OV..
[I
__ L
j , j t ~,
I
I
1
I
I
1
,
1
1
,
I
I
1
-:
1
'
__
-,~ ~ ~ ~
1
1
1
1
1
1
tIl
til
- - , - -,- - , - - , - - 'T - -
r - - r - -, -
1
1
[
1
1
,
-1- - . , - - , - -
1
I
-r -I
- -:- - -:- -~- - -i - - t -- t - - ~ - -~ - -:- -~- -~ - - t -- -:- - -:- --:- -,- - t - -t - - ~ - -:- - -:- - -:- -,- - t -I
DBG140BWB104
01-408-17

Using the current diagnostic tool
Caution
The PCM terminal voltage 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, diagnosis will be incorrect.
Note
PIDs for the following parts are not available on this model. Go to the appropriate part inspection page.
Fuel injector
CMP sensor
EGR solenoid valve
IAT sensor No.2
1. Connect the current diagnostic tool to the DLC. (See 01-02B-7 ON-BOARD DIAGNOSTIC TEST [WL-C, WEC].)
2. Measure the PID value .
If PID value is not within the specification, follow the instructions in ACTION column.
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.
For input/output signals except those of the monitoring items, use a voltmeter to measure the PCM
terminal voltage.
The simulation items that are used in the ENGINE CONTROL SYSTEM OPERATION INSPECTION are
as follows.
- ACCS, EGRV2, GP_LMP, GPC, IASV, IASV2, INL1, INJ_2, INJ_3, INL4, SEGRP, VBCV
PIO Monitor Table (Reference)
Monitor item
(Definition)
AAT
(Ambient temperature)
AC_REQ
(AIC request signal)
Unit/Condition
Condition/Specification (Reference)
Inspection item
Ambient temperature
PCM
terminal
On/Off
Refrigerant pressure switch is off: Off

Others: On
AlC switch
239
ACCS
(Air conditioning
compressor cycling
switch)
On/Off
AlC switch ON and fan switch ON: On

Others: Off

START_SW, CPP, CPP/PNP,
IVS, AC_REQ, APS1, APS2,
ECT, RPM
128
APP
(Accelerator pedal
position)
Accelerator pedal released: 0 %

Accelerator pedal depressed: 100 %
Inspect following PIDs: APP1 ,

APP2
209,222
Accelerator pedal
Accelerator pedal
Accelerator pedal
Below 1.0 V
Accelerator pedal
Approx. 3.6 V
%
APP1
(Accelerator pedal
position sensor No.1 )
APP2
(Accelerator pedal
position sensor No.2)
ARPMDES
(Target engine speed)
BARO
(Barometric pressure)
01-408-18
released: 0%
depressed: 100%
released:
Accelerator pedal released: 0%

Accelerator pedal depressed: 100%
Accelerator pedal released:

Below 1.0 V
Accelerator pedal depressed:
Approx. 3.6 V
kPa Bar

AlC ON: 725-775 rpm
I psi
222
APP sensor
209
depressed:
RPM
APP sensor

IVS, AC_REQ, IAT, IAT2, ECT,
BOOST_DSD, FRP, FRP_A,
RPM,VSS
BARO sensor
Indicate Barometric pressure

BARO 103 kPa {1.03 Bar, 14.9 psi}:
Approx. 4.0 V
.'

Monitor item
(Definition)
Unit/Condition
BOO
(Brake switch)
On/Off
CPP
(CPP switch)
On/Off
DTCCNT
(DTC count)
Brake pedal released: Off
Brake pedal depressed: On
Clutch pedal released: On
Clutch pedal depressed: Off
Number of DTCs stored in the PCM is
displayed.
Engine coolant temperature is displayed
ECT 30C {86 OF}: Approx. 2.6 V
PCM
terminal
Inspection item
Brake switch
238
CPP switch
228
Perform applicable DTC

troubleshooting.
Inspect ECT sensor.
167
Engine switch ON: ON

Idle: OFF
Inspect EGR control solenoid

valve.
177
Engine switch ON: 1.35 A

Idle: Approx. 1.45 A
Engine switch ON: 14.6 %
Idle: 37.6 %
179

IVS, AC_REQ, IAT1, IAT2, ECT,
BOOST_DSD, FRP, FRP _A,
RPM,VSS
FIP_SCV
(Fuel metering valve)
Engine switch ON: Approx. 580 mA

Idle: 1.45 A

IVS, AC_REQ, IAT1, IAT2, ECT,
BOOST_DSD, FRP, FRP _A,
RPM, VSS
179
FLT
(Fuel temperature)
Fuel temperature is displayed.
115
ECT
(Engine coolant
temperature)
EGRV2
(EGR control solenoid
valve)
FIP_FL
(Supply pump flow
control)
On/Off
Engine switch ON: 0 kPa {O psi, 0 Bar}

FRP
kPa Bar
(Fuel pressure sensor)
GP_LMP
(Glow indicator light)
On/Off
GPC
(Glow plug relay)
On/Off
IASV
(Intake shutter
solenoid valve (half))
On/Off
IASV2
(Intake shutter
solenoid valve (full))
On/Off
IAT
(Intake air
temperature (lAT
sensor No.1))
INGEAR
(Load/no load
condition)
IVS
(Idle switch)
LOAD
(Engine load)
MAF
(Mass airflow amount)
psi
Idle: Approx. 32 MPa (WL-C),

Approx. 33 MPa {330 Bar, 4,786 psi}
(WE-C)
2,000 rpm: Approx. 58 MPa {580 Bar,
8,412 psi}
Glow indicator light Off: Off
Glow indicator light ON: On
13s from when engine switch is turned
to ON position with ECT at 20 C{68 OF}
of less
ECT, BOOST_DSD, VSS
Cranking: On (ECT at 60 O{140 OF} or
less)
Idle: Off (2m or more after engine is
started)
Engine switch ON: OFF
Idle: OFF (WL-C), ON (WE-C)
140
233
182
152
Intake air shutter valve
Engine switch ON: OFF
30C {86 OF}: Approx. 1.4 V

50C {104 OF}: Approx. 1.2 V
Intake air temperature is display
On/Off
Idle/Off Idle
%
g/s
V
Neutral: On
Others: Off
CTP: Idle
Others: Off Idle
Engine switch ON: 0%
Idle: Approx. 22 %
Engine switch ON: 2 g/s
Idle: Approx. 8 g/s
Engine switch ON: Below 1.0 V.
Idle: Approx. 1.76 V
155
IAT sensor
141
Inspect following PIDs: CPP
240
APP sensor
161
MAF sensor
MAF sensor
190
01-408-19

Monitor item
(Definition)
MAP
(Boost sensor)
MIL
(Malfunction indicator
lamp)
MIL_DIS
(The distance travelled
since the MIL was
activated)
RPM
(Engine speed)
SEGRP DSD
(Desired EGR valve
position)
SELTESTDTC
(Diagnostic trouble
codes)
VBCV
(VBC solenoid valve)
VPWR
(Module supply
voltage)
VSS
(Vehicle speed)
Unit/Condition
kPa Bar
I psi
V
On/Off
Km
Manifold absolute pressure is displayed
Engine switch ON: Approx. 1.65 V
Idle: Approx. 1.65 V
Engine switch ON: On
Idle: Off
Inspection item
PCM
terminal
MAP sensor
189

troubleshooting.
256
Indicate the travelled distance since the MIL illuminated
Engine switch ON: 0 RPM

rpm
Idle
I No load: 695-745 rpm
CKP sensor
193
Desired SEGRP valve position

troubleshooting
178
AlC ON: 725-775 rpm
Engine switch ON: Approx. 4.68 %

Idle: Approx. 78 %
Engine speed 2,000 rpm: Approx. 94 %
Engine switch ON: Approx. 4.99 %

Idle: Approx. 79 %
Inspect following PIDs: IVS,

MAF, ECT, RPM
Inspect VBC solenoid valve.
Indicate the battery positive voltage
Battery
Main relay
Vehicle speed is displayed

troubleshooting.
km/h
PCM CONFIGURATION [WL-C, WE-C]
201,
203,205
184
dcf014018880w03
Using PDS/IDS
1. Connect the PDS/IDS to DLC-2.
1. Select the "Module Programming".
1. Select "Programming".
2. Select "Module Programming".
3. Then, select the "Programmable Module
Installation", "PCM" and perform procedures
DBG110BWBA01
Note
If the PCM is replaced with a new one, the
PCM stores DTCs P0602 and P1675, illuminates the MIL even though no malfunction is detected. When
the configuration is completed, DTCs P0602 and P1675 are cleared.
4. Retrieve DTC's using the PDS/IDS, then verify if DTCs are present.
If a DTC is present, perform the applicable DTC inspection.
01-408-20
CONTROL SYSTEM [WL-C, WE .. C]

Using WDS
1. Connect the WDS to DLC-2.
2. Set up the WDS (including the vehicle
recognition).
3. Select "Module Programming."
4. Select "Programmable Module Installation."
5. Select "PCM" and perform procedures according
to directions on the WDS screen.
Note
If the PCM is replaced with a new one, the
PCM stores DTCs P0602 and P1675,
illuminates the MIL even though no
malfunction is detected. When the
configuration is completed, DTCs P0602
and P1675 are cleared.
6. Retrieve DTC's using the WDS, then verify if DTCs are present.
FUEL INJECTOR CODE PROGRAM [WL-C, WE-C]
Using PDS/IDS
1. Select the "Module Programming".
1. Select "Programming".
3. Then, select the "Programmable Parameters",
"Injector Correction Factors" and perform
IDS screen.
4. Retrieve DTC's using the PDS/IDS, then verify if
DTCs are present.
Using WDS
recognition).
4. Select "Programmable Parameters".
5. Select "Injector Correction Factors" and perform
procedures according to directions on the WDS
screen.
6. Retrieve DTC's using the WDS, then verify if
DTCs are present.
If a DTC is present, perform the applicable
DTC inspection.
DBG110BWBA01
DBG110BWBA01
01-408-21

PCM DATA RESET [WL-C, WE-C]
Using PDS/IDS
'2. After the vehicle is identified, select the following
2. Select the "Data Reset".
2. Select "Data Reset".
3. Then, select the "PCM" and perform procedures
4. Perform the data reset according to the directions
on the PDS/IDS screen.
5. Retrieve DTC's using the PDS/IDS, then if that
DTCs are present.
dcf014018880w05
DBG110BWBA01
Using WDS
recognition).
3. Select "Powertrain".
5. Select "PCM" and perform procedures according
to directions on the WDS screen.
DTCs are present.
DTC inspection.
DBG110BWBA01
MASS AIR FLOW (MAF) SENSOR DATA RESET [Wl-C, WE-C]

Using PDS/IDS
2. Select the "Data Reset".
3. Then, select the "MAF sensor" and perform
IDS screen.
4. Perform the data reset according to the directions
on the PDS/IDS screen.
5. Retrieve DTC's using the PDS/IDS, then verify if DTCs are present.
01-408-22
dcf014018880w06
DBG110BWBA01

Using WOS
recognition).
3. Select "Powertrain".
5. Select "MAF sensor" and perform procedures
according to directions on the WDS screen.
DTCs are present.
DTC inspection.
MAIN RELAY INSPECTION [WL-C, WE-C]
1. Verify the continuity between the main relay

terminals.
0-0 : Continuity
Step
Terminal
-0
B+
GROUND
-0
DBG113BWB321

main relay.
MAIN RELAY
rcfAl
[ill]
DBG113AWB3R
MASS AIR FLOW (MAF) SENSORIINTAKE AIR TEMPERATURE (IAT) SENSOR NO.2 INSPECTION [WL-C,
WE-C]
dcf014013215w02
Note
Perform the following inspection only when directed.
MAF Sensor Voltage Inspection
2. Set the current diagnostic tool and monitor the MAF PID.(See 01-028-8 PID/DATA Monitor And Record
Procedure.)
If not as specified, perform the "Circuit Open/Short Inspection".
If there is no open/short circuit, replace the MAF sensor/IAT sensor No.2.01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
MAF PIO (Reference)
below 1.0 V
3. Start the engine and warm up the engine completely.

4. Monitor the MAF PID at idle.
If there is no open/short circuit, replace the MAF sensor/IAT sensor No.2.01-138-3INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
MAF PIO (Reference)
1.6-2.0 V
01-408-23

1. Disconnect the MAF sensor/lAT sensor No.2 connector.
2. Disconnect the PCM connector.(See01-40B-9 PCM REMOVAUINSTALLATION [WL-C, WE-C]
If there is an open or short circuit, repair or
r----------------------,
replace wiring harnesses.
~EIDmBIA~
I~~I
DBG140AWB302
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (MAF sensor/lAT sensor No.2 connector terminal A and main relay connector terminal D)
Signal circuit (MAF sensor/lAT sensor No.2 connector terminal C and PCM connector terminal 190)
Ground circuit (MAF sensor/lAT sensor No.2 connector terminal Band PCM connector terminal 169)
Short circuit
MAF sensor/lAT sensor No.2 connector terminal A and main relay connector terminal D short to ground
MAF sensor/lAT sensor No.2 connector terminal C and PCM connector terminal 190 short to ground
IAT Sensor No.2 Resistance Inspection
1. Disconnect the MAF sensor/lAT sensor No.2 connector.
01-408-24

2. Measure the resistance between MAF sensor/IAT
sensor No.2 terminals D and E using an
ohmmeter.
If not as specified, replace the MAF sensor/
IAT sensor NO.2.
Short Inspection".
30
20 ~
E
.c
Specification
Ambient temperature (Oe eF})
Resistance (kilohm)
20 {68}
60 {140}
2.21-2.69
0.493-0.667
~
w
()
z
~
en
10
7
5
13.6-18.4 kilohm
~"
!'\.~
\..~
3
2
~ ~ 2.21-2.69 kil ohm
Ci5
w
a:
0.7
0.5
0.493 0.667
kilohm
I
0.3
0.2 -20
{-4}
1'................
~
0
20
40
60
80
{32} {68} {104} {140} {176}
INTAKE AIR TEMPERATURE rC {'F})
~EIDfflBIA~
I~~I
DBG140AWB303

1. Disconnect the MAF sensor/IAT sensor No.2 connector.
2. Disconnect the PCM connector.(See01-40B-9 peM REMOVAUINSTALLATION [WL-C, WE-C].)
,---------------------,
~EIDfflBIA~
I~~I
DBG140AWB302
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
01-408-25

Open circuit
Signal circuit (MAF sensor/IAT sensor No.2 connector terminal D and PCM connector terminal 188)
Ground circuit (MAF sensor/IAT sensor No.2 connector terminal E and PCM connector terminal 154)
Short circuit
MAF sensor/I AT sensor No.2 connector terminal D and PCM connector terminal 188 to GND
INTAKE AIR TEMPERATURE (IAT) SENSOR NO.1 INSPECTION [WL-C, WE-C]
dcf014018842w02
Note
1. Disconnect the boost sensor/IAT sensor No.1 connector.
2. Measure the resistance between IAT sensor No.1
IAT SENSOR NO.1
terminals A and B using an ohmmeter.
If not as specified, replace the boost sensor/
18
IAT sensor No.1.
16
'E14
Short inspection".
..c:
0.12
:2
Specification
Water temperature eC eF})
20 {68}
80 {176}
;U-10
Resistance (kilohm)
2.41-2.61
0.32-0.34
CI)
j:5
1i5
II
2
0_
20 -10
{-4} {14}
0
10 20
30
40
50
60
70 80
{32} {50} {68} {86} {104}{122}{140}{158}{176}
INTAKE AIR TEMPERATURE (OC {OF} )
DBG140BWB304
BOOST SENSORJIAT SENSOR NO.1
DBG140AWB556

2. Disconnect the PCM connector.(See01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
3. Inspect for an open or short circuit in the following siring harnesses.
,------------------------,
BOOST SENSORJIAT SENSOR NO.1
milla
I~~
DBG140BWB301
01-408-26

PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
Open circuit
Signal circuit (8oost sensor/IAT sensor No.1 connector terminal A and PCM connector terminal 111)
Ground circuit (8oost sensor/I AT sensor No.1 connector terminal 8 and PCM connector terminal 141)
Short circuit
IAT sensor No.1 connector terminal A and PCM connector terminal 111 to ground
BOOST SENSOR INSPECTION [WL-C, WE-C]
dcf014018212w02
Note
Visual Inspection
1. Inspect the boost sensor for damage and cracks.
If there is any malfunction, replace the boost sensor/I AT sensor No.1.
If there is not any malfunction, perform the "Voltage Inspection".
Voltage Inspection
2. Set the current diagnostic tool and monitor the MAP PID.(See 01-028-8 PID/DATA Monitor And Record
Procedure.)
.
- If there is no open/short circuit, replace the boost sensor/IAT sensor No.1. (See 01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C).)
MAP PIO (Reference)
Approx. 1.65 V [Atmospheric pressure 101 kPa {757.5 mmHg, 29.8 inHg}]
4. Monitor the MAP PID using the current diagnostic tool at idle.
- If there is no open/short circuit, replace the boost sensor/IAT sensor No.1. (See 01-138-3 INTAKE-AIR
SYSTEM REMOVAUINSTALLATION [WL-C, WE-C).)
MAP PIO (Reference)
Approx. 1.65 V [Atmospheric pressure 101 kPa {757.5 mmHg, 29.8 inHg}]
01-408-27

1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C).)
3. Inspect for open/short circuit in the following wiring harnesses.
If there is open/short circuit, repair or replace
,----------------------,
wiring harnesses.
ffiWm6ID
I~~
DBG140BWB301
PCM

124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (Boost sensor/IAT sensor No.1 connector terminal D and PCM connector terminal 189)
Signal circuit (Boost sensor/IAT sensor No.1 connector terminal C and PCM connector terminal 133)
Ground circuit (Boost sensor/IAT sensor No.1 connector terminal A and PCM connector terminal 111)
Short circuit
Boost sensor/IAT sensor No.1
connector terminal
connector terminal
connector terminal
connector terminal
connector terminal
A and
C and
C and
D and
D and
PCM
PCM
PCM
PCM
PCM
connector terminal
connector terminal
connector terminal
connector terminal
connector terminal
ACCELERATOR PEDAL POSITION (APP) SENSOR INSPECTION [WL-C, WE-C]

Note
Voltage Inspection
1. Verify that the APP sensor is installed to the accelerator pedal properly.
2. Visually inspect all accelerato[ pedal components for looseness.
01-408-28
111 short to
133 short to
133 short to
189 short to
189 short to
power supply
power supply
body ground
power supply
body ground
dcf014041609w02

3. Check the power circuit voltage.
(1) Verify that the voltage between the APP
sensor terminals A (power circuit) and D
(ground circuit) is 4.9-5.1 V.
APP SENSOR
APPSENSOR
DBG140AWB311
4. Verify that the voltage between the APP sensor terminals B-D, and C-D is as shown below according to the
accelerator pedal conditions.
If not as specified, carry out the "Circuit
Open/Short Inspection:'
APP SENSOR
If there is no open/short circuit,
replace the APP sensor.(See01-13B3 INTAKE-AIR SYSTEM REMOVAU
INSTALLATION [WL-C, WE-C]
0
[ 1: I C I B I A: IJ
Specification (Reference)
Accelerator pedal
condition
Fully released
Gradually depressed
Fully depressed
Output voltage (V)
0.4-0.8
Increases linearly
3.4-3.8
I~~I
DBG140AWB311
01-408-29

2. Disconnect the APP sensor connector.
,-------------------,
APP SENSOR
DBG140AWB311
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
Power circuit (APP sensor connector terminal A and PCM connector terminal 213)
Signal circuit (APP sensor connector terminal 8 and PCM connector terminal 222)
Signal circuit (APP sensor connector terminal C and PCM connector terminal 209)
Ground circuit (APP sensor connector terminal D and PCM connector terminal 212)
Short circuit
APP sensor connector terminal A and PCM connector terminal 213 short to ground
APP sensor connector terminal 8 and PCM connector terminal 222 short to power supply
APP sensor connector terminal 8 and PCM connector terminal 222 short to ground
APP sensor connector terminal C and PCM connector terminal 209 short to power supply
APP sensor connector terminal C and PCM connector terminal 209 short to ground
APP sensor connector terminal D and PCM connector terminal 212 short to power supply
IDLE SWITCH INSPECTION [WL-C, WE-C]
Note
1. Disconnect the idle switch connector.
01-408-30
dcf014066470w02

2. Inspect continuity between the idle switch
terminals A and 8 using an ohmmeter.
Irnot as specified, replace the idle switch.
If as specified, carry out the "Circuit
Open/Short Inspection".
Specification
Push the rod
Accelerator
pedal
Released
Except above
Depressed
Idle switch
Continuity
condition
Continuity
IDLE SWITCH
OFF - : - ON
,,,
,
PUSH ROD
No continuity .
Circuit open/short inspection

1. Disconnect the idle switch connector.
2. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C, WE-CD
r----------------------,
IDLE SWITCH
DBG140AWB313
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (idle switch connector terminal A and PCM connector terminal 161)
Ground circuit (idle switch connector terminal 8 and ground.)
Short circuit
Idle switch connector terminal A and PCM connector terminal 161 short to ground
01-408-31

FUEL TEMPERATURE SENSOR INSPECTION [WL-C, WE-C]
dcf014018843w02
Note
1. Remove the supply pump. (See 01-148-11 SUPPLY PUMP REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Measure the resistance between the fuel temperature sensor terminals using an ohmmeter.
If not as specified, repair the supply pump. (See 01-148-13 SUPPLY PUMP INSPECTION [WL-C, WE-C].)
Short Inspection".
Specification
Ambient temperature
(OC {OF})
-10 {14}
20 {68}
80 {176}
Resistance (kilohm)
8.244-10.661
2.262-2.760
0.304-0.342
DBG140BWB302

1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
r----------------------,
wiring harness.
DBG140BWB303
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (Fuel temperature sensor connector terminal A and PCM connector terminal 115
Ground circuit (Fuel temperature sensor connector terminal 8 and PCM connector terminal 170
Short circuit
Fuel temperature sensor connector terminal A and PCM connector terminal 115 short to power
Fuel temperature sensor connector terminal A and PCM connector terminal 115 short to ground
Fuel temperature sensor connector terminal 8 and PCM connector terminal 170 short to power
01-408-32

FUEL PRESSURE SENSOR INSPECTION [WL-C, WE-C]
dcf014018213w01
Note
Voltage Inspection
2. Measure the voltage between fuel pressure sensor terminals A and 8 using a voltmeter at idle .
If there is no open/short circuit, replace the common rail.
Specification (Reverence)
Approx. 1.25 V

DBG140BWB305
3. Turn off the engine and wait three minutes.

4. Turn the engine switch to the ON position (Engine
off).
5. Measure the voltage between fuel pressure
sensor terminals A and 8 using a voltmeter.
If not as specified, perform the "Circuit Open/
Short Inspection".
If there is no open/short circuit, replace
the common rail.
0.494-0.506 V
FUEL PRESSURE SENSOR CHARACTERISTIC (REFERENCE)
5.0
~ 4.0
~ 3.0
!j 2.0
~ 1.0 /
0.00
{O,O}
----
I-""
V r--
40
80
120
160
200
{4.1,
{8.2,
{12.2, {16.3,
{2.0,
5,801} 11,603} 17,404} 23,206} 29007}
FUEL PRESSURE (MPa {kgf/m2, psi}))
DBG140AWB558

1. Disconnect the fuel pressure sensor connector.
2. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAUINSTALLATION [WL-C, WE-C])
01-408-33

r--------------------,
wiring harnesses.
DBG140BWB305
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBGl13BWB319
Open circuit
Power circuit (Fuel pressure sensor connector terminal C and PCM connector terminal 109)
Signal circuit (Fuel pressure sensor connector terminal 8 and PCM connector terminal 140)
Ground circuit (Fuel pressure sensor connector terminal A and PCM connector terminal 191)
Short circuit
Fuel pressure
Fuel pressure
Fuel pressure
Fuel pressure
Fuel pressure
sensor connector terminal

A and PCM connector terminal

8 and PCM connector terminal
8 and PCM connector terminal
C and PCM connector terminal
C and PCM connector terminal
191 short to power supply

140 short to body ground
109 short to body ground
ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAUINSTALLATION [WL-C, WE-C]
dcf014018841w03
Warning
When the engine is hot, it can badly burn. Turn off the engine and wait until it is cool before
removing the ECT sensor.
1.
2.
3.
4.
5.

Remove the common rail. (See 01-148-11 SUPPLY PUMP REMOVAUINSTALLATION [WL-C, WE-C].)
Remove the ECT sensor.
15.7-23.5 N.m
{1.61-2.39 kgfm,
11.6-17.3 ftlbf}
DBGl16BWB201
01-408-34

ENGINE COOLANT TEMPERATURE (ECT) SENSOR INSPECTION [WL-C, WE-C]
dcf014018841w04
Note
1. Remove the ECT sensor. (See01-40B-34 ENGINE COOLANT TEMPERATURE (ECT) SENSOR REMOVAL!
INSTALLATION [WL-C, WE-C]
2. Measure the resistance between the ECT sensor
If not as specified, replace the ECT sensor.
Short Inspection".
Specification
Engine coolant temperature (OC eF})
20 {68}
80 {176}
110 {176}
Resistance
(kilohm)
2.37-2.53
0.31-0.32
0.137-0.146
DBG140BWB306
ECT SENSOR SIGNAL CHARACTERISTIC (REFERENCE)

10
~7
::!6
~
w5
()
z4
~
~3
C/)
~2
\
\
r--..,
--
l- I--
-20
0
20
40
60
SO
100 120
{-4} {32} {6S} {104} {140} {176} {212} {24S}
ENGINE COOLANT TEMPERATURE (OC {OF})
DBG140AWB333
01-408-35

1. Disconnect the PCM connector. (See 01-408-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
,--------EC-T-S-E-N-S-O-R---------,
replace wiring harness.
DBG140BWB307
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (ECT sensor connector terminal A and PCM connector terminal 156)
Ground circuit (ECT sensor connector terminal 8 and PCM connector terminal 167)
Short circuit
ECT sensor connector terminal A and PCM connector terminal 156 short to ground
ECT sensor connector terminal A and PCM connector terminal 167 short to power
CAMSHAFT POSITION (CMP) SENSOR REMOVAUINSTALLATION [WL-C, WE-C]
dcf014018230w01
Caution
When replacing the CKP sensor, make sure there is no foreign material on it such as metal
shavings. If it is installed with foreign material, the sensor output signal will malfunction resulting
from fluctuation in magnetic flux and cause a deterioration in engine control.
2. Remove the CMP sensor.
CMP sensor tightening torque

7.8-10.8 Nm {80-110 kgfcm, 70-95
in.lbf}
DBG116BWB202
01-408-36

CAMSHAFT POSITION (CMP) SENSOR INSPECTION [WL-C, WE-C]
dcf014018230w02
Note
8efore performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart. (See 00-00-5 Troubleshooting Procedure.)
Visual Inspection
1. Remove the CMP sensor. (See 01-408-36 CAMSHAFT POSITION (CMP) SENSOR REMOVAL!
2. Verify that there are no metal shavings on the sensor.
3. Install the CMP sensor. (See 01-408-36 CAMSHAFT POSITION (CMP) SENSOR REMOVAUINSTALLATION
[WL-C, WE-C].)
Voltage Inspection
1. Idle the engine.
Caution
Water penetrating the connector will cause sensor malfunction. To prevent this, be careful not to
damage the wiring harnesses or the waterproof connector so as to cause water penetration.
2. Measure the output voltage using a oscilloscope .
CMP sensor. (See 01-408-36 CAMSHAFT
POSITION (CMP) SENSOR REMOVAU
if there is an open or short circuit, repair or
CMP sensor voltage

Terminal
A
B
C
*
Voltage (V)
Condition
approx.O
approx.5
Under any condition
approx.O
approx.5
High output*
Low output*
Under any condition
CMP SENSOR
MM
I~'I
DBG140BWB308
Output voltage varies with camshaft rotation.
01-408-37

2. Disconnect the CMP sensor connector.
3. Inspect the following wiring harness for open or short circuit (continuity check).
if there is an open or short circuit, repair or replace wiring harnesses.
,-------------------------------------,
CMPSENSOR
@!rJ
I~~I
DBG140BWB308
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (CMP sensor connector terminal C and PCM connector terminal 129)
Signal circuit (CMP sensor connector terminal 8 and PCM connector terminal 160)
Ground circuit (CMP sensor connector terminal A and PCM connector terminal 114)
Short circuit
CMP sensor connector terminal
A and
8 and
8 and
C and
PCM connector terminal

114 short to
160 short to
160 short to
129 short to
body ground
power supply
body ground
power supply
CRANKSHAFT POSITION (CKP) SENSOR REMOVAL/INSTALLATION [WL-C, WE-C]
dcf014018220w03
Caution
When foreign material, such as iron chips, gets on the CKP sensor, it can cause abnormal output
from the sensor because of flux turbulence and adversely affect engine control. Be sure there is
no foreign material on the CKP sensor when replacing.
Do not forcefully pull the wiring harness of the CKP sensor. DOing so will break the wiring
harness.
01-408-38

2. Remove the under cover (AT).
3. Remove the insulator (AT).
1
CKP sensor installation bolt

CKP sensor (See 01-408-1 CKP Sensor Installation
Note.)
CKP Sensor Installation Note

1. Verify that there is no foreign material on the CKP sensor flange surface and the installation surface.
2. Verify that the O-ring is not damaged.
If there is a damage, replace the CKP sensor.
3. Apply a small amount of clean oil to the O-ring and the head cover.
4. Press in the CKP sensor until the CMP sensor flange surface firmly adheres to the installation surface.
5. Verify that the O-ring is installed correctly to the sensor installation hole.
6. Tighten the bolt.
CRANKSHAFT POSITION (CKP) SENSOR INSPECTION [WL-C, WE-C]
dcf014018220w04
Note
Before performing the following inspection, make sure to follow the procedure as indicated in the
troubleshooting flowchart.
Wave profile Inspection
1. Measure the wave profile between CKP sensor
connector terminal A-body ground, and CKP
sensor connector terminal B-body ground.
If not within the specification, replace the CKP
sensor.
If as specified, carry out the "Circuit Open!
Short Inspection".
CKPSENSOR
wll
I
I~~
DBG140BWB310
Wave profile (Reference)

Vehicle condition
Idle after warm up
1
:
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
-
- -r - -,- -,- - - - T -
I
1
r - - r - -r - -.- -
- -, - -
[
I
T--
--:- --:- + - -~+

--~ --~ --:- --:- - --,- -+--: -
ov
+~l( '_
I
- - t - - T-
I
-:
I
:t:' ',:t 1
I
_ _ _ J..
_'
__
I
.J
I
I
[I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
r
--r--,--'-- --T--r-- --r--'--'--'--T-r
--.--'--1-- --T--r-- --,---.--,--'--7-r
--'---'---1-- --I--r-- --,---,---,--,--.-I
I
DBG140AWB560
01-408-39

1. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-C].)
2. Inspect the following wiring harnesses for an open or short circuit. (Continuity check)
if there is an open or short circuit, repair or replace wiring harnesses.
,------------------------------------,
CKP SENSOR
lEThl
I~~I
DBG140BWB310
PCM
124 123 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Positive signal circuit (CKP sensor connector terminal A and PCM connector terminal 192)
Negative signal circuit (CKP sensor connector terminal Band PCM connector terminal 193)
Short circuit
CKP sensor connector terminal
A and
A and
Band
Band
PCM
PCM
PCM
PCM
connector terminal
connector terminal
connector terminal
connector terminal
192 short to
192 short to
193 short to
193 short to
power supply
body ground
power supply
body ground
EGR VALVE POSITION SENSOR INSPECTION [WL-C, WE-C]
dcf014020300w02
Note
1. Disconnect the EGR valve connector.
2. Measure the resistance between EGR valve
connector terminals A and B.
EGR valve.
Short Inspection".
Resistance
Approx. 5 kilohm
I~~I
DBG140AWB557
01-408-40

Voltage Inspection
3. Measure the voltage between EGR valve connector terminal C and body ground.
If not as specified, perform the "Circuit Open/short Inspection".
- If there is no open/short circuit replace the EGR valve. (See 01-168-4 EGR SYSTEM REMOVAU
Approx. 0.6 V
4. Start the engine and warm up the engine
completely.

WIRING HARNESSSIDE CONNECTOR
@ibm
I~"
I
DBG140BWB311
5. Measure the voltage between EGR valve

If not as specified, perform the "Circuit Open/
Short inspection".
If there is no open/short circuit replace the
EGR valve. (See 01-168-4 EGR SYSTEM
REMOVAUINSTALLATION [WL-C, WEC].)

Above 3.0 V
DBG140BWB311
01-408-41

2. Disconnect the PCM connector. (See 01-40B-9 PCM REMOVAL/INSTALLATION [WL-C, WE-CD
,---------------------,
mI
I~~
DBG140BWB311
PCM
124 123. 122 121 120 119 118 117 116 115 114 113 112 111 110 109 108 107 106 105 104 103 102 101
148 147 146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128 127 126 125
172 171 170 169 168 167 166 165 164 163 162 161 160 159 158 157 156 155 154 153 152 151 150 149
196 195 194 193 192 191 190 189 188 187 186 185 184 183 182 181 180 179 178 177 176 175 174 173
DBG113BWB319
Open circuit
Power circuit (EGR valve position sensor connector terminal Band PCM connector terminal 106)
Signal circuit (EGR valve position sensor connector terminal C and PCM connector terminal 116)
Ground circuit (EGR valve position sensor connector terminal A and PCM connector terminal 110)
Short circuit
EGR valve position sensor connector terminal Band PCM connector terminal 106 short to ground
EGR valve position sensor connector terminal C and PCM connector terminal 116 short to ground
CLUTCH PEDAL POSITION (CPP) SWITCH INSPECTION [WL-C, WE-C]
dcf014018660w02
Note
1. Disconnect the CPP switch connector.
2. Inspect for continuity between the CPP switch
If not as specified, replace the CPP switch.
Short Inspection".
Specification
cpp switch
Clutch pedal
Continuity
condition
Push the rod
Released
No continuity
Except above
Depressed
Continuity
..
CPPSWITCH
ROD
PUSH
DBG140AWB328
01-408-42

,-----------------------,
CPPSWITCH
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
Power circuit (CPP switch connector terminal A and PCM connector terminal 228)
Ground circuit (CPP switch connector terminal 8 and ground.)
Short circuit
CPP switch connector terminal A and PCM connector terminal 228 short to ground.
NEUTRAL SWITCH INSPECTION [WL-C, WE-C]
dcf014017640w02
Note
1. Disconnect the neutral switch connector.
2. Inspect for continuity between the neutral switch terminals using an ohmmeter.
If not as specified, replace the neutral switch.
If as specified, carry out the "Circuit Open/Short Inspection".
,-----------------------,
Specification
NEUTRAL SWITCH
Continuity
condition
Neutral switch
Shift lever
Push the rod
In neutral
Continuity
Except above
Others
No continuity
ROD
DBG140BWB312
01-408-43

,-----------------------,
NEUTRAL SWITCH
DBG140BWB313
PCM
219 218 217 216 215 214 213 212 211 210 209 208 207
202 201
232 231 230 229 228 227 226 225 224 223 222 221 220
204 203
245 244 243 242 241 240 239 238 237 236 235 234 233
206 205
258 257 256 255 254 253 252 251 250 249 248 247 246
DBG113BWB318
Open circuit
Power circuit (neutral switch connector terminal A and PCM connector terminal 240)
Ground circuit (neutral switch terminal 8 and ground)
Short circuit
Neutral switch connector terminal A and PCM connector terminal 240 short to ground
01-408-44
t.
01-508 TECHNICAL DATA [WL-C, WE-C]

ENGINE TECHNICAL DATA
[WL-C, WE-C] .................... 01-508-1
ENGINE TECHNICAL DATA[WL-C, WE-C]

Item

Compression (kPa {kgf/cm 2, psi} [rpm])
Pushing distance of the camshaft cap lower oil seal

Pushing distance of the front oil seal
Pushing distance of the rear oil seal
Full open life
Battery quick charge current [30 min.]
Generator standard voltage [Engine switch ON]
id0150b6800100
Specification
IN: 0.10-0.16 mm {0.0040-0.0062 in}
EX: 0.17-0.23 mm {0.0067-0.0090 in}
Standard: 2,942 {30, 427} [200]
Minimum: 2,648 {27, 384} [200]
Bolt head mark W
Bolt head mark N
Bolt head mark I
Standard length: 149-150 mm {5.867-5.905 in}
0.0-0.4 mm {0.0-0.015 in}
0.5-1.0 mm {0.02-0.03 in}
0.0-0.4 mm {0.0-0.015 in}
0.0-0.5 mm {0.0-0.019 in}
410-570 kPa {4.19-5.81 kgf/cm 2, 59.6-82.6 psi}

0.0-0.40 mm {0.O-O.015 in}
0.0-0.40 mm {0.0-0.015 in}
0.10-0.19 mm {0.004D-0.0074 in}
0.20 mm {0.0079 in}
0.04-0.09 mm {0.0016-0.0035 in}
0.15 mm {0.0059 in}
43.8 mm {1.72 in}
Without heater: 8.8 L {9.3 US qt, 7.7 Imp qt}
With heater: 9.4 L {9.9 US qt, 8.3 Imp qt}
93.2-122.6 kPa {0.95-1.25 kgf/cm2, 13.5-17.8 psi}
80-84 C {176-183 OF}
95C {203 OF}
1.22-1.29
65031 R (56): 165 A
75026R (52): 195 A
75026L (55): 195 A
95031 R (64): 250 A
65031 R (56): 4.0-5.0 A
75026R (52): 5.0-6.0 A
75026L (55): 5.0-6.0 A
95031 R (64): 6.5-8.0 A
65031 R (56): 30 A
75026R (52): 35 A
75026L (55): 35 A
95031 R (64): 40 A
Terminal B: B+
Terminal S: B+
01-508-1

Item
Specification
Terminal 8: 14.1-14.7 V
Generator standard voltage [Idle, 20C {68 OF})

Generator rotor resistance (between slip rings) [20C
{68 OF})
2.3-2.7 ohms
Standard: 4.8-6.0 N {0.49-0.61 kgf, 1.08-1.34Ibf}
Minimum: 2.16 N {0.22 kgf, 0.49 Ibf}
11 V
130 A or less
o mm {O in}
0.1 mm {0.039 in} max.
Standard: 26.7-36.1 N {2.73-3.68 kgf, 6.01-8.11 Ibf}
Minimum: 14.7 N {1.5 kgf, 3.3 Ibf}

Starter pinion gap
(mm {in})
Drive Belt
New'
7.4-9.4
{0.30-0.37}
6.1-6.9
{0.24-0.27}
10.0-11.0
{0.40-0.43}
Generator
a
AlC
b
Used
Limit
8.7-10.4
{0.35-0.40}
7.1-8.0
{0.28-0.31 }
11.3-12.6
{0.45-0.49}
14.3 {0.56} or more

11.3 {0.44} or more
17.4 {0.69} or more
Drive Belt Tension

Drive Belt
Generator
AlC
(N {kgf, Ibf})
New'
490-637
{50.0-64.9, 111-143}
455-572
{46.4-58.3,103-128}
Used
Limit
431-539
{44.0-54.9,96.9-121}
353-431
{36.0-43.9,79.4-96.8}
225 {22.9, 50.6} or less

156 {15.9, 35.1} or less

Item
Grade
Viscosity (SAE)
Specification
Europe
API CF-4 or ACEA
81/83/85
5W-30
Except Europe
API CD/CE/CF-4 or ACEA 81/B3/85
5W-30, 10W-30, 10W-40
13.5 V, Engine hot
Engine speed (rpm)
1,000
2,000
01-508-2

0-55 A
0-70 A
01-608 SERVICE TOOLS [WL-C, WE-C]

ENGINE SST[WL-C, WE-C] .......... 01-608-1
ENGINE SST[WL-C, WE-C]

1: Mazda SST number
Example
1:49 UN30 3050
2:303-050
Engine lifting
brackets
2:-
1:498011102A
1 :49 UN30 3050

2:303-050
Crankshaft lock
tool
Engine lifting
brackets
1:498010 1AO
2:Compression
gauge set
(Part of 498013
1A1A)
1:49 F027 009
2:Oil seal installer
1 :49 0187 280A

2:-
t
e
""
..
1 :49 8010 301
2:-
Adapter
(Part of 49 8013
1A1A)
Oil seal installer
1:49 8010 001

2:-
2:-
Oil seal installer
Oil seal installer
1:49 9200 146

2:Adapter A
(Part of 49 9200
145)
1:49 9200 020A
1:498019005
2:-
Belt tension
gauge
Oil seal puller
1:49 H033 101
1 :49 G028 208

2:-
Bearing
remover
Installer
(Part of 49
G0282A1)
2:-
8upport hanger
1:498013102
2:-
Oil pressure
gauge
2:-
1:49 L017 5AO
2:-
1 :498011 103
1 :499200 147
2:-
Handle
(Part of 49 B025
OAO)
Adapter B
(Part of 49 9200
145)
1 :49 G030 797
2:-
0
01-608-1
SUSPENSION
GENERAL PROCEDURES ...
WHEEL ALIGNMENT .......
WHEEL AND TIRES ........
FRONT SUSPENSION .......
02-10
02-10
02-11
02-12
02-13
REAR SUSPENSION ........ 02-14

TECHNICAL DATA .......... 02-50
SERVICE TOOLS ........... 02-60
GENERAL PROCEDURES
GENERAL PROCEDURES
(SUSPENSION) .................. 02-10-1
GENERAL PROCEDURES (SUSPENSION)
dcf02100000Ow01
Wheel And Tire Installation

1. When installing the wheels and tires, tighten the wheel nuts in a criss-cross pattern to the following tightening
torque.
Tightening torque
88.2-117.6 Nm {9.00-11.99 kgfm, 65.06-86.73 ftlbf}
Suspension Links Removal/Installation

1. For the jOint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installatio!l bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.
Connector Disconnection
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
02-10-1
'-'!I.
IiIiiiI
WHEEL ALIGNMENT
02-11
WHEEL ALIGNMENT
VEHICLE HEIGHT
ADJUSTMENT [4x2] .............. 02-11-1
VEHICLE HEIGHT'
ADJUSTMENT [4x4] . .............. 02-11-2
WHEEL ALIGNMENT
PRE-INSPECTION . ............... . 02-11-2
FRONT WHEEL ALIGNMENT [4x2] .... 02-11-3
FRONT WHEEL ALIGNMENT [4x4] .... 02-11-5
VEHICLE HEIGHT ADJUSTMENT [4x2]
dcf02110000Ow01
Caution
If the vehicle height on a winch or towbar (bull bar or similar accessory) equipped vehicle is
adjusted, it is possible that the vehicle height will drop below specification again or the tires will
be subject to uneven wear. Without adjusting the vehicle height, adjust only the difference
between the left and right sides and perform a wheel alignmenUo specification.
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.
yEASURIN: POINT
Standard vehicle height

Except Hi-Rider: 416-456 mm {16.4-17.9
in}
Hi-Rider: 512-552 mm {20.2-21.7 in}
SEC.
A-A
Left/right difference
10 mm {0.39 in} max.
Caution
Adjust the vehicle height at the left and
right wheels at the same time. Otherwise,
the vehicle height may not be adjusted correctly.
AVF7412W005
4. If the difference between left and right is not within the speCification, adjust the vehicle height by turning the
torsion bar spring anchor bolt.
EXCEPT Hi-Rider
Hi-Rider
DCF211ZWB001
5. Move the vehicle forward and back to seat each part.

6. Verify that the vehicle height is within the standard.
If not, readjust the vehicle height.
02-11-1
WHEEL ALIGNMENT
VEHICLE HEIGHT ADJUSTMENT [4x4]
dcf02110000Ow02
Caution
If the vehicle height on a winch or towbar (bullbar or similar accessory) equipped vehicle is
adjusted, it is possible that the vehicle height will drop below specification again or the tires will
be subject to uneven wear. Without adjusting the vehicle height, adjust only the difference
between the left and right sides and perform a wheel alignment to specification.
2. Inspect the front and rear tire pressure and adjust it as necessary.
3. Measure the distance from the center of each
r-------------------,
front wheel to the fender brim.
ySURINAG POINT
Standard vehicle height
Regular cab and Stretch cab (with Rear
Access System): 512-552 mm {20.2-21. 7
SEC.
A
in}
A-A
Double cab: 502-542 mm {19.8-21.3 in}
Left/right difference
10 mm {0.39 in} max.
Caution
Adjust the vehicle height at the left and
right wheels at the same time. Otherwise,
the vehicle height may not be adjusted correctly.
AVF7412W005
4. If the difference between left and right is not

within the specification, adjust the vehicle height
by turning the torsion bar spring anchor bolt.
Note
The vehicle height increases/decreases 3.3
mm {0.13 in} per anchor bolt rotation.
5. Move the vehicle forward and back to seat each
part.
6. Verify that the vehicle height is within the
standard.
If not, readjust the vehicle height.
WHEEL ALIGNMENT PRE-INSPECTION
AVF7412W004
dcf02110000Ow03
1. Inspect the tire pressure.

Adjust to the recommended pressure if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
2. Inspect the wheel bearing play.
Correct if necessary. (See 03-11-3 WHEEL HUB, STEERING KNUCKLE INSPECTION [4x2 (EXCEPT HiRider)].) (See 03-11-4 WHEEL HUB, STEERING KNUCKLE INSPECTION [Hi-Rider, 4x4].) (See 03-12-1
REAR AXLE INSPECTION.)
3. Inspect the wheel runout.
Correct if necessary. (See 02-50-1 SUSPENSION TECHNICAL DATA.)
4. Inspect the ball joints and steering linkage for excessive looseness.
5. Park the vehicle on a level ground, in an unloaded condition*, and with the wheels straight forward.
Unloaded vehicle ..... Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are in
designated position.
02-11-2
WHEEL ALIGNMENT
6. Measure height H from the center of the wheel to
the fender brim.
7. Verify that the difference between the left and
right dimension H is within the specification .
If it exceeds the specification, repeat the Step
FENDER BRIM
MEASUREMENT POINT
2-6.
Standard
10 mm {0.39 in} or less
CHU0211W001
FRONT WHEEL ALIGNMENT [4x2]
dcf02110000Ow04
Front wheel alignment [4x2] (Unloaded)

Item
Total toe-in
Tire
[Tolerance
3 {0.12}]
Maximum steering angle
Specifications
Hi-Rider (Stretch
Double cab
cab (with Rear
Access System)
Regular cab
5 {0.19}
(mm {in})
Inner
Outer
Camber angle [Tolerance 1 0]

Caster angle [Tolerance 1 0]
(reference value)
Hi-Rider (Double
cab)
3300'-3700'
3000'-3500'
035'
156'
154'
31 30'-3530'
2700'-3200'
825'
044'
207'
045'
206'
1037'
1035'
Note
Unloaded vehicle: Fuel tank is full. Engine coolant and engine oil are at specified level. Jack and tools are
in designated position.
Difference between the left and right dimension for camber is within 30'.
Difference between the left and right dimension for caster is within 45'.
Maximum Steering Angle Adjustment
1. Loosen the adjusting bolt locknut.
2. Turn the adjusting bolt to provide the correct
turning angle.
Standard steering angle
Except Hi-Rider
Inner: 3300'-3700'
Outer: 3000'-3500'
Hi-Rider
Inner: 31 30'-3530'
Outer: 2700'-3200'
3. After adjustment, tighten the locknut to the
specified torque.
ADJUSTING
BOL~
DBG0211ZWBOO
Tightening torque
39-59 N?m {4.0-S.0 kgf?m, 29-43 ft?lbf}
4. After adjusting the steering angle, always inspect and adjust the toe angle. (See 02-11-4 Total Toe-in
Adj ustment.)
02-11-3
WHEEL ALIGNMENT
Caster And Camber Adjustment
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct
angle.
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}
1.0 {0.039}
1.6 {0.063}
2.0 {0.079}
3.2 {0.126}
4.0 {0.157}
No.
1
2
3
4
5
6
7
8
9
10
11
FRONT
Note
Shims No.1-5 are used on either side. Do
not use more than two.
Shims No.6-11 are used at the front and
rear of either sides. Do not use more than
one.
Camber (Shims No.1-5): A change of shim
thickness of 1 mm {0.039 in} results as follows:
Shim thickness
Add
Reduce
AVF7412W003
Variation/1 mm {O.039 in}

Negative 15'
Positive 15'
Caster (Shims No.6-11): A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results as
follows:
Front side
Rear side
Shim
thickness
Add
Reduce
Add
Reduce

Increase 30'
Decrease 30'
Decrease 30'
Increase 30'
2. After adjustment, tighten the upper arm shaft bolt to the specified torque.
Tightening torque
150-172 Nm {15.3-17.5 kgfm, 111-126 ftlbf}
Total Toe-in Adjustment
1. Loosen the locknut of the tie-rod end.
2. Turn the tie rods by the same amount in the opposite direction.
Total Toe-in Standard
2-8 mm {0.08-0.31 in}
Note
One turn of the tie rod (both sides) changes the toe-in by about approx. 30 mm {1.18 in}.
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.
02-11-4
'(;
WHEEL ALIGNMENT
3. Tighten the tie-rod end locknuts.
Tightening torque
68.6-78.5 N?m {7.00-8.00 kgf?m, 50.6-57.8
ft?lbf}
FRONT WHEEL ALIGNMENT [4x4]
dcf02110000Ow05

Specifications
Regular cab and Stretch cab
(with Rear Access System)
Item
Total toe-in
jTire
[Tolerance 3 {0.12}]
6 {0.23}
(mm {in})
31 30'-3530'
2700'-3200'
Inner
Outer
Camber angle (reference value) [Tolerance 1]

Caster angle (reference value) [Tolerance 1 0]
Steering axis inclination (reference value)
Double cab
044'
207'
1037'
045'
206'
1035'
Note
in deSignated position.
Difference between the left and right dimension for camber is within 30'.
Difference between the left and right dimension for caster is within 45'.
Maximum Steering Angle Adjustment
1. Remove the cap.
2. Loosen the adjusting bolt locknut.
3. Turn the adjusting bolt to provide the correct turning angle.
Standard steering angle
Inner: 31 30'-3530'
Outer: 2700'-3200'
4. After adjustment, tighten the locknut to the
specified torque.
Tightening torque
39-59 N?m {4.0-6.0 kgf?m, 29-43 ft?lbf}
5. Install the cap.
02-11-5
WHEEL ALIGNMENT
Caster and Camber Adjustment
1. Loosen the upper arm shaft bolt and insert or
remove adjustment shims to provide the correct
angle.
Adjusting shim
Thickness (mm (in})
No.
1.0 {0.039}
1
1.6 {0.063}
2
2.0 {0.079}
3
3.2 {0.126}
4
4.0 {0.157}
5
0.6 {0.024}
6
1.0 {0.039}
7
1.6 {0.063}
8
2.0
{0.079}
9
3.2 {0.126}
10
4.0 {0.157}
11
FRONT
\::J
Note
Shims No.1-5 are used on either side. Do
not use more than two.
Shims No.6-11 are used at the front and
rear of either sides. Do not use more than
one.
Camber (Shims No.1-5): A change of shim
thickness of 1 mm {0.039 in} results as follows:
Shim thickness
Add
Reduce
AVF7412W003

Negative 15'
Positive 15'
Caster (Shims No.6-11): A change of shim thickness (at front or rear only) of 1 mm {0.039 in} results as
follows:
Front side
Rear side
Shim
thickness
Add
Reduce
Add
Reduce

Increase 30'
Decrease 30'
Decrease 30'
Increase 30'
2. After adjustment, tighten the upper arm shaft bolt to the specified torque.
Tightening torque
150-172 Nm {15.3-17.5 kgf.m, 111-126 ft.lbf}
3. Confirm the front wheel alignment as in the specification.
If not within the specification, adjust the front wheel alignment again.
Total Toe-in Adjustment
1. Loosen the tie-rod end locknuts.
2. Turn the tie rods by the same amount in the opposite direction.
Total Toe-in Standard
3-9 mm {0.12-0.35 in}
Note
One turn of the tie rod (both sides) changes the toe-in by about 30 mm {1.18 in}.
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.
02-11-6
WHEEL ALIGNMENT
3. Tighten the tie-rod end locknuts.
Tightening torque
68.6-78.5 Nm {7.00-8.00 kgf.m, 50.6-57.8
ft.lbf}
02-11-7
WHEEL AND TIRES
02-12
WHEEL AND TIRES
WHEEL AND TIRE

SPECiFiCATION ........... 02-12-1
WHEEL AND TIRE

SPECIFICATION ............. 02-12-1
WHEEL AND TIRE SPECIFICATION
id0212008001 b1
Wheel and tires

Specification
Item
Wheel
Size
Offset
(mm {in})
(mm {in})
Material
Size
Up to full
persons
Air pressure
Full load
Tire
(kPa ((kgf/cm 2),
Up to full
<psi>})
persons
Rear
Full load
Remaining tread
(mm {in})
(Nm {kgfm,
Lug nut tightening torque
ftlbf})
Wheel Wheel and tire runout
Radial direction
and tire
(mm {in}) Lateral direction
Front
220 {(2.2), <32>}
210 {(2.1), <30>} 210 {(2.1), <30>}
210 {(2.1), <30>}
210 {(2.1), <30>} 210 {(2.1), <30>}
375 {(3.S), <54>}
290 {(2.9), <42>} 270 {(2.7), <39>}

1.6 {0.06}
SS.2-117.6 {9.0Q-11.99, 65.06-S6.73}

1.5 {0.06} max.
2.0 {O.OS} max.
(g {oz})
Wheel imbalance*2
*1 :
*2 :
16 x 7J
15x61/2J
10 {0.39}
25 {0.9S}
139.7 {5.500}
Aluminum
Aluminum alloy
Steel
Steel
alloy
215170R15C 10611 04S
235175R 15 109S 245170R16111S
15x61/2J
20 {0.79}
10 {0.35} max.
Total weight exceeds 120 9 {4.24 OZ}.

One balance weight: 60 9 {2.12 oz} max. If the total weight exceeds 120 9 {4.24 oz} on one side, rebalance
after moving the tire around on the rim. Do not use three or more balance weights.
WHEEL AND TIRE SPECIFICATION
id0212008001 b2
Wheel and tires

Item
Wheel
Specification
15 x 6 1/2J
Size
Offset
(mm {in})
(mm {in})
Steel
Size
Air pressure
(kPa {(kgf/cm 2),
<psi>})
Remaining tread
Front
Rear
No loaded
Loaded
No loaded
Loaded
(mm {in})
(Nm {kgfm,
ftlbf})
Radial direction
and tire
Wheel imbalance*2
*1 :
*2 :
15x61/2J
25 {0.9S}
139.7 {5.500}
Aluminum
alloy
215170R15C 106/104S
Material
Tire
20 {0.79}
(g {oz})
Steel
16 x 7J
10 {0.39}
Aluminum alloy
235/75R 15 109S 245/70R16111S
220 {(2.2), <32>}
210 {(2.1), <30>} 210 {(2.1), <30>}
210 {(2.1), <30>}

375 {(3.S), <54>}
210 {(2.1), <30>} 210 {(2.1), <30>}

290 {(2.9), <42>} 270 {(2.7), <39>}
1.6 {0.06}
SS.2-117.6 {9.00-11.99, 65.06-S6.73}

1.5 {0.06} max.
2.0 {O.OS} max.
10 {0.35} max.

One balance weight: 60 9 {2.12 oz} max. If the total weight exceeds 120 9 {4.24 oz} on one side, rebalance
02-12-1
FRONT SUSPENSION
02-13
FRONT SUSPENSION
FRONT SUSPENSION LOCATION

INDEX [4x2 (EXCEPT Hi-Rider)] .....
INDEX [Hi-Rider] . .................
INDEX [4x4] . .....................
REMOVAL/INSTALLATION . .........
02-13-1
02-13-2
02-13-3
02-13-4
INSPECTION . .................... 02-13-4
DISPOSAL. . . . . . . . . . . . . . . . . . . . . . . 02-13-5
TORSION BAR SPRING AND LOWER
ARM REMOVAL/INSTALLATION
[4x2 (EXCEPT Hi-Rider)] . .......... 02-13-5

ARM REMOVAL/INSTALLATION
[Hi-Rider, 4x4] ................... . 02-13-9
FRONT LOWER ARM INSPECTION .... 02-13-13
FRONT UPPER ARM
REMOVAL/INSTALLATION .......... 02-13-14
FRONT UPPER ARM INSPECTION .... 02-13-16
FRONT STABILIZER AND TENSION
ROD REMOVAL/INSTALLATION
[4x2 (EXCEPT Hi-Rider)] .......... . 02-13-16
FRONT STABILIZER
REMOVAL/INSTALLATION
[Hi-Rider, 4x4] . .................. . 02-13-17
FRONT SUSPENSION LOCATION INDEX [4x2 (EXCEPT Hi-Rider)]
dcf02130000Ow01
DBG213ZWB028
Front shock absorber

(See 02-13-4 FRONT SHOCK ABSORBER
INSPECTION.)
DISPOSAL.)
Torsion bar spring, lower arm
(See 02-13-5 TORSION BAR SPRING AND
LOWER ARM REMOVAUINSTALLATION [4x2
(EXCEPT Hi-Rider)].)
(See 02-13-13 FRONT LOWER ARM
INSPECTION.)
Front upper arm

(See 02-13-14 FRONT UPPER ARM REMOVAU
INSTALLATION.)
(See 02-13-16 FRONT UPPER ARM
INSPECTION.)
Front stabilizer
(See 02-13-16 FRONT STABILIZER AND TENSION
ROD REMOVAUINSTALLATION [4x2 (EXCEPT HiRider)].)
02-13-1
FRONT SUSPENSION
FRONT SUSPENSION LOCATION INDEX [Hi-Rider]
dcf021300000w02
DBG213ZWB029

INSPECTION.)
DISPOSAL.)
LOWER ARM REMOVAUINSTALLATION [Hi-Rider,
4x4].)
INSPECTION.)
02-13-2
Front upper arm

INSTALLATION.)
INSPECTION.)
Front stabilizer
(See 02-13-17 FRONT STABILIZER REMOVAU
INSTALLATION [Hi-Rider, 4x4].)
FRONT SUSPENSION
FRONT SUSPENSION LOCATION INDEX [4x4]
dcf021300000w03
L---------------------------------------------------------------------~D~BG~2~13~~~B==030

INSPECTION.)
DISPOSAL.)
4x4].)
INSPECTION.)
r!I1
Front upper arm

INSTALLATION.)
INSPECTION.)
Front stabilizer
02-13-3
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAUINSTALLATION
dcf021334700w01

Nm {kgf.m, ftlbf}
DBG0213ZWBOO
Nut
(See 02-13-4 Nut Installation Note.)
Retainer, bushing
3
4
5
Bolt
Washer and nut
Nut Installation Note

1. Tighten the nut so that the exposed thread of the
shock absorber piston is 6-8 mm {O.24-0.31
in}.
DBG0213ZWBOO
FRONT SHOCK ABSORBER INSPECTION
dcf021334700w02
1. Remove the front shock absorber.

2. Inspect for damage and oil leakage.
3. Compress and extend the shock absorber piston rod at least three times at a steady speed. From the fourth
compression stroke, verify that the operational force does not change and that there is no unusual noise.
If there is any malfunction, replace the shock absorber.
02-13-4
FRONT SUSPENSION
FRONT SHOCK ABSORBER DffiPOSAL
dcf021334700w03
Warning
Whenever drilling into a shock absorber, wear protective eye wear. The gas in the shock absorber
is pressurized, and could spray metal chips into the eyes and face when drilling.
1. Clamp a shock absorber on a flat surface or with the piston pointing downwards.
2. Drill a 2-3 mm {0.OS-0.12 in} hole at a point
r-------------------....,
20-30 mm {0.S-1.2 in} from the bottom of the
tube, so that the gas can escape.
3. Turn the hole downwards.
4. The oil can be collected by moving the piston rod
several times up and down and cutting the tube at
the end.
5. Dispose of waste oil according to the waste
disposal law.
Note
Shock absorber gas is nitrogen gas.
Shock absorber oil is mineral oil.
ABR7412W003
TORSION BAR SPRING AND LOWER ARM REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]
1. Remove the ASS sensor wiring harness brackets
installed to the upper arm and steering knuckle,
then move aside the ASS sensor.
4. Inspect the vehicle height and adjust it if
necessary. (See 02-11-1 VEHICLE HEIGHT
ADJUSTMENT [4x2].)
5. Inspect the front wheel alignment and adjust it if
necessary. (See 02-11-3 FRONT WHEEL
ALIGNMENT [4x2].)
dcf021334130w01
lim
19-25
{2.0-2.5,
15-18}
N'm {kgf.m, ftlbf}
DBG213ZWB033
02-13-5
FRONT SUSPENSION
124-155
{12.7-15.8,
91.5-114}
APPLY THREAD
LOCKING COMPOUND
19
mJ
iii
VEHICLE
FORWARD
DIRECTION
INSERT COTTER PIN

FROM VEHICLE FORWARD
DIRECTION
Nm {kgf.m, ftlbf}
DBG0213ZWBOO
Cotter pin
12
Lower arm spindle, washer, and nut
Nut
Front lower arm ball joint
(See 02-13-7 Front Lower Arm Ball Joint Removal
Note.)
Shock absorber lower bolt and nut
13
Rubber bushing
(See 02-13-7 Rubber Bushing Removal Note.)
(See 02-13-8 Rubber Bushing Installation Note.)
14
Tension rod bolt

Stabilizer bolt, bushing, retainer, spacer, and nut
(See 02-13-8 Stabilizer Bolt, Bushing, Retainer,
Spacer, And Nut Installation Note.)
15
Anchor bolt
(See 02-13-7 Anchor Bolt Removal Note.)
(See 02-13-9 Anchor Bolt Installation Note.)
Anchor swivel
16
17
7
8
Bolt and washer
18
Torsion bar component

Anchor arm
19
10
Torsion bar spring

(See 02-13-7 Torsion Bar Spring Removal Note.)
(See 02-13-8 Torsion Bar Spring Installation Note.)
20
Dust boot
21
Clip
(See 02-13-8 Clip Installation Note.)
11
Torque plate
22
Dust boot
02-13-6
Front lower arm

Bound stopper
Clip
FRONT SUSPENSION
Front Lower Arm Ball Joint Removal Note
1. Separate the ball joint from the knuckle arm using
the SST.
DBG0213ZWBOO
Anchor Bolt Removal Note

1. Mark the anchor bolt and swivel for reference
during installation.
Torsion Bar Spring Removal Note

1. Mark the torsion bar spring, anchor arm, the
torsion bar spring and torque plate for reference
MATCHING MARK
DBG0213ZWBOO
Rubber Bushing Removal Note

1. Remove the rubber bushing from the body using
the SST.
DBG0213ZWBOO
02-13-7
FRONT SUSPENSION
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.
I:
DBG0213ZWBOO
Stabilizer Bolt, Bushing, Retainer, Spacer, And Nut Installation Note

1. Tighten the nuts so that 17.5-20.5 mm {0.689.---,--------------:----,-",----,--r---:--/----:-/------,
0.807 in} of thread is exposed at the end of the
/
bolt.
17.5-20.5 mm
{0.689-O.807 in}
DBG0213ZWBOO
Rubber Bushing Installation Note

1. Install a new bushing using the SST.
DBG0213ZWB01
Torsion Bar Spring Installation Note

1. Before installation, check the identification mark
on the end of the torsion bar spring.
OUTSIDE
OFTHE
VEHICLE
:J
- G)
~
LEFT SIDE
RIGHT SIDE
OUT SIDE
OFTHE
VEHICLE
DBG213ZWB031
02-13-8
FRONT SUSPENSION
2. Align the marks made during removal, and
connect the torsion bar spring to the torque plate.
DBG0213ZWBOO
Anchor Bolt Installation Note

1. Install the anchor bolt, and tighten it until the
marks made during removal are aligned.
Note
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 25-34.
DBG0213ZWB01
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION [Hi-Rider, 4x4]

4. Inspect the vehicle height and adjust it as
necessary. (See 02-11-2 VEHICLE HEIGHT
ADJUSTMENT [4x4].)
5. Inspect the front wheel alignment as necessary.
(See 02-11-5 FRONT WHEEL ALIGNMENT
[4x4].)
19-25
{2.0-2.5,
15-18}
dcf021334130w02
19-25
{2.0-2.5,
15-18}
Nm {kgfm, ft.lbf}
DBG213ZWB034
02-13-9
FRONT SUSPENSION
124-155
{12.7-15.8,92-114}
APPLY THREAD
LOCKING COMPOUND
lP~
VEHICLE
FORWARD
DIRECTION
INSERT COTTER PIN

FROM VEHICLE FORWARD
DIRECTION
muJ
Ii)
70-93
{7.2-9.4,
52-58}
Nm {kgfm, ft.lbf}
DBG0213ZWB01
Cotter pin
11
Nut
(See 02-13-7 Front Lower Arm Ball Joint Removal
Note.)
12
Shock absorber lower bolt and nut
Anchor bolt
(See 02-13-13 Anchor Bolt Installation Note.)
6
7
8
Torsion bar spring component
Anchor arm
(See 02-13-11 Anchor Arm Removal Note.)
(See 02-13-12 Anchor Arm Installation Note.)
10
Torsion bar spring

(See 02-13-11 Torsion Bar Spring Removal Note.)
(See 02-13-12 Torsion Bar Spring Installation Note.)
13
14
Torque plate
Lower arm spindle (rear), washer and nut
Lower arm spindle (front), washer and nut
Stabilizer bolt, bushing, retainer, spacer and nut
15
Front lower arm
Anchor swivel
16
17
Bound stopper
Bolt and washer
18
Clip
19
20
Dust boot
Front lower arm bushing
(See 02-13-11 Front Lower Arm Bushing Removal
Note.)
(See 02-13-12 Front Lower Arm Bushing Installation
Note.)
02-13-10
FRONT SUSPENSION
Anchor Arm Removal Note
1. Mark the anchor arm and body for reference
DBG0213ZWB01
Torsion Bar Spring Removal Note

1. Mark the torsion bar spring and anchor arm, and
torsion bar spring and torque plate for reference
DBG0213ZWB01
Front Lower Arm Bushing Removal Note

1. Remove the front lower arm bushing using the
SST.
DBG0213ZWB01
02-13-11
FRONT SUSPENSION
Front Lower Arm Bushing Installation Note
1. Apply soapy water to the new bushing.
2. Install the bushing using the SST.
y.
DBG0213ZWB01
Torsion Bar Spring Installation Note

1. Before installation, check the identification mark
on the end of the torsion bar spring.
OUTSIDE
OFTHE
VEHICLE
:J
CD CD
LEFT SIDE
RIGHT SIDE
OUT SIDE
OFTHE
VEHICLE
DBG213ZWB031
2. Align the marks made during removal, and

connect the torsion bar spring to the torque plate.
~~
JI)(
c'
Y
DBG0213ZWB01
Anchor Arm Installation Note

1. Align the marks made during removal, and install
the anchor arm onto the torsion bar spring.
DBG0213ZWB01
02-13-12
FRONT SUSPENSION
Anchor Bolt Installation Note
1. Install the anchor bolt, and tighten it until the
marks made during removal are aligned.
Note
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.
DBG0213ZWB01
2. Install the anchor arm so that the angle

A is 5530'-6430'.
DBG0213ZWB02
FRONT LOWER ARM INSPECTION

1.
2.
3.
4.
5.
dcf021334130w03
Remove the front lower arm from the vehicle.

Inspect the front lower arm for bending or damage. If there is any malfunction, replace it.
Inspect the ball joint for excessive play. If there is any malfunction, replace the front lower arm.
Rotate the ball joint 5 times.
Measure the ball-joint rotational torque using the
SST and torque wrench.
Front lower arm ball joint rotational torque
[pull scale reading]
20-34 N {2.0-3.5 kgf, 4.4-7.7Ibf}

If not within the specification, replace the front
lower arm.
DBG0213ZWB02
02-13-13
FRONT SUSPENSION
FRONT UPPER ARM REMOVAUINSTALLATION
dcf021334200w01
Caution
Performing the following procedures without first removing the ABS wheel-speed sensor may
possibly cause an open circuit in the wiring harness if it is pulled by mistake. Before performing
the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an
appropriate place where the sensor will not be pulled while servicing the vehicle.
4. Inspect the front wheel alignment and adjust it as
necessary. (See 02-11-3 FRONT WH EEL
ALIGNMENT [4x2]) (See 02-11-5 FRONT
WHEEL ALIGNMENT [4x4].)
19-25
{2.0-2.5,
15-18}
19-25
{2.0-2.5,
15-18}
Hi-Rider, 4x4
19-25
{2.0-2.5,
15-18}
19-25
{2.0-2.5,
15-18} ~-_;A/
Nm {kgfm, ftlbf}
DCF213ZWBOOl
VEHICLE
FORWARD
DIRECTION
INSERT COTTER PIN FROM

VEHICLE FORWARD DIRECTION
Nm {kgfm, ftlbf}
DBG213ZWB032
1
2
3
Brake hose bracket

Cotter pin and nut
Front upper arm ball joint
(See 02-13-15 Front Upper Arm Ball Joint Removal
Note.)
02-13-14
Bolt and washer

(See 02-13-15 Bolt and Washer Installation Note.)
Adjustment shim
(See 02-13-15 Adjustment Shim Removal Note.)
6
7
Front upper arm component

Bolt and washer
FRONT SUSPENSION
8
IFront upper arm ball joint
9
10
Clip
Dust boot
Front Upper Arm Ball Joint Removal Note

1. Separate the upper arm ball joint from the knuckle
arm using the SST.
DBG0213ZWB02
Adjustment Shim Removal Note

1. Note the number, amount and position of the shims so that they are reinstalled in the correct positions.
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 using the
,-----------------------,
SST.
A'
P.'!'
IiiiiI
I'
DBG0213ZWB02
Bolt and Washer Installation Note

Note
Be sure to use a pre-set torque wrench to precisely tighten the upper arm shaft.
1. Install the bolt and washer, and tighten the bolt to
the specified torque.
Tightening torque
150-172 Nm {15.3-17.5 kgfm, 111-126
ftlbf}
02-13-15
FRONT SUSPENSION
FRONT UPPER ARM INSPECTION
1.
2.
3.
4.
5.
dcf021334200w02
Remove the front upper arm from the vehicle.

Inspect the front upper arm for bending or damage. If there is any malfunction, replace it.
Inspect the ball joint for excessive play, and if there is any malfunction, replace the front upper arm.
Rotate the ball joint 5 times.
Measure the ball-joint rotational torque using the
I:
SST and pull scale.
Front upper arm ball joint rotational torque
[pull scale reading]
4.9-25 N {O.5-2.5 kgf, 1.1-5.5Ibf}

If not within the specification, replace the front
upper arm.
DBG0213ZWB02
FRONT STABILIZER AND TENSION ROD REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf021334100w01

24.5-36.2
{2.50-3.69,
18.1-26.6}
~94-116
{9.5-13.0,
69-94}
{9.5-11.9,
69-86}
Nm {kgfm, ttlbf}
DBG0213ZWB02
Nut
Retainer
Bolt
Bushing, retainer and spacer
4
5
Stabilizer bracket
02-13-16
Stabilizer bushing
Front stabilizer
Tension rod nut
(See 02-13-17 Tension Rod Nut Installation Note.)
9
10
Bushing and retainer

Tension rod
FRONT SUSPENSION
Tension Rod Nut I
1. Tighten the t ~stallation Note
enslon
98 .5 mm {3.88
in}. r0 d nuts so that length L is
DBG0213ZWB02
FRONT STABILIZER REMO

1. Remove in the
. VAL/INSTALLATION [ . .
2. Install in the order Indicated in th
HI-Rlder,4x41
___
,everse order of removal.
e table.
dcf021334100w02
.:...::.~r
Nm {kgf.m, ft.lbf}
Nut
(See 02-13-8
Stablhzer
..
Spacer
A
Bolt B
.
Retainer,
Reta. ' nd Nut Installation'
mer
and
bush.
e.
Bolt
mg
------
Retainer and b
N~:h)1n9,
DBG0213ZWB02
5
R
ushlng
etainer, bushin g, and ssprua;-;c::;;e:;:-r- - - - - -::6:-1f-:S':":ta=b=T'"
I Izer bracket
Stabilizer bushing
Front stabilizer
02-13-17
REAR SUSPENSION
02-14
REAR SUSPENSION
REAR SUSPENSION
LOCATION INDEX ................. 02-14-1
REAR SHOCK ABSORBER

INSPECTION . ................... . 02-14-4
SPRING REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] . .......... 02-14-2
DISPOSAL. ..................... . 02-14-4

REAR STABILIZER REMOVAU
REAR SHOCK ABSORBER AND LEAF
[Hi-Rider, 4x4] ................... 02-14-3
REAR SHOCK ABSORBER
REAR SUSPENSION LOCATION INDEX
dcf02140000Ow01
Hi-Rider, 4x4
DCF214ZWB001
Leaf spring
(See 02-14-2 REAR SHOCK ABSORBER AND
LEAF SPRING REMOVAUINSTALLATION [4x2
(See 02-14-3 REAR SHOCK ABSORBER AND
LEAF SPRING REMOVAUINSTALLATION [HiRider, 4x4].)
Rear shock absorber

(See 02-14-4 REAR SHOCK ABSORBER
INSPECTION.)
(See 02-14-4 REAR SHOCK ABSORBER
DISPOSAL.)
Rear stabilizer (WL-C and WE-C)

(See 02-14-5 REAR STABILIZER REMOVAU
02-14-1
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf021405910w01
Warning
.
Use safety stands for support of the left and right axle casings, and while supporting the
differential casing with a jack, raise or lower the jack as necessary.
1.
2.
3.
4.
Support the frame with safety stands and place a jack under the differential casing.
After installation, tighten the bolt (leaf spring front side) completely on the ground.
59-78 {G.O-8.0, 44-57}
...
-!i!
78-98
{8.0-10.0, 58-72}
III
Nm {kgfm, ttlbf}
DBG214ZWB001
1
2
3
4
5
6
7
Nut and washer

Rear shock absorber
Nut
U-bolt
Spring clamp
Stopper rubber
Bolt
02 .. 14-2
8
9
10
11
Shackle pin
Shackle plate
Leaf spring component
Leaf spring bushing
(See 02-14~3 Leaf Spring Bushing Removal Note.)
(See 02-14-3 Leaf Spring Bushing Installation
Note.)
REAR SUSPENSION
Leaf Spring Bushing Removal Note
1. Secure the leaf spring in a vise and remove the
bushing using a chisel.
AVF7416W004
Leaf Spring Bushing Installation Note

1. Press in the bushing using a suitable pipe.
DBG214ZWB100
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAUINSTALLATION [Hi-Rider, 4x4]
dcf021405910w02
Warning
Use safety stands for support of the left and right axle casings, and while supporting the
differential casing with a jack, raise or lower the jack as necessary.
1.
2.
3.
4.
Support the frame with safety stands and place a jack under the differential casing.
After installation, tighten the bolt (leaf spring front side) completely on the ground.
02-14-3
REAR SUSPENSION
APPLY THREAD
LOCKING
COMP~ ~'-'-~1'5'
4W
~.H'"
~~
I
59-78 {6.1-7.9, 44-57} -
Nm {kgf.m, ftlbf}
DBG214ZWB006
1
2
3
4
5
6
7
8
Bolt, washer and nut

Nut, washer, and retainer
Shock absorber
Nut and washer
U-bolt
Set plate
Spring clamp
Bound stopper
9
10
11
12
13
Bolt
Shackle pin
Shackle plate
Leaf spring component
Leaf spring bushing
(See 02-14-3 Leaf Spring Bushing Removal Note.)
(See 02-14-3 Leaf Spring Bushing Installation
Note.)
REAR SHOCK ABSORBER INSPECTION
dcf021428700w01
1. Inspect the rear shock absorber in the same way as the front shock absorber.
(See 02-13-4 FRONT SHOCK ABSORBER INSPECTION.)
REAR SHOCK ABSORBER DISPOSAL
dcf021428700w02
1. Dispose the rear shock absorber in the same way as the front shock absorber. (See 02-13-5 FRONT SHOCK
ABSORBER DISPOSAL.)
02.-14-4
REAR SUSPENSION
REAR STABILIZER REMOVAL/INSTALLATION [WL-C, WE-C]
dcf02142810OW01

3. After installation, tighten the control link installation bolt completely on the ground.
<G
J~
36-54
{3.7-5.5,
27-39}
~[)) ~~
'-..,.
:::::::=~~::::===:::::/
36-45
~{3.7-4.5,
~~
27-33}
Nm {kgfm, ftlbf}
DBG214ZWB003
Rear stabilizer component

(See 02-14-6 Rear Stabilizer Component
Installation Note.)
3
4
Stabilizer control link

(See 02-14-6 Stabilizer Control Link Installation
Note.)
Stabilizer bracket
Bushing
(See 02-14-5 Bushing Installation Note.)
Rear stabilizer
Bushing Installation Note

1. Install the bushings aligned with the painting part.
FRONT
~===:::- t
BUSHING
DBG214ZWB004
02-14-5
REAR SUSPENSION
Stabilizer Control Link Installation Note
1. Install the stabilizer control link with the painted area pointing towards the under side and inside of the vehicle.
Rear Stabilizer Component Installation Note
1. Temporarily install the rear stabilizer component.
2. Tighten the stabilizer control link nut.
3. Tighten the stabilizer bracket nut.
02-14-6
TECHNICAL DATA
02-50
TECHNICAL DATA
SUSPENSION TECHNICAL DATA . .... 02-50-1
SUSPENSION TECHNICAL DATA
dcf02500000Ow01
Item
Total toe-in
Specifications .
Hi-Rider (Stretch
Double cab
cab (with Rear
Access System)
Regular cab
Tire
[Tolerance
3 {0.12})
(mm {in})
5 {0.19}
3300/-3700/
3000/-3500/
035/
156/
154/
Inner
Outer
Hi-Rider (Double
cab)
Camber angle [Tolerance 1 0]

Caster angle [Tolerance 1 0]
(reference value)
825/
31 30/-3530/
2700/-3200/
044/
207'
045/
206/
1037'
1035/
Note
Difference between the left and right dimension for camber is within 30/.
Difference between the left and right dimension for caster is within 45/.
Specifications
Stretch cab
(with Rear Access System)
Item
Total toe-in
ITire
[Tolerance 3 {0.12}]
(mm {in})
Inner
Outer
Camber angle (reference value) [Tolerance 1]
Caster angle (reference value) [Tolerance 1 0]
Steering axis inclination (reference value)
Double cab
6 {0.23}
31 30/-3530/
2700/-3200/
044/
207'
1037'
045/
206/
1035/
Note
Difference between the left and right dimension for camber is within 30/.
Difference between the left and right dimension for caster is within 45/.
02-50-1
TECHNICAL DATA
Wheel and tires [Australian Specs.]
Item
Wheel
Size
Offset
(mm {in})
(mm {in})
Steel
Material
Size
Up to full
Front persons
Air pressure
Full load
Tire
(kPa ((kgf/cm 2),
Up to full
<psi>})
persons
Rear
Full load
(mm {in})
Remaining tread
(N?m {kgf?m
ft?lbf})
Radial direction
and tire
Wheel imbalance*2
(g {oz})
Specification
15x61/2J
25 {0.98}
139.7 {5.500}
Aluminum
Steel
alloy
15x61/2J
20 {0.79}
16 x 7J
10 {0.39}
Aluminum alloy
215/70R15C 106/1048
235/75R 15 109S 245/70R16 111 S
220 {(2.2), <32>}
210 {(2.1), <30>} 210 {(2.1), <30>}
210 {(2.1), <30>}
210 {(2.1), <30>} 210 {(2.1), <30>}
375 {(3.8), <54>}
290 {(2.9), <42>} 270 {(2.7), <39>}

1.6 {0.06}
88.2-117.6 {9.00-11.99, 65.06-86.73}

1.5 {0.06} max.
2.0 {0.08} max.
10 {0.35} max.

*2 : One balance weight: 60 9 {2.12 oz} max. If the total weight exceeds 120 9 {4.24 oz} on one side, rebalance
*1 :
Suspension
Item
Front lower arm ball joint rotational torque [pull scale
reading]
Front upper arm ball joint rotational torque [pull scale
reading]
02-50-2
Specification
20-34 N {2.0-3.5 kgf, 4.4-7.7Ibf}

4.9-25 N {0.5-2.5 kgf, 1.1-5.5 Ibf}
SERVICE TOOLS
02-60
SERVICE TOOLS
SUSPENSiON ..................... 02-60-1
SUSPENSION
dcf026000000w01
49 T028 3AO
49 0180 510B
49 U0342AO
Ball joint puller

set
Preload
measuring
attachment
Lower arm
bushing puller &
installer set
49 UB39 615
49 U034208
Bushing puller&
installer set
49 U034 209
CHpgu;de
r.4~9~G~03~2~3~4~1----------------r-----------------------+---------------------~1!!J
Oil seal installer
02-60-1
DRIVELINE/AXLE
ON-BOARD DIAGNOSTIC ....
SYMPTOM
TROUBLESHOOTING
[LSD (LIMITED SLIP
DIFFERENTIAL)] ..........
GENERAL PROCEDURES ...
FRONT AXLE ..............
REAR AXLE ...............
03-02
03-03
03-10
03-11
03-12
DRIVE SHAFT.............. 03-13

DIFFERENTIAL [FRONT] ..... 03-14A
DIFFERENTIAL [REAR] ...... 03-14B
PROPELLER SHAFT ........ 03-15
TRANSFER ................ 03-16
4-WHEEL DRIVE ........... 03-18
SERVICE TOOLS ........... 03-60
ON-BOARD DIAGNOSTIC
03-02
RFW (REMOTE FREEWHEEL)

SYSTEM WIRING DIAGRAM ......
ON-BOARD DIAGNOSiS .......
DTC P1812 ........... , ...........
DTC P1813 .......................
03-02-1
03-02-1
03-02-2
03-02-4
DTC
DTC
DTC
DTC
DTC
DTC
P1814 ........................ 03-02-6

P1815 ........................ 03-02-8
P1878 ........................ 03-02-10
P1879 ........................ 03-02-11
P1880 ........................ 03-02-12
P1885 ........................ 03-02-14
RFW (REMOTE FREEWHEEL) SYSTEM WIRING DIAGRAM
dcf03022710Ow01
MAIN RELAY
ENGINE
SWITCH
RFW FREE
SOLENOID
BATTERY
4x4 INDICATOR
LIGHT
PCM (RFW CONTROL)
RFW INDICATOR
LIGHT
DBG302ZWB003
RFW (REMOTE FREEWHEEL) ON-BOARD DIAGNOSIS
dcf03022710Ow02
The on-board diagnostic procedures are mentioned in Section 01. (See 01-028-6 FOREWORD [WL-C, WEC].)
03-02-1
ON-BOARD DIAGNOSTIC
DTCTable
DTC
P1812
P1813
P1814
P1815
P1878
P1879
P1880
P1885
RFW
RFW
RFW
RFW
RFW
RFW
RFW
RFW
Diagnosis system component

Lock solenoid valve circuit failure
Lock solenoid valve open circuit
Lock solenoid valve circuit/short to battery
Lock solenoid valve circuit/short to ground
Free solenoid valve circuit failure
Free solenoid valve open circuit
Free solenoid valve circuit/short to battery
Free solenoid valve circuit/short to ground
(See
(See
(See
(See
03-02-2
03-02-4
03-02-6
03-02-8
(See
(See
(See
(See
03-02-10
03-02-11
03-02-12
03-02-14
OTC
OTC
OTC
OTC
Page
P1812.)
P1813.)
P1814.)
P1815.)
OTC
OTC
OTC
OTC
P1878.)
P1879.)
P1880.)
P1885.)
Simulation Item Table

Output part
Command name
4WOMOOE_L
HUBLOCK
HUBLOCK_L
NTFLAMP
Operation
Operating condition
On/Off
Engine switch at ON
4x4 indicator light

RFW Lock solenoid valve
RFW Free solenoid valve
RFW indicator light
DTC P1812
DTC P1812
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf030227100w03

Circuit malfunction has been detected in the Lock solenoid valve.
Lock solenoid valve malfunction

PCM malfunction
B~--------------------~
BATTERY
T
PCM
PCM
MAIN RELAY WIRING

HARNESS-SIDE CONNECTOR
rciAl
254 253
03-02-2
CETIJ
RFW LOCK SOLENOID VALVE

WIRING HARNESS-SIDE
CONNECTOR
ON-BOARD DIAGNOSTIC
STEP
INSPECTION
INSPECT LOCK SOLENOID VALVE
1
Remove the Lock solenoid valve.
Inspect the Lock solenoid valve.
(See 03-18-4 LOCK AND FREE SOLENOID
VALVES INSPECTION.)
2
COMPLETED
connectors.
Start the engine.
Shift the transfer select lever.
3
Yes
No
ACTION
Replace the Lock solenoid valve, then go to the next step.
Yes

WE-C].)
No
Yes

No
03-02-3
ON-BOARD DIAGNOSTIC
DTC P1813
DTC P1813
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf030227100w04
Open circuit has been detected in the Lock solenoid valve wiring harness.

Open circuit in wiring harness between Lock solenoid valve terminal A and main relay
Open circuit in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
Short to ground in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
PCM malfunction
BATTERY
T
I
I
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rciAl
CilTI
STEP
INSPECTION
1
Yes
No
Disconnect the Lock solenoid valve connector.
2
Yes
CONNECTION
No
03-02-4
ACTION

ON-BOARD DIAGNOSTIC
INSPECT LOCK SOLENOID VALVE CIRCUIT

FOR OPEN CIRCUIT
circuits:
- Lock solenoid valve terminal A (wiring
harness-side) and main relay terminal D
- Lock solenoid valve terminal B (wiring
harness-side)
FOR SHORT TO GROUND
circuits:
- Lock solenoid valve terminal A (wiring
VALVES INSPECTION.)
COMPLETED
connectors.
Start the engine.
Is the same DTC nro,,,ont'}
(See01-02B-10AFTER REPAIR
Are
DTCs present?

Yes
No
Yes
No
Yes
No
or replace the wiring harness for a possible short to

, then go to Step 6.

WE-C].)

03-02-5
ON-BOARD DIAGNOSTIC
DTC P1814
DTC P1814
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf03022710OW05

Short to power circuit has been detected in the Lock solenoid valve wiring harness.

Short to power supply in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
PCM malfunction
BATTERY
T
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rciAl
INSPECTION
STEP
INSPECT
LOCK
SOLENOID
VALVE
Yes
1
No
Yes
2
CONNECTION
No
03-02-6
ACTION

ON-BOARD DIAGNOSTIC
STEP
3
INSPECTION
(Engine off).
circuits:
Is the voltage B+?
VALVES INSPECTION.)
COMPLETED
connectors.
Start the engine.
Yes
ACTION
supply, then go to the Step 5.
No
Yes
No
Yes

WE-C).)
No
Yes

No
II
03-02-7
ON-BOARD DIAGNOSTIC
DTC P1815
DTC P1815
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf030227100w06

Short to ground circuit has been detected in the Lock solenoid valve wiring harness.

Open circuit in wiring harness between Lock solenoid valve terminal A and main relay
Open circuit in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
Short to ground in wiring harness between Lock solenoid valve terminal Band PCM terminal 253
PCM malfunction
Br------------------------.
D~----_.----------~
BATTERY
T
I
I
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rciAl
219
254 253
STEP
INSPECTION

Yes
No

Yes
CONNECTION
No
03-02-8
ACTION

ON-BOARD DIAGNOSTIC
STEP
3
INSPECTION
INSPECT LOCK SOLENOID VALVE POWER
SUPPLY CIRCUIT FOR OPEN CIRCUIT
(Engine off).
Measure the voltage between Lock solenoid
body ground.
Is the voltage B+?
FOR SHORT TO GROUND
Inspect for continuity between Lock solenoid
body ground.
FOR OPEN CIRCUIT
circuits:
harness-side)
VALVES INSPECTION.)
COMPLETED
connectors.
Start the engine.
ACTION
Yes
No
Repair or replace the wiring harness for open, then go to

Step 7.
Yes

No
Yes
No

Yes
No

Yes

WE-C].)
No
Yes

No
03-02-9
ON-BOARD DIAGNOSTIC
DTC P1878
DTC P1878
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf030227100w07

Circuit malfunction has been detected in the Free solenoid valve.
Free solenoid valve malfunction
PCM malfunction
BATTERY
RFW FREE
SOLENOID
VALVE
PCM
PCM
MAIN RELAY WIRING

RFW FREE SOLENOID VALVE

WIRING HARNESS-SIDE
CONNECTOR
rc1Al
ITTIJ
INSPECTION
STEP
1
INSPECT FREE SOLENOID VALVE

Remove the Free solenoid valve.
Inspect the Free solenoid valve.
VALVES INSPECTION.)

COMPLETED
connectors.
Start the engine.
PROCEDURE [WL-C, WE-CJ.)
03-02-10
ACTION
Yes
No
Replace the Free solenoid valve, then go to the next step.

Yes

WE-C].)
No
Yes

(See 01-02B-11 DTC TABLE [WL-C, WE-CJ.)
No
ON-BOARD DIAGNOSTIC
DTC P1879
dcfD3D2271 DOwDS
Open circuit has been detected in the Free solenoid valve wiring harness.
POSSIBLE
CAUSE

Open circuit in wiring harness between Free solenoid valve terminal A and main relay
Open circuit in wiring harness between Free solenoid valve terminal Band PCM terminal 254
Short to ground in wiring harness between Free solenoid valve terminal Band PCM terminal 254
PCM malfunction
BATTERY
RFW FREE
SOLENOID
VALVE
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rc1Al
[BTI
STEP
INSPECTION
Yes
No
Disconnect the Free solenoid valve connector.
Yes
CONNECTION
No
ACTION

03-02-11
ON-BOARD DIAGNOSTIC
STEP
3
INSPECTION
INSPECT FREE SOLENOID VALVE CIRCUIT
FOR OPEN CIRCUIT
circuits:
- Free solenoid valve terminal A (wiring
harness-side) and main relay terminal D
- Free solenoid valve terminal B (wiring
harness-side)
FOR SHORT TO GROUND
circuits:
- Free solenoid valve terminal A (wiring
VALVES INSPECTION.)
COMPLETED
connectors.
Start the engine.
ACTION
Yes
No

Yes

No
Yes

No
Yes

WE-C].)
No
Yes

(See 01-02B-11 DTC TABLE [WL -C, WE-C].)
No
DTC P1880
DTC P1880
DETECTION
CONDITION
POSSIBLE
CAUSE
03-02-12
dcf030227100w09
Short to power circuit has been detected in the Free solenoid valve wiring harness.

Short to power supply in wiring harness between Free solenoid valve terminal Band PCM terminal 254
PCM malfunction
ON-BOARD DIAGNOSTIC
DTC P1880
RFW Free solenoid valve circuiUshort to battery
BATTERY
RFW FREE
SOLENOID
VALVE
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rc1Al
STEP
INSPECTION
ACTION
1
2
CONNECTION
pulled~out pins, and corrosion).
3
Yes Repair or replace the wiring harness for short to power
supply, then go to the Step 5.
(Engine off).
circuits:
Is the voltage B+?
03-02-13
ON-BOARD DIAGNOSTIC
STEP
4
ACTION
INSPECTION
VALVES INSPECTION.)
COMPLETED
connectors.
Start the engine.
Yes
No
Yes

WE-C].)
No
Yes

No
DTe P1885
DTC P1885
DETECTION
CONDITION
POSSIBLE
CAUSE
03-02-14
dcf0302271 OOw1 0
RFW Free solenoid valve circuiUshort to ground
Short to ground circuit has been detected in the Free solenoid valve wiring harness.

Open circuit in wiring harness between Free solenoid valve terminal A and main relay
Open circuit in wiring harness between Free solenoid valve terminal Band PCM terminal 254
Short to GND in wiring harness between Free solenoid valve terminal Band PCM terminal 254
PCM malfunction
ON-BOARD DIAGNOSTIC
BATIERY
RFW FREE
SOLENOID
VALVE
T
I
I
PCM
PCM
MAIN RELAY WIRING


WIRING HARNESS-SIDE
CONNECTOR
rciAl
CilTI
254 253
STEP
1
INSPECTION
ACTION

CONNECTION
INSPECT FREE SOLENOID VALVE POWER
SUPPLY CIRCUIT FOR OPEN CIRCUIT
No Repair or replace the wiring harness for open, then go to
Step 7.
(Engine off).
Measure the voltage between Free solenoid
body ground.
Is the voltage B+?
03-02-15
ON-BOARD DIAGNOSTIC
STEP
4
INSPECTION
FOR SHORT TO GROUND
Inspect for continuity between Free solenoid
valve terminal 8 (wiring harness-side) and
body ground.
FOR OPEN CIRCUIT
circuits:
- Free solenoid valve terminal 8 (wiring
harness-side)
VALVES INSPECTION.)

COMPLETED
connectors.
Start the engine.
03-02-16
ACTION
Yes

No
Yes
No

Yes
No
Yes

WE-C].)
No
Yes

No
ON-BOARD DIAGNOSTIC [4x4 control module]
03-02
4x4 CONTROL SYSTEM WIRING DIAGRAM

[4x4 control module] .............. 03-02:-2
4x4 CONTROL SYSTEM ON-BOARD
DIAGNOSIS [4x4 control module] .... 03-02-2
DTC No.1 [4x4 control module] ....... 03-02-4
DTC No.2 [4x4 control module] ....... 03-02-5
DTe
DTe
DTe
DTe
DTe
No.3 [4x4 control

No.4 [4x4 control
No.5 [4x4 control
No.6 [4x4 control
No.7 [4x4 control
module]
module]
module]
module]
module]
....... 03-02-6
....... 03-02-8
....... 03-02-9
....... 03-02-11
....... 03-02-12
03-02-1

4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]
B+
4x4
CONTROL
MODULE
id0302a1801500
IG1
TRANSFER CASE
CLUTCH COIL
TCM
DLC
4x4 SWITCH
4x2 HI
4x4 HI
4x4LO
A
D
C
F
DIGITAL TR SENSOR J ] - - - - - (
FREE SOLENOID
arnffw00001937
4x4 CONTROL SYSTEM ON-BOARD DlAGNOSIS[4x4 control module]
id0302a1801600
Reading DTC procedure

1. Turn the engine switch off.
2. Connect an inspection lamp to the DLC terminal
FAT and battery.
(Engine off)
4. The inspection lamp will indicate a DTC by
flashing.
Note
A verified DTC is flashed 3 times repeatedly
by the inspection lamp.
If more than one DTC is detected, the first
DTC is displayed, and then next one is
displayed.
5. Repair the malfunctioning part using the verified
DTC.
6. After completion of repairs, clear all DTCs from
memory.
03-02-2
BATTERY
arnffwOOOO 1958

Clearing DTC procedure
1. Turn the engine switch off.
2. Attach a jumper wire to the DLC terminal FAT and
ground.
(Engine off)
4. Turn the engine switch off after 5 s or more has
elapsed.
5. Remove the jumper wire.
6. Verify that the same DTC is not present.
JUMPER
WIRE
FAT
ili
BODY GROUND
DTCTable
DTC
Inspection lamp flashing pattern
No.
~
~
~
~
~GINE SWITCH ON,
0.6 sec.
3 sec.
~
'5sec.
0.5 sec.
'~
0.5 sec.
3 sec.
1 sec.
0.5 sec.
1 sec.
0.5 sec.
--------1
3 sec.
Clutch coil
malfunction
(See OTC NO.3 [4x4

control module].)
Speed sensor
malfunction
(See OTC No.4 [4x4

control module].)
Solenoid valve
malfunction
(See OTC NO.5 [4x4

control module].)
4x4 switch
malfunction
(See OTC No.6 [4x4

control module].)
Motor component
(position sensor)
malfunction
(See OTC NO.7 [4x4

control module].)
.-ON
.-OFF
3 sec.
0.5 sec.
ENGINESWITCHON'~DEFECTIVECODE
.~
1 sec. 0.5 sec. 1 sec.
.-ON
1...-------1
3 sec.
0.5 sec.
'-OFF
DEFECTIVE CODE
ENGINE SWITCH ON
(See OTC No.2 [4x4

control module].)
'-OFF
'~
I...-_ _ _ _----J
3 sec.
Motor component
(shift motor)
malfunction
'-ON
ENGINE SWITCH ON, ~DEFECTIVE CODE

0.5 sec.
0.6 sec.
1 sec.
3 sec.
(See OTC No.1 [4x4

control module].)
'-ON
'-OFF
'I
.ENGINESWITCHON,~~CODE
3 sec.
4x4 control module

malfunction
'-OFF
3 sec.
I...-_ _ _ _----l
0.6 sec.
ENGINESWITCHON,~DEFECTIVECODE
0.5 sec.
0.6 sec.
1 sec. 0.5 sec.
3 sec.
Page
1 sec.! _ _ _ _ _----l .-ON
0.5 sec.
0.6 sec.
,~
DEFECTIVE CODE
Possible cause
I_~~se_c_._ _ _ _~~ ~ fl~ec_'_ _ _ _----l~:~~F

3 sec.
7
I,ENGINE SWITCH O~ I
'
~.
0.5 sec.
3 sec.
DEFECTIVE CODE
1 sec.
0.5 sec.
1 sec.
3 sec.
03-02-3

DTC No.1 [4x4 control module]
DTC No.1
DETECTION
CONDITION
id0302a1801700
4x4 CM malfunction
Open circuit or short to ground has been detected in the 4x4 CM wiring harness.
Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals T, Y, Z and
battery
Open circuit in the wiring harness between the following 4x4 CM terminals W, X and ground
4x4 CM malfunction
Poor connection at connector (female terminal)
POSSIBLE
CAUSE
ENGINE SWITCH
- .--
--v'
- - -
BATTERY
r-r-
1-':-
I
I
Q9
'-- t-
(6)
\:!)
CD
4x4CM
7.7-
7i74x4CM
_0
cc=l
I~~
n
E
II
A
B
STEP
1
INSPECTION
MEASURE VOLTAGE BETWEEN 4x4 CONTROL
MODULE CONNECTOR TERMINAL T, Y, Z AND
GROUND
Turn engine switch ON.
Is the voltage greater than 10 V?
ACTION
Yes
No
Repair or replace the wiring harness, then go to step 3.
INSPECT FOR CONTINUITY BETWEEN 4x4

CONTROL MODULE CONNECTOR TERMINAL
W, X AND GROUND
Turn engine switch OFF.
Yes
No
Repair or replace the wiring harness, then go to next step.
VERIFY THAT THE SAME DTC IS NOT

PRESENT
Clear the DTCs from the memory.
(See 03-02-2 4x4 CONTROL SYSTEM ONBOARD DIAGNOSIS[4x4 control module].)
VERIFY THAT NO OTHER DTCS ARE PRESENT
Yes
If the malfunction recurs, replace the 4x4 CM, then go to

the next step.
(See 03-18-5 4x4 CONTROL MODULE REMOVAU
INSTALLATION [AT (5R55S)].)
No
Yes

(See 03-02-2 4x4 CONTROL SYSTEM ON-BOARD
DIAGNOSIS[4x4 control module].)
No
03-02-4

DTC No.2
id0302a1801800
DETECTION
CONDITION
POSSIBLE
CAUSE
Open circuit or short to ground has been detected in the motor component (shift motor) wiring harness.
Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (shift motor) terminals:
- 4x4 CM terminal A- motor component (shift motor) terminal C
- 4x4 CM terminal B- motor component (shift motor) terminal C
- 4x4 CM terminal C- motor component (shift motor) terminal F
- 4x4 CM terminal D- motor component (shift motor) terminal F
4x4 CM
TRANSFER CASE
MOTOR COMPONENT
4x4CM
~;:=r
MOTOR COMPONENT
n
A
B
STEP
INSPECTION
INSPECT MOTOR COMPONENT (SHIFT
MOTOR)
Inspect the motor component (shift motor).
(See 03-16-4 MOTOR INSPECTION [5R55S].)
Is the motor component (shift motor)?
MOTOR) WIRING HARNESS FOR SHORT TO
GROUND
Disconnect the 4x4 CM connector.
Disconnect the motor component connector.
Inspect for continuity between the motor
component connector terminals A, B, C, D
(vehicle harness-side) and body ground.
Yes
No
ACTION
Replace the motor component, then go to step 4.
Yes
No

03-02-5

INSPECTION
ACTION
STEP
3
MOTOR) WIRING HARNESS FOR OPEN
No Repair or replace the wiring harness, then go to next step.
CIRCUIT
Inspect for continuity between the 4x4 CM
connector (vehicle harness-side) and the
following vehicle harness-side terminals of
motor component:
- 4x4 CM connector A- Motor component
(shift motor) terminal C
- 4x4 CM connector B- Motor component
(shift motor) terminal C
- 4x4 CM connector C- Motor component
(shift motor) terminal F
- 4x4 CM connector D- Motor component
(shift motor) terminal F
Yes Repeat the inspection from Step 1.
4
PRESENT
the
next step.
Reconnect
all
disconnected
connectors.
(See 03-18-S 4x4 CONTROL MODULE REMOVAU

INSTALLATION [AT (SRSSS)].)
Change the current transfer mode by operating
the 4x4 switch.(2H-4H-4L)
VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.
S
id0302a1801900
DTC No.3
DETECTION
Open circuit, short to ground or short to battery has been detected in the clutch coil wiring harness.
CONDITION
Open circuit in the wiring harness between 4x4CM terminal U and clutch coil terminal C, short to battery or
POSSIBLE
to ground
CAUSE
4x4CM
TRANSFER CASE
cg:
4x4CM
fl
=r
I~~
03-02-6
V CLUTCH COIL
SPEED SENSOR
n
A
L....I
~I I I In
C
I~~I

STEP
INSPECTION
1
INSPECT CLUTCH COIL
Inspect the clutch coil.
(See 03-16-6 CLUTCH COIL INSPECTION
[5R55S].)
Is the clutch coil normal?
2
INSPECT CLUTCH COIL WIRING HARNESS

FOR SHORT TO GROUND
Disconnect the clutch coil connector.
connector terminal U (vehicle harness-side)
and body ground.
FOR SHORT TO POWER SUPPLY CIRCUIT
Measure voltage between the clutch coil
connector terminal C (vehicle harness-side)
and body ground.
Is the voltage 1 V or less?
FOR OPEN CIRCUIT
connector U (vehicle harness-side) and the
vehicle harness-side terminal C of clutch coil.
PRESENT
Reconnect all disconnected connectors.
the 4x4 switch.(2H-4H)
ACTION
Yes
No
Replace the clutch coil, then go to step 5.
Yes
No
Yes

No
Yes
No
Yes
Repeat the inspection from step 1.

the next step.
(See 03-18-5 4x4 CONTROL MODULE REMOVALJ
No
Yes

No
03-02-7

id0302a 1802000

DTC No.4
DETECTION
Open circuit or short to ground has been detected in the speed sensor wiring harness.
CONDITION
Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the
speed sensor terminals:
- 4x4 CM terminal M- speed sensor terminal B
- 4x4 CM terminal N- speed sensor terminal A
POSSIBLE
CAUSE
4x4CM
TRANSFER CASE
I~ ~~~~~R II
4x4CM
lEt rrl
I~~
SPEED SENSOR
rl
A
B
~I:I
ID
I~~I
STEP
1
INSPECTION
INSPECT SPEED SENSOR
Inspect the speed sensor.
(See 03-16-3 SPEED SENSOR INSPECTION
[5R55S].)
Is the speed sensor normal?
Yes
No
ACTION
Replace the speed sensor, then go to step 4.
(See 03-16-4 SPEED SENSOR REMOVAUINSTALLATION
[5R55S].)
INSPECT SPEED SENSOR WIRING HARNESS

FOR SHORT TO GROUND
Disconnect the speed sensor connector.
connector terminals M, N (vehicle harnessside) and body ground.
Yes
No
INSPECT SPEED SENSOR WIRING HARNESS

FOR OPEN CIRCUIT
speed sensor:
- 4x4 CM connector M- speed sensor
terminal B
- 4x4 CM connector N- speed sensor
terminal A
Yes
No
Repair or replace the wiring harness, then go to next step.

PRESENT
Yes

the next step.
No
03-02-8

STEP
INSPECTION
VERIFY THAT NO OTHER DTCS ARE PRESENT Yes
No
ACTION
id0302a1802100
Solenoid valve malfunction

DTC No.5
DETECTION
Open circuit or short to ground has been detected in the solenoid valve wiring harness.
CONDITION
Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the lock solenoid
valve terminal B
Open circuit or short to ground in the wiring harness between the 4x4 CM terminal V and the 4x4 relay
terminal E
Open circuit or short to ground in the wiring harness between the free solenoid valve terminal B and the
POSSIBLE
4x4 relay terminal B
CAUSE
Open circuit in the wiring harness between the lock solenoid valve terminal A and ground
Open circuit in the wiring harness between the 4x4 relay terminal A, D and ground
Open circuit in the wiring harness between the free solenoid valve terminal A and battery
lock solenoid malfunction
LOCK SOLENOID
4x4CM
ENGINE SWITCH
BATTERY
T
FREE SOLENOID
4x4CM
_n
1=L? 1
4x4 RELAY WIRING

HARNESS-SIDE
CONNECTOR
n
A
LE
~ IA
LOCK AND FREE SOLENOID

VALVES WIRING HARNESS-SIDE
CONNECTOR
STEP
1
INSPECTION
INSPECT SOLENOID VALVE WIRING HARNESS
FOR SHORT TO GROUND
Disconnect the lock solenoid connector.
Disconnect the 4x4 relay connector.
connector terminal V (vehicle harness-side)
and body ground.
Inspect for continuity between the 4x4 relay
connector terminal B (vehicle harness-side)
and body ground.
Yes
No
ACTION
03-02-9

INSPECTION
STEP
2
INSPECT SOLENOID VALVE WIRING HARNESS

FOR OPEN CIRCUIT
and the vehicle harness-side terminal B of lock
solenoid.
and the vehicle harness-side terminal E of 4x4
relay.
Inspect for continuity between the lock solenoid
connector terminal A (vehicle harness-side)
and body ground.
Inspect for continuity between the 4x4 relay
connector terminals A, D (vehicle harnessside) and body ground.
Inspect for continuity between the free solenoid
connector terminal B (vehicle harness-side)
and the vehicle harness-side terminal B of 4x4
relay.
MEASURE VOLTAGE BETWEEN FREE

SOLENOID VALVE CONNECTOR TERMINAL A
AND GROUND
INSPECT SOLENOID VALVE
Inspect the lock and free solenoid valves.
Is the lock and free solenoid valves normal?
INSPECT 4x4 RELAY
Inspect the 4x4 relay.
Is the 4x4 relay normal?
ACTION
Yes
No
Yes

No
Yes
No

Replace the solenoid valve, then go to the step 6.
Yes
No

Replace the 4x4 relay, then go to the next step.

Yes Repeat the inspection from step 1.
PRESENT
the next step.
the 4x4 switch.(2H-4H)
VERIFY THAT NO OTHER DTCS ARE PRESENT Yes Go to the applicable DTC troubleshooting.
03-02-10

id0302a1802200
DTC No.6
DETECTION
Open circuit or short to ground has been detected in the 4x4 switch wiring harness.
CONDITION
Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the 4x4
switch terminals:
POSSIBLE
- 4x4 CM terminal G- 4x4 switch terminal A
- 4x4 CM terminal F- 4x4 switch terminal C
CAUSE
4x4SWITCH
4x4CM
G l I - - - - - - - { A 4x2 HI
F~-----~
}-~~o
F}-------'
4x4CM
r-a==t ;=r 1
4x4SWITCH
n
A
STEP
INSPECTION
INSPECT 4x4 SWITCH
1
Inspect the 4x4 switch.
(See 03-18-2 4x4 SWITCH INSPECTION [AT
(5R55S)].)
Is the 4x4 switch normal?
INSPECT 4x4 SWITCH WIRING HARNESS FOR
2
SHORT TO GROUND
Disconnect the 4x4 switch connector.
connector terminals G, F (vehicle harnessside) and body ground.
INSPECT 4x4 SWITCH WIRING HARNESS FOR
3
OPEN CIRCUIT
following vehicle harness-side terminals of 4x4
switch:
- 4x4 CM connector G- 4x4 switch terminal
A
- 4x4 CM connector F- 4x4 switch terminal
C
Yes
No
ACTION
Replace the 4x4 switch, then go to step 4.
(See 03-18-3 4x4 SWITCH REMOVAUINSTALLATION [AT
(5R55S)].)
Yes
No

Yes
No

03-02-11

INSPECTION
STEP
4
Yes
PRESENT
No
S
VERIFY THAT NO OTHER DTCS ARE PRESENT Yes
ACTION
the next step.
(See 03-18-3 4x4 SWITCH REMOVAUINSTALLATION [AT
(SRSSS)].)

No
OTC No.7 [4x4 control module]
id0302a 1802300

Open circuit or short to ground has been detected in the motor component (position sensor) wiring
harness.
Open circuit or short to ground in the wiring harness between the following 4x4 CM terminals and the motor
component (position sensor) terminals:
- 4x4 CM terminal N- motor component (position sensor) terminal G
- 4x4 CM terminal J- motor component (position sensor) terminal E
- 4x4 CM terminal 1- motor component (position sensor) terminal B
- 4x4 CM terminal L- motor component (position sensor) terminal A
- 4x4 eM terminal H- motor component (position sensor) terminal D
DTC No.2
DETECTION
CONDITION
POSSIBLE
CAUSE
4x4 CM
TRANSFER CASE
MOTOR COMPONENT
POSITION 4
4x4CM
r"E::L
=r 1
03-02-12
MOTOR COMPONENT
n
A

STEP
INSPECTION
INSPECT MOTOR COMP(jNENT (POSITION
1
SENSOR)
Inspect the Motor component (position sensor)
Is the Motor component (position sensor)
normal?
INSPECT MOTOR COMPONENT (POSITION
2
SENSOR) FOR SHORT TO GROUND
Disconnect the motor component connector.
Inspect for continuity between the motor
component connector terminals N, J, I, L, H
(vehicle harness-side) and body ground.
3
SENSOR) WIRING HARNESS FOR OPEN
CIRCUIT
motor component:
- 4x4 CM connector N- Motor component
terminal G
- 4x4 CM connector J- Motor component
terminal E
- 4x4 CM connector 1- Motor component
terminal B
- 4x4 CM connector L- Motor component
terminal A
- 4x4 CM connector H- Motor component
terminal D
4
PRESENT
5
ACTION
Yes
No
Replace the motor component, then go to the next step.

(See 03-16-5 MOTOR REMOVAUINSTALLATION
[5R55S].)
Yes
No
Yes
No
Yes

the next step.
No
Yes

No
03-02-13
SYMPTOM TROUBLESHOOTING [LSD (LIMITED SLIP DIFFERENTIAL)]
03-03 SYMPTOM TROUBLESHOOTING [LSD (LIMITED

SLIP DIFFERENTIAL)]
FOREWORD ......................
PRECAUTION . ....................
SYMPTOM TROUBLESHOOTING . ....
NO.1 NO RFW OPERATION FROM
FREE TO LOCK (RFW INDICATOR
LIGHT DOES NOT ILLUMINATE) ....
03-03-1
03-03-2
03-03-2
03-03-3

LOCK TO FREE (RFW INDICATOR
LIGHT DOES NOT GO OFF) ........ . 03-03-5
NO.3 NOISE . ..................... . 03-03-7
NO.4 OIL LEAKAGE . ............... . 03-03-8
FOREWORD
dcf03032710Ow01
Malfunction vehicle delivered
Questionnaire
Verify malfunction symptoms
I Symptom troubleshooting [
Confirm all customer problems using a questionnaire.
Confirm malfunction on actual vehicle.
OTC inspection
[Inspect for OTCs using current diagnostic tool.
Perform applicable troubleshooting inspection according to

diagnostic index.
Verify that malfunctions have been repaired
Troubleshooting completed
DCF303ZWBOOl
03-03-1

PRECAUTION
dcf030327100w02
This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair if necessary for
trouble caused by other sources.
Inspect the connector and terminal connections when inspecting the wiring harness. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harness.)
. Quick Diagnosis Chart
x: Applicable
Possible factor
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iii
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No RFW operation from lock to free
Noise
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a.
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CC
X X
X X
X X
X X
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X X
4
Oil leakage
--
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>
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CC
No RFW operation from free to lock
'~
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X
X
DBG303ZWB001
. SYMPTOM TROUBLESHOOTING
dcf03032710OW03
Verify the symptoms, and perform troubleshooting according to the appropriate number.
Symptom
No.
1
No RFW operation from free to lock (RFW

indicator light does not illuminate.)
03-03-2
Description
RFW indicator light bulb malfunction
RFW actuator malfunction
RFW switch malfunction
Print plate in instrument cluster malfunction
Main fuse malfunction
Transfer neutral switch malfunction
4x4 indicator switch malfunction
peM malfunction
RFW control box malfunction
Air leakage from vacuum hose
One-way check valve malfunction
Related fusses and/or harness malfunction

No.
Symptom
No RFW operation from lock to free (RFW

indicator light does not go off.)
3
4
Noise
Oil leakage
Description
Main fuse malfunction
RFW main switch malfunction
PCM malfunction
Related fuses and/or harness malfunction
Joint shaft bearing abrasion or damage
RFW hub abrasion
Joint shaft abrasion
RFW control box is poorly installed
NO.1 NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
dcf030327100w04
1
NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE.)
DESCRIPTION RFW does not change from free to lock.
PCM malfunction
RFW indicator light bulb malfunction
Main fuse and/or main relay malfunction
Related fuses and/or harnesses malfunction
STEP
1
INSPECTION
INSPECT MAIN FUSE.
Is it OK?
INSPECT RFW INDICATOR LIGHT BULB

Is it OK?
MEASURE VOLTAGE BETWEEN

INSTRUMENT CLUSTER CONNECTOR
TERMINAL 1 F AND GROUND.
MEASURE VOLTAGE BETWEEN
INSTRUMENT CLUSTER CONNECTOR
TERMINAL 1 D AND GROUND.
SOLENOID VALVE CONNECTOR TERMINAL
A AND GROUND.
Disconnect free solenoid valve connector.
measure voltage between free solenoid
valve connector terminal A and ground.
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Go to next step.
Replace main fuse, then go to Step 27.
Go to next step.
Replace the RFW indicator light bulb, then go to Step 27.
Go to next step.
' Repair wiring harness between main fuse and instrument
cluster, then go to Step 27.
Repair wiring harness between instrument cluster and PCM,
then go to Step 27.
Replace print plate in instrument cluster, then go to Step 27.
Connect free solenoid valve, then go to next step.
Repair wiring harness between main relay and free solenoid
valve connector, then go to Step 27.
03-03-3

STEP
6
10
11
12
13
14
15
16
17
18
19
20
21
INSPECTION
B AND GROUND.
ACTION
Yes
Go to next step.
No
Inspect free solenoid valve, then go to Step 27.
MEASURE VOLTAGE BETWEEN PCM

CONNECTOR TERMINAL 254 AND GROUND.
Yes
No
Go to next step.
Repair'wiring harness between free solenoid valve and
PCM, then go to Step 27.
MEASURE VOLTAGE BETWEEN LOCK

A AND GROUND.
Disconnect lock solenoid valve connector.
B AND GROUND.
Yes
Connect lock solenoid valve, then go to next step.
No
Repair wiring harness between main relay and lock solenoid

Yes
No
Go to next step.
Repair wiring harness between PCM and ground, then go to
Step 27.
Yes
No
Go to next step.
Inspect lock solenoid valve, then go to Step 27.
INSPECT FOR CONTINUITY BETWEEN PCM

CONNECTOR TERMINAL 202/204/206 AND
GROUND.
Yes
Go to next step.
No

Step 27.

INSPECT FOR CONTINUITY BETWEEN
TRANSFER NEUTRAL SWITCH CONNECTOR
TERMINAL A AND GROUND.
INSPECT TRANSFER NEUTRAL SWITCH.
Is it OK?
Yes
No
Go to Step 16.
Go to next step.
Yes
Repair wiring harness between PCM and transfer neutral

switch, then go to Step 27.
No
Go to next step.
Yes
Go to next step.
Replace transfer neutral switch, then go to Step 27.
No

TERMINAL B AND GROUND.
Yes
No

Shift select lever to 4x4 indicator position.
Yes
Go to Step 20.
No
Go to next step.
Yes
Repair wiring harness between 4x4 indicator switch and

No
Go to next step.
INSPECT 4X4 INDICATOR SWITCH.

Is it OK?
Yes
No
Go to next step.
Replace 4x4 indicator switch, then go to Step 27.
INSPECT FOR CONTINUITY BETWEEN 4X4

INDICATOR SWITCH CONNECTOR
Yes
Go to next step.
No


Go to next step.
Repair wiring harness between transfer neutral switch and

Shift select lever to 4H position.
Yes
Go to Step 24.
No
Go to next step.
INSPECT FOR CONTINUITY BETWEEN RFW

SWITCH CONNECTOR TERMINAL A AND
GROUND.
Yes
Repair wiring harness between PCM and RFW switch, then

go to Step 27.
No
Go to next step.
03-03-4

INSPECTION
STEP
22
INSPECT RFW SWITCH.
Is it OK?
ACTION
Yes
No
Go to next step.

SWITCH CONNECTOR TERMINAL BAND
GROUND.
INSPECT ONE-WAY CHECK VALVE.
Is it OK?
Yes
No
Go to next step.
Repair wiring harness between RFW switch and ground,
then go to Step 27.
Yes
Go to next step.
No
Replace one-way check valve, then go to Step 27.
25
INSPECT RFW CONTROL BOX.

Is it OK?
Yes
No
Go to next step.
Replace RFW control box, then go to Step 27.
26
INSPECT VACUUM IN VACUUM HOSES.

Is it OK?
Yes
Go to next step.
No
Yes
Replace vacuum in vacuum hoses, then go to Step 27.

Troubleshooting completed. Explain repairs to customer.
No
Inspect malfunction symptoms again, then repeat from Step

1 if malfunction occurs again.
23
24
27
DOES RFW OPERATE FROM FREE TO

LOCK?
Shift select lever from 2H to 4H position.
Does RFW operate from free to lock?
Replace RFW switch, then go to Step 27.
NO.2 NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
2
dcf030327100wOS
NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF.)
DESCRIPTION RFW does not change from lock to free.

RFW main switch malfunction
PCM malfunction
Air leakage from vacuum reservoir or actuator system
One-way check valve
INSPECTION
STEP
1
INSTRUMENT CLUSTER TERMINAL 1 F AND
GROUND.
Disconnect instrument cluster connector
NO.1.
INSPECT MAIN RELAY.
2
Inspect main relay.
Is it OK?
3

A AND GROUND.
B AND GROUND.
Yes
No
Yes
No
Yes
ACTION
Repair wiring harness between PCM and instrument cluster,
then go to Step 30.
Inspect for no continuity between instrument cluster terminal
1F and ground
Repair wiring harness between main relay and PCM, then

go to Step 29.
Replace the main relay, then go to Step 29.
No

Yes
No
Go to next step.
Inspect free solenoid valve, then go to Step 29.
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and

03-03-5

INSPECTION
STEP
6
10
11
13
14
15
16
17
18
19
20
21
22

A AND GROUND.
Disconnect lock solenoid valve connector.
Yes
No
ACTION
Yes
No
Go to next step.

Yes

CONNECTOR TERMINAL 202/204/206 AND
GROUND.
Shift select lever to N position.
Shift select lever to 2 H position.
INSPECT 4X4 INDICATOR SWITCH.
Is it OK?
Yes
No
Go to next step.
Repair wiring harness between lock solenoid valve and
Go to next step.

B AND GROUND.

No
Yes
No
Yes
No

Step 29.
Go to Step 14.
Go to next step.
Repair wiring harness between PCM and transfer neutral

Go to next step.
Yes
No
Go to next step.
Repair wiring harness between transfer neutral switch and
Yes
No
Go to Step 18.
Go to next step.
Yes
Repair wiring harness between PCM and 4x4 indicator

No
Go to next step.
Yes
Go to next step.
No
Yes
No
Replace 4x4 indicator switch, then go to Step 29.

Go to next step.

SWITCH CONNECTOR TERMINAL A AND
GROUND.
INSPECT RFW SWITCH.
Is it OK?
Yes
No

SWITCH CONNECTOR TERMINAL BAND
GROUND.
MAIN SWITCH CONNECTOR TERMINAL D
AND GROUND.
03-03-6
Inspect lock solenoid valve, then go to Step 29.

Go to Step 25.
Go to next step.
Yes
Repair wiring harness between RFW switch, then go to Step

29.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Replace RFW switch, then go to Step 29.

Repair wiring harness between RFW switch and ground,
then go to Step 29.
Yes
Repair wiring harness between RFW main switch and PCM,

then go to Step 29.
No
Go to next step.

STEP
INSPECTION
23
INSPECT RFW MAIN SWITCH.
Is it OK?
24
25

MAIN SWITCH CONNECTOR TERMINAL B
AND GROUND.
INSPECT ONE-WAY CHECK VALVE.
Is it OK?
26
INSPECT RFW ACTUATOR.

Is it OK?
27
INSPECT VACUUM IN VACUUM HOSES.

Is it OK?
28
INSPECT PCM.
Is it OK?
29
DOES RFW OPERATE FROM FREE TO

LOCK?
Move selector lever from 2H to 4H position.
Does RFW operate from free to lock?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Go to next step.
Replace RFW main switch.
Go to next step.
Repair wiring harness between RFW main switch and
Go to next step.
Replace one-way check valve, then go to Step 29.
Go to next step.
Replace RFW actuator, then go to Step 29.
Go to next step.
Replace vacuum in vacuum hoses, then go to Step 29.
Go to next step.
Repair or replace PCM, then go to next step.
NO.3 NOISE
3
NOISE
DESCRIPTION Noise is heard from front differential.
Joint shaft bearing abrasion or damage.
RFW hub abrasion
Conventional front differential parts malfunction
STEP
1
INSPECTION
INSPECT JOINT SHAFT BEARING.
Is it OK?
INSPECT RFW HUB

Is it OK?
INSPECT JOINT SHAFT.

Is it OK?
INSPECT CONVENTIONAL FRONT

DIFFERENTIAL PARTS.
Are they OK?
VERIFY THERE IS NO NOISE.
Has front differential noise stopped?
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Go to next step.
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).
03-03-7

NO.4 OIL LEAKAGE
dcf030327100w07
4
lOlL LEAKAGE
DESCRIPTION The oil leaks from front differential.
Poor installation of the RFW control box .
Malfunction of conventional front differential parts .
INSPECTION
STEP
1
VERIFY CONDITION RFW CONTROL BOX

INSTALLATION
Is RFW control box installed completely?
DIFFERENTIAL PARTS.
Are they OK?
VERIFY THERE IS NO OIL LEAKAGE FROM
FRONT DIFFERENTIAL.
Is there any oil leakage from front
differential?
03-03-8
ACTION
Yes
Go to next step.
No
Install RFW control box securely, then go to Step 3.
Yes
No
Go to next step.
Replace defective part(s).
Yes

1 if malfunction still occurs.
No
SYMPTOM TROUBLESHOOTING [4x4 control module]
03-03 SYMPTOM TROUBLESHOOTING [4x4 control

module]
.
4x4 CONTROL SYSTEM WIRING DIAGRAM
[4x4 control module] ........... 03-03-1
PRECAUTION [4x4 control module] ... 03-03-2
SYMPTOM TROUBLESHOOTING
[4x4 control module] ............ 03-03-2
NO.1 NO RFW OPERATION
[4x4 control module] ........ 03-03-3
NO.2 4x4/4L INDICATOR DOSE NOT

ILLUMINATE [4x4 control module] . 03-03-5
NO.3 NO CHANGE FORM 4x2 TO 4x4
[4x4 control module] .......... 03-03-6
NO.4 NO CHANGE FORM 4H TO 4L
[4x4 control module] ......... 03-03-7
NO.5 NOISE [4x4 control module] .... 03-03-9
NO.6 OIL LEAKAGE
[4x4 control module] ........... 03-03-10
4x4 CONTROL SYSTEM WIRING DIAGRAM [4x4 control module]
B+
4x4
CONTROL
MODULE
id03031 0802800
IG1
TRANSFER CASE
r---~Cr--------.
CLUTCH COIL
TCM
MOTOR COMPONENT
DLC
4x4SWITCH
DIGITAL TR SENSOR J } - - - - - (
FREE SOLENOID
arnffw00001937
03-03-1

PRECAUTION [4x4 control module]
id03031 0801500
This section only mentions unique symptoms of the trouble caused by 4x4 system,
Inspect and repair if necessary for trouble caused by other sources,
Inspect the connector and terminal connections when inspecting the wiring harness,
(The cause of the malfunction may be a poor connection in the connectors, terminals, or wiring harness,)
Quick Diagnosis Chart
x: Applicable
Possible factor
-;:::0
(il
ai 1-;:-
1ii
OJ
C3
'00
g
:J
(!)
-3: I~ c
'Cij
C
C .c
(!) (!)
:J C
0
0..
(!)
'S
"C
0
C)
~
C
E E 'c
"C
(!) 0
0 .....
C)
C)
E
.....
2 0 0 c ::2!
1ii (5 (5 ctI ()
c ::2! ::2!
'*
X X
1 No RFW operation
2 4x4/4L indicator dose not illuminate
I-
0en ~ ~
C
(!)
8 '~
en en
..l<:
(!)
~ ~ is .3 tt
'0
XX X
"C "C
C)
~e
:J
..l<:
C)
(!)
i'n'
:5:
cb
c
~a: a:
~0
.....
.....
..e
"C
:J
:J
'6
OJ
C
'c
OJ
C
ctI ctI
al en (!)
.c
0 en
C)
.c :J
C
.0
E(!)
ca
.c
5 ~ ~
'0
en '0
c c
.c a: (!)
(!)
C .8 I- (5 (5
(!)
- 'iii
"C
(!)
:J
.0
'iii 8l
en
:J .c
.c .c
en
en
"til C
(jj
~ a: '0J
~a:
C.
'0 ~
J
i=
-e e
"fa ca (il
(!) (!) c
.0
.0 OJ 0
..... ..... :;::;
c
c c c~
'* '*
ctI ctI
6 FF
0
()
.0
C
0
C)
(!)
(5
C)
.0
OJ
,;
~
a: U)
(il
(!)
.....
CD
.c (il
'*
"til (!)
en c
~
CO
ctI
6 F
X XX X X XX
X X
3 No change from 4x2 to 4x4
X X XX X X
4 No change from 4H to 4L
X X
X X X X
X XX X X X X X
5 Noise
ca
0..
(il
en
(!)
en
en
(!)
c
en.8
c 0
~ E
'00 :'!:;
0 .c
CD
en
6 Oil leakage
X X X XX X
arnffw00001938
id03031 0800300
Verify the symptoms, and perform troubleshooting according to the appropriate number,
No,
Symptom
Description
No RFW operation
4x4/4L indicator dose not illuminate
3
No change form 4x2 to 4x4
4
No change form 4H to 4L
03-03-2

Related fuses and lor harnesses malfunction
TCM malfunction
TCM malfunction
Drive chain malfunction
TCM malfunction
Digital TR sensor malfunction

No.
5
Symptom
Noise
6
Oil leakage
Description
RFW hub abrasion
Incorrect tire pressure
Improper oil level
Transfer bearing damaged
Transfer gear damaged
Transfer drive chain damaged
Transfer case malfunction
Improper oil level
Loosened sealing bolts
Breather clogging
Improper oil seal
NO.1 NO RFW OPERATION [4x4 control module]
id03031 0802000
1
NO RFW OPERATION
DESCRIPTION RFW dose not change from lock to free or from free to lock.
TROUBLESHO
OTING HINTS
INSPECTION
STEP
1
AANDGROUND
Measure voltage between free solenoid valve
connector terminal A and ground.
2
B AND GROUND
MEASURE VOLTAGE BETWEEN 4x4
3
CONTROL MODULE CONNECTOR
TERMINAL V AND GROUND
4
AANDGROUND
Measure voltage between free solenoid valve
connector terminal A and ground.
5
BANDGROUND
Yes
No
ACTION
valve connector.
Then go to Step 14.
Yes
No
Go to next step.
Inspect free solenoid valve.
Then go to Step 14.
Yes
Go to next step.
No
Repair wiring harness between free solenoid valve and 4x4

control module.
Then go to Step 14.
Yes
No

valve connector.
Then go to Step 14.
Yes
No
Go to next step.
Inspect lock solenoid valve.
Then go to Step 14.
03-03-3

INSPECTION
STEP
10
11
12
13
14

TERMINAL V AND GROUND
TERMINAL W, X AND GROUND
TERMINAL T, Y, Z AND GROUND
INSPECT 4x4 SWITCH
Is 4x4 switch OK?
INSPECT CONTINUITY FOR 4x4 SWITCH
Between 4x4 switch connector terminal A
and 4x4 control module terminal G.
Between 4x4 switch connector terminal C
and 4x4 control module terminal F.
Between 4x4 switch connector terminal F
and ground.
ACTION
Yes
Go to next step.
No
Repair wiring harness between lock solenoid valve and 4x4

control module.
Then go to Step 14.
Yes
Go to next step.
No
Repair wiring harness between 4x4 control module and

ground.
Then go to Step 14.
Yes
Go to next step.
No
Repair related wiring harness and related fuses.

Then go to Step 14.
Yes
Go to next step.
No
Repair or replace 4x4 switch.

Then go to step 14.
Yes
No
Go to next step.
Repair wiring harness between 4x4 switch and 4x4 control
module.
Then go to Step 14.
INSPECT ONE-WAY CHECK VALVE

Is one-way check valve OK?
Yes
No
INSPECT RFW ACTUATOR

Is RFW actuator OK?
Yes
INSPECT VACUUM HOSE

Is vacuum hose OK?
Yes
No
No
Go to next step.
Replace one-way check valve.
Then go to step 14.
Go to next step.
Replace RFW actuator.
Then go to step 14.
Go to next step.
Repair or Replace vacuum hose.
Then go to step 14.

- If normal, return to the diagnostic index to service any additional symptoms.
- If malfunction remains, inspect the related Service Bulletins and/or On-line Repair Information and perform
repair or diagnosis.
If the vehicle is repaired, troubleshooting completed.
If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 control module.
03-03-4

NO.2 4x4/4L INDICATOR DOSE NOT ILLUMINATE [4x4 control module]
id03031 0802600
4x4/4L INDICATOR DOSE NOT ILLUMINATE
DESCRIPTION 4x4/4L indicator dose not illuminate when select 4H or 4L position.

TROUBLESHO
OTING HINTS

TCM malfunction
STEP
1
INSPECTION
INSPECT CONTINUITY FOR 4x4 CONTROL
MODULE AND TCM
Between 4x4 control module terminal Sand
TCM terminal BB.
Between 4x4 control module terminal Rand
TCM terminal BA.
ACTION
Yes
No
Go to next step.
Repair wiring harness between 4x4 control module terminal
and TCM.
Then go to Step 5.
INSPECT CONTINUITY FOR TCM AND

Yes Inspect the instrument cluster.
Then go to next step.
INSTRUMENT CLUSTER
Between
TCM
terminal
N
and
instrument
No
Repair wiring harness between TCM and instrument cluster.
cluster terminal 1D.

Then go to Step 5.
Between TCM terminal R and instrument
cluster terminal 1F.
Yes Go to next step.
No Repair wiring harness between 4x4 control module and
ground.
Then go to Step 5.
No Repair related wiring harness and related fuses.
Then go to Step 5.
If the vehicle is not repaired or additional diagnostic information is not available, replace the TCM.
03-03-5

NO.3 NO CHANGE FORM 4x2 TO 4x4 [4x4 control module]
id03031 0802700
NO CHANGE FORM 4x2 TO 4x4

3
DESCRIPTION 4x4 system dose not operate when select 4H position.
TROUBLESHO TCM malfunction
OTING HINTS 4x4 control module malfunction
Drive chain malfunction
STEP
INSPECTION
INSPECT 4x4 SWITCH
1
Is 4x4 switch OK?
ACTION
Yes
Go to next step.
No
Repair or replace 4x4 switch.

Then go to step 10.

AND 4x4 CONTROL MODULE
Between 4x4 switch connector terminal C
and ground.
MODULE AND MOTOR COMPONENT (SHIFT
MOTOR)
Between 4x4 control module connector
terminal A, B and transfer case connector
terminal C.
terminal C, D and transfer case connector
terminal F.
MOTOR)
Is motor component (shift motor) OK?
Yes
Go to next step.
No

module.
Then go to Step 10.
Yes
Go to next step.
transfer case connector.
Then go to Step 10.

MODULE AND MOTOR COMPONENT
(POSITION SENSOR)
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
SENSOR)
Is motor component (position sensor) OK?
Yes
Go to next step.
No

Then go to Step 10.
Yes
Go to next step.
No
Repair or replace motor component.

Then go to Step 10.
Yes
No
Go to next step.
ground.
Then go to Step 10.

03-03-6
No
Yes
No
Go to next step.
Then go to Step 10.

STEP
10
INSPECTION
INSPECT TRANSFER
Is transfer OK?
ACTION
Yes
No
Yes
No
Go to next step.
Repair related wiring harness and related fuses.
Then go to Step 10.
Go to next step.
Overhaul and check for wear and damage.
Then go to Step 10.

If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
NO.4 NO CHANGE FORM 4H TO 4L [4x4 control module]
TROUBLESHO
OTING HINTS
id03031 0802900

TCM malfunction
TR sensor malfunction
STEP
1
INSPECTION
INSPECT 4x4 SWITCH
Is 4x4 switch OK?
AND 4x4 CONTROL MODULE
Between 4x4 switch connector terminal B
and ground.
ACTION
Go to next step.
No . Repair or replace 4x4 switch.
Then go to step 11.
Yes
Yes
No
Go to next step.
module.
Then go to Step 11.
INSPECT DIGITAL TR SENSOR

Is digital TR sensor OK?
Yes
INSPECT CONTINUITY FOR DIGITAL TR

SENSOR AND 4x4 CONTROL MODULE
Between digital TR sensor connector
terminal J and 4x4 control module terminal
E.
MODULE AND MOTOR COMPONENT (SHIFT
MOTOR)
terminal A, B and transfer case connector
terminal C.
terminal C, 0 and transfer case connector
terminal F.
Yes
Go to next step.
Repair or replace digital TR sensor.
Then go to step 11 .
Go to next step.

MOTOR)
Is motor component (shift motor) OK?
No
No
Repair wiring harness between digital TR sensor and 4x4

control module.
Then go to Step 11.
Yes
No
Go to next step.
Then go to Step 11.
Yes
Go to next step.
No

Then go to Step 11.
03-03-7

INSPECTION
STEP
ACTION
Go to next step.
Then go to Step 11.
Yes
No

MODULE AND MOTOR COMPONENT
(POSITION SENSOR)
terminal J and transfer case connector
terminal E.
terminal I and transfer case connector
terminal B.
terminal L and transfer case connector
terminal A.
terminal H and transfer case connector
terminal D.
SENSOR)
Is motor component (position sensor) OK?
Yes
No

Yes
No
No Repair related wiring harness and related fuses.
Then go to Step 11.
If
the
vehicle is repaired, troubleshooting completed.
If the vehicle is not repaired or additional diagnostic information is not available, replace the 4x4 Control Module.
10
11
03-03-8
Go to next step.
Then go to Step 11.
Go to next step.
ground.
Then go to Step 11.

NO.5 NOISE [4x4 control module]
id030310802400
5
NOISE
DESCRIPTION Noise is heard from front differential or transfer case.
TROUBLESHO
OTING HINTS

RFW hub abrasion
Incorrect tire pressure
Improper oil level
Transfer bearing damaged
Transfer gear damaged
Transfer drive chain damaged
nr"""''''ure
Is it OK?
INSPECT RFW HUB

Is it OK?
INSPECT JOINT SHAFT

Is it OK?

DIFFERENTIAL PARTS
Are they OK?
INSPECT TIRE PRESSURE
Are they OK?
5
6
INSPECT TRANSFER OIL LEVEL

Is oil level OK?
INSPECT TRANSFER INNER PARTS

Transfer bearing
Overhaul and check for wear and damage.
Transfer gear
Transfer drive chain
Are they OK?
-If normal, return to the diagnostic index to service any additional symptoms.
If the vehicle is not
or additional
information is not available.
03-03-9

NO.6 OIL LEAKAGE [4x4 control module]
id03031 0802500
OIL LEAKEGE
6
DESCRIPTION The oil leaks from front differential or transfer case.
Transfer case malfunction
TROUBLESHO
Improper oil level
OTING HINTS
Loosened sealing bolts
Breather clogging
Improper oil seal
INSPECTION
STEP
VERIFY RFW CONTROL BOX INSTALLATION
1
CONDITION
Is RFW control box installed completely?
ACTION
Yes
Go to next step.
No
Install RFW control box securely, then go to Step.

DIFFERENTIAL PARTS
Are they OK?
INSPECT TRANSFER CASE
Is it OK?
Yes
Go to next step.
No
Replace defective part (s).
Yes
Go to next step.
No
Replace transfer case.
INSPECT TRANSFER OIL LEVEL

Is oil level OK?
Yes
No
Go to next step.
Adjust the oil level.
INSPECT TRANSFER SEALING BOLTS

Are sealing bolts OK?
Yes
No
Go to next step.
INSPECT BREATHER NIPPLE FOR

CLOGGING
Is it OK?
INSPECT OIL SEAL
Is it OK?
Yes
Go to next step.
Clean or replace breather nipple.
7
8
No
Yes
No
Re-tighten the sealing bolts.
Go to next step.
Replace damaged oil seal.

If the vehicle is not repaired or additional diagnostic information is not available.
03-03-10
GENERAL PROCEDURES
03-10
GENERAL PROCEDURES
GENERAL PROCEDURES
(FRONT AND REAR AXLES) ....... 03-10-1
GENERAL PROCEDURES (FRONT AND REAR AXLES)
dcf031000000w01
Wheel And Tire Installation

torque.
Tightening torque
88.2-117.6 Nm {9.0-12.0 kgf.m, 65.0-87.0 ft.lbf}
1. Disconnect the negative battery cable before performing any work that requires handling of connectors.
Suspension Links Removal/Installation
1. For the joint sections with rubber bushings, raise the vehicle using a lift, and then temporarily tighten the
installation bolts and nuts. Lower the vehicle to the ground and tighten them completely with the specified
torque.
Brake Lines Disconnection/Connection
Caution
Brake fluid will damage painted surfaces. If brake fluid does get on a painted surface, wipe it off
immediately.
1. Tighten the brake pipe flare nut 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.
(See 00-00-16 Torque Formulas.)
2. If any brake line has been disconnected anytime during the procedure, add brake fluid, bleed the brakes, and
inspect for leakage after the procedure has been completed.
03-10-1
FRONT AXLE
03-11
FRONT AXLE
FRONT AXLE LOCATION INDEX

[4x2 (EXCEPT Hi-Rider)] .......
[Hi-Rider] .................
[4x4] ...................
WHEEL HUB BOLT REPLACEMENT
[Hi-Rider,4x4] ...............
WHEEL HUB, STEERING KNUCKLE
INSPECTION
[4x2 (EXCEPT Hi-Rider)] .......
03-11-1
03-11-2
03-11-2
03-11-3
03-11-3

INSPECTION [Hi-Rider, 4x4] ....... 03-11-4
REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] ...... 03-11-4
REMOVAUINSTALLATION
[Hi-Rider] ............... 03-11-8
REMOVAUINSTALLATION [4x4] .... 03-11-14
FRONT AXLE LOCATION INDEX [4x2 (EXCEPT Hi-Rider)]
dcf03110400Ow01
DBG311ZWB001
Wheel hub, steering knuckle

(See 03-11-3 WHEEL HUB, STEERING KNUCKLE
INSPECTION [4x2 (EXCEPT Hi-Rider)].)
REMOVAUINSTALLATION [4x2 (EXCEPT HiRider)].)
03-11-1
FRONT AXLE
FRONT AXLE LOCATION INDEX [Hi-Rider]
dcf03110400Ow02
""""-----<D
DBG311ZWB003
Wheel hub bolt

(See 03-11-3 WHEEL HUB BOLT REPLACEMENT
[Hi-Rider, 4x4].)
FRONT AXLE LOCATION INDEX [4x4]

INSPECTION [Hi-Rider, 4x4])
REMOVAUINSTALLATION [Hi-Rider])
dcf03110400Ow03
DBG311ZWB002
Wheel hub bolt

(See 03-11-3 WHEEL HUB BOLT REPLACEMENT
[Hi-Rider,4x4].)
03-11-2

INSPECTION [Hi-Rider, 4x4])
(See 03-11-14 WHEEL HUB, STEERING
KNUCKLE REMOVAUINSTALLATION [4x4].)
FRONT AXLE
WHEEL HUB BOLT REPLACEMENT [Hi-Rider, 4x4]
dcf03113306Ow01
1. Remove the brake caliper component and disc plate.

2. Remove the hub bolt using the SST.
3. Place a new wheel hub bolt in the wheel hub.
ABR6312W024
4. Install the wheel hub bolt by placing a proper

sized washer on the hub, and tightening the nut
HUB BOLT
BRASS BAR
WASHER
WHEEL HUB, STEERING KNUCKLE INSPECTION [4x2 (EXCEPT Hi-Rider)]
dcf03110406Ow01
Wheel Bearing Looseness Inspection

1. 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.
Maximum wheel bearing play [4x2 (Except Hi-Rider)]
o mm {O in}
Preload Adjustment
1. Inspect that the tire rotates smoothly when rotated strongly, and there is no rough feeling or no abnormal noise
from the bearing.
2. Attach a pull scale to a hub bolt and measure the preload.
Front wheel axle preload [4x2 (Except Hi-Rider)]
5.6-11.2 N {0.58-1.14 kgf, 1.26-2.51 Ibf}
If not an specification, adjust the front wheel bearing preload.
When replacing the bearing

1. Remove the brake caliper component and suspend it by a rope.
2. Remove the hub cap, pull out the cotter pin and remove the set cover.
3. Tighten the wheel hub locknut with 20-30 Nm {2.1-3.0 kgfm, 15-22 ft.lbf} to fit the bearing.
4. Loosen the locknut to the extent that it can be turned by hand.
5. Attach a pull scale to a hub bolt and adjust the preload.
Front wheel axle preload [4x2 (Except Hi-Rider)]
5.6-11.2 N {0.58-1.14 kgf, 1.26-2.51 Ibf}
6. Tighten the locknut until the reading reaches the specified amount.
03-11-3
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE INSPECTION [Hi-Rider, 4x4]
dcf03110406Ow02
Wheel Bearing Play Inspection

1. 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.
Maximum front wheel bearing play [Hi-Rider, 4x4]
0.05 mm {0.002 in}
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf03110406Ow03
Caution
the following procedures, disconnect the ABS wheel-speed sensor harness connector (axle side)
and fix it to an appropriate place where the sensor will not be pulled by mistake while servicing the
vehicle.

mimi)
I
I
I
11
441-<88
{4.50-5.99,
32.6-43.3}
:
I
""m
1m
157-209
{16.1-21.3,
116-154}
19-25
{2.0-2.5,
15-18}
Nm {kgfm, ft-lbf}
DBG311ZWB010
ABS wheel-speed sensor (with ABS)
2
3
4
5
6
7
Clip
Hub cap
Cotter pin
Brake caliper component

(See 03-11-5 Brake Caliper Component Removal
Note.)
Hub and disc plate component

(See 03-11-7 Hub And Disc Plate Component
Installation Note.)
Set cover
Locknut
10
Dust cover
Washer
11
Tie-rod end
(See 06-14-10 STEERING GEAR AND LINKAGE
03-11-4
FRONT AXLE
12
13
14
15
16
17
Knuckle arm
Lower arm ball joint
LOWER ARM REMOVAUINSTALLATION [4x2
18
Hub bolt
(See 03-11-5 Disc Plate, Wheel Hub, Hub Bolt
Removal Note.)
(See 03-11-7 Hub Bolt Installation Note.)
19
Outer bearing inner race
Upper arm ball joint

Note.)
Steering knuckle
20
Oil seal
(See 03-11-7 Oil Seal Installation Note.)
21
Inner bearing inner race
22
Inner bearing outer race

(See 03-11-6 Inner Bearing Outer Race, Outer
Bearing Outer Race Removal Note.)
(See 03-11-7 Outer Bearing Outer Race, Inner
Bearing Outer Race Installation Note.)
23
Outer bearing outer race

(See 03-11-6 Inner Bearing Outer Race, Outer
Bearing Outer Race Removal Note.)
(See 03-11-7 Outer Bearing Outer Race, Inner
Bearing Outer Race Installation Note.)
24
ABS sensor rotor (with ABS)

(See 03-11-6 ABS Sensor Rotor Removal Note.)
(See 03-11-6 ABS Sensor Rotor Installation Note.)
Disc plate
Removal Note.)
Installation Note.)
Wheel hub
Removal Note.)
Installation Note.)
Brake Caliper Component Removal Note

1. Remove the brake caliper component installation
bolt, and suspend it with a cable in place out of
the way.
DBG311ZWB011
Disc Plate, Wheel Hub, Hub Bolt Removal Note

Note
The hub bolt does not need to be removed unless replacing them.
1. After putting markings on the disc plate and the
wheel hub, remove the bolt and disassemble the
plate and hub.
2. Remove the hub bolt using a press as necessary.
DBG311ZWB012
03-11-5
FRONT AXLE
Inner Bearing Outer Race, Outer Bearing Outer Race Removal Note
Note
When inner bearing outer race is removed, inner race and oil seal are removed together.
1. Remove the bearing outer race using a suitable
round bar and a hammer. For other side, reverse
the wheel hub and remove the outer race.
DBG311ZWB004
ABS Sensor Rotor Removal Note

Note
The sensor rotor does not need to be removed unless it is being replaced.
1. Remove the sensor rotor using a chisel.
ABR6312W002
ABS Sensor Rotor Installation Note

1. Set the SST shown in the figure.
ABR6312W003
2. Press the new sensor rotor in unit flush with the

end of the wheel hub using the SST and a press.
-0.3-0.3 mm
{-0.012-0. 011 in}
ABS SENSOR
ROTOR
WHEEL HUB
ABR6312W023
03-11-6
FRONT AXLE
Outer Bearing Outer Race, Inner Bearing Outer Race Installation Note
1. Install the bearing outer race using the SSTs and
,------------------------,
a press. For other side, reverse the wheel hub
OUTSIDE BEARING
and install the outer race.
IU':!'SS'"''
DBG311 ZWB005
Oil Seal Installation Note

1. After inserting the bearing in the hub, tap in the oil
seal until it is flush with the hub end surface using
the SST.
2. Apply grease to the oil seal lip.
Hub Bolt Installation Note

1. Press new hub bolts into the wheel hub using a
press.
DBG311ZWB006
Hub And Disc Plate Component Installation Note

1. Apply grease to the areas indicated in the figure.
Grease amount
68-76 g {2.5-2.6 oz}
2. Install the hub and disc plate component, then
adjust the preload. (See 03-11-3 WHEEL HUB,
STEERING KNUCKLE INSPECTION [4x2
DBG311ZWB017
03-11-7
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAUINSTALLATION [Hi-Rider]
dcf0311 0406OW04
Caution
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an appropriate
place where the sensor will not be pulled by mistake while the vehicle is being serviced.
24.5-36.2 {2.5-3.6, 18.1-26.6}
19-25 {2.0-2.5, 15-18}
88.2-117.6
{9.00-11.99,
65.06-86.73}
WHEEL
BEARING
SIDE
Nm {kgfm, ftlbf}
DBG311ZWB013
ABS wheel-speed sensor (with ABS)
Hub cap
Locknut
(See 03-11-9 Locknut Removal Note)
(See 03-11-13 Locknut Installation Note)

Note)
Disc plate
Tie-rod end ball joint
(See 03-11-10 Tie-rod End Ball Joint Removal Note)
Wheel and tire
03-11-8
FRONT AXLE
8
9
10
11
12
13
Bolt (stabilizer)
Bolt (shock absorber)
Note.)
4x4j
Wheel hub, steering knuckle, dust cover
Wheel hub component
(See 03-11-10 Wheel Hub Component Removal
Note)
(See 03-11-13 Wheel Hub Component Installation
Note)
14
15
16
17
18
19
ABS sensor rotor (with ABS) or spacer (without

ABS)
Retaining ring
Wheel bearing
(See 03-11-11 Wheel Bearing Removal Note)
(See 03-11-12 Wheel Bearing Installation Note)
Dust cover
(See 03-11-11 Dust Cover Removal Note)
(See 03-11-12 Dust Cover Installation Note)
Steering knuckle
Hub bolt
(See 03-11-11 Hub Bolt Removal Note)
(See 03-11-12 Hub Bolt Installation Note)
Locknut Removal Note

Note
Remove the locknut with the vehicle on level ground.
1. Knock the crimped portion of the locknut outward
using a small chisel and a hammer.
--
-----~----~
AVF6312W051
03-11-9
FRONT AXLE
1. Remove the brake caliper component, and
suspend it with rope.
AVF6312W002
Tie-rod End Ball Joint Removal Note

1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
"
"
Wheel Hub Component Removal Note

1. Remove the wheel hub component using the
SSTs and a press.
AVF6312W004
2. If the bearing inner race remains on the front

wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
AVF6312W005
03-11-10
FRONT AXLE
Wheel Bearing Removal Note
1. Remove the wheel bearing using the SSTs and a
press.
ABR6312W007
Dust Cover Removal Note

Note
The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for

proper installation.
MARK
ABR6312W008
2. Remove the dust cover using a chisel.
ABR6312W009
Hub Bolt Removal Note

Note
The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolts using a press.
AVF6312W006
03-11-11
FRONT AXLE
1. Install the new hub bolts using a press.
AVF6312W007
DustCover Installation Note

1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
ABR6312W010
3. Install the new dust cover using the SSTs and a

press.
~.
DBG311ZWB015
Wheel Bearing Installation Note

1. Install the new wheel bearing using the SSTs and
a press.
ABR6312W012
03-11-12
FRONT AXLE
Wheel Hub Component Installation Note
1. Install the wheel hub component using the SSTs
and a press.
Locknut Installation Note

Note
Install the locknut with the vehicle on level ground.
1. Install a new locknut and stake it as shown.
03-11-13
FRONT AXLE
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION [4x4]
dcf03110406OwOS
Caution'

24.5-36.2 {2.5-3.6, 18.1-26.6}
iii
69.2-93.2
{7.06-9.50,
51.1-68.7}
19-25
{2.0-2.5,
15-18}
mI~
~.'
10 . .
235-314
{24.o-32.0,
174-231}
iii
1
Nm {kgfm, ft.lbf}
DBG311ZWB014
Locknut
(See 03-11-15 Locknut Removal Note)
(See 03-11-19 Locknut Installation Note)

Note)
Disc plate
03-11-14
Tie-rod end ball joint

(See 03-11-15 Tie-rod End Ball Joint Removal Note)
Bolt (stabilizer)
Bolt (shock absorber)
Wheel hub, steering knuckle, dust cover
FRONT AXLE
10
Oil seal
(See 03-11-16 Oil Seal Removal Note)
(See 03-11-19 Oil Seal Installation Note)
14
11
Wheel hub component

(See 03-11-16 Wheel Hub Component Removal
Note)
(See 03-11-18 Wheel Hub Component Installation
Note)
Retaining ring
15
16
12
13
Dust cover
(See 03-11-17 Dust Cover Removal Note)
(See 03-11-18 Dust Cover Installation Note)
Steering knuckle
Hub bolt
(See 03-11-17 Hub Bolt Removal Note)
(See 03-11-17 Hub Bolt Installation Note)
Wheel bearing
(See 03-11-16 Wheel Bearing Removal Note)
(See 03-11-18 Wheel Bearing Installation Note)
Locknut Removal Note

1. Knock the crimped portion of the locknut outward using a small chisel and a hammer.
2. Lock the hub by applying the brakes.
ABR6312W005

1. Remove the brake caliper component, and
.suspend it with rope.
ABR6312W015
Tie-rod End Ball Joint Removal Note

1. Remove the tie rod-nut.
2. Separate the tie-rod end from the steering
knuckle using the SSTs.
03-11-15
FRONT AXLE
Oil Seal Removal Note
1. Remove the oil seal by using a screwdriver.
Wheel Hub Component J:lemoval Note

1. Remove the wheel hub component using the
SSTs and a press.
I
ABR6312W006
2. If the bearing inner race remains on the front

wheel hub component, grind a section of the
bearing inner race until approx. 0.5 mm {0.02 in}
remains. Then remove it using a chisel.
ABR6312W016
Wheel Bearing Removal Note

1. Remove the wheel bearing using the SSTs and a
press.
ABR6312W007
03-11-16
FRONT AXLE
Dust Cover Removal Note
Note
The dust cover does not need to be removed unless it is being replaced.
1. Mark the dust cover and steering knuckle for
proper installation.
MARK
ABR6312W008
2. Remove the dust cover using a chisel.
Hub Bolt Removal Note

Note
The hub bolts do not need to be removed unless they are being replaced.
1. Remove the hub bolts using a press.
ABR6312W019

1. Install the new hub bolts using a press.
ABR6312W022
03-11-17
FRONT AXLE
Dust Cover Installation Note
1. Mark the new dust cover in the same way as the
removed one.
2. Align the marks of the new dust cover and the
knuckle.
ABR6312W010
3. Install the new dust cover using the SSTs and a

press.
DBG311ZWB015
Wheel Bearing Installation Note

1. Install the new wheel bearing using the SSTs and
a press.
ABR6312W012
Wheel Hub Component Installation Note

1. Install the wheel hub component using the SSTs
and a press.
DBG311ZWB016
03-11-18
FRONT AXLE
Oil Seal Installation Note
1. Apply grease to the new oil seal lip.
2. Install the new oil seal flush with the knuckle using
the SSTs.
PLATE
Locknut Installation Note

1. Install a new locknut and stake it as shown.
ORG I
0.5 mm {0.02 m}
03-11-19
REAR AXLE
03-12
REAR AXLE
REAR AXLE LOCATION INDEX ....... 03-12-1

REAR AXLE INSPECTION ........... 03-12-1
REAR AXLE ADJUSTMENT .......... 03-12-2
AXLE SHAFT
REAR AXLE LOCATION INDEX
dcf03120S00Ow01
Hi-Rider, 4x4
DCF312ZWB001
Axle shaft
(See 03-12-1 REAR AXLE INSPECTION.)
(See 03-12-2 REAR AXLE ADJUSTMENT.)
(See 03-12-2 AXLE SHAFT REMOVAU
INSTALLATION.)
REAR AXLE INSPECTION
dcf03122611Ow01
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.
Rear wheel bearing play
0.05-0.25 mm {0.002-0.010 in}
4. If the bearing play exceeds the specification, adjust the bearing play.
03-12-1
REAR AXLE
REAR AXLE ADJUSTMENT
dcf03122611OW02
Wheel Bearing Play Adjustment

1. Adjust the bearing end play in the axial direction
using the following procedures. (Only when the
bearing is replaced.)
(1) Press one side of the rear axle shaft
components to the thrust bearing on the
differential.
(2) Measure the clearance between the bearing
housing and the axle housing (part A in the
figure).
(3) Select a shim that is 0.65-0.95 mm {0.026SHIM
0.037 in} thicker than the clearance
measured in Step 2 and install it.
ABR6314W011
(4) Measure the clearance of the rear axle shaft
component on the opposite side using the
same procedure in Steps 1 and 2 above.
(5) Select a shim that is 0.05-0.25 mm {0.002-0.009 in} thicker than the clearance measured in Step 4 and
install it.
(6) Verify that the rear axle bearing end play is within a range of 0.05-0.25 mm {0.002-0.009 in}.
If it is not within the range, adjust the rear axle bearing end play again.
Rear axle bearing play in axial direction
0.05-0.25 mm {0.002-0.009 in}
AXLE SHAFT REMOVAUINSTALLATION
03-12-2
dcf03122611 OW03
REAR AXLE
1mB 275-313
8
{28.1-31.9,203-230}
1mB
12.8-21.6 N'm 3
{131-220 kgfcm,
114-191 inlbf}
15
WITHABS
s;,b}"-..
19-25
{2.0-2.5,
16
."(2 ~1:;'
iii
~~"w~(J "~~."
108-128
{11.1-13.0,
79.7-94.4}
~~
I I" "
iii
*490259770B
Nm {kgf.m, ft.lbf}
DBG312ZWB001
Brake drum
Parking brake cable connecting pin
3
4
Brake pipe
Nut
Axle shaft and back plate component
(See 03-12-7 Axle Shaft and Back Plate
Component, Shim Installation Note (Bearing play
adjustment))
Shim
(See 03-12-7 Axle Shaft and Back Plate
Component, Shim Installation Note (Bearing play
adjustment))
11
12
13
14
15
Bearing inner race

(See 03-12-6 Bearing Inner Race, Bearing Locknut
Installation Note)
Bearing spacer
Oil seal (bearing housing side)
(See 03-12-6 Bearing Outer Race, Oil Seal (Bearing
Housing Side) Installation Note)
Bearing outer race
(See 03-12-5 Bearing Outer Race Removal Note)
(See 03-12-6 Bearing Outer Race, Oil Seal (Bearing
Housing Side) Installation Note)
Back plate component
ABS sensor rotor (with ABS)

(See 03-12-4 ABS Sensor Rotor Removal Note)
(See 03-12-6 ABS Sensor Rotor Installation Note)
16
17
Axle shaft
18
Bearing locknut
(See 03-12-4 Bearing Locknut Removal Note)
(See 03-12-6 Bearing Inner Race, Bearing Locknut
Installation Note)
19
9
10
Lock washer
Bearing housing
(See 03-12-4 Bearing Housing Removal Note)
Baffle
Oil seal (axle casing side)
(See 03-12-5 Oil Seal (Axle Casing Side) Removal
Note)
(See 03-12-5 Oil Seal (Axle Casing Side)
Installation Note)
20
Hub bolt
O-ring
03-12-3
REAR AXLE
ABS Sensor Rotor Removal Note
Warning
When grinding, be careful of debris coming from the grinder or bearing collar. Always wear eye
protectors.
Caution
Because the ABS sensor rotor and rear wheel hub edge are almost flush even if the axle shaft is
moved as far as it will go, be careful not to damage the rear wheel hub when grinding.
1. Grind a part of the ABS sensor rotor using a
grinder until 0.5 mm {0.02 in} remains, and then
brake it using a chisel and remove from the shaft.
Bearing Locknut Removal Note

Note
Be careful when removing or installing the bearing locknuts for the left wheels because they are left
threaded (tightened by turning counterclockwise).
1. Set the SSTs as shown in the figure, and remove
the bearing locknut from the rear axle shaft.
Bearing Housing Removal Note

1. Remove the bearing and bearing housing using
the SSTs.
03-12-4
REAR AXLE
Bearing Outer Race Removal Note
1. 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.
Oil Seal (Axle Casing Side) Removal Note

1. remove the oil seal from the axle casing using a
screwdriver.
Oil Seal (Axle Casing Side) Installation Note

1. Tap the oil seal in until it is flush with the end of
the axle casing using the SST.
2. After installation, apply grease to the oil seal lip.
AXLE CASING
AXLE CASING
OIL SEAL
OIL SEAL PRESS IN VALUE: 40.0-41.0 mm {1.58-1.68 in}

ABR6314W007
03-12-5
REAR AXLE
Bearing Outer Race, Oil Seal (Bearing Housing Side) Installation Note
1. Press the bearing outer race and the oil seal
,----------------.,-----using the SSTs.
BEARING
OIL SEAL
ABR6314WOOB
Bearing Inner Race, Bearing Locknut Installation Note

1. Set the SST and then press the bearing 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.
2. Remove the SST, and then install the bearing
locknut to the axle shaft.
3. Tighten the bearing locknut using the SST (49
0603 635A) to press in the bearing inner race.
4. Remove the bearing locknut and install the lock
washer so that its tab fits into the groove of the
axle shaft.
5. Re-install the bearing locknut and tighten it to the
specified torque.
ABR6314W013
Tightening torque
275-313 Nm {28.1-31.9 kgfm, 203-230 ftlbf}
6. Bend the lock washer tab securely in the slot in
the locknut.
Caution
The torque wrench must be attached
perpendicular to the SST.
ABR6314W010
ABS Sensor Rotor Installation Note

Note
Install the ABS sensor rotor in the direction
BEARING LOCKNUT SIDE
I
\
f
ABR6314W012
03-12-6
REAR AXLE
1. Press the ASS sensor rotor in until it is flush with
the end of the bearing lock nut using the SST.
ABR6314W009
Axle Shaft and Back Plate Component, Shim Installation Note (Bearing play adjustment)
1. Adjust the bearing end play in the axial direction
using the following procedures. (Only when the
bearing is replaced.)
(1) Press one side of the rear axle shaft
components to the thrust bearing on the
differential.
(2) Measure the clearance between the bearing
housing and the axle housing (part A in the
figure).
(3) Select a shim that is 0.65-0.S5 mm {0.026SHIM
0.037 in} thicker than the clearance
measured in Step 2 and install it.
ABR6314W011
(4) Measure the clearance of the rear axle shaft
component on the opposite side using the
same procedure in Steps 1 and 2 above.
(5) Select a shim that is 0.05-0.25 mm {0.002-0.00S in} thicker than the clearance measured in Step 4 and
install it.
(6) Verify that the rear axle bearing end play is within a range of 0.05-0.25 mm {0.002-0.00S in} .
If it is not within the range, adjust the rear axle bearing end play again.
Rear axle bearing play in axial direction
0.05 -0.25 mm {0.002-0.00S in}
03-12-7
DRIVE SHAFT
03-13
DRIVE SHAFT
I
DRIVE SHAFT LOCATION INDEX ..... 03-13-1

FRONT DRIVE SHAFT
INSPECTION . .................... 03-13-1
FRONT DRIVE SHAFT

FRONT DRIVE SHAFT
DiSASSEMBLy/ASSEMBLy ......... 03-13-4
DRIVE SHAFT LOCATION INDEX
dcf031325501w01
DBG313ZWB001
Front drive shaft

(See 03-13-1 FRONT DRIVE SHAFT
INSPECTION.)
(See 03-13-2 FRONT DRIVE SHAFT REMOVAU
INSTALLATION.)
(See 03-13-4 FRONT DRIVE SHAFT
DISASSEMBLY/ASSEMBLY.)
FRONT DRIVE SHAFT INSPECTION
dcf031325501w02
1. Verify that the drive shaft is not twisted or damaged.

If there is any malfunction, replace the applicable part.
2. Inspect the dust boot for damage and cracks.
If there is any malfunGtion, replace the applicable part.
3. Move the spline and joint up and down, left and right by hand and verify that there is no roughness.
If there is any malfunction, replace the applicable part.
03-13-1
DRIVE SHAFT
FRONT DRIVE SHAFT REMOVAUINSTALLATION
dcf031325501 w03
Caution
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. If removing the RH drive shaft, drain the front differential oil.

DBG313ZWB002

(See 03-11-4 WHEEL HUB, STEERINGKNUCKLE
REMOVAUINSTALLATION [4x2 (EXCEPT HiRider)].)
REMOVAUINSTALLATION [Hi-Rider].)
(See 03-11-14 WHEEL HUB, STEERING
KNUCKLE REMOVAUINSTALLATION [4x4].)
Drive shaft
(See 03-13-2 Drive Shaft Removal Note)
(See 03-13-3 Drive Shaft Installation Note)
Clip
Drive Shaft Removal Note

Caution
Do not damage the dust cover or the ABS sensor rotor on the drive shaft. These parts cannot be
purchased separately. Replace the assembled unit if the dust cover or the ABS sensor rotor is
damaged.
The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when removing the
drive shaft from the front differential.
03-13-2
DRIVE SHAFT
1. Remove the drive shaft by prying with a bar
inserted between the differential casing and the
drive shaft, as shown in the figure.
ABR6316W003
Drive Shaft Installation Note

Caution
The sharp edges of the drive shaft can slice or puncture the oil seal. Be careful when installing the
drive shaft to the front differential .
The oil seals are damaged easily if this procedure is not done correctly.
(LH)
1. Install a new clip onto the output shaft with the
opening facing upward. Ensure that the diameter
of the clip does not exceed the specification for
installation.
2. After installation, measure the outer diameter.
If it exceeds the specification, repeat Steps
1-2 using a new clip.
Outer diameter specification
31.2 mm {1.23 in}
3.
4.
5.
6.
OPENING
OUTER
DIAMETER
Apply differential oil to the oil seal lip.

ABR6316W012
Insert the drive shaft into the output shaft.
Push the drive shaft into the wheel hub.
After installation, pull the output shaft side outer ring forward to confirm that the drive shaft is securely held by
the clip.
(RH)
1. Install a new clip onto the drive shaft with the
opening of a new clip faCing upward.
2. After installation, measure the outer diameter.
If it exceeds the specification, repeat Steps
1-2 using a new clip.
Outer diameter specification
33.2 mm {1.31 in}
3. Install the drive shaft into the front differential.

4. Push the drive shaft into the wheel hub.
5. After installation, pull the front differential side
outer ring forward to confirm that the drive shaft is
securely held by the clip.
OUTER
DIAMETER
ABR6316W005
03-13-3
DRIVE SHAFT
FRONT DRIVE SHAFT DISASSEMBLY/ASSEMBLY
dcf031325501 w04
Caution
Do not damage and remove the dust cover or the ABS sensor rotor on the drive shaft. These parts
cannot be purchased separately. Replace the assembled unit if the dust cover or the ABS sensor
rotor is damaged and removed.

RH
iii
2
iii
1
LH
iii
1
-!j!
II
DBG313ZWB003
Boot band
(See 03-13-5 Boot Band Disassembly Note)
(See 03-13-7 Boot Band Assembly Note)
Clip
Outer ring
(See 03-13-5 Outer Ring Disassembly Note)
(See 03-13-7 Outer Ring Assembly Note)
Snap ring
(See 03-13-6 Cage, Inner Ring, Balls, Snap Ring
Assembly Note)
Balls
(See 03-13-5 Balls, Inner Ring, Cage Disassembly
Note)
Assembly Note)
03-13-4
Inner ring
Note)
Assembly Note)
Cage
Note)
Assembly Note)
Boot
(See 03-13-6 Boot Disassembly Note)
(See 03-13-6 Boot Assembly Note)
Shaft and bell joint component
DRIVE SHAFT
Boot Band Disassembly Note
Note
The wheel side boot band does not need to be removed unless replacing it.
1. Pry up the locking clips using a screwdriver.
2. Remove the band using pliers.
3. Slide the boot along the shaft to expose the jOint.
ABR6316W006
Outer Ring Disassembly Note

1. Mark the cage and outer ring for proper assembly.
Caution
Mark with paint; do not use a punch.
2. Remove the clip using a screwdriver.
3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.
Balls, Inner Ring, Cage Disassembly Note

1. Mark the inner ring and cage.
Caution
Mark with paint; do not use a punch.
2. Remove the snap ring using snap-ring pliers.
3. Disassemble the balls, inner ring, cage from the drive shaft as component.
4. Turn the cage approx. 22.5 degree and pull the
.----------------------,
cage and balls away from the inner ring.
DBG313ZWB005
I
\",
03-13-5
DRIVE SHAFT
Boot Disassembly Note
Note
The wheel side boot does not need to be removed unless replacing it or the bell joint and shaft
component.
Do not strip the tape until the boot is assembled.
1. Wrap the shaft splines with tape.

2. Remove the boot.
TAPE
ABR6316W008
Boot Assembly Note

1. Fill the boot (wheel side) with the specified grease from a tube, not by hand.
Caution
Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Note
The wheel side and differential side boots are different.
Use the specified grease supplied in the boot kit.
Grease amount
110-130 g {3.88-4.58 oz}
2. With the splines of the shaft still wrapped in tape from disassembly, install the boot.
3. Remove the tape.
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.
CAGE
BALLS
Caution
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.
SNAP RING
GROOVE
INNER
RING
DBG313ZWB006
03-13-6
DRIVE SHAFT
Outer Ring Assembly Note
1. Fill the outer ring and boot with the specified grease.
Caution
Do not touch the grease with your hand. Apply it from the tube to prevent foreign matter from
entering the boot.
Note
Use the specified grease supplied in the boot kit.
Grease amount
115-135 g {4.06-4.76 oz}
2.
3.
4.
5.
Align the marks, and install the outer ring on to the shaft.
Install a new clip.
Install the boot.
Set the drive shaft to the standard length.
Front drive shaft standard length
LH: 507.8-517.8 mm {20.00-20.38 in}
RH: 596.7-606.7 mm {23.50-23.88 in}
6. Release any trapped air from the boots by

carefully lifting up the small end of each boot with
a cloth wrapped screwdriver.
Caution
Be careful not to allow the grease to leak.
Do not damage the boot.
7. Verify that the drive shaft length is within the

specification.
\\
ABR6316W010
Boot Band Assembly Note

Differential side
1. Fold the band in the direction opposite to the
forward revolving direction of the drive shaft and
use pliers to pull it tight.
2. Lock the end of the band by bending the locking
clips.
Caution
Install the band into the groove securely.
A6E6316W008
03-13-7
DRIVE SHAFT
Wheel side
1. Adjust clearance A by turning the adjusting bolt of
the SST.
Clearance A
2.9 mm {O.11 in}
~A
ADJUSTING BOLT
00
A6E0350W012
2. Crimp the wheel side small boot band using the

SST. Verify that clearance B is within the
specification.
If clearance B is more than the specification,
reduce clearance A of the SST and crimp the
boot again.
If clearance B is less than the specification,
replace the boot band, increase clearance A
of the SST, and crimp the new boot.
Clearance B
2.4-2.8 mm {O.095-0.11 0 in}
A6E0350W013
3. Verify that the boot band does not protrude from

the boot band installation area.
If it does, replace the boot band and repeat Steps 2 and 3.
4. Fill the boot with the repair kit grease.
5. Adjust clearance A by turning the adjusting bolt of the SST.
Clearance A
3.2 mm {O.13 in}
6. Crimp the wheel side big boot band using the SST.
7. Verify that clearance B is within the specification.
If clearance B is more than the specification, reduce clearance A of the SST and crimp the boot again.
If clearance B is less than the specification, replace the boot band, increase clearance A of the SST and
crimp the new boot.
Clearance B
2.4-2.8 mm {O.095-0.11 0 in}
8. Verify that the boot band does not protrude from the boot band installation area.
If it does, replace the boot band and repeat Steps 7 and 8.
03-13-8
DIFFERENTIAL [FRONT]
03-14A DIFFERENTIAL [FRONT]

FRONT DIFFERENTIAL
LOCATION INDEX ................. 03-14A-1
FRONT DIFFERENTIAL OIL
INSPECTION ..................... 03-14A-1
FRONT DIFFERENTIAL OIL
REPLACEMENT .................. 03-14A-2
FRONT DIFFERENTIAL
REMOVAL/INSTALLATION ......... . 03-14A-2
FRONT DIFFERENTIAL
DISASSEMBLY ............... 03-14A-4
FRONT DIFFERENTIAL ASSEMBLY ... 03-14A-8
FRONT DIFFERENTIAL LOCATION INDEX
dcf03142710Ow01
DBG314ZWB052
Front differential
(See 03-14A-1 FRONT DIFFERENTIAL OIL
INSPECTION.)
(See 03-14A-2 FRONT DIFFERENTIAL OIL
REPLACEMENT.)
(See 03-14A-2 FRONT DIFFERENTIAL REMOVAU
INSTALLATION.)
(See 03-14A-4 FRONT DIFFERENTIAL
DISASSEMBLY.)
(See 03-14A-8 FRONT DIFFERENTIAL
ASSEMBLY.)
FRONT DIFFERENTIAL OIL INSPECTION

1.
2.
3.
4.
dcf031427000w01

Remove the oil-fill plug and the washer.
Inspect if the oil level is close to the rim of the oil-fill plug hole.
If the oil is not close to the rim of the oil-fill plug hole, add oil.
03-14A-1
5. Install the oil-fill plug with a new washer and
tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgfm, 29.0-39.7
ftlbf}
OIL LEVEL PLUG
~)
WASHER
FRONT DIFFERENTIAL OIL REPLACEMENT

1.
2.
3.
4.
DBG314ZWB001
dcf031427000w02

Remove the oil-fill plug.
Remove the drain plug and drain the oil.
Install the drain plug with a new washer and tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgfm, 29.0-39.7 ft.lbf}
5. Add the specified oil through the oil-fill plug hole.

Type: API service GL-5
Viscosity (above -1 SOC): SAE 90
Viscosity (below -1S0C): SAE SO
Oil capacity (approx. quantity): 1.8-2.0 L {2.0-2.1 US qt, 1.6-1.7 Imp qt}
6. After adding the oil, perform the oil level inspection.
7. Install the oil-fill plug with a new washer and tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgfm, 29.0-39.7 ft.lbf}
FRONT DIFFERENTIAL REMOVAL/INSTALLATION
dcf031427100w02
Caution
the following procedures, remove the ABS wheel-speed sensor (axle side) and fix it to an
appropriate place where the sensor will not be pulled by mistake while servicing the vehicle.
1.
2.
3.
4.
5.
Drain the front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.)
Remove the front propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
Add front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.) .
03-14A-2
APPLY SCREW LOCK AGENT

107-131
~)~~~6~'
5
,,~8-30 ~
____--v
$.----,
"/3
4
a.
,~
a'-r
"bSI!l<::if@)?'A"
fo107-131
APPLY SCREW/'
LOCK AGENT
~11.0-13.3,
79.0-96.6}
36.3-53.9
{3.71"'::5.49,
26.8-39.7}
Nm {kgf.m, ttlbf}
2
3
Drive shaft
INSTALLATION.)
Vacuum hose
RFW switch connector
Front differential, joint shaft component

(See 03-14A-3 Front Differential, Joint Shaft
Component Removal Note.)
Front differential
Front Differential, Joint Shaft Component Removal Note

1. Set the transmission jack on the differential.
2. Remove the bolts and nuts indicated in the figure.
DBG314ZWB035
03-14A-3
3. Remove the front differential and joint shaft
component from the vehicle using the
transmission jack.
DBG314ZWB036
FRONT DIFFERENTIAL DISASSEMBLY
dcf031427100w03
~S);~
I@.
~
18
14
12
mil
DBG314ZWB037
1
2
3
Bolt
Differential caSing
Side bearing outer race
Locknut
(See 03-14A-5 Locknut Disassembly Note.)
10
11
Washer
Oil baffle
Differential component
(See 03-14A-5 Differential Component Disassembly
Note.)
Lock plate
Bearing cap
(See 03-14A-5 Bearing Cap Disassembly Note.)
Adjusting screw
03-14A-4
12
Companion flange
(See 03-14A-6 Companion Flange Disassembly
Note.)
Oil seal
(See 03-14A-6 Oil Seal Disassembly Note.)
13
14
15
16
17
18
19
20
Drive pinion
(See 03-14A-6 Drive Pinion Disassembly Note.)
Front bearing inner race
Collapsible spacer
Rear bearing inner race
(See 03-14A-6 Rear Bearing Inner Race
Disassembly Note.)
Spacer
Front bearing outer race
(See 03-14A-7 Front Bearing Outer Race, Rear
Bearing Outer Race Disassembly Note.)
Rear bearing outer race
(See 03-14A-7 Front Bearing Outer Race, Rear
Differential carrier
21
22
23
24
25
26
27
28
29
30
31
Bolt
Ring gear
Knock pin
(See 03-14A-7 Knock Pin Disassembly Note.)
Pinion shaft
Pinion gear
Thrust washer
Side gear
Thrust washer
Side bearing inner race
(See 03-14A-7 Side Bearing Inner Race
Disassembly Note.)
Gear case
Oil seal
Differential Component Disassembly Note

1. Install the differential component to the SSTs.
Bearing Cap Disassembly Note

1. Place a mark on one of the bearing caps so that
the left and right bearing caps won't get mixed up.
Use the mark for matching at the time of
assembly.
Locknut Disassembly Note

1. Hold the companion flange using the SST and
remove the locknut.
DBG314ZWB012
03-14A-S
1. Pull the companion flange out using the SST.
DBG314ZWB006
Oil Seal Disassembly Note

1. Remove the oil seal using a screw driver.
DBG314ZWB007
Drive Pinion Disassembly Note

1. Remove the drive pinion by tapping with a plastic
hammer.
Rear Bearing Inner Race Disassembly Note

Note
Mark or otherwise distinguish between the front and rear inner races so that they are not mixed at the time
of reassembly.
1. Remove the rear bearing inner race using the
SST.
DBG314ZWB009
03-14A-6
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.
1. Remove the bearing outer race by using the two
grooves on the carrier and tapping the outer races
alternately.
DBG314ZWB010
Knock Pin Disassembly Note

Caution
Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
1. Secure the gear case in a vise and remove the
knock pin using a 4 mm {O.16 in} diameter bar
DBG314ZWB011
Side Bearing Inner Race Disassembly Note

Caution
Mark the left bearing in order to install in the same position.
1. Remove the side bearing inner race from the gear
case using the SST.
BHJ0314W020
03-14A-7
FRONT DIFFERENTIAL ASSEMBLY
dcf031427100w04

184-284
{18.8-28.9, 136-209}
30 22.6-26.4
73-107
{7.5-10.7,
53.9-78.9}
.~
11
{16.7-2.69,
16.7-19.4}
~,
61
~ r::r:":I
~
~mDi
ml
17.7-25.4
~
{1.81-2.59,______
"'1 ~
13.1-18.7}
~
mD
18
19
61 -'---
Nm {kgfm, ft.lbf}
DBG314ZWB040
14
Gear case
Thrust washer
Side gear
15
Thrust washer
5
6
Pinion gear
16
Pinion shaft
Knock pin
(See 03-14A-9 Knock Pin Assembly Note.)
17
Ring gear
(See 03-14A-9 Ring Gear Assembly Note.)
19

(See 03-14A-9 Side Bearing Inner Race Assembly
Note.)
10
11
Bolt
12

(See 03-14A-9 Front Bearing Outer Race Assembly
Note.)
(See 03-14A-10 Rear Bearing Outer Race
Assembly Note.)
13
03-14A-8
18
Spacer
(See 03-14A-10 Spacer Assembly Note)
(See 03-14A-12 Rear Bearing Inner Race Assembly
Note.)
Drive pinion
(See 03-14A-12 Drive Pinion Assembly Note.)
Collapsible spacer
Oil seal (companion flange)
(See 03-14A-13 Oil Seal (Companion Flange)
Assembly Note.}
20
Companion flange
21
Washer
22
Locknut
(See 03-14A-13 Locknut Assembly Note.)
(See 03-14A-13'Side Bearing Outer Race, Adjusting
Screw, Bearing Cap Assembly Note.)
23
24
25
26
Adjusting screw
(See 03-14A-13 Side Bearing Outer Race, Adjusting
Bearing cap
(See 03-14A-13 Side Bearing Outer Race, Adjusting
Lock plate
27
Differential casing
28
Oil seal (differential casing)

(See 03-14A-15 Oil Seal (Differential Casing)
Assembly Note.)
29
Oil baffle
30
Bolt
Knock Pin Assembly Note

1. 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.
DBG314ZWB014
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.
Tightening torque
68.6-83.3 Nm {7.00-8.49 kgfm, 50.6-61.4 ft.lbf}
Side Bearing Inner Race Assembly Note
Caution
Bearings should be assembled to the original positions.
1. Press the side gearings into the gear case using
the SST.
DBG314ZWB041
Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the carrier
using the SST and a press.
~.
"
II
DBG314ZWB042
03-14A-9
Rear Bearing Outer Race Assembly Note
1. Press the rear bearing outer race into the carrier
..'
DBG314ZWB043
Spacer Assembly Note

Pinion height adjustment
Note
Use the installed spacer when adjusting.
Be careful to install SSTs in the correct position and facing in the correct direction.
1. Assemble the spacer, rear bearing inner race,
and the SST (49 8531 568) on to the SST (49
8531 565) as shown in the figure.
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.
FRONT BEARING
DBG314ZWB068
4. Place the SST on the surface plate and set the

dial gauge to zero.
5. Place the SST (49 0660 555) on top of the SST
(498531 565), and then set the SST (49 0727
570) on top of the SST (49 0660 555).
A6A63192026
03-14A-10
6. Place the measuring probe of the dial gauge at
the point where the side bearing is installed in the
differential carrier and measure at the lowest
position. Measure the left and right sides.
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 sum, subtract the sum of
the number inscribed on the end of the drive
pinion divided by 100. (If there is no figure
inscribed, use 0.) This is the pinion height
adjustment value.
(t)
..........I-~~--O
e+
Note
For example, the measured results obtained
step 6 are 0.06 mm {0.0024 in} and 0.04 mm
{0.0016 in}, the formula is (0.06+0.04)/
2=0.05.
Therefore, replace it with a spacer 0.05 mm
{0.002 in} thicker than the currently used one.
Spacer table
Identification mark
08
09
11
12
14
15
17
18
20
21
23
24
26
27
Thickness (mm {in})

3.080 {0.1213}
3.095 {0.1220}
3.110 {0.1224}
3.125 {0.1230}
3.140 {0.1234}
3.155 {0.1242}
3.170 {0.1248}
3.185 {0.1254}
3.200 fO.1260}
3.215 {0.1266}
3.230 {0.1271}
3.245 {0.1278}
3.260 {0.1283}
3.275 {0.1289}
Identification mark
29
30
32
33
35
36
38
39
41
42
44
45
47
-
Thickness (mm {in})

3.290 {0.1295}
3.305 {0.1301}
3.320 {0.1307}
3.335 {0.1313}
3.350 {0.1319}
3.365 {0.1325}
3.380 {0.1331}
3.395 {0.1337}
3.410 {0.1343}
3.425 {0.1348}
3.440 {0.1354}
3.455 {0.1360}
3.470 {0.1366}
-
03-14A-11
Rear Bearing Inner Race Assembly Note
Caution
Press in until the force required suddenly increases.
Install the spacer selected for the pinion height adjustment, confirm that the installation direction
is correct.
1. Press the rear bearing inner race in using the
SSTs.
SPACER
DBG314ZWB053
Drive Pinion Assembly Note

Drive pinion preload adjustment
Caution
Do not install the oil seal.
1. Assemble the following parts to the drive pinion.
New collapsible spacer
Front bearing
New spacer
Companion flange
New washer
New locknut
2, Turn the serrated part of the drive pinion by hand to seat the bearing.
3. Tighten the locknut temporarily tightened in Step
,-------::------------------,
1 from the lower limit of the specified tightening
torque using the SST, and obtain the specified
preload. Record the tightening torque at this time ..
Tightening torque
128-284 Nm {13.1-28.9 kgf.m, 94.5-209
ftlbf}
Front differential drive pinion preload
1.28-1.76 Nm {13.1-17.9 kgf.cm, 11.415.5 inlbf}
If the specified preload cannot be obtained
within the specified tightening torque, replace with a new collapsible spacer and adjust again.
4. Remove the locknut, washer, and companion flange.
03-14A-12
DBG314ZWB016
Oil Seal (Companion Flange) Assembly Note
1. Apply differential oil to the lip of a new oil seal.
2. Assemble the oil seal using the SST.
DBG314ZWB071
Locknut Assembly Note

1. Assemble the companion flange and washer.
2. Tighten a new locknut using the SST.
Tightening torque
128-284 Nm {13.1-28.9 kgfm, 94.5-209
ft.lbf}
Side Bearing Outer Race, Adjusting Screw, Bearing Cap Assembly Note
1. Install the differeritial 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.
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 0 intervals and mount a dial indicator to the
carrier so that the feeler comes in contact at a
90 0 angle with one of the ring gear teeth.
DBG314ZWB045
(2) Turn both bearing adjusters equally until the

backlash becomes 0.09-0.11 mm {0.00350.0043 in} using the SST.
DBG314ZWB046
03-14A-13
(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}.
DBG314ZWB019
(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

73-107 Nm {7.45-10.9 kgfm, 53.9-78.9
ftlbf}
Distance L
204.5 mm {8.052 in}
DBG314ZWB047
3. The inspection and adjustment procedure is as

follows:
(1) Coat both surfaces of 6-8 teeth of the ring
gear uniformly with a tooth marking
compound.
(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.
Toe and flank contact

1. Replace the spacer with a thinner one, and move
the drive pinion outward.
TOOTH MARKING COMPOUND
CHU0314W020
TOE CONTACT
FLANK CONTACT
CHU0314W021
03-14A-14
Heel and face contact
1. Replace the spacer with a thicker one. Bring the
drive pinion inward.
HEEL CONTACT
FACE CONTACT
CHU0314W022
Oil Seal (Differential Casing) Assembly Note

1. Tap in the new oil seal to the front differential
casing using the SSTs.
03-14A-1S
DIFFERENTIAL [REAR]
03-148 DIFFERENTIAL [REAR]

REAR DIFFERENTIAL
LOCATION INDEX .................
REAR DIFFERENTIAL OIL
INSPECTION . ....................
REAR DIFFERENTIAL OIL
REPLACEMENT ..................
REAR DIFFERENTIAL
REMOVAL/INSTALLATION ..........
03-14B-1
03-14B-2
03-14B-2
03-14B-3
REAR DIFFERENTIAL DISASSEMBLY

[STANDARD DIFFERENTIAL] ...... . 03-14B-4
REAR DIFFERENTIAL ASSEMBLY
[STANDARD DIFFERENTIAL] ...... . 03-14B-7
[LSD (LIMITED SLIP
DIFFERENTIAL)] . ................ . 03-14B-16
[LSD (LIMITED SLIP
DIFFERENTIAL)] ................. . 03-14B-18
REAR DIFFERENTIAL LOCATION INDEX
dcf031427100wOS
4x2 EXPECT Hi-Rider
Hi-Rider, 4x4
DCF314ZWB006
Rear differential
(See 03-14B-2 REAR DIFFERENTIAL OIL
INSPECTION.)
(See 03-14B-2 REAR DIFFERENTIAL OIL
REPLACEMENT.)
(See 03-14B-3 REAR DIFFERENTIAL REMOVAU
INSTALLATION.)
(See 03-14B-4 REAR DIFFERENTIAL
DISASSEMBLY [STANDARD DIFFERENTIAL].)
(See 03-14B-7 REAR DIFFERENTIAL ASSEMBLY
[STANDARD DIFFERENTIAL].)
(See 03-14B-16 REAR DIFFERENTIAL
DISASSEMBLY [LSD (LIMITED SLIP
DIFFERENTIAL)].)
(See 03-14B-18 REAR DIFFERENTIAL ASSEMBLY
[LSD (LIMITED SLIP DIFFERENTIAL)].)
03-148-1
I,
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL OIL INSPECTION
1. Position the vehicle on level ground.
2. Remove the oil-fill plug and the washer.
3. Inspect if the oil level is close to the rim of the oilfill plug hole.
If the oil is not close to the rim of the oil-fill
plug hole, add oil.
4. Install the oil-fill plug with a new washer and
tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgf.m, 29.0-39.7
ft.lbf}
dcf031427000w03
OIL LEVEL PLUG
~)
WASHER
U
~
DBG314ZWB001
REAR DIFFERENTIAL OIL REPLACEMENT

1.
2.
3.
4.
dcf031427000w04

Remove the oil-fill plug.
Remove the drain plug and drain the oil.
Install the drain plug with a new washer and
tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgfm, 29.0-39.7
ftlbf}
5. Add the specified oil through the oil-fill plug hole.
Rear differential oil [STANDARD

DIFFERENTIAL]
Viscosity: SAE 90
Oil capacity (approx. quantity): 1.3-1.5 L {1.3-1.4 US qt, 1.1-1.2 Imp qt} (WL-3)
Oil capacity (approx. quantity): 2.35-2.55 L {2.23-2.41 US qt, 1.96-2.12 Imp qt} (WL-C)
Rear differential oil [LSD]
Viscosity: SAE 90
Oil capacity (approx. quantity): 2.25-2.45 L {2.13-2.31 US qt, 1.88-2.03 Imp qt}
6. After adding the oil, perform the oil level inspection.
7. Install the oil-fill plug with a new washer and tighten.
Tightening torque
39.2-53.9 Nm {4.00-5.49 kgfm, 29.0-39.7 ftlbf}
03-148-2
DBG314ZWB002
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL REMOVAL/INSTALLATION
dcf031427100w06
Caution
Clean away the ole sealant before applying the new sealant.
Install the differential carrier 10 min. after applying sealant.
Allow the sealant to set at least 30 min. after installation before filling the differential with the
specified oil.
1.
2.
3.
4.
5.
Drain the rear differential oil.

Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
Add rear differential oil. (See 03-148-2 REAR DIFFERENTIAL OIL REPLACEMENT.)
26-28
{2.6-2.9, 19-20}
Nm {kgf.m, ftlbf}
DCF314ZWB003
Axle shaft and back plate component

(See 03-12-2 AXLE SHAFT REMOVAU
INSTALLATION.)
Rear differential component

(See 03-14A-3 Front Differential, Joint Shaft
Component Removal Note.)
Rear Differential Component Removal Note

1. To prevent the rear differential from dropping,
leave the two bolts loosely tightened, then tap the
rear differential carrier using a wooden hammer.
03-148-3
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL DISASSEMBLY [STANDARD DIFFERENTIAL]
dcf03142710Dw07
Warning
The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted,
the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it
could cause injury, therefore do not maintain the rear differential tilted. When turning the rear
differential, grasp the rotation handle firmly.
9
WITH
REAR ASS
DCF314ZWB004
(See 03-14B-5 Differential Component Disassembly
Note.)
Bearing cap
(See 03-14B-5 Bearing Cap Disassembly Note.)
Adjusting shim

(See 03-14B-5 Side Bearing Inner Race
Disassembly Note.)
Locknut
(See 03-14B-5 Locknut Disassembly Note.)
Companion flange
(See 03-14B-6 Companion Flange Disassembly
Note.)
Drive pinion
(See 03-14B-6 Drive Pinion Disassembly Note.)
8
9
Oil seal
(See 03-14B-6 Oil Seal Disassembly Note.)
10
Thrust washer
14
15
Adjusting shim
(See 03-14B-7 Front Bearing Outer Race, Rear
16
17
Oil baffle
18
19
20
Bolt
Ring gear
21
Knock pin
(See 03-14B-7 Knock Pin Disassembly Note.)
22
Pinion shaft
23
Thrust block
24
25
Pinion gear
Thrust washer
26
27
Side gear
11
28
Thrust washer
Differential case
12
Collapsible spacer
(See 03-14B-6 Rear Bearing Inner Race
Disassembly Note.)
29
ABS sensor rotor (with rear ABS)
13
03-148-4
DIFFERENTIAL [REAR]
Differential Component Disassembly Note
1. Install the differential component to the SSTs.
DBG314ZWB032
Bearing Cap Disassembly Note

1. Place a mark on one of the bearing caps so that
the left and right bearing caps won't get mixed up.
Use the mark for matching at the time if assembly.
Side Bearing Inner Race Disassembly Note

Caution
Mark the left bearing in order to install in the same position.
1. Remove the side bearing inner race from the gear
case using the SSTs.
Locknut Disassembly Note

1. Hold the companion flange using the SST and
remove the locknut.
DBG314ZWB012
03-148-5
DIFFERENTIAL [REAR]
1. Pull the companion flange out using the SST.
Drive Pinion Disassembly Note

1. Remove the drive pinion by tapping with a plastic
hammer.
2. Remove the drive pinion component by tapping
the locknut lightly using a plastic hammer.
3. Remove the locknut in.stalled in Step 1.

1. Remove the oil seal using a screw driver.
DBG314ZWB007
Rear Bearing Inner Race Disassembly Note

Note
Mark or otherwise distinguish between the front and rear inner races so that they are not mixed at the time
of reassembly.
1. Remove the rear bearing inner race using the
SST.
03-148-6
DIFFERENTIAL [REAR]
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.
1. Remove the bearing outer race by lightly tapping
the edge of the bearing outer race using a
DBG314ZWB010
Knock Pin Disassembly Note

Caution
Insert the bar from the knock pin hole at the opposite side from where the ring gear is installed.
1. Secure the gear case in a vise and remove the
knock pin by using a 4 mm {O.16 in} diameter bar.
DBG314ZWB011
REAR DIFFERENTIAL ASSEMBLY [STANDARD DIFFERENTIAL]
dcf031427100w08
Warning
The engine stand is equipped with a self-lock mechanism, however, if the rear differential is tilted,
the self-lock mechanism could become inoperative. If the rear differential unexpectedly rotates, it
could cause injury, therefore do not maintain the rear differential tilted. When turning the rear
differential, grasp the rotation handle firmly.
Note
Clean away the old silicone sealant before applying the new silicone sealant.
Install the rear cover within 10 min after applying the silicone sealant.
Allow the sealant to set at least 30 min or more after installation before filling the differential with
differential oil.
03-148-7
1
DIFFEREN
. Assemble in the orde' .
TIAL
r Indicated in th e t able
75 95
[REAR]
1m
mm
____
N_.m{.kgt.m, tt-lbf}
Adjusting shim
Differential case
19
DCF314ZWB005
(See 03-14B-11 Adjustlng

. Shi A
R
(Sear bearing inner rae
m ssembly Note.)
ee03-14B-13
e
Note.}
Rear Bearing Inner RaceAsse bl
.
Dnve pinion
m y
nve
p
..
(See 03-14B-13 D .
Inion Assembly Note.)
Collapsible spacer
Thrust was-;::-h-er--=-~
23
24
25
27
Locknut
(See
S.d 03-14B-14 Locknut Ass b
e bearing outer rac
em Iy Note.)
ee 03-14B-14 S.
e
.
Shim, Bearin C Ide Bearing Outer R
Adjusting
ap Assembly Note.) ace, Adjusting
28
(See 03-14B-14
SIde Bearing 0
Shim
. Cap
,B
eanng
A
uter Race Ad .
Bearing cap
ssembly Note.)
, Jus,,"g
26
_1_3_,Differential carrier
14 Oil baffle
15 (See 03-14B-10 Oil Baffle A
F~ont bearing outer rac ssembly Note [WL-C] )
ee 03-14B-1 0 F e
Assembly Note.} ront Bearing Outer Race
16
Rear bearing
(See 03-14B- f~ter race
Assembly Note.) Rear Bearing Outer Race
03-148-8
Oil seal
(See 03-14B-14 Oil S
Companion flange eal Assembly Note.}
Shl~
(See03-14B-14
. A Bearin g 0 uter Race Ad .
Side
Shim , Beanng
. Cap
ssembly Note.)
,justlng
DIFFERENTIAL [REAR]
Thrust Washer Assembly Note

1. Adjust the backlash of the side gear$ and pinion 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.
Backlash of side gear and pinion gear
0-0.1 mm {0-0.004 in}
(4) If the backlash exceeds the standard, use the
thrust washers to adjust.
Knock Pin Assembly Note

1. 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.
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
Bearings should be assembled to the original positions.
1. Press the side bearings into the gear case using
the SST.
DBG314ZWB041
03-148-9
DIFFERENTIAL [REAR]
Oil Baffle Assembly Note [WL-C]
1. Tap the oil baffle into the differential carrier using
the SSTs.
DBG314ZWB058
Front Bearing Outer Race Assembly Note

1. Press the front bearing outer race into the carrier
DBG314ZWB059
Rear Bearing Outer Race Assembly Note

WL-3
1. Press the rear bearing outer race into the differential carrier using the SSTs and a press.
DBG314ZWB043
WL-C
1. Press the rear bearing outer race into the
differential carrier using the SSTs and a press.
0...",..",..
DBG314ZWB060
03-148-10
DIFFERENTIAL [REAR]
Adjusting Shim Assembly Note
Pinion height adjustment [WL-3]
Note
1. Assemble the spacer, rear bearing inner race and
SST (49 UN27 004) on to the SST (49 8531 565).
Secure the collar with the O-ring, then install this
to the carrier.
UN27 003), companion flange, washer and nut to
the SST (49 8531 565).
~.
I I :
SPACER
REAR BEARING
FRONT BEARING

dial indicator to zero.
5. Place the SST (49 U027 008) on top of the SST
570) on top of the SST (49 U027 008).
A6A63192026
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.
DBG314ZWB073

inscribed, use 0.) This is the pinion height
adjustment value.
t
...........J-~*---O
Note
When the values obtained by the
measurements taken in Step 7 are 0.06 mm
{00.003 in}, 0.04 mm {0.002 in} and the tip
surface of the drive pinion value is 2, the
formula is ((0.06+0.04)/2)-(2/100)=0.03.
Therefore, assemble a spacer 0.03 mm {0.001 in} thicker than the currently assembled one.
DBG314ZWB049
03-148-11
DIFFERENTIAL [REAR]
Pinion height adjustment [WL-C]
Note

SST (49 U027 015) on to the SST (49 8531 565).
to the carrier.
E027 007), companion flange, washer and nut to
the SST (49 8531 565).
SPACER
REAR BEARING
ORI
FRONT BEARING
DBG314ZWB069

5. Place the SST (491361 555) on top of the SST
570) on top of the SST (49 1361 555).
A6A63192026

inscribed, use 0.)
DBG314ZWB048
8. Subtract 3 from measurement taken in Step 7.

This is the pinion height adjustment value.
Note
measurements taken in Step 7 and 8 are
3.06 mm {0.1205 in}, 3.04 mm {0.1197 in}
and the tip surface of the drive pinion value
is 2, the formula is ((3.06+3.04)/2)-(2/100)3=0.03. Therefore, assemble a spacer 0.03
mm {0.001 in} thicker than the currently
assembled one.
03-148-12
........,./-~.....---O+
+
8
{ ..
DBG314ZWB049
DIFFERENTIAL [REAR]
Rear Bearing Inner Race Assembly Note
Caution
Press in until the force required suddenly increases.
Install the spacer selected for the pinion height adjustment, confirm that the installation direction
is correct.
1. Press the rear bearing inner race using the SST.
WL-3
SPACER
WL-C

Caution

Front bearing
New spacer
Companion flange
New washer
New locknut
2. Adjust the preload of the drive pinion 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.
Tightening torque
298-500 Nm {30.4-50.9 kgfm, 220-368
ft.lbf}
Rear differential drive pinion preload
WL-3: 2.0-3.5 Nm {21-35 kgfcm, 18-30
in.lbf}
WL-C, WE-C: 2.55-4.00 Nm {26.1-40.7 kgfcm, 22.6-35.4 inlbf}
DBG314ZWB016
(3) If the specified preload can't be obtained within the specified tightening torque range, replace the
collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion flange.
03-148-13
DIFFERENTIAL [REAR]
Oil Seal Assembly Note
1. Apply differential oil to the lip of a new oil seal.
2. Press the oil seal in until it touches the end of the
differential carrier using the SST.
WL-3
WL-C
DBG314ZWB017
Locknut Assembly Note

1. Assemble the companion flange and washer.
2. Tighten the new locknut using the SST.
3. Verify that the preload is within the specification.
WL-3: 2.0-3.5 Nm {21-35 kgfcm, 18-30
in.lbf}
WL-C, WE-C: 2.55-4.00 N'm {26.1-40.7 kgfcm,
22.6-35.4 inlbf}
DBG314ZWB018
Side Bearing Outer Race, Adjusting Shim, Bearing Cap Assembly Note
Ring gear backlash adjustment
1. Install the gear case component on the differential carrier.
2. Push the gear case component tot he left side of the differential carrier and measure the clearance between the
side bearing and differential 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
90 angle with one of the ring gear teeth.
5. Inspect 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 0.03 mm {0.001 in}.
Ring gear backlash
0.12-0.20 mm {0.005-0.007 in}
6. If backlash is not as specified, correct the
backlash by switching whims from one side of the
differential case to the other.
7. Using a torque wrench, inspect the total rotating
torque of the pinion three complete revolutions,
and then reading the rotating torque. The
readings should not exceed 2.4 Nm {24.0
kgf.cm, 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.
03-148-14
r
A6A63192036
DIFFERENTIAL [REAR]
8. The inspection and adjustment procedure is as follows:
(1) Coat both surfaces of 6-8 teeth of the ring
gear uniformly with a tooth marking
compound.
(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.
r--------------------,
Ivl"r~"'I"'\.:1 COMPOUND
CHU0314W020
Toe and flank contact

1. Replace the spacer with a thinner one, and move
the drive pinion outward.
Heel and face contact

1. Replace the spacer with a thicker one. Bring the
drive pinon inward.
TOE CONTACT
FLANK CONTACT
HEEL CONTACT
FACE CONTACT
CHU0314W022
03-148-15
DIFFERENTIAL [REAR]
REAR DIFFERENTIAL DISASSEMBLY [LSD (LIMITED SLIP DIFFERENTIAL)]
dcf031427101w01
DBG314ZWB020
2
3
4
5
(See 03-14B-5 Differential Component Disassembly
Note.)
Bearing cap
(See 03-14B-5 Bearing Cap Disassembly Note)
Adjusting shim
(See 03-14B-5 Side Bearing Inner Race
Disassembly Note)
Locknut
(See 03-14B-5 Locknut Disassembly Note)
Companion flange
(See 03-14B-6 Companion Flange Disassembly
Note)
Drive pinion
(See 03-14B-6 Drive Pinion Disassembly Note)
14
Adjusting shim
15
16

Bearing Outer Race Disassembly Note)
Oil baffle
17
18
19
20
Bolt
21
22
23
24
Oil seal
(See 03-14B-6 Oil Seal Disassembly Note)
25
26
10
Thrust washer
(See 03-14B-6 Oil Seal Disassembly Note)
27
11
12
13
Collapsible spacer

(See 03-14B-6 Rear Bearing Inner Race
Disassembly Note)
03-148-16
Ring gear
Knock pin
(See 03-14B-7 Knock Pin Disassembly Note)
Pinion shaft
Thrust block
Limited slip differential component
(See 03-14B-17 Limited Slip Differential Component
Disassembly Note.)
Pinion gear thrust washer
Pinion gear
Side gear
29
Side gear thrust washer

LSD clutches
30
Differential case
28
DIFFERENTIAL [REAR]
Limited Slip Differential Component Disassembly Note
1. Place one of the axle shafts, which was removed
,------------------------,
from the component, into a vise, with the splines
extending above the jaws of the vise far enough to
component. Position the differential case onto the
axle shaft as a holding fixture by aligning the
splines of the side gear with those of the axle
shaft.
DBG314ZWB021
2. Install the SST into the bottom of the side gear,

and apply grease to the centering hole of it.
3. Install the SSTs into the differential case.
DBG314ZWB023
4. Tighten the SSTs to move the side gears away

from the pinion gears and relieve the normal
loaded condition.
5. Push out the thrust washers located behind the
pinion gears.
6. Momentarily loosen the SST. Retighten the SST
until a very slight movement of the pinion gears is
seen.
03-148-17
DIFFERENTIAL [REAR]
7. Insert SST into the bore of the pinion shaft and
rotate the differential case until the pinion gears
can be removed through the large openings in the
differential case.
DBG314ZWB025
8. Retain the top side gear and clutch pack in the
differential case by hand and remove the SSTs.

9. Remove the top side gear and clutch pack. Keep
the stack of the clutch plates and clutch discs in
exact order.
10. Remove the retainer clips from both clutch packs
to allow separation of the clutch discs and clutch
plates for cleaning and inspection.
DIFFERENTIAL
CLUTCH PACK
DBG314ZWB026
REAR DIFFERENTIAL ASSEMBLY [LSD (LIMITED SLIP DIFFERENTIAL)]
dcf031427101w02
Note
Clean away the old sealant before applying the new sealant.
Install the rear cover within 10 minutes after applying sealant.
Allow the sealant to set at least 30 minutes after installation before filling the differential with the specified
oil.

75-95
{7.6-9.7,
55-70}
iii 130-150
gZJ
{13.2-15.3,
96-110}
iii
I
6
mJ
iii
iii
15 mJ
iii
mJ
mJ
-,.....-..
298-500
{30.3-50.9,
220-368}
~__tD_i_ffe_r_en_t_ia_lc_a_se______________________~1
2 . LSD clutches
.
03-148-18
mJ
Nm {kgfm, ftlbf}
__
DBG314ZWB027
~ 34-+I_s_ld_e~g_ea_r_th_r_us_t_w_a_sh_e_r________________~
.
. Side gear
DIFFERENTIAL [REAR]
5
6
7
8
9
10
11
12
13
14
15
16
17
Pinion gear
Pinion gear thrust washer
Limited slip differential component
(See 03-14B-21 Limited Slip Differential Component
Assembly Note.)
Thrust block
Pinion shaft
Knock pin
(See 03-14B-9 Knock Pin Assembly Note.)
Ring gear
(See 03-14B-9 Ring Gear Assembly Note.)
Bolt
(See 03-14B-9 Side Bearing Inner Race Assembly
Note.)
Oil baffle
(See 03-14B-10 Oil Baffle Assembly Note [WL-C].)
(See 03-14B-1 0 Front Bearing Outer Race
Assembly Note.)
(See 03-14B-1 0 Rear Bearing Outer Race
Assembly Note.)
18
19
20
21
22
23
24
25
26
27
28
29
Adjusting shim
(See 03-14B-19 Adjusting Shim Assembly Note.)
(See 03-14B-13 Rear Bearing Inner Race Assembly
Note.)
Drive pinion
(See 03-14B-20 Drive Pinion Assembly Note.)
Collapsible spacer
Thrust washer
Oil seal
(See 03-14B-10 Oil Baffle Assembly Note [WL-C].)
Companion flange
Locknut
(See 03-14B-14 Locknut Assembly Note.)
(See 03-14B-14 Side Bearing Outer Race, Adjusting
Shim, Bearing Cap Assembly Note.)
Adjusting shim
Bearing cap
Adjusting Shim Assembly Note

Pinion height adjustment
Note
SST (49 U027 015) on to the SST (49 8531 565).
to the carrier.
E027 007), companion flange, washer and nut to
the SST (49 8531 565).
SPACER
REAR BEARING
o RING
FRONT BEARING
DBG314ZWB070
03-148-19
DIFFERENTIAL [REAR]
5. Place the SST (491361 555) on top of the SST
570) on top of the SST (49 1361 555).
A6A63192026

7. Add the 1wo (left and right) values obtained by the
inscribed, use 0.)
8. Subtract 3 from measurement taken in Step 7.

This is the pinion height adjustment value.
Note
measurements taken in Step 7 and 8 are
3.06 mm {0.1205 in}, 3.04 mm {0.1197 in}
and the tip surface of the drive pinion value
is 2, the formula is ((3.06+3.04)/2)-(2/100)3=0.03. Therefore, assemble a spacer 0.03
mm {0.001 in} thicker than the currently
assembled one.
Caution

Front bearing
New spacer
Companion flange
New washer
New locknut
2. Adjust the preload of the drive pinion bearing as follows:
(1) Turn the companion flange by hand to seat the bearing.
03-148-20
........,J-~~--O+
e+
DBG314ZWB049
DIFFERENTIAL [REAR]
(2) Usea 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.
Tightening torque
298-S00 Nm {30.4-S0.9 kgf.m, 220-368
ft.lbf}
2.SS-4.00 Nm {26.1-40.7 kgfcm, 22.63S.4 inlbf}
DBG314ZWB016
(3) If the specified preload can't be obtained within the specified tightening torque range, replace the
collapsible spacer and inspect again.
(4) Remove the locknut, washer and companion flange.
Limited Slip Differential Component Assembly Note
Note
Always replace the entire disc and plate kits, even if only one component requires it.
1. Assemble the retainer clips to the ears of the clutch plates. Make sure both clips are completely assembled or
seated onto the ears of the clutch plates.
2. Place the differential case on a bench. Assemble the clutch pack and side gear into the differential case. Make
sure the clutch pack stays assembled to the splines of side gear, and the retainer clips differential case.
3. Install the SSTs to the differential case.
4. With tools assembled to the differential case,
position the differential case onto the axle shaft by
aligning the splines of the differential side gear
with those of the axle shaft.
5. Position both pinion gears opposite one another
through the openings in the differential case. Align
holes of the differential pinion gears with each
other. Hold the pinion gears by hand.
6. Tighten the SST so the side gears move away
condition.
DBG314ZWB028
7. While holding the pinion gears in place, insert

SST into the hole of pinion shaft in the differential
case. Pull on the SST rotating differential case
allowing the differential pinion gears to rotate and
enter into the differential case.
8. Adjust the SST by very slightly loosening or
tightening until the required load is applied to
allow the side gears and pinion gears to rotate.
9. Rotate the differential case until the holes of both
pinion gears are aligned with those of the
differential case.
DBG314ZWB029
03-148-21
DIFFERENTIAL [REAR]
10. Apply torque to the SST for clearance to
assemble the differential thrust washers.
Note
During assembly, be sure the holes of the
thrust washers and gears are lined up
exactly with those of the differential case.
DBG314ZWB030
11. Assemble thrust washers into the differential

case. Use a very small screwdriver or shim stock
to push the washers into place.
DBG314ZWB031
'~,.,
03-148-22
PROPELLER SHAFT
03-15
PROPELLER SHAFT
PROPELLER SHAFT
PROPELLER SHAFT INSPECTION .... 03-15-4
PROPELLER SHAFT
LOCATION INDEX ................. 03-15-1
PROPELLER SHAFT LOCATION INDEX
dcf031525002w01
4x2
;~'
4x4
DBG315ZWB004
(See 03-15-2 PROPELLER SHAFT REMOVAU

INSTALLATION.)
(See 03-15-4 PROPELLER SHAFT INSPECTION.)

INSTALLATION.)
(See 03-15-4 PROPELLER SHAFT INSPECTION.)
03-15-1
PROPELLER SHAFT
PROPELLER SHAFT REMOVAL/INSTALLATION
dcf031525002w02
1. Remove the member.

4x2
::~
{5H9'~~if~
JP
~36-52
{3.7-5.3,27-38}
S15M-D
~ru
<::".
98-117
P
J
~36-52
{3.7-5.3,27-38}
Nm {kgfm, ftlbf}
DBG315ZWB002
2
3
Nut
Nut
Propeller shaft
(See 03-15-3 Propeller Shaft Removal Note.)
(See 03-15-3 Propeller Shaft Installation Note.)
4x4
98-117
{10.0-11.9, 72.3-86.2}
~@)
Nm {kgf.m, ftlbf}
DBG315ZWB003
1
2
Nut
Propeller shaft
Nut
Nut
Propeller shaft
03-15-2
PROPELLER SHAFT
Propeller Shaft Removal Note
Caution
When replacing with a new propeller shaft, mark the companion flange to match the position of the
tag on the propeller shaft.
1. Before removing the propeller shaft, make alignment marks on the yoke and differential companion flange.
FRONT PROPELLER SHAFT (4x4)
DBG315ZWB007
REAR PROPELLER SHAFT
MARKING
DBG315ZWB001
2. Install the SST to the extension housing. (R15MD)
DBG511AWB013
Propeller Shaft Installation Note

1. Align the marks and install the propeller shaft.
2. When installing a new propeller shaft, align the differential companion flange mark with the tag on the propeller
shaft and assemble.
03-15-3
PROPELLER SHAFT
FRONT PROPELLER SHAFT (4x4)
DBG315ZWB007
REAR PROPELLER SHAFT
MARKING
DBG315ZWB001
PROPELLER SHAFT INSPECTION
dcf031525002w03
1. Use a dial gauge to measure the runout of the

propeller shaft at each position.
replace the propeller shaft.
Propeller shaft maximum runout

0.4 mm {0.016 in}
MEASURE
MEASURE
MEASURE
KJOd@
POSITION
POSITION
POSITION
DBG315ZWB005
2. Inspect the play and rotation of the joint by turning

the universal joint in the direction shown by the
arrow.
Propeller shaft initial torque (Reference value)

0.29-1.76 Nm {3.0-17.9 kgfcm, 2.6-15.5
inlbf}
If there is excessive play or initial torque,
(
DBG315ZWB006
03-15-4
PROPELLER SHAFT [SAT]
03-15
PROPELLER SHAFT LOCATION INDEX

[SAT] ........................... 03-15-1
PROPELLER SHAFT
REMOVAL/INSTALLATION [SAT] .... . 03-15-2
PROPELLER SHAFT INSPECTION
[SAT] ............................ 03-15-6
PROPELLER SHAFT LOCATION INDEX [SAT]
id0315b38001 00
4x2
absggw00000989

INSTALLATION [5ATJ.)
(See 03-15-6 PROPELLER SHAFT INSPECTION
[5ATJ)

INSTALLATION [5AT].)
(See 03-15-6 PROPELLER SHAFT INSPECTION
[5ATJ)
03-15-1

PROPELLER SHAFT REMOVAUINSTALLATION [SAT]
id0315b3800300
1. Remove the member.

4x2
@)
@
"36-S2
{3.7-S.3,27-38}
Nm {kgfm, ttlbf}
absggw00000990
INut
Nut
03-15-2
Propeller shaft

4x4
98-117
{10.Q-11.9, 72.3-86.2} ~
!J
49-58
{5.0-5.9, 37-42}
Nm {kgf.m, ttlbf}
Nut
Nut


Nut
03-15-3

Propeller Shaft Removal Note
Caution
When replacing with a new propeller shaft, mark the companion flange to match the position of the
tag on the propeller shaft.
1. Before removing the propeller shaft, make alignment marks on the yoke and differential or transfer companion
flange.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
~-4='~~
__'!=--1";"~
'-- MARKING
absggw00000995

TRANSFER SIDE
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15-4

Propeller Shaft Installation Note
1. Align the marks and install the propeller shaft.
2. When installing a new propeller shaft, align the differential or transfer companion flange mark with the tag on
the propeller shaft and assemble.
Front propeller shaft (4x4)
FRONT DIFFERENTIAL SIDE
REAR DIFFERENTIAL SIDE
MARKING
absggw00001021
03-15-5

PROPELLER SHAFT INSPECTION [5AT]
id0315b3800500
Front Propeller Shaft (4x4) Inspection

MEASURE
POSITION
Front propeller shaft maximum runout

0.4 mm {0.016 in}
absggw00001007
Rear Propeller Shaft (4x2,4x4) Inspection

MEASURE
POSITION
Rear propeller shaft maximum runout

0.4 mm {O.016 in}
MEASURE
POSITION
MEASURE
POSITION
~D[j@
absggw00001003
2. Inspect the play and rotation of the joint by turning

the universal joint in the direction shown by the
arrow.
Rear propeller shaft initial torque (Reference

value)
0.29-1.76 Nm {3.0-17.9 kgfcm, 2.6-15.5
inlbf}
If there is excessive play or initial torque,
absggw00001004
03-15-6
TRANSFER
03-16
TRANSFER
TRANSFER LOCATION INDEX ....... 03-16-1

TRANSFER OIL INSPECTION ........ 03-16-1
TRANSFER OIL REPLACEMENT ..... 03-16-2
VEHICLE SPEED SENSOR (VSS)

REMOVAUINSTALLATION
[S15MX-D] ....................... 03-16-2
INSPECTION [S15MX-D] ........... 03-16-2
TRANSFER LOCATION INDEX
dcf03160000Ow01
DBG316ZWB003
1
2
Transfer oil
(See03-16-1 TRANSFER OIL INSPECTION.)
(See03-16-2 TRANSFER OIL REPLACEMENT.)
(See 03-16-2 VEHICLE SPEED SENSOR (VSS)
REMOVAUINSTALLATION [S15MX-D].)
INSPECTION [S15MX-D].)
TRANSFER OIL INSPECTION
Transmission and transfer

(See 05-11 8-1 0 TRANSMISSION AND TRANSFER
(See 05-118-12 INSPECTION AFTER
TRANSMISSION AND TRANSFER INSTALLATION
[S15MX-D].)
dcf031617001w01
1. Park the vehicle on level ground.

2. Remove the filler plug and with the packing.
3. Verify that the oil is near the brim of the plug port.
If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Transfer oil
Type: Mercon Multi-purpose AFT XT-2-QDX
4. Tighten the filler plug with a new packing.
Tightening torque
39-59 Nm {4.0-6.0 kgfm, 29-43 ftlbf}
DBG316ZWB001
03-16-1
TRANSFER
TRANSFER OIL REPLACEMENT
dcf031617001w02
1. Park the vehicle on level ground.

2. Remove the transfer under cover. (See 05-118-10 TRANSMISSION AND TRANSFER REMOVAU
INSTALLATION [S15MX-D].)
3. Remove the drain plug with the packing.
4. Drain the oil into a suitable container.
5. Tighten the drain plug with a new packing.
FILLER PLUG
Tightening torque
39-59 Nm {4.0-S.0 kgfm, 29-43 ft.lbf}
6. Remove the filler plug with the packing and add
the specified amount and type of oil through the
filler plug hole until the level reaches the bottom of
the filler plug hole.
DRAIN PLUG
Transfer oil
Capacity (approximate quantity): 1.85 L
{1.95 US qt, 1.S3 Imp qt}
DBG316ZWB002
7. Tighten the filler plug with a new packing.

Tightening torque
39-59 Nm {4.0-S.0 kgfm, 29-43 ftlbf}
8. Install the transfer under cover. (See 05-118-10 TRANSMISSION AND TRANSFER REMOVAU
INSTALLATION [S15MX-D].)
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S15MX-D]
dcf031600000w02
Caution
Water or foreign material entering the connector can cause a poor connection or corrosion. Be
sure not to drop water or foreign material on the connector when disconnecting it.
1.
2.
3.
4.

Disconnect the VSS connector.
Remove the VSS.
Apply the specified oil to a new O-ring and install
it on a VSS.
5. Install the VSS.
Tightening torque
7.8-11.0 Nm {80-112 kgfcm, 70-97
inlbf}
6. Connect the VSS connector.
7. Connect the negative battery cable.
DBG316ZWB005
VEHICLE SPEED SENSOR (VSS) INSPECTION [S15MX-D]
dcf031600000w03
1. Remove the VSS. (See 03-16-2 VEHICLE SPEED SENSOR (VSS) REMOVAUINSTALLATION [S15MX-D].)
2. Measure voltage between terminals of the VSS
while the gear is turning.
Vehicle speed sensor (VSS) voltage [S15MXD]

5 V or less
If the voltage is within the specification, the
VSS is normal. Repair the related wiring
harness.
If the voltage is not within the specification
(tester needle does not move), replace the
VSS.
3. Install the VSS. (See 03-16-2 VEHICLE SPEED
SENSOR (VSS) REMOVAUINSTALLATION
[S15MX-D].)
03-16-2
@ill)
I~~I
DBG316ZWB006
TRANSFER [SRSSS]
03-16
TRANSFER [5R55S]
TRANSFER LOCATION INDEX

[5R55S] .........................
TRANSFER CASE OIL INSPECTION
[5R55S] .........................
TRANSFER CASE OIL REPLACEMENT
[5R55S] .........................
SPEED SENSOR INSPECTION
[5R55S] .........................
03-16-1
03-16-2
03-16-2
03-16-3
SPEED SENSOR REMOVAUINSTALLATION

[5R55S] . ........................ . 03-16-4
MOTOR INSPECTION [5R55S] ....... . 03-16-4
MOTOR REMOVAUINSTALLATION
[5R55S] . ......................... 03-16-5
CLUTCH COIL INSPECTION [5R55S] ... 03-16-6
TRANSFER CASE REMOVAUINSTALLATION
[5R55S] . ........................ . 03-16-7
TRANSFER LOCATION INDEX [5R55S]
id0316c1800100
u
1
Transfer case oil

(See 03-16-2 TRANSFER CASE OIL INSPECTION
[5R55S].)
(See 03-16-2 TRANSFER CASE OIL
REPLACEMENT [5R55S].)
Speed sensor
[5R55S].)
(See 03-16-4 SPEED SENSOR REMOVAU
INSTALLATION [5R55S].)
Motor
[5R55S].)
Clutch coil
[5R55S].)
Transfer case
(See 03-16-7 TRANSFER CASE REMOVAU
03-16-1
TRANSFER [5R55S]
TRANSFER CASE OIL INSPECTION [5R55S]
id0316c1816200
1. Warm up the transfer case.
Caution
Do not use an impact wrench when removing the filler plug. It may damage the transfer case.
2. Remove the filler plug from the transfer case.
If the oil level is low, add the specified amount
and type of oil through the filler plug hole.
Transfer case oil

Type: Mercon V
4. Tighten the new filler plug.
Tightening torque
19-30 Nm {2.0-3.0 kgf.m, 15-22 ft.lbf}
TRANSFER CASE OIL REPLACEMENT [5R55S]
id0316c1816300
1. Warm up the transfer case.

2. Remove the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAU
Caution
Do not use an impact wrench when removing the filler plug or drain plug. It may damage the
transfer case.
3. Remove the drain plug from the transfer case.
4. Drain the oil into a suitable container.
5. Tighten the new drain plug.
Tightening torque
19-30 Nm {2.0-3.0 kgf.m, 15-22 ft.lbf}
6. Remove the filler plug and add the specified
amount and type of oil through the filler plug hole
until the level reaches the bottom of the filler plug
hole.
Transfer case oil

Type: Mercon V
Capacity (approx. quantity): 1.2 L {1.3 US qt, 1.1 Imp qt}
arnffw00001909
7. Tighten the new filler plug.
Tightening torque
19-30 Nm {2.0-3.0 kgf.m, 15-22 ftlbf}
8. Install the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
03-16-2
TRANSFER [5R55S]
SPEED SENSOR INSPECTION [5R55S]
id0316c1816000
Caution
Water or foreign material entering the connector can cause poor connections or corrosion. Be
sure that water or foreign material do not enter the connector when disconnecting it.

2. Remove the transfer case under cover. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL!
3. Disconnect the speed sensor connector.
Caution
Do not apply a shock in the speed
sensor.
Do not damage the terminals.
SPEED SENSOR
arnffw00001910
4. Measure the resistance between the speed

sensor terminals A and B.
If there is any malfunction, replace the speed
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAU
Transfer case speed sensor resistance
Approx. 300 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-1345 AUTOMATIC TRANSMISSION REMOVAU
arnffw00001911
03-16-3
TRANSFER [5R55S]
SPEED SENSOR REMOVAUINSTALLATION [5R55S]
id0316c1815700
Caution
Do not damage the speed sensor.
8-11 Nm {82-112 kgfcm,
1
Connector (wiring harness-side)
2
3
4
5
6
7
Connector (part side)

Connector cover
71-97 inlbf}
Clutch coil terminal

Speed sensor bracket
Wiring harness bracket
Speed sensor
arnffw00001914
MOTOR INSPECTION [5R55S]
id0316c1815900
Motor Operating Inspection

Caution
3. Remove the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
Caution
Do not apply a shock in the speed sensor.
4. Connect battery positive voltage to motor terminal
F, connect terminal C to ground, and then verify
that the motor operates as shown in the table.
5. Connect battery positive voltage to motor terminal
C, connect terminal F to ground, and then verify
that the motor operates as shown in the table.
If the operation condition is not normal,
replace the motor. (See 03-16-5 MOTOR
REMOVAUINSTALLATION [5R55S].)
Terminal
C
Ground
B+
F
B+
Ground
Motor position
2H~4H~4L
arnffw00001912
4L~4H~2H
6. Measure the resistance between the motor terminals C and F.

If there is any malfunction, replace the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
Transfer case motor resistance

approx. 117 ohms
03-16-4
TRANSFER [5R55S]
7. Install the motor. (See 03-16-5 MOTOR REMOVAUINSTALLATION [5R55S].)
[5R55S].)
Motor Position Inspection
3. Measure the resistance between the motor
terminals
If there is any malfunction, replace the motor.
(See 03-16-5 MOTOR REMOVAU
0-0 : Continuity
Terminal
Motor position
0
0
2H
4H
4L
'-"
"'-"
arnffwOOOO 1912
D--- f-O
D
arnffw00001913
[5R55S].)
MOTOR REMOVAUINSTALLATION [SRSSS]
id0316c1815800
Caution
Do not damage the motor.

1
2
3
4
Speed sensor connector

Connector
Speed sensor bracket
Motor
arnffw00001915
03-16-5
TRANSFER [5R55S]
CLUTCH COIL INSPECTION [5R55S] .
id0316c1816100
Caution

3. Disconnect the speed sensor connector.
Caution
Do not apply a shock in the speed
sensor.
Cl
SPEED SENSOR ~
CONNECTOR
-'"
arnffw00001910
4. Measure the resistance between the speed

sensor terminal C and body ground.
If there is any malfunction, replace the clutch
coil.
Transfer case clutch coil resistance
Approx. 3 ohms
5. Connect the speed sensor connector.

6. Install the transfer case under cover. (See 05-1345 AUTOMATIC TRANSMISSION REMOVAU
03-16-6
arnffw00001911
TRANSFER [5R55S]
TRANSFER CASE REMOVAL/INSTALLATION [5R55S]
id0316c1816400

3. Remove the oxidation catalytic converter (See 01-15-1 EXHAUST SYSTEM REMOVAUINSTALLATION [WL-C,
WE-C (RANGER (AT))].)
4. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
5. Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
REMOVAUINSTALLATION [5R55S])
6. Lower the transmission slightly.
38.0-52.0 Nm
{3.9-5.3 kgfm,
28.1-38.3 ft.lbf}
arnffw00001916
1
2
3
Speed sensor connector

Motor connector
Breather hose
4
5
6
Bolt
Bracket
Transfer case
03-16-7
4-WHEEL DRIVE
03-18
4-WHEEL DRIVE
4-WHEEL DRIVE LOCATION INDEX ...

4x4 INDICATOR SWITCH
INSPECTION ....................
TRANSFER NEUTRAL SWITCH
INSPECTION . ....................
RFW SWITCH INSPECTION ..........
RFW MAIN SWITCH
REMOVAL/INSTALLATION . .........
RFW MAIN SWITCH INSPECTION .....
ONE-WAY CHECK VALVE
INSPECTION . ...................
VALVES INSPECTION .............
03-18-1
03-18-2
03-18-2
03-18-3
03-18-3
03-18-4
03-18-4
03-18-4
RFW ACTUATOR INSPECTION ........ 03-18-5

JOINT SHAFT COMPONENT
REMOVAL/INSTALLATION ......... . 03-18-5
DISASSEMBLY ............. . 03-18-7
ASSEMBLy ...................... 03-18-9
CONTROL BOX
CONTROL BOX
DiSASSEMBLy/ASSEMBLy ......... 03-18-13
SHIFT FORK INSPECTION ........... 03-18-14
4-WHEEL DRIVE LOCATION INDEX
dcf03182730Ow01
DBG318ZWB040

(See 03-18-2 4x41NDICATOR SWITCH
INSPECTION.)
Lock and free solenoid valve

VALVES INSPECTION.)

(See 03-18-2 TRANSFER NEUTRAL SWITCH
INSPECTION.)
RFW switch
(See 03-18-3 RFW SWITCH INSPECTION.)
RFWactuator
(See 03-18-5 RFW ACTUATOR INSPECTION.)
PCM (RFW control)
RFW main switch

(See 03-18-3 RFW MAIN SWITCH REMOVAU
INSTALLATION.)
(See 03-18-4 RFW MAIN SWITCH INSPECTION.)
One-way check valve

(See 03-18-4 ONE-WAY CHECK VALVE
INSPECTION. )
8
9
Joint shaft component

(See 03-18-5 JOINT SHAFT COMPONENT
DISASSEMBLY.)
ASSEMBLY.)
03-18-1
4-WHEEL DRIVE
10
Control box
(See 03-18-12 CONTROL BOX REMOVAU
INSTALLATION.)
(See 03-18-13 CONTROL BOX DISASSEMBLY/
ASSEMBLY.)
(See 03-18-14 SHIFT FORK INSPECTION.)
4x4 INDICATOR SWITCH INSPECTION
dcf031827461w01
1. Jack up the vehicle and support it on safety stands.
2. Remove the 4x4 indicator switch.

3. Inspect for continuity between the terminals as
shown using a tester.
If not correct, replace the 4x4 indicator switch.
Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
DBG318ZWB001
4. Install the 4x4 indicator switch.
Tightening torque
25-34 Nm {2.6-3.4 kgfm, 19-25 ft.lbf}
12 mm {O.472 in}
13 mm {O.512 in}
DBG318ZWB002
TRANSFER NEUTRAL SWITCH INSPECTION
dcf031827462w01

2. Remove the transfer neutral switch.
3. Inspect for continuity at the switch using a tester.
If not correct, replace the transfer neutral
switch.
Continuity
Switch
Yes
Depressed (ON)
Released (OFF)
No
4. Install the transfer neutral switch.
Tightening torque
25-34 Nm {2.6-3.4 kgfm, 19-25 ft.lbf}
12 mm {O.472 in}
13 mm {O.512 in}
DBG318ZWB004
03-18-2
4-WHEEL DRIVE
RFW SWITCH INSPECTION
dcf031827463wO 1

2. Remove the RFW switch.
3. Inspect for continuity at the switch using a tester.
If not correct, replace the RFW switch.
Continuity
Switch
Yes
Depressed (ON)
No
Released (OFF)
-DBG318ZWB005
4. Install the RFW switch.
Tightening torque
24.5-34.3 Nm {2.50-3.49 kgf.m, 18.1-25.2
ttlbf}
OFF
12 mm {0.472 in}
13 mm {O.512 in}
RFW MAIN SWITCH REMOVAUINSTALLATION

1. Remove the lower panel. (See 09-17-10 LOWER PANEL REMOVAUINSTALLATION.)
IGonnector
DBG318ZWB039
03-18-3
4-WHEEL DRIVE
RFW MAIN SWITCH INSPECTION
dcf031827464w02
1. Remove the RFW main switch.

2. Inspect for continuity between the terminals as
shown using a tester.
0-0 : Continuity
Switch
DEPRESSED
RELEASED
r'f1"1 ,--, !"It
Terminal
A
!@..
-0
!@..
-0
1><1
BIE
-0
DBG318ZWB007
If not correct, replace the switch.
DBG318ZWB008
ONE-WAY CHECK VALVE INSPECTION
1. Remove the one-way 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.
If not correct, replace the one-way check
valve.
dcf031813995wOl
A
ONE-WAY CHECK VALVE
DBG318ZWB009
LOCK AND FREE SOLENOID VALVES INSPECTION
dcf031827740wOl
1.
2.
3.
4.
Disconnect the vacuum hoses and the connector from each solenoid valve.
Blow through each valve from port B.
,..---'-'- - - - - - - - - - - - - - - - - - ,
Inspect that air flows from the air filter.
BLOW
Connect 12 V and a ground to the terminals of
B
each valve.
5. Blow through each valve from port B.
AIR FILTER
DBG318ZWB010
6. Inspect that air flows from port A.

If not correct, replace the lock and free
solenoid valve(s).
AIR FILTER
DBG318ZWBOll
03-18-4
4-WHEEL DRIVE
RFW ACTUATOR INSPECTION
dcf03182731Ow01
1.
2.
3.
4.
Jack up the vehicle and support it on safety stands.

Disconnect the vacuum hoses from the actuator.
Connect a vacuum pump tester to the actuator (free side) as shown.
Apply 26.66 kPa {200 mmHg, 7.87 inHg}
,---------------------,
vacuum, and verify that the rod moves toward the
left.
5. Disconnect the vacuum pump tester.
6. Connect the vacuum pump tester tot he actuator
(lock side) as shown.
DBG318ZWB012
7. Apply 26.66 kPa {200 mmHg, 7.87 inHg}

vacuum, and inspect that the rod moves toward
the right.
If not correct, replace the RFW actuator.
JOINT SHAFT COMPONENT REMOVAL/INSTALLATION

1.
2.
3.
4.
dcf031827300w02
Drain the front differential oil.

Add the front differential oil. (See 03-14A-2 FRONT DIFFERENTIAL OIL REPLACEMENT.)
03-18-5
4-WHEEL DRIVE
43.1-60.8
{4.4D-6.19,
31.8-44.8}
36.3-53.9
{3.71-5.49,26.8-39.7}
Nm {kgfm, ftlbf}
DBG318ZWB014
2
3
Drive shaft
INSTALLATION. )
Vacuum hose
Snap pin
Joint shaft component, control box component
Gear sleeve
Output shaft
(See 03-18-6 Output Shaft Removal Note.)
Output Shaft Removal Note

1. Remove the output shaft using the SST.
DBG318ZWB015
03-18-6
4-WHEEL DRIVE
JOINT SHAFT COMPONENT DISASSEMBLY
dcf031827300w03
1. Disassemble in the order indicated in the table
1Q
Imil
Imil
DBG318ZWB016
Control box
Dust seal
2
3
Clip
Remote freewheel hub
(See03-18-7 Remote Freewheel Hub Disassembly
Note.)
Bearing
(See 03-18-8 Bearing Disassembly Note.)
10
12
Oil seal
(See 03-18-8 Oil Seal Disassembly Note.)
Joint shaft
Needle bearing
13
14
Clip
Casing
5
6
7
Spacer
Retaining ring
Ball bearing
(See 03-18-8 Ball Bearing Disassembly Note.)
Adjusting shim(s}
11
Remote Freewheel Hub Disassembly Note

1. Remove the remote freewheel hub using the SST.
"
DBG318ZWB017
03-18-7
4-WHEEL DRIVE
Ball Bearing Disassembly Note
1. Remove the ball bearing and the joint shaft using
a press.
DBG318ZWB018
2. Remove the ball bearing using a press.
DBG318ZWB019
Bearing Disassembly Note

1. Remove the dust seal and bearing using the SST
and a suitable bar.
DBG318ZWB020

1. Remove the oil seal using the SST.
DBG318ZWB021
03-18-8
4-WHEEL DRIVE
JOINT SHAFT COMPONENT ASSEMBLY
dcf031827300w04
mJ
Nm {kgfm, ftlbf}
DBG318ZWB023
1
2
3
5
6
Casing
Oil seal
(See 03-18-10 Oil Seal Assembly Note.)
Adjustment shim(s)
(See 03-18-10 Adjustment Shim(s), Ball Bearing
Assembly Note.)
Ball bearing
(See 03-18-10 Adjustment Shim(s), Ball Bearing
Assembly Note.)
Joint shaft
(See 03-18-10 Joint Shaft Assembly Note.)
Bearing
(See 03-18-11 Bearing Assembly Note.)
Retaining ring
Spacer
(See 03-18-11 Spacer, Remote Freewheel Hub
Assembly Note.)
Remote freewheel hub

(See 03-18-11 Spacer, Remote Freewheel Hub
Assembly Note.)
10
11
Clip
Dust seal
(See 03-18-11 Dust Seal Assembly Note.)
12
Needle bearing
13
Clip
Control box
14
03-18-9
4-WHEEL DRIVE
1. Apply differential oil to a new oil seal.
2. Install the new oil seal using the SST and a press.
~.
I I
DBG318ZWB024
Adjustment Shim(s), Ball Bearing Assembly Note

1. Install the removed shim(s) and the ball bearing
2. Install a new retaining ring.
PLATE
DBG318ZWB025
3. Measure the clearance between the ball bearing

and the retaining ring.
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
0.30 mm
0.35 mm
0040 mm
0.50 mm
{0.0059 in}
{0.0118 in}
{0.0138 in}
{0.0157 in}
{0.0197 in}
DBG318ZWB026
Joint Shaft Assembly Note

1. Install the joint shaft using the SST and a press.
II.
DBG318ZWB027
03-18-10
4-WHEEL DRIVE
Bearing Assembly Note
1. Install the bearing using the SSTs and a press.
DBG318ZWB028
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.
2. Install a new clip.
3. Measure the clearance between the remote

freewheel hub and the clip.
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}
DBG318ZWB030
0.35 mm {0.0138 in}

0040 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.
J.
II
DBG318ZWB031
03-18-11
4-WHEEL DRIVE
CONTROL BOX REMOVAUINSTALLATION
1.
2.
3.
4.
1
2
3
dcf031827750w01
Drain the front differential oil into a container.

Add the specified front differential oil.
Vacuum hose
Control box
22.6-26.4
{2.31-2.69,16.7-19.4}
15.7-22.5
{1.61-2.29,
11.6-16.5}
Nm {kgfm, ftlbf}
DBG318ZWB032
03-18-12
4-WHEEL DRIVE
CONTROL BOX DISASSEMBLY/ASSEMBLY
dcf03182775Ow02

7m
iii
Nm {kgfm, ftlbf}
DBG318ZWB033
1
2
3
Washer
RFW switch and washer
Spring cap
6
7
Spring and ball
Snap ring
RFW actuator
Washer
Roll pin
(See 03-18-13 Roll Pin Disassembly Note.)
(See 03-18-14 Roll Pin Assembly Note.)
Change rod
10
Shift fork
11
Boot
(See 03-18-14 Boot Assembly Note.)
12
Oil seal
13
Control box
Roll Pin Disassembly Note

1. Remove the roll pin as shown in the figure.
DBG318ZWB034
03-18-13
4-WHEEL DRIVE
1. Assemble a new oil seal using the SST and a
press.
,.
II
DBG318ZWB035
Boot Assembly Note

1. Assemble the boot as shown in the figure.
DBG318ZWB036
Roll Pin Assembly Note

1. Install a new roll pin as shown in the figure.
DBG318ZWB037
SHIFT FORK INSPECTION
dcf031827300w05
1. Measure the clearance between the gear sleeve

and the shift fork.
Standard clearance
0.1-0.4 mm {0.0040-0.0157 in}
Maximum clearance
0.50 mm {0.0197 in}
2. Inspect the output shaft and gear sleeve of the
splines for damage and wear.
If not correct, replace the output shaft and
gear sleeve as necessary.
03-18-14
DBG318ZWB038
4-WHEEL DRIVE
03-18
4-WHEEL DRIVE
4-WHEEL DRIVE LOCATION INDEX

[AT (5R55S)] ..................... 03-18-1
4x4 SWITCH INSPECTION
[AT (5R55S)] ..................... 03-18-2
4x4 SWITCH REMOVAL/INSTALLATION
[AT (5R55S)] ..................... 03-18-3
4x4 CONTROL MODULE INSPECTION

[AT (5R55S)] . .................... . 03-18-3
4x4 CONTROL MODULE
[AT (5R55S)] . .................... . 03-18-5
4-WHEEL DRIVE LOCATION INDEX [AT (5R55S)]
id0318008005d2
arnffw00001888
Motor. component
[5R55S].)
Speed sensor
[5R55S].)
(See 03-16-4 SPEED SENSOR REMOVAU
Clutch coil
[5R55S].)
Digital TR sensor
(See 05-13-20 DIGITAL TRANSMISSION RANGE
(TR) SENSOR INSPECTION [5R55S].)
(TR) SENSOR REMOVAUINSTALLATION
[5R55S].)
4x4 switch
(See 03-18-2 4x4 SWITCH INSPECTION [AT
(5R55S)].)
(See 03-18-3 4x4 SWITCH REMOVAU
4x4 control module

(See 03-18-3 4x4 CONTROL MODULE
INSPECTION [AT (5R55S)].)
Lock and free solenoid valve

One-way check valve
9
10
11
Joint shaft component

Control box
RFW actuator
03-18-1
4-WHEEL DRIVE.
4x4 SWITCH INSPECTION [AT (5R55S)]
id0318008050d2
Caution
2. Remove the boot panel.
3. Verify that the continuity is as indicated in the
table.
E
0-0 : Continuity
Connector terminal
Position
2H
4H
4L
iJ
0- -Q
arnffw00001882
If there is any malfunction, replace the 4x4

switch. (See 03-18-3 4x4 SWITCH
REMOVAL/INSTALLATION [AT (5R55S)].)
4. Install the boot panel.
0-0 : Continuity
Connector terminal
arnffw00001883
03-18-2
4-WHEEL DRIVE
4x4 SWITCH REMOVAUINSTALLATION [AT (SRSSS)]
1.
2.
3.
4.
id0318008051 d2

Remove the boot panel. (See .)
Iknob
4x4 sWitch
4x4 CONTROL MODULE INSPECTION [AT (SRSSS)]
id0318008049d2
1. Remove the lower panel.

3. Attach the tester lead to the control module connector and inspect the voltage and continuity according to the
Terminal Voltage Table (Reference).
Terminal Voltage Table (Reference)
.......
Signal name
I~~
Terminal
Connected to
Motor control (4L4H-2H)
Motor component
(shift motor)
Motor control (4L4H-2H)
Motor component
(shift motor)
Motor control (2H4H-4L)
Motor component
(shift motor)
arnffw00001875
condition
Motor operating
Voltage (V)
Below 1.0
Motor not operating
B+
Motor operating
Below 1.0
Motor not operating
B+
Motor operating
Below 1.0
Motor not operating
B+
Inspection item(s)
Inspect related wiring
harness
Motor component (shift
motor)
harness
motor)
harness
motor)
03-18-3
4-WHEEL DRIVE
Terminal
Signal name
Motor control (2H4H-4L)
Motor component
(shift motor)
Neutral signal
Digital TR sensor
4H or 4L mode
signal
2H or4H mode
signal
Position 4
Position 2
Position 1
K
L
Position 3
Vehicle speed
03-18-4
4x4 switch
4x4 switch
Motor component
(position sensor)
Motor component
(position sensor)
Motor component
Motor component
(position sensor)
Speed sensor
Speed sensor or
motor component
Ground
0
Q
Connected to
DTC output
4x4 indicator light
4L indicator light
IG 1
Clutch coil
Motor not operating
B+
N position
Below 1.0
Except N position
Approx.4.3
2H or 4H position
B+
4L position
Below 1.0
2H position
Below 1.0
4H or 4L position
B+
2H position
4H position
Approx.5.0
Approx.5.0
4L position
Approx.4.2
2H position
Approx.5.0
4H position
Approx.5.0
4L position
Approx.4.2
2H position
Approx.5.0
4H position
Approx.5.0
4L position
Below 1.0
Engine switch OFF
Below 1.0
Engine switch ON
Approx.5.0
Engine switch OFF
Below 1.0
Engine switch ON
Approx.5.0
4L indicator light
OFF
Below 1.0
Approx.5.0
B+
Below 1.0
B+
4L indicator light ON
Engine switch OFF
Below 1.0
Below 1.0
Engine switch ON
B+
Clutch coil operating

Clutch coil not
operating
B+
Below 1.0
Lock solenoid valve

operating
Below 1.0
Lock solenoid valve

not operating
B+
Under any condition
Below 1.0
Inspection item(s)
harness
motor)
harness
Digital TR sensor
harness
4x4 switch
harness
4x4 switch
harness
Motor component
(position sensor)
harness
Motor component
(position sensor)
harness
Motor component
(position sensor)
-
Approx.4.2
Body ground
4L position
Clutch coil
Approx.5.0
Approx.5.0
Data link connector Engine switch OFF

(DLC)
Engine switch ON
4x4 indicator light
OFF
4x4 indicator light
4x4 indicator light
ON
Engine fuse
2H position
4H position
4L indicator light
Voltage (V)
Below 1.0
Lock solenoid valve Lock solenoid valve
Ground
condition
Motor operating

harness
Motor component
(position sensor)
harness
Speed sensor
harness
Speed sensor
Motor component
-

harness

harness
4x4 indicator light

harness
4L indicator light
harness
Engine fuse
harness
Clutch coil
harness
Lock solenoid valve
harness
(W-ground)
4-WHEEL DRIVE
Terminal
Signal name
Connected to
Ground
Body ground
B+
PTC/AT fuse
B+
PTC/ATfuse
Voltage (V)
condition
Under any condition

Engine
Engine
Engine
Engine
switch
switch
switch
switch
OFF
ON
OFF
ON
Below 1.0
Inspection item(s)
harness
(X-ground)
B+

harness
B+

harness
4x4 CONTROL MODULE REMOVAUINSTALLATION [AT (5R55S)]
1.
2.
3.
4.
id0318008048d2

Remove the lower paneL
Install in the reverse order of removaL
18.6-25.5 Nm
{1.90-2.60 kgfm.
13.8-18.8 ftlbf}
7.8-10.8 Nm {80-110 kgfcm. 70-95 inlbf}

arnffw00001874
IConnector
IBracket
4x4CM
03-18-5
TECHNICAL DATA
03-50
TECHNICAL DATA
DRIVELINEIAXLE TECHNICAL DATA ~. 03-50-1

DRIVELINEIAXLE TECHNICAL DATA
Front drive shaft standard length
Rear differential oil [STANDARD DIFFERENTIAL]
Rear differential oil [LSD]
dcf035000000w02
LH: 507.8-517.8 mm {20.00-20.38 in}

RH: 596.7-606.7 mm {23.50-23.88 in}
Viscosity (above -18C): SAE 90
Viscosity (below -18C): SAE 80
Oil capacity (approx. quantity): 1.8-2.0 L {2.0-2.1 US qt, 1.6-1.7
Imp qt}
Viscosity: SAE 90
Oil capacity (approx. quantity): 1.3-1.5 L {1.3-1.4 US qt, 1.1-1.2
Imp qt} (WL-3)
Oil capacity (approx. quantity): 2.35-2.55 L {2.23-2.41 US qt,
1.96-2.12 Imp qt} (WL-C)
Viscosity: SAE 90
Oil capacity (approx. quantity): 2.25-2.45 L {2.13-2.31 US qt,
1.88-2.03 Imp qt}

Capacity (approximate quantity): 1.85 L {1.95 US qt, 1.63 Imp qt}
Type: Mercon V
03-50-1
SERVICE TOOLS
03-60
SERVICE TOOLS
DRIVELINEIAXLE SST ... ........... 03-60-1
DRIVELINE/AXLE SST
dcf03600000Ow02
1: Mazda SST number

Example
1 :49 UN30 3050
2:303-050
Engine lifting
brackets
1:49 T028 3AO
1:49 G019 017
1:49 G030 797
2:-
2:-
2:-
Ball joint puller

set
Oil seal installer
Handle
1 :49 8033 107
1:49 F027 007
1 :49 8033 106
2:-
2:-
2:-
Oil seal installer
Attachment for
Oil seal installer
072
1:49 H033 101
1:49 B025 001
1 :49 F019 001
2:-
2:-
2:-
Bearing
remover
Body
Oil seal
installerg
1:49 0603 635A
1 :498120 645A
1:498120710
2:-
2:-
2:-
Rear shaft
holder
Rear sahft nut

wrench
Coupling flange
holder
1:49 0839 425C
2:-
1:49 8026 2A 1
~
Bearing puller
set
1 :49 0107 680A
2:-
2:Rear axle shaft

bearing puller
set
Engine stand
~~~~;;;;;2;;;;;8
03-60-1
SERVICE TOOLS
1 :49 M005 561
2:-
2:-
1 :49 F027 004
2:-
Differential
carrier hunger
Attachment for
080
Attachment
1:49 0660 555
1 :49 0727 570

2:-
Gauge block
Pinion height
gauge body
1:498531 565
2:-
Drive pinion
model
/n
~
O~
1:49 H027 002
1:49 S120 748
2:-
1:49 UB71 525
1:49 F027 009
2:-
2:-
2:-
Bearing
remover
Bearing installer
Attachment for
068&77
1:49 F027 004
2:-
2:-
1:49 F027 003
1 :49 U027 008

2:-
Attachment for
080
Handle
Gauge block
1 :49 UN27 004

2:-
1 :49 UN27 003

2:-
1 :49 F401 331

2:-
Collar B
Collar A
1 :49 U027 009

2:-
1 :49 U027 013

2:-
Oil seal installer
1:49 U027 012

2:Attachment A
B
@
Attachment B
1:49 U027 011

2:Shaft
Body
Bolt
Oil seal installer
1 :49 F401 337A

2:-
1 :49 U027 007

2:-
1 :49 8531 567

2:-
Attachment C
Oil seal installer
Collar A
03-60-2
..
-::'~~-; ,
1:49 U027 014

2:-
1 :49 G030 796

2:-
~
(ID
SERVICE TOOLS
1:498531 568
2:Collar B
(@)
1:49 0259 720

2:-
1:49 0710 520

2:-
Side bearing
adjustment
wrench
Bearing puller
1:49 U027 005

2:-
1:49 U027 004

2:-
1:49 U027 006

2:-
Bearing installer
Oil seal remover
Bearing installer
1:49 W027 001

2:-
1:49 M005 796

2:-
1:49 G033 102

2:-
Body
Handle
1:49 W010
107A
2:-
1:49 0026 102

2:-
Body
1:49 F026 103

2:Wheel hub
puller
@
c::=:::=J
Oil seal installer
Sensor rotor
installer
1:49 G019 011

2:-
1:49 F026 102

2:-
1:491011748
2:-
Bearing installer
Bearing installer
Attachment
1 :49 G033 105

2:-
1:49 W033 101

2:-
1:49 T019 001

2:-
Body
Attachment
1:49 1361 555

2:-
1:49 J027 002

2:-
1:49 E027 007

2:-
Gauge block
Collar
Collar
2:-
1:490727415
1:49 UN20 4069

2:204-069
Bearing installer
Remover
1: 49 UN20
500180
2:205-0018
Attachment
E:J
~~d
Attachment
03-60-3
SERVICE TOOLS
1: 49 UN20
500020
2:205-0002
1: 49 F401 331
2:-
1: 49 U027 010
2:-
Body
Bearing installer
Remover
1:498120440 .
2:Mainshaft
holder
03-60-4
W08
BRAKES
ON-BOARD DIAGNOSTIC
SYSTEM (ABS)] ... . . . . . . . 04-02A
ON-BOARD DIAGNOSTIC
[4-WHEEL ANTI LOCK BRAKE
SYSTEM (4W-ABS)] ....... 04-02B
SYMPTOM
TROUBLESHOOTING
[REAR ANTILOCK
BRAKE SYSTEM (ABS)] ... 04-03A
SYMPTOM
TROUBLESHOOTING
[4-WHEEL ANTILOCK
BRAKE SYSTEM
(4W-ABS)] ............... 04-03B
GENERAL PROCEDURES .... 04-10

CONVENTIONAL
BRAKE SYSTEM .......... 04-11
PARKING BRAKE SYSTEM ... 04-12
ANTILOCK BRAKE SYSTEM
SYSTEM (ABS)] ........... 04-13A
SYSTEM (4W-ABS)] ........ 04-13B
SERVICE TOOLS ........... 04-60
04-02A-1
04-02B ON-BOARD DIAGNOSTIC [4-WHEEL ANTILOCK

[4W-ABS] . ............. " ........
ON-BOARD DIAGNOSIS [4W-ABS] . ...
DTC B1317, B1318 [4W-ABS] ........
DTC B1342 [4W-ABS] . .... '" .......
DTC B1484 [4W-ABS] ... ............
DTC Cl095, Cl096 [4W-ABS] ........
DTC Cl145, Cl155, Cl165, Cl175
[4W-ABS] . .......................
04-02B-l
04-02B-2
04-02B-7
04-02B-8
04-02B-8
04-02B-9
04-02B-ll
DTC Cl186 [4W-ABS] .............. . 04-02B-12

DTC Cl194, Cl198, C1202, C1206,
C1210, C1214 [4W-ABS] ., ......... . 04-02B-13
DTC C1222 [4W-ABS] .............. . 04-02B-14
DTC C1233, C1234, C1235, C1236
[4W-ABS] ............ , .......... . 04-02B-16
DTC C1414 [4W-ABS] .............. . 04-02B-17
DTC C1730, C1949, C1950 [4W-ABS] ... 04-02B-18
ABS SYSTEM WIRING DIAGRAM [4W-ABS]
dcf040200000w15
ABS/SOL20A
Hi-Rider, 4x4
}-----+-OIG SENSOR
ABS40A
BRAKE SWITCH
~~Nt-~~~~~~
BRAKE
LIGHT
ABSWARNING
LIGHT
~~--~~--------~S
ABS HU/CM
Q}------{)
INSTRUMENT CLUSTER
DCF413BWB001
04-028-1

ON-BOARD DIAGNOSIS [4W-ABS]
dcf040200000w16
On-Board Diagnostic (OBD) Test Description

The OBD test inspects the integrity and function of the ABS and outputs the results when requested by the
specific tests.
On-board diagnostic test also:
Provides a quick inspection of the ABS usually performed at the start of each diagnostic procedure.
Provides verification after repairs to ensure that no other faults occurred during service.
The OBD test is divided into 3 tests:
Read/clear diagnostic results, PID monitor and record and active command modes.
Read/clear diagnostic results
This function allows you to read or clear DTCs in the ABS HU/CM memory.
PID/Data monitor and record
This function allows you to access certain data values, input signals, calculated values, and system status
information.
Active command modes
This function allows you to control devices through the current diagnostic tool.
Reading DTCs Procedure
Using WDS
1. Connect the WDS to the DLC-2 connector.
2. Retrieve DTC using the WDS.
DBR402ZTB003
Using IDS/PDS
1. Connect the IDS/PDS to the DLC-2 connector.
items from the initialization screen of the IDS/
PDS.
2. Select "Self Test".
3. Select "Module".
4. Select "ABS".
2. Select" ABS" .
DBR402ZTB003
3. Verify the DTC according to the directions on the
screen.
4. After completion of repairs, clear all DTCs stored in the ABS HU/CM. (See 04-02B-2 Clearing DTCs
Procedures.)
Clearing DTCs Procedures
Using WDS
1. After repairs have been made, perform the DTCs reading procedure.
2. Erase DTC using the WDS.
3. Ensure that the customer's concern has been resolved.
04-028-2

Using IDS/PDS
1. Connect the 10S/POS to the vehicle OLC-2
connector.
items from the initialization screen of the 10S/
POS .
3. Select "Module".
4. Select "ASS".
2. Select "ASS".
3. Verify the OTC according to the directions on the screen.
4. Press the clear button on the OTC screen to clear the OTC.
5. Verify that no OTCs are displayed.
DBR402ZTB003
PID/Data Monitor and Record Procedure

Using WDS
1. Connect the WOS to the vehicle OLC-2
connector.
2. Access and monitor PIOs using the WOS.
DBR402ZTB003
Using IDS/PDS
1. Connect the 10S/POS to the OLC-2 connector.
POS .
2. Select "OataLogger".
3. Select "Module".
4. Select "ASS".
2. Select "ASS".
3. Select the applicable PIO from the PIO table.
4. Verify the PIO data according to the directions on the screen.
DBR402ZTB003
Note
The PIO data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually using a active command modes function.
04-028-3

Active Command Modes Procedure
Using WDS
1. Connect the WDS to the vehicle DLC-2
connector.
2. Turn the engine switch to the ON position (engine
off) or start the engine.
3. Activate active command modes using the WDS.
DBR402ZTB003
Using IDS/PDS
PDS.
1. Select the 'Toolbox" tab.
3. Select "Module".
4. Select "ASS".
2. Select "ASS".
DBR402ZTB003
3. Select the active command modes from the PID
table.
4. Perform the active commands modes, inspect the operations for each parts.
If there is no operation sound from the relay, motor, and solenoid after the active commands mode
inspection is performed, it is possible that there ia an open or short circuit in the wiring harness, relay, motor
or solenoid, or sticking and operation malfunction.
DTCTable
B1317
Power supply system
Page
(See 04-02B-7 DTC B1317, B1318 [4W-ABS].)
B1318
B1342
Power supply system

ABS HUlCM system
(See 04-02B-7 DTC B1317, B1318 [4W-ABS].)

(See 04-02B-8 DTC B1342 [4W-ABS].)
B1484
Brake switch system

Pump motor, motor relay system
(See 04-02B-8 DTC B1484 [4W-ABS].)

(See 04-02B-9 DTC C1095, C1096 [4W-ABS].)
DTC
C1095
C1096
System malfunction location
(See 04-02B-9 DTC C1095, C1096 [4W-ABS].)
C1145
RF ABS wheel-speed sensor system
(See 04-02B-11 DTC C1145, C1155, C1165, C1175

[4W-ABS].)
C1155
LF ABS wheel-speed sensor system
(See 04-02B-11 DTC C1145, C1155, C1165, C1175

[4W-ABS].)
C1165
RR ABS wheel-speed sensor system
(See04-02B-11 DTCC1145, C1155, C1165, C1175

[4W-ABS].)
C1175
LR ABS wheel-speed sensor system
C1186
Fail-safe relay system
C1194
LF outlet solenoid valve system
C1198
LF inlet solenoid valve system
C1202
Rear outlet solenoid valve system
(See 04-02B-13 DTC C1194, C1198, C1202,

C1206, C1210, C1214 [4W-ABS].)
C1206
Rear inlet solenoid valve system
(See 04-02B-13 DTC C1194, C1198, C1202,

C1206, C1210, C1214 [4W-ABS].)
04-028-4
(See 04-02B-11 DTC C1145, C1155, C1165, C1175

[4W-ABS].)
(See 04-02B-12 DTC C1186 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1206, C1210, C1214 [4W-ABS].)
(See 04-02B-13 DTC C1194, C1198, C1202,
C1206, C1210, C1214 [4W-ABS].)

System malfunction location
OTC
C1210
RF outlet solenoid valve system
C1214
RF inlet solenoid valve system
C1222
ABS wheel-speed sensor (slip monitor) system
C1233
C1234
C1235
C1236
Page
(See 04-02B-13 OTC C1194, C1198, C1202,
C1206, C121 0, C1214 [4W-ABS].)
(See 04-02B-13 OTC C1194, C1198, C1202,
C1206, C1210, C1214 [4W-ABS].)
(See 04-02B-14 OTC C1222 [4W-ABS].)

(See 04-02B-16 OTC C1233, C1234, C1235, C1236
LF ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
RF ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
[4W-ABS].)
(See 04-02B-16 OTC C1233, C1234, C1235, C1236
LR ABS wheel-speed sensor/ABS sensor rotor system
[4W-ABS].)
RR ABS wheel-speed sensor/ABS sensor rotor system
C1414
Incorrect ABS HU/CM installed
C1730 *
G sensor system
C1949*
G sensor system
C1950 *
G sensor system
(See 04-02B-17
(See 04-02B-18
ABS].)
(See 04-02B-18
ABS].)
(See 04-02B-18
ABS].)
OTC C1414 [4W-ABS].)

OTC C1730, C1949, C1950 [4WOTC C1730, C1949, C1950 [4WOTC C1730, C1949, C1950 [4W-
: Hi-Rider, 4x4
PID/DATA Monitor Table
PIO name
(definition)
ABS_LAMP
(ABS warning light
driver output state)
ABS_VOLT
(System battery
voltage value)
ACCLMTR*
(Forward-G sensor
input)
BOO_ABS
(Brake pedal switch
input)
CCNTABS
(Number of continuous
codes)
On/Off
On/Off
PMP_MOTOR
(Pump motor output
state)
On/Off
RLY_PMP
(Pump motor relay
output state)
On/Off
RLY_VLV
(Solenoid valve relay
output state)
On/Off
V_LF_INL
(Left front inlet solenoid
valve output state)
Operation condition
(reference)
Unit/Condition
ABS warning light is

illuminated: ON
ABS warning light is not
illuminated: Off .
OTCs detected:
1-255
Inspect the power supply circuit.

(See 04-13B-5 ABS HU/CM
INSPECTION [4W-ABS].)
Relay activated: On
Relay not activated: Off
Solenoid valve relay is

activated: On
Solenoid valve relay is
deactivated: Off
Solenoid valve activated:
On
Solenoid valve not
activated: Off
Perform the OTC inspection.
No OTCs detected: 0
Pump motor activated: On

Pump motor not activated:
Off
ASS HUlCM
terminal
Inspect the ABS warning light.
Vehicle is stopped or
driving at a constant
speed: 0 G
Inspect the G sensor.
Cornering to left: Changes
(See 04-13B-13 G SENSOR
between 0 G and 1.5 G
INSPECTION [4W-ABS].)
Cornering to right:
Changes between 0 G and
-1.5 G
Inspect the brake switch.
Brake pedal depressed:
(See 04-11-6 BRAKE SWITCH
On
Brake pedal released: Off INSPECTION.)
On/Off
Engine switch at ON:

Approx. 12.2 V
Idling: Approx. 14.1 V
Action
Inspect the ABS HU/CM.

SYSTEM INSPECTION [4WABS].)
Inspect ABS HU/CM.
04-028-5

PIO name
(definition)
V_LF_OTL
(Left front outlet
solenoid valve output
state)
V_RF_INL
(Right front inlet
state)
V_RF_OTL
(Right front outlet
state)
Unit/Condition
On/Off
On/Off
On/Off
V_Rear_INL
(Rear inlet solenoid
valve output state)
On/Off
V_Rear_OTL
(Rear outlet solenoid
valve output state)
On/Off
WSPD_LF
(Left front ABS wheelspeed sensor input)
KPH,MPH
WSPD_LR
(Left rear ABS wheelspeed sensor input)
KPH,MPH
WSPD_RF
(Right front ABS wheelspeed sensor input)
KPH,MPH
WSPD_RR
(Right rear ABS wheelspeed sensor input)
KPH,MPH
Operation condition
Action
(reference)
On
Solenoid valve not
SYSTEM INSPECTION [4Wactivated: Off
ABS].)
On
Solenoid valve not
ABS].)
On
Solenoid valve not
ABS].)
Inspect the ABS HUiCM.
On
Solenoid valve not
ABS].)
(See 04-13B-2 ABS HUlCM
On
SYSTEM INSPECTION [4WSolenoid valve not
activated: Off
ABS].)
Vehicle stopped: 0 KPH, 0
MPH
Inspect the ABS wheel-speed
Vehicle running: Vehicle
sensor.
speed
MPH
sensor.
speed
MPH
sensor.
speed
MPH
sensor.
speed
ABS HUlCM
terminal
E,F
I,G
O,M
L,K
: Hi-Rider, 4x4
Active Command Modes Table

Command name
PM P_MOTOR
V_LF_INL
Output part
V_ReaUNL
V_RF_OTL
04028-6
Operating
condition
On/Off
Engine switch at
ON
Pump motor
V_LF_OTL
V_ReacOTL
V_RF_INL
Operation


DTe 81317, 81318 [4W-A8S]
DTC
dcf04020000Ow17
IPower supply system
B1317, B1318
DETECTION
CONDITION
POSSIBLE
CAUSE
B1317
- The voltage at ABS HUlCM terminal J 16.8 V or more.
B1318
- The vehicle speed exceeds 6 km/h {3.7 mph} and the voltage at ABS HU/CM terminal J is less than
9.6 V.
ENGINE 15 A fuse malfunction
Open circuit or short to ground in the wiring harness between the ABS HU/CM terminal J and the
battery
Open circuit or faulty ground in the wiring harness between the ABS HUlCM terminal D and the body
ground
Battery deterioration
Generator malfunction
Poor connection at connectors (female terminal)
ENGINESW
""
-~
ENGINE 15A
ABS HU/CM
,.II
I
-'-
BATTERY
ABS HU/CM WIRING HARNESS-SIDE CONNECTOR
GI Iwi
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STEP
1
INSPECTION
INSPECT BATTERY VOLTAGE
Is the battery terminal voltage normal?
Yes
No
INSPECT BATTERY GRAVITY

Is battery specific gravity as specified?
Yes
INSPECT CHARGING SYSTEM

Are the generator and drive belt tensions
normal?
Yes
INSPECT ABS HUlCM POWER SUPPLY FOR

OPEN CIRCUIT
Start the engine.
Measure the voltage between ABS HU/CM
terminal J and ground.
Is the voltage approx. 10 V?
Yes
INSPECT ABS HUlCM GROUND FOR POOR

GROUND OR OPEN CIRCUIT
Measure the resistance between ground and
ABS HU/CM terminal D.
Is the resistance within 0-1 ohm?
No
No
ACTION
Make sure that battery terminal connection is normal.
Charge or replace the battery, then go to Step 6.
(See 01-17-4 BATTERY RECHARGING.)
Replace the battery, then go to Step 6.
Inspect generator and/or drive belt as necessary, then go to
Step 6.
(See 01-10A-3 DRIVE BELT INSPECTION [WL-3].)
(See 01-10B-3 DRIVE BELT INSPECTION [WL-C, WE-C].)
No

Repair or replace the wiring harness for open circuit
between the ABS HUlCM and ground, then go to Step 6.
Yes
No
If there is no continuity:
between the ABS HU/CM and ground, then go to the
next step.
If the resistance is not within 0-1 ohm:
Repair or replace harness for poor ground, then go to
the next step.
04-028-7

INSPECTION
STEP
VERIFY TROUBLESHOOTING COMPLETED
6
connectors.
Clear the DTC from the memory.
(See 04-02B-2 Clearing DTCs Procedures.)
Start the engine and drive the vehicle at 6
kmlh {3.S mph} or more.
7
Are any other DTCs present?
Yes
ACTION
Replace the ABS HUlCM, then go to the next step.
(See 04-13B-3 ABS HU/CM REMOVAUINSTALLATION
[4W-ABS].)
No
Yes

(See 04-02B-4 DTC Table.)
No
DTC B1342 [4W-ABS]

DTC B1342
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf040200000w18
lABS HUlCM system

The ABS HU/CM on-board diagnostic function detects control module malfunction.
ABS HU/CM internal malfunction
INSPECTION
STEP
VERIFY CURRENT STATUS OF
1
MALFUNCTION
2
Yes
No
Yes
No
ACTION
Replace the ABS HU/CM, then go to the next step.
[4W-ABS].)
DTC B1484 [4W-ABS]
dcf040200000w19
IBrake switch system
DTC B1484
DETECTION
CONDITION
POSSIBLE
CAUSE
Open circuit in the wiring harness between the ABS HU/CM terminal and the brake switch terminal
Brake switch malfunction
Open circuit in the wiring harness between the ABS HU/CM terminal N and the brake switch terminal
BRAKE SWITCH
@;
~~-->-o{A
ABS HU/CM
~ BRAKE LIGHT
!oo
wi
10 10 I
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04-028-8
II 0 IC I B IA9
BRAKE SWITCH WIRING

ffi
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INSPECTION
STEP
INSPECT WIRING HARNESS BETWEEN ABS
1
HUlCM AND BRAKE SWITCH FOR
CONTINUITY
Disconnect the ABS HU/CM connector.
Is B+ correctly applied to ABS HU/CM
connector terminal N when brake pedal
depressed?
INSPECT BRAKE SWITCH
2
Inspect the brake switch.
(See 04-11-6 BRAKE SWITCH
INSPECTION.)
Is the brake switch normal?
3

connectors.
Are the same DTCs present?
Are any other DTC present?
ACTION
Yes
Go to Step 3.
No
Yes

between ABS HU/CM and brake switch, then go to the next
step.
No
Replace the brake switch, then go to the next step.

(See 04-11-5 BRAKE SWITCH REMOVAUINSTALLATION.)
Yes

[4W-ABS].)
No
Yes

No
DTC C1095, C1096 [4W-ABS]
dcf040200000w20

C1095, C1096
C1095
- When the pump motor monitor voltage remains at 2.0 V or more for 1 s.
- ABS motor monitor OFF signal is input within specified time limit when the motor signal is switched
DETECTION
from ON to OFF by ABS CM.
CONDITION
C1096
- When the difference between the battery power supply voltage and pump motor power supply
voltage remains at 4.0 V or more for 0.1 s or more while the pump motor is operating.
ABS 40 A fus_e malfunction
Open or short to ground circuit in the wiring harness between the battery and the ABS HUlCM terminal
B
POSSIBLE
Open circuit in the wiring harness between the ABS HU/CM terminal A and the body ground
CAUSE
Open or short circuit in the ABS HU/CM internal motor relay, or stuck motor relay
Open or short circuit in the ABS HU/CM internal motor, or frozen motor
Fail-safe relay malfunction
DTC
ABS HU/CM
ABS40A
I-
,.
I
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BATTERY
PUMP
MOTOR
IJ
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04-028-9

STEP
1
2
INSPECTION
INSPECT ABS FUSE CONDITION
Is the ABS 40A fuse normal?
INSPECT MOTOR RELAY POWER SUPPLY
FOR OPEN CIRCUIT
Disconnect ABS HU/CM connector.
(engine off).
Measure voltage between ABS HUlCM
terminal B (harness-side) and ground.
Is the voltage B+?
INSPECT PUMP MOTOR GROUND FOR
OPEN CIRCUIT
Inspect for continuity between ABS HU/CM
terminal A (harness-side) and ground.
VERIFY PUMP MOTOR OPERATION

Connect the current diagnostic tool to the
DLC-2.
(engine off).
Access PMP_MOTOR active command
modes using the current diagnostic tool.
Does the pump motor operate?
connectors.
ACTION
Yes
No

Replace the fuse, then go to Step 5.
Yes
No

between battery positive terminal and ABS HU/CM terminal
B, then go to Step 5.
Yes

between ABS HU/CM terminal A and ground, then go to the
next step.
No
Yes
No

[4W-ABS].)
Yes

[4W-ABS].)
No
Yes

No
km/h {7.S mph} or more.
Gradually slow down and stop the vehicle.


04-028-10

DTC C1145, C1155, C1165, C1175 [4W-ABS]
dcf04020000Dw21
C1145
C1155
C1165
C1175
DETECTION
CONDITION
RF ABS wheel-speed sensor system

LF ABS wheel-speed sensor system
RR ABS wheel-speed sensor system
LR ABS wheel-speed sensor system
Open circuit or short to ground has been detected in the ASS wheel-speed sensor wiring harness on
any of the four vehicle wheels.
POSSIBLE
CAUSE
Open circuit or short to ground in the wiring harness between the following ASS HU/CM terminal and
the ASS wheel-speed sensor terminal:
- ASS HUlCM terminal O-RF ASS wheel-speed sensor terminal A
- ASS HU/CM terminal M-RF ASS wheel-speed sensor terminal S
- ASS HU/CM terminal E-LF ASS wheel-speed sensor terminal A
- ASS HU/CM terminal F-LF ASS wheel-speed sensor terminal S
- ASS HUlCM terminal L-RR ASS wheel-speed sensor terminal A
- ASS HU/CM terminal K-RR ASS wheel-speed sensor terminal S
- ASS HU/CM terminal I-LR ASS wheel-speed sensor terminal A
- ASS HU/CM terminal G-LR ASS wheel-speed sensor terminal S
ASS wheel-speed sensor malfunction
DTC
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ASS WHEEL-SPEED SENSOR WIRING

ASS HU/CM WIRING HARNESS-SIDE CONNECTOR
STEP
INSPECTION
INSPECT PID TO VERIFY THAT WHEEL
1
SPEED-SIGNALS ARE TRANSMITTED FROM
ABS WHEEL- SPEED SENSOR USING
CURRENT DIAGNOSTIC TOOL
DLC-2.
Select the following PIDs using the current
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
Drive the vehicle.
Verify that the wheel speed-signals are
transmitted from each ASS wheel-speed
sensor.
Are the wheel-speed signals transmitted?
ACTION
Yes
No
Go to Step 3.
04-028-11

INSPECTION
STEP
2
INSPECT FOR OPEN CIRCUIT IN WIRING

HARNESS BETWEEN ABS HUlCM AND ABS
WHEEL-SPEED SENSOR
Disconnect the ABS HU/CM connector and
ABS wheel-speed sensor.
Inspect for continuity in the wiring harness
between the following ABS wheel-speed
sensor connectors on the vehicle wiring
harness-side and ABS HU/CM connectors.
- RF ABS wheel-speed sensor (+): O-A
- RF ABS wheel-speed sensor (-): M-B
- LF ABS wheel-speed sensor (+): E-A
- LF ABS wheel-speed sensor (-): F-B
- RR ABS wheel-speed sensor (+): L-A
- RR ABS wheel-speed sensor (-): K-B
- LR ABS wheel-speed sensor (+): I-A
- LR ABS wheel-speed sensor (-): G-B

PRESENT
VERIFY THAT NO OTHER DTCS ARE
PRESENT
Are any other DTCs output?
ACTION
Yes
Replace the ABS wheel-speed sensor, then go to the next

step.
(See 04-13B-7 FRONT ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT HiRider))].)
REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)).)
(See 04-13B-10 REAR ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)).)
No
Repair or replace the wiring harness, then go to the next

step.
Yes
Repeat the inspection from Step 1.

If the malfunction recurs, replace the ABS HU/CM, then go
to the next step.
[4W-ABS).)
No
Yes

No
OTC C1186 [4W-ABS]

DTC C1186
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf040200000w23
I Fail-safe relay system

ABS HU/CM internal valve relay remains OFF when valve relay ON is commanded.
ABS HUlCM internal valve relay remains ON (stuck) when valve relay OFF is commanded.
ABS/SOL 20 A fuse malfunction
Open circuit or short to ground in the wiring harness between the battery and the ABS HU/CM terminal
C
Open or short circuit in the ABS HUlCM internal valve relay, or stuck valve relay
ABS/SOL 20A
T
I
I
...J...
ABS HU/CM
hr
~~
BATTERY
... ~
J) ~
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[zlxlvITIRlpINILIJIHIFI
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04-028-12

INSPECTION
STEP
INSPECT ABS FUSE CONDITION
1
Is the ABS/SOL 20 A fuse normal?
2
INSPECT VALVE RELAY POWER SUPPLY

FOR OPEN CIRCUIT
Disconnect ABS HU/CM connector.
(engine off).
Measure voltage between ABS HUlCM
terminal C (harness-side) and ground.
Is voltage B+?
ACTION
Yes . Go to the next step.
No Replace the fuse, then go to Step 3.
No Repair or replace the wiring harness for open circuit
between battery positive terminal and ABS HU/CM terminal
C, then go to the next step.
Yes
No
Yes
No
Replace the ABS HUlCM, then go to next step.

[4W-ABS].)
DTC C1194, C1198, C1202, C1206, C1210, C1214 [4W-ABS]

C 1194
C 1198
C 1202
DTC
C 1206
C 1210
C 1214
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf04020000Ow24
LF outlet solenoid valve system

LF inlet solenoid valve system
Rear outlet solenoid valve system
Rear inlet solenoid valve system
RF outlet solenoid valve system
RF inlet solenoid valve system
Solenoid valve operation does not correspond to solenoid ON/OFF commands from the ABS HU/CM.
Open or short circuit in the ABS HUlCM internal solenoid valves

Solenoid valve malfunction
II
INSPECTION
STEP
VERIFY SOLENOID VALVE OPERATION
1
DLC-2.
(engine off).
Access the active command mode for the
solenoid valve using the current diagnostic
tool.
Does the solenoid valve operate?
VERIFY DTC TROUBLESHOOTING
2
COMPLETED
Gradually slow down and stop vehicle.
3
Yes
No
Yes
No
Yes
No
ACTION
Replace the ABS HUlCM, then go to the next step.
[4W-ABS].)

to the next step.
[4W-ABS].)
04-028-:13

OTC C1222 [4W-ABS]
dcf04020000OW25
Note
DTC C1222 will be detected when
DTC C1222
DETECTION
CONDITION
POSSIBLE
CAUSE
a malfunctioning ASS wheel-speed sensor cannot be specified.

ABS wheel-speed sensor (slip monitor) system
Difference between any vehicle wheel speeds exceeds specification when driving at a constant speed.
ASS control operates for 60 s or more.
ASS wheel-speed sensor malfunction (low output, metal shavings on sensor)
ASS sensor rotor malfunction (chipping of sensor rotor teeth)
Poor installation of ASS wheel-speed sensor and/or sensor rotor (If the sensor rotor is installed at an
. angle, it may cause output of abnormal wave pattern at high speeds.)
Excessive clearance between the ASS wheel-speed sensor and sensor rotor
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ASS WHEEL-SPEED SENSOR WIRING

04-028-14

INSPECTION
STEP
INSPECT PID FOR ABNORMAL OUTPUT
1
FROM ABS WHEEL-SPEED SENSOR USING
DLC-2.
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
Start the engine and drive the vehicle.
Verify that the PIDs ofthe four ABS wheelspeed sensors correspond approximately.
Do the vehicle speeds correspond?
INSPECT IF MALFUNCTION OCCURRED
2
DUE TO IMPROPER SENSOR CLEARANCE
Inspect the clearance between the ABS
wheel-speed sensor and the ABS sensor
rotor.
Clearance
0.30-1.1 mm {0.012-0.043 in}
Yes
No
Yes
No
VISUALLY INSPECT ABS SENSOR ROTOR

FOR FOREIGN MATERIAL ADHERING OR
IMPROPER INSTALLATION
Is the result normal?
Yes

COMPLETED
connectors.
Yes
No
ACTION
Go to Step 4.
If there is a difference in speeds of the four wheels, go to the
next step.

Replace the rear ABS wheel-speed sensor, then go to Step
4.
REMOVAUINSTALLATION [4W-ABS (Hi-Rider, 4x4)].)
Replace the front wheel hub component, front drive shaft or
rear axle shaft, then go to the next step.
REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)].)
INSTALLATION.)
(See 03-12-2 AXLE SHAFT REMOVAUINSTALLATION.)
If the malfunction recurs, replace the ABS HU/CM.
(See 04-13B-3 ABS HUlCM REMOVAUINSTALLATION
[4W-ABS].)
No
Yes

No
04-028-15

DTC C1233, C1234, C1235, C1236 [4W-ABS]
C1233
C1234
C1235
C1236
DETECTION
CONDITION
DTC
POSSIBLE
CAUSE
dcf04020000Dw26
LF ABS wheel-speed sensor (short to ground) system

RF ABS wheel-speed sensor (short to ground) system
RR ABS wheel-speed sensor (short to ground) system
LR ABS wheel-speed sensor (short to ground) system
The vehicle wheel speed of any of the four vehicle wheels is 2.75 km/h {1.71 mph} or less when
driving at the specified vehicle speed or more.
Short to ground in the wiring harness between the following ABS HU/CM terminal and the ABS wheelspeed sensor terminal:
- ABS HU/CM terminal O-RF ABS wheel-speed sensor terminal A
- ABS HU/CM terminal M-RF ABS wheel-speed sensor terminal B
- ABS HU/CM terminal E-LF ABS wheel-speed sensor terminal A
- ABS HU/CM terminal F-LF ABS wheel-speed sensor terminal B
- ABS HU/CM terminal L-RR ABS wheel-speed sensor terminal A
- ABS HU/CM terminal K-RR ABS wheel-speed sensor terminal B
- ABS HU/CM terminall-LR ABS wheel-speed sensor terminal A
- ABS HU/CM terminal G-LR ABS wheel-speed sensor terminal B
ABS wheel-speed sensor malfunction
ASS HU/CM
RF
ASS WHEEL-SPEED
SENSOR
LF
ASS WHEEL-SPEED
SENSOR
RR
ASS WHEEL-SPEED
SENSOR
LR
ASS WHEEL-SPEED
SENSOR
ABS WHEEL-SPEED SENSOR WIRING

ASS HUlCM WIRING HARNESS-SIDE CONNECTOR
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STEP
INSPECTION
INSPECT PID TO VERIFY THAT WHEEL
1
SPEED-SIGNALS ARE TRANSMITTED FROM
ABS WHEEL- SPEED SENSOR USING
DLC-2.
diagnostic tool:
WSPD_LF
WSPD_LR
WSPD_RF
WSPD_RR
Drive the vehicle.
Verify that the wheel speed-signals are
transmitted from each ABS wheel-speed
sensor.
Are the wheel-speed signals transmitted?
04-028-16
ACTION
Yes
No
Go to Step 3.

STEP
2
INSPECTION
INSPECT A SHORT TO GROUND IN THE
WIRING HARNESS BETWEEN THE ABS Hut
CM AND THE ABS WHEEL-SPEED SENSOR
Disconnect the ABS HU/CM connector and
the ABS wheel-speed sensor connector.
Inspect for a short to ground in the wiring
harness between the following ABS wheelspeed sensor connectors on the vehicle
wiring harness-side and ABS HU/CM
connectors.
- RF ABS wheel-speed sensor (+): O-A
- RF ABS wheel-speed sensor (-): M-B
- LF ABS wheel-speed sensor (+): E-A
- LF ABS wheel-speed sensor (-): F-B
- RR ABS wheel-speed sensor (+): L-A
- RR ABS wheel-speed sensor (-): K-B
- LR ABS wheel-speed sensor (+): I-A
- LR ABS wheel-speed sensor (-): G-B
PRESENT
kmlh {7.S mph} or more.
PRESENT
Yes
No
ACTION
Replace the rear ABS wheel-speed sensor, then go to Step
4.
HEMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT HiRider].)
step.
Yes

to the next step.
[4W-ABS].)
No
Yes

DTC C1414 [4W-ABS]

DTC C1414
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf040200000w27
lABS HutCM unit mismatched installation

When G sensor signal input for more than 1 s to 4x2 (except Hi-Rider) vehicle-type ABS HU/CM.
Mismatched installation of ABS HU/CM

- 4x2 (except Hi-Rider) vehicle type ABS HU/CM is mismatched installed on Hi-Rider and 4x4 vehicle.
INSPECTION
STEP
1
INSPECT ABS HutCM FOR MISMATCHED
INSTALLATION
Verify ABS HU/CM part number
Has a ABS HU/CM with the correct part
number been installed?
2
VERIFY CURRENT STATUS OF

MALFUNCTION
Clear DTC from memory.
(See 04-02B-2 Clearing DTCs Procedures)
PRESENT
ACTION
Yes
No
Go to next step.
Yes
Replace ABS HU/CM.

(See 04-13B-3 ABS HUlCM REMOVAUINSTALLATION
[4W-ABS].)
No
Go to next step.
Yes

Replace with correct ABS HU/CM part number, then go to

next step.
04-028-17

DTC C1730, C1949, C1950 [4W-ABS]
dcf04020000OW28
C1730,C1949,C1950
IG sensor
C1730
- Voltage to G sensor is detected out of range
C1949
DETECTION
- Monitor voltage of G sensor is detected at 4.7 V or more, or 0.3 V or less for more than 1 s.
CONDITION
C1950
- G sensor O-point correction value is default or more
- Output voltage value from G sensor remains absolutely unchanged
Open circuit in harness between ABS HU/CM terminal V and G sensor terminal C
Open, short to power, or short to ground circuit in harness between ABS HU/CM terminal P and G
POSSIBLE
sensor terminal B
CAUSE
Open circuit in harness between ABS HU/CM terminal Wand G sensor terminal A
Malfunction of G sensor
DTC
'c'
~
ABS HU/CM
?A
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G SENSOR
G SENSOR WIRING
(CIBI!)
I~~
STEP
1
INSPECTION
INSPECT G SENSOR POWER SUPPLY
Turn engine switch to ON (engine OFF).
Measure voltage between G sensor terminal
C (harness side) and ground.
Is voltage B+?
INSPECT G SENSOR GROUND CIRCUIT FOR
OPEN CIRCUIT
Turn engine switch to OFF.
Disconnect ABS HU/CM and G sensor
connectors.
Inspect continuity between ABS HU/CM
terminal W (harness side) and G sensor
terminal A (harness side).
INSPECT G SENSOR SIGNAL CIRCUIT FOR
OPEN CIRCUIT
terminal P (harness side) and G sensor
terminal B (harness side).
SHORT TO POWER
Turn engine switch to ON (engine OFF).
Measure voltage between ABS HU/CM
terminal P (harness side) and ground.
Is voltage B+?
04-028-18
ACTION
Yes
No

Repair or replace harness for open circuit between G
sensor terminal C and engine switch, then go to Step 7.
Yes
No

Repair or replace harness for open circuit between ABS HU/
CM terminal Wand G sensorterminal A, then go to Step 7.
Yes
No

Repair or replace harness for open circuit between ABS HU/
CM terminal P and G sensor terminal B, then go to Step 7.
Yes
Repair or replace harness for short to power circuit between

ABS HU/CM terminal P and G sensor terminal B, then go to
Step 7.
No

STEP
INSPECTION
SHORT TO GROUND
Turn engine switch to OFF.
terminal P (harness side) and ground.
INSPECT G SENSOR
Inspect the G sensor.
(See 04-13B-13 G SENSOR INSPECTION
[4W-ABS])
Is it normal?
COMPLETED
connectors.
Clear the OTC from the memory.
(See 04-02B-2 Clearing OTCs Procedures.)
Are the same OTCs present?
Are any other OTCs present?
ACTION
Yes
Repair or replace harness for short to ground circuit

between ABS HUlCM terminal P and G sensor terminal B,
then go to Step 7.
No
Yes
No
Replace the G sensor, then go to next step.

(See 04-13B-12 G SENSOR REMOVAUINSTALLATION
[4W-ABS].}
Yes
Replace the ABS HU/CM, then go to next step.

[4W-ABS].)
No
Yes
Go to the applicable OTC inspection.

(See 04-02B-4 OTC Table.)
No
OTC troubleshooting completed.
04-02B-1Sj
SYMPTOM TROUBLESHOOTING [4-WHEEL ANTILOCK

04-03B SYMPTOM TROUBLESHOOTING [4-WHEEL

ANTI LOCK BRAKE SYSTEM (4W-ABS)]
[4W-ABS] ....................
FOREWORD [4W-ABS] .........
PRECAUTION [4W-ABS] ......
[4W-ABS] ...............
NO.1 ABS WARNING LIGHT
ILLUMINATE WHEN THE ENGINE
SWITCH IS TURNED TO THE ON
POSITION [4W-ABS] .........
04-03B-1
04-03B-2
04-03B-2
04-03B-5
04-03B-6

DOES NOT ILLUMINATE WHEN
THE ENGINE SWITCH IS TURNED
TO THE ON POSITION [4W-ABS] ..... 04-03B-7
NO.3 ABS WARNING LIGHT STAYS
ON 4 S OR MORE WHEN THE ENGINE
POSITION [4W-ABS] ......... 04-03B-7
NO.4 THERE IS MALFUNCTION IN
THE SYSTEM EVEN THOUGH ABS
WARNING LIGHT, DO NOT
ILLUMINATE [4W-ABS] ............. 04-03B-8
SYSTEM WIRING DIAGRAM [4W-ABS]
dcf04030000Ow22
ABS/SOL20A
I
Hi-Rider, 4x4
:
:
Vl------I-.nI
P
G SENSOR
I
I
ABS 40A
I
I
1I __ -
_______________________ _
BRAKE SWITCH
~~N~~~j{~~~
BRAKE
LIGHT
ABSWARNING
LIGHT
~~--~~---------4S
ABS HUlCM
Ql------n
INSTRUMENT CLUSTER
DCF413BWB001
04-038-1

FOREWORD [4W-ABS]
dcf040300000w23
Before performing the steps in Symptom Troubleshooting, perform the On-board Diagnostic inspection. To
inspect the DTC, follow the DTC Inspection steps. (See 04-02B-4 DTC Table.)
PRECAUTION [4W-ABS]
dcf040300000w24
1. Anyone or a combination of the ABS warning illuminates even when the system is normal.
Warning lights that may
illuminate and/or flash
ABS warning light
*1
*2
Cases in which the light may

illuminate
When the front wheels are
jacked up, stuck, or placed on
a chassis roller, and only the
front wheel ABS wheel-speed
sensors are spun.
Parking brake is not fully
released while driving.
Brake drag.
Sudden accelerationl
deceleration.
Left/right or front/rear tires are
different. (Size, radius, tire
pressure, or wear is other than
that listed on tire label.)
Battery voltage at ABS HU/CM
ignition terminal J drops
below approx. 10 V.(1)
Battery voltage at ABS HU/CM
ignition terminal J rises above
approx. 16 V.(2)
Conditions in which the

ABS control
light will go out
After turning ehgine switch
ABS: Cuts control.
off, vehicle is driven at speed
greater than 12 km/h {7.5
mph} and normal operation is
confirmed.
Battery voltage rises above

approx. 10 V.
ABS: Cuts control.
Battery voltage drops below

approx. 16 V.
ABS: Cuts control.
If battery voltage drops below 10 V while vehicle speed is greater than 6 km/h {3.7 mph} ,ABS Hu/CM
records DTC B1318.
: If battery voltage rises above 16 V ,ABS HU/CM records DTC B1317.
:
2. Precautions during servicing of ABS

The ABS is composed of electrical and mechanical parts. It is necessary to categorize malfunctions as being
either electrical or hydraulic when performing troubleshooting.
(1) Malfunctions in electrical system
The ABS hydraulic unit and control module (ABS HU/CM) has an on-board diagnostic function. With
this function, the ABS warning light and/or BRAKE system warning light will illuminate when there is a
problem in the electrical system. Also, past and present malfunctions are recorded in the ABS HU/CM.
This function can find malfunctions that do not occur during periodiC inspections. Connect the current
diagnostic tool to the DLC-2. The stored malfunctions will be displayed in the order of occurrence. To
find out the causes of ABS malfunctions, use these on-board diagnostic results.
If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor connection
of the wiring harness. The ABS HU/CM usually operates normally. Be careful when searching for the
cause of malfunction.
After repair, it is necessary to clear the DTC from the ABS HU/CM memory. Also, if the ABS related
parts have been replaced, verify that the no DTC has been displayed after repairs.
After repairing the ABS wheel-speed sensor or ABS sensor rotor, or after replacing the ABS CM (ABS
motor or ABS motor relay or solenoid valve), the ABS warning light may not go out even when the
engine switch is turned to the ON position. In this case, drive the vehicle at a speed of 12 km/h {7.5
mph} or more, make sure that ABS warning light goes out, and then clear the DTC.
When repairing, if the ABS related connectors are disconnected and the engine switch is turned to the
ON position, the ABS CM will mistakenly detect a fault and record it as a malfunction.
To protect the ABS HU/CM, make sure the engine switch is turned off before connecting or
disconnecting the ABS CM connector.
(2) Malfunctions in hydraulic system
Symptoms in a hydraulic system malfunction are similar to those in a conventional brake malfunction.
However, it is necessary to determine if the malfunction is in an ABS component or the conventional
brake system.
The ABS hydraulic unit contains delicate mechanical parts. If foreign material enters into the
component, the ABS may fail to operate. Also, it will likely become extremely difficult to find the location
of the malfunction in the event that the brakes operate but the ABS does not. Make sure foreign
material does not enter when servicing the ABS (e.g. brake fluid replacement, pipe removal).
04-038-2
SYMPTOM TROUBLESHOOTING [4-WHEEL ANTI LOCK

Intermittent Concern Troubleshooting
Vibration method
If a malfunction occurs or becomes worse while driving on a rough road or when engine is vibrating, perform
the following steps.
Note
There are several reasons why vehicle or engine vibration could cause an electrical malfunction. Inspect
the following:
Connectors not fully seated.
- Wiring harness not having full play.
- Wiring harness laying across brackets or moving parts.
- Wiring harness routed too close to hot parts.
An improperly routed, improperly clamped, or loose wiring harness can cause pinching between parts.
The connector joints, points of vibration, and places where wiring harness pass through the firewall, body
panels, etc. are the major areas to be inspected.
Inspection method for switch connectors or wiring harnesses
2. Turn the engine switch to the ON position (Engine OFF).
Note
4. Turn the switch on manually.
5. Slightly shake each connector or wiring harness
PID .
If the PID value is unstable, inspect poor
connection.
/..4 /
/!J/
1.;
/
/
/ -I
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I
B3E0403W005
Inspection method for sensor connectors or wiring harnesses

Note
4. Slightly shake each connector or wiring harness
PID .
If the PID value is unstable, inspect poor
connection.
B3E0403W006
04-038-3

Inspection method for sensors
Note
4. Vibrate the sensor slightly with your finger.
If the PID value is unstable or a malfunction occurs, inspect the sensor for poor connection and/or poor
mounting.
Malfunction data monitor method
1. Perform malfunction reappearance test according to malfunction reappearance mode and malfunction data
monitor. The malfunction cause is found in the malfunction data.
Connector terminal inspection method
1. Inspect the connection of each female terminal.
2. Insert the male terminal to the female terminal
and Inspect the female terminal for looseness.
83E0403W007
04-038-4

SYMPTOM TROUBLESHOOTING [4W-ABS]
dcf040300000w25
Verify the symptoms, and perform troubleshooting according to the appropriate number.
No.
1
2
3
4
Symptom
ABS warning light illuminate when the engine switch is turned to the ON position.
ABS warning light does not illuminate when the engine switch is turned to the ON position.
ABS warning light stays on 4 s or more when the engine switch is turned to the ON position.
There is a malfunction in the system even through ABS warning light, do not illuminate.
x: Applicable
Possible factor
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iii
ABS warning light illuminate when the engine

switch is turned to the ON position.
ABS warning light does not illuminate when

the engine switch is turned to the ON
position.
ABS warning light stays on 4 s or more when

the engine switch is turned to the ON
position.
There is a malfunction in the system even

though ABS warning light, do not illuminate.
E
OJ
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..... U
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C/)=
..... 0')
C
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Com
3:
X
DBR403ZWB001
04-038-5

NO.1 ABS WARNING LIGHT ILLUMINATE WHEN THE ENGINE SWITCH IS TURNED TO THE ON POSITION
[4W-ABS]
dcf04030000Ow26
IABS warning light illuminate when the engine switch is turned to the ON position.
Instrument cluster or ABS HUlCM malfunction
INSPECTION
STEP
1
*4
ACTION
INSPECT FOR DTCs IN ABS HUlCM

Have OTCs been stored in memory?
Yes
Perform the applicable OTC inspection.

(See 04-02B-4 OTC Table.)
No
VERIFY WHETHER MALFUNCTION IS IN

WARNING LIGHTS AND INDICATOR LIGHT'S
COMMON POWER SUPPLY, OR IN OTHER
WARNING LIGHTS AND INDICATOR LIGHTS
Do other warning and indicator lights
illuminate when the engine switch is turned
to the ON position?
INSPECT INSTRUMENT CLUSTER POWER
SUPPLY FUSE
Is the instrument cluster ignition power
supply fuse normal?
Yes
Inspect the instrument cluster.

If the instrument cluster is normal, inspect CAN
communication.
If instrument cluster has a malfunction, go to the next step.
Replace the instrument cluster. (open circuit in instrument
cluster)
INSTALLATION.)

WIRING HARNESS (BETWEEN INSTRUMENT
CLUSTER POWER SUPPLY AND
INSTRUMENT CLUSTER FOR CONTINUITY)
OR INSTRUMENT CLUSTER
Measure voltage at instrument cluster
connector terminal 2A.
Yes
No
Yes

Inspect for a short to ground on circuit of blown fuse.
Install appropriate amperage fuse.
No
No
Replace the instrument cluster (open circuit in instrument

cluster).
INSTALLATION.)
Inspect for open circuit in wiring harness between the
instrument cluster and ground.
Replace the ABS HU/CM.
[4W-ABS].)
INSTRUMENT CLUSTER WIRING HARNESS-SIDE CONNECTOR
:><:
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2WI2UI2S 2QI20 2MI2K 2112G 2E 12CI2A
2xI2VI2T 2RI2P 2N 12L 2J 12H 2FI2012B
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Inl
1101
1011MI1KI1111GI1EI1CI1A
1pI1NI1LI1JI1HI1FI1011B
I~,
When performing an asterisked () troubleshooting inspection, slightly shake the wiring harness and connectors
while performing the inspection to discover whether poor contact pOints are the cause of any intermittent
malfunction. If there is a problem, verify that the connectors, terminals and wiring harness are connected
correctly and undamaged.
04-038-6

NO.2 ABS WARNING LIGHT DOES NOT ILLUMINATE WHEN THE ENGINE SWITCH IS TURNED TO THE ON
POSITION [4W-ABS]
dcf040300000w27
2
ABS warning light does not illuminate when the engine switch is turned to the ON position.
Open circuit between ABS HUlCM and instrument cluster
INSPECTION
STEP
1
WIRING LIGHT OR CONTROL CIRCUIT
Turn the engine switch OFF.
Disconnect ABS HUlCM connector.
Short to ground at ABS HU/CM harness-side
connector terminal S using a jumper wire.
Turn the engine switch ON.
Does the ABS warning light illuminate?
Yes
No
ACTION
Inspect for open circuit between ABS HU/CM terminal Sand
instrument cluster terminal 2L.
Replace instrument cluster.
INSTALLATION.)
If
I I I
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2wI2UI2S 20120 2MI2K 2112G 2EI2CI2A

2xl2Vl2T 2RI2P 2N 12L 2J 12H 2FI2DI2S
1011MI1KI11 1GI1EI1CL1A
1pI1NI1LI1J 1HI1FI1Dhs
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I~~I
NO.3 ABS WARNING LIGHT STAYS ON 4 S OR MORE WHEN THE ENGINE SWITCH IS TURNED TO THE ON
POSITION [4W-ABS]
dcf040300000w29
3
ABS warning light stays on 4 s or more when the engine switch is turned to the ON position.
ABS CM detects ABS system malfunction.
Short to ground in ABS warning light control circuit
INSPECTION
STEP
1
Have DTCs been stored in memory?
\,

WARNING LIGHT OR CONTROL CIRCUIT
Disconnect the ABS HU/CM connector.
Turn the engine switch to ON.
Does the ABS warning light stay on 4 s or
more?
Yes
No
Yes
No
ACTION
Perform the applicable DTC inspection.
Inspect the instrument cluster
If the instrument cluster is normal, go to the next step.
If the instrument cluster has a malfunction, repair the
instrument cluster, go to the next step.
[4W-ABS].)
04-038-7

STEP
3
INSPECTION
INSPECT ABS WARNING LIGHT CONTROL
ABS HU/CM connector disconnected.
Disconnect the instrument cluster connector.
Verify continuity between ABS HU/CM
harness-side connector terminal S and body
ground.
ACTION
Yes
No
Repair or replace for short to ground.

Replace instrument cluster.
INSTALLATION.)
ABS HUlCM WIRING HARNESS-SIDE CONNECTOR
GI I
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rzlxlvlTIRlplNILIJ IHIFI
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2wI2UI2S 20120
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2MI2K 2112G 2E 12CI2A
2xI2VI2T 2RI2P 2N 12L 2J 12H 2FI2DI2B
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'11P11N11L11J 1HI1FI1DI1B
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NO.4 THERE IS MALFUNCTION IN THE SYSTEM EVEN THOUGH ABS WARNING LIGHT, DO NOT
ILLUMINATE [4W-ABS]
4
dcf04030000Ow31
I There is a malfunction in system even though ABS warning light, do not illuminate.
There is a difference in size or air pressure between the front and rear tires.
INSPECTION
STEP
1
Have DTCs been stored in memory?
Yes
No
INSPECT ABS HYDRAULIC UNIT

Perform the ABS hydraulic unit system
inspection.
Is the system normal?
Yes
No
ACTION
Perform the applicable DTC inspection.
Inspect the conventional brake system.
If the wheels do not rotate:
[4W-ABS].)
If the wheels rotate but order in which wheels rotate is
incorrect:
Inspect the brake pipe passage to the ABS HU/CM.
i;
04-038-8
GENERAL PROCEDURES
04-10
GENERAL PROCEDURES
GENERAL PROCEDURES (BRAKE) ... 04-10-1
GENERAL PROCEDURES (BRAKE)
dcf04100000Ow01
Wheel and Tire Installation

torque.
Tightening torque
88.2-117.6 Nm {9.00-11.99 Kgf.m, 65.06-86.73 ft.lbf}
Brake Lines Disconnection
1. If any brake line has been disconnected during the procedures, add brake fluid, bleed the brakes, and inspect
for leakage after the procedure has been completed.
Caution
Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
spilled, wipe it off immediately.
Brake Pipe Flare Nut Tightening
1. Tighten the brake pipe flare nut using the SST (49 0259 770B).
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAUINSTALLATION.)
ABS Related Parts
1. Make sure that there are no DTCs in the ABS memory after working on ABS related parts. If there are any
DTCs in the memory, clear them.
04-10-1
04-11

LOCATION INDEX ..............
AIR BLEEDING .............
VACUUM LINE INSPECTION ......
BRAKE PEDAL INSPECTION ......
BRAKE PEDAL
REMOVAL/INSTALLATION .......
BRAKE SWITCH
REMOVAL/INSTALLATION ........
BRAKE SWITCH INSPECTION .......
MASTER CYLINDER
REMOVAL/INSTALLATION .....
BRAKE FLUID LEVEL SENSOR
INSPECTION ..............
MASTER CYLINDER
DISASSEMBLY/ASSEMBLY ......
POWER BRAKE UNIT INSPECTION ...
POWER BRAKE UNIT
REMOVAL/INSTALLATION .....
VACUUM PUMP INSPECTION ......
VACUUM PUMP
REMOVAL/INSTALLATION .........
VALVE (LSPV) INSPECTION ........
VALVE (LSPV) ADJUSTMENT ....
04-11-2
04-11-3
04-11-3
04-11-4
04-11-5
04-11-5
04-11-6
04-11-6
04-11-7
04-11-8
04-11-9
04-11-10
04-11-11
04-11-11
04-11-12
04-11-13

VALVE (LSPV)
REMOVAL/INSTALLATION ....... 04-11-14
FRONT BRAKE (DISC) INSPECTION ... 04-11-15
FRONT BRAKE (DISC)
[4x2 (EXCEPT Hi-Rider)] .......... 04-11-16
FRONT BRAKE (DISC)
[Hi-Rider,4x4] ............. 04-11-17
DISC PAD (FRONT) REPLACEMENT
[4x2 (EXCEPT Hi-Rider)] .......... 04-11-19
[H i-Rider, 4x4] .............. 04-11-20
CALIPER (FRONT)
[4x2 (EXCEPT Hi-Rider)] ........... 04-11-20
CALIPER (FRONT)
[Hi-Rider, 4x4] ............ 04-11-21
REAR BRAKE (DRUM) INSPECTION .. 04-11-22
REAR BRAKE (DRUM)
REMOVAL/INSTALLATION ........ 04-11-23
WHEEL CYLINDER
DISASSEMBLY/ASSEMBLY ........ 04-11-25
04-11-1

CONVENTIONAL BRAKE SYSTEM LOCATION INDEX
dcf04110000Ow01
DCF411 ZWB001
Brake fluid
(See 04-11-3 AIR BLEEDING.)
Vacuum line
(See 04-11-3 VACUUM LINE INSPECTION.)
Brake pedal
(See 04-11-4 BRAKE PEDAL INSPECTION.)
(See 04-11-5 BRAKE PEDAL REMOVAU
INSTALLATION.)
Brake switch
(See 04-11-5 BRAKE SWITCH REMOVAU
INSTALLATION.)
(See 04-11-6 BRAKE SWITCH INSPECTION.)
Master cylinder
(See 04-11-6 MASTER CYLINDER REMOVAU
INSTALLATION.)
(See 04-11-7 BRAKE FLUID LEVEL SENSOR
INSPECTION.)
(See 04-11-8 MASTER CYLINDER DISASSEMBLY/
ASSEMBLY.)
Power brake unit

(See 04-11-9 POWER BRAKE UNIT INSPECTION.)
(See 04-11-10 POWER BRAKE UNIT REMOVAU
INSTALLATION.)
Vacuum pump
(See 04-11-11 VACUUM PUMP INSPECTION.)
(See 04-11-11 VACUUM PUMP REMOVAU
INSTALLATION.)
Load sensing proportioning valve (LSPV)

(See 04-11-12 LOAD SENSING PROPORTIONING
VALVE (LSPV) INSPECTION.)
VALVE (LSPV) ADJUSTMENT.)
VALVE (LSPV) REMOVAUINSTALLATION.)
04-11-2
Front brake (disc)

(See 04-11-15 FRONT BRAKE (DISC)
INSPECTION.)
(See 04-11-16 FRONT BRAKE (QISC) REMOVAU
INSTALLATION [4x2 (EXCEPT Hi-Rider)].)
(See 04-11-17 FRONT BRAKE (DISC) REMOVAU
(See 04-11-19 DISC PAD (FRONT)
REPLACEMENT [4x2 (EXCEPT Hi-Rider)].)
(See 04-11-20 DISC PAD (FRONT)
REPLACEMENT [Hi-Rider, 4x4].)
(See 04-11-20 CALIPER (FRONT) DISASSEMBLY/
ASSEMBLY [4x2 (EXCEPT Hi-Rider)].)
(See 04-11-21 CALIPER (FRONT) DISASSEMBLY/
ASSEMBLY [Hi-Rider, 4x4].)
10
Rear brake (drum)

(See 04-11-22 REAR BRAKE (DRUM)
INSPECTION.)
(See 04-11-23 REAR BRAKE (DRUM) REMOVAU
INSTALLATION.)
(See 04-11-25 WHEEL CYLINDER DISASSEMBLY/
ASSEMBLY.)

AIR BLEEDING
dcf04110000Ow02
Caution
Brake fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If it is
Note
Keep the fluid level in the reserve tank at 3/4 full or more during the air bleeding.
Begin air bleeding with the brake caliper that is furthest from the master cylinder.
Brake fluid type
SAE J1703, FMVSS 116 DOT-3
1. Remove the bleeder cap on the brake caliper, and attach a vinyl tube to the bleeder screw.
2. Place the other end of the vinyl tube in a clear container and fill the container with fluid during air bleeding.
3. Working with two people, one should pump the brake pedal several times and depress and hold the pedal
down.
4. While the brake pedal is depressed, the other
should loosen the bleeder screw using the SST,
drain out any fluid containing air bubbles, and
tighten the bleeder screw.
Tightening torque
Front (4x2 (except Hi-Rider: 9-14 Nm
{92-142 kgfcm, 80-123 in.lbf}
Front (Hi-Rider, 4x4): 5.9-8.8 Nm {61-89
kgfcm, 53-77 in.lbf}
Rear: 5.9-8.8 Nm {61-89 kgf.cm, 53-77
in.lbf}
DBR411ZWB002 ~
IWII
5. Repeat Steps 3 and 4 until no air bubbles are

seen.
6. Perform air bleeding as described in the above procedures for all brake calipers.
7. After air bleeding, inspect the following:
Brake operation
Fluid leakage
Fluid level
VACUUM LINE INSPECTION
1. Remove the vacuum hose.
2. Verify that air can be blown from the power brake
unit side of the vacuum hose towards the vacuum
pump side, and that air cannot be blown in the
opposite direction.
If there is any malfunction of the inner check
valve, replace it together with the vacuum
hose as a single unit.
dcf04114364Ow01
WL-3
WL-C, WE-C
TO VACUUM PUMP
DBR411ZWB003
04-11-3

BRAKE PEDAL INSPECTION
Brake pedal Height Inspection
1. Measure the distance from the center of the
upper surface of the pedal pad to the floor panel
and verify that it is as specified.
brake pedal.
dcf04114330Ow01
PEDAL HEIGHT
Brake pedal height

214-219 mm {8.43-8.62 in}
DBR411ZWB004
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 turn rod C with locknut D.
Tightening torque
24-34 Nm {2.5-3.4 kgfm, 18-25 ft.lbf}
5. Tighten the bolt with locknut B so that clearance
between the bolt for brake switch A and pedal
stopper is within the specification.
Specification
0.1-1.0 mm {0.004-0.039}
Tightening torque
13.7-17.6 Nm {140-179 kgfcm, 122-155
in.lbf}
6. Connect the brake switch connector.

7. After adjustment, inspect the pedal play and the
brake light operation.
DBR411 ZWB005
Brake Pedal Play Inspection

1. Pump the pedal several times to release the vacuum in the power brake unit.
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. 20 N {2.0 kgf, 4.5 Ibf}) and
measure the pedal play.
Standard pedal play
3.0-8.0 mm {0.12-0.31 in}
DBR411ZWB006
04-11-4

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 ant the snap pin.
4. Tighten locknut D.
Tightening torque
24-34 Nm {2.5-3.4 kgf.m, 18-25 ft.lbf}
5. After adjustment, inspect the pedal height and the
brake light operation.
DBR411 ZWB007
Pedal-to-floor Clearance Inspection

1. Start the engine and depress the brake pedal with a force of 589 N {GO kgf, 132 Ibf}.
2. Measure the distance from the center of the
upper surface of the pedal pad to the floor
covering and verify that it is as specified .
If it is less than the specification, inspect the
following:
Air in brake system
Malfunction of the automatic adjuster
Excessive shoe clearance
Standard pedal-to-floor clearance
105 mm {4.14 in} or more
L---------------~------------~DB~R~41~1Z~W~BO~08
BRAKE PEDAL REMOVAL/INSTALLATION
II
dcf041143300w02
1. The brake pedal is mounted on the bracket integrated with the clutch pedal and accelerator pedal. Refer to
section 01, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAL/INSTALLATION for the brake pedal
removal/installation. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL3].) (See 01-13B-11 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-C, WE-C).)
BRAKE SWITCH REMOVAL/INSTALLATION
dcf041166490w01

1
2
3

Brake switch
Nut

3. After installation, inspect the brake pedal. (See
04-11-4 BRAKE PEDAL INSPECTION.)
Nm {kgfcm, in.lbf}
DBR411 ZWB053
04-11-5

BRAKE SWITCH INSPECTION
dcf041166490w02
1. Remove the lower panel.

2. Disconnect the brake switch connector.
table.
brake switch. (See 04-11-5 BRAKE SWITCH
0--0 : Continuity
Terminal
Condition
When the brake pedal

is depressed
DBR41 1ZWB009
When the brake pedal

is not depressed
DBR41 1ZWB052
MASTER CYLINDER REMOVAUINSTALLATION
dcf041143400w01

mI" WITHOUT 4WABS

12.8-21.6
{131-220,114-191}
N.m {kgf.cm, in.lbf}

arnffw00001966
Brake fluid level sensor connector
2
3
Brake pipe
Bracket
04-11-6
4
5
IMaster cylinder
O-ring (AT)

BRAKE FLUID LEVEL SENSOR INSPECTION
dcf041143400w02
1. Disconnect the brake fluid level sensor connector from the master cylinder.
2. Inspect for continuity according to fluid level
...--------------------,
between the brake fluid level sensor terminals.
brake fluid level sensor. (See 04-11-6
MASTER CYLINDER REMOVAU
INSTALLATION.)
0--0: Continuity
Condition
Terminal
A
B
DBR411ZWB017
Above MIN
Below MIN
CHU0411W017
04-11-7

MASTER CYLINDER DISASSEMBLY/ASSEMBLY
dcf04114340OW03
1. After removing the brake fluid, disassemble in the order indicated in the table.
WITHOUT 4W-ABS
8
WITH4W-ABS
1
~~e
.~~
~~ "1lI
~1iI
~.~ I
iii
A
18
~~
1.47-2.94
{15.0-29.9,13.1-26.0}
Nm {kgfcm, inlbf}
DCF411ZWB003
1
2
3
4
5
6
7
8
9
10
11
Cap set
Pin
Reservoir
Joint bushing
Brake fluid level sensor
Seal and plate assembly
Snap ring
Spacer
Piston guide
O-ring
Cup
04-11-8
12
13
14
15
16
17
18
Primary piston stopper

Primary piston
Stop screw (without 4W-ABS)
(See 04-11-9 Stop Screw (without 4W-ABS)
Assembly Note)
Stop screw (with 4W-ABS)
(See 04-11-9 Stop Screw (with 4W-ABS) Assembly
Note.)
Gasket
Secondary piston
Master cylinder body

Stop Screw (with 4W-ABS) Assembly Note
1. Install the secondary piston component with the piston hole facing the stop pin.
2. Install and tighten a new gasket and the stop pin.
3. Push and release the piston to verify that it is held
by the stop pin.
A6E6912W043
Stop Screw (without 4W-ABS) Assembly Note

1. Push the primary piston component in fully.
2. Install and tighten a new gasket and the stop
screw.
3. Push and release the piston to verify that it is held
by the stop screw.
POWER BRAKE UNIT INSPECTION
A6E6912W025
dcf041143800wOl
Power Brake Unit Function Inspection (Inspection using gauges)

1. Connect the SST gauges, a vacuum gauge, and a
pedal depression gauge as shown in the figure.
I
Bleed the air from the SST gauges before
performing the following tests.
r-=----.:=--ii]Dimmm---------1
DBR411 ZWB019
Checking for vacuum loss (unloaded condition)

1. Start the engine.
2. Stop the engine when the vacuum gauge indicates 67 kPa {500 mmHg, 20 inHg}.
3. Observe the vacuum gauge for 15 s .
If the gauge indicates 64-66 kPa {476-499 mmHg, 18.8-19.6 inHg}, the unit is operating.
Checking for vacuum loss (loaded condition)
2. Depress the brake pedal with a force of 200 N {20 kgf, 45 Ibf}.
3. With the brake pedal held depressed, stop the engine when the vacuum gauge indicates 67 kPa {500 mmHg,
20 inHg}.
4. Observe the vacuum gauge for 15 s .
If the gauge indicates 64-66 kPa {476-499 mmHg, 18.8-19.6 inHg}, the unit is operating.
04-11-9

Checking for hydraulic pressure
1. If the engine is stopped (vacuum 0 kPa {O mmHg, 0 inHg}) and the fluid pressure is within the specification,
the unit is operating.
Power brake unit fluid pressure when pedal depressed at 200 N {20 kgf, 45 Ibf}
At 0 kPa {O mmHg, 0 inHg}: 593 kPa {6.1 kgf/cm 2 , 87 psi} or more
2. Start the engine. Depress the brake pedal when the vacuum reaches 67 kPa {500 mmHg, 20 inHg}.
If the fluid pressure is within the specification, the unit is operating.
If the fluid pressure is not as specified, inspect for damage to the check valve or vacuum hose, and fluid
leakage of the hydraulic line. Repair as necessary, and inspect again.
Power brake unit fluid pressure when pedal depressed at 200 N {20 kgf, 45 Ibf}
At 67 kPa {500 mmHg, 20 inHg}: 6,950 kPa {71 kgflcm 2 , 1,008 psi} or more
POWER BRAKE UNIT REMOVAUINSTALLATION
dcf04114380Ow02
1. Remove the master cylinder. (See 04-11-6 MASTER CYLINDER REMOVAUINSTALLATION.)

2. For vehicles with 4W-ABS, disconnect all the ABS
HU/CM brake pipes shown inthe figure. (See 0416-22
13B-3 ABS HU/CM REMOVAUINSTALLATION
{1.7-2.2,
[4W-ABS].)
12-16}
3. Remove the brake pipe (ABS HU/CM-master
cylinder).
Nm {kgfm, ttlbf}
DBR411 ZWB049

1
2
3
4
5
6
7
8
Vacuum hose
Snap pin
Clevis pin
Nut
Power brake unit
Gasket
Fork
Nut
23.54-34.32
{2.401-3.499,17.37-25.31}
5
Nm {kgfm, ttlbf}
DBR411 ZWB020
04-11-10

,
VACUUM PUMP INSPECTION
dcf041118777w01
1. Warn up the engine.

2. Disconnect the vacuum hose from the vacuum
pump and connect a vacuum gauge as shown in
the figure, then check the vacuum.
If the pressure is less than the specification,
inspect for the following.
- Malfunction of the vacuum pump
- Shortage of the lubrication oil pressure
Vacuum specification (In 20 s)
Engine speed 1,270 rpm: 74 kPa {550 mmHg,
22 inHg} or more
Engine speed 2,450 rpm: 94 kPa {700 mmHg,
28 inHg} or more
DBR411 ZWB023
VACUUM PUMP REMOVAUINSTALLATION
dcf041118777w02
1. Remove the battery and battery tray. (See 01-17-2 BATTERY REMOVAUINSTALLATION.)
2. Remove the clip shown in the figure.
CLIP
'-----_ _~II
DBR614ZWB020

1
2
3
4
5
Bracket (WL-C, WE-C)

Vacuum hose
Bolt
Vacuum pump
O-ring
18.6-25.5
{1.9-2.6,
13.8-18.8}
18.6-25.5
{1.9-2.6,13.8-18.8}
Nm {kgfm, ft.lbf}
DBR411ZWB022
04-11-11

LOAD SENSING PROPORTIONING VALVE (LSPV) INSPECTION
dcf041143903w01

2. Check the tire inflations and set them to the recommended pressure if necessary.
If not as specified, replace or adjust.
3. Check the vehicle with a person in the driver's seat; include the standard vehicle tools, the spare wheel and tire,
and a full tank of fuel.
4. Install the SST to the front wheel cylinder and rear
wheel cylinder, then bleed the air in the brake line
and LSPV using a air bleed valve A.
DBR411 ZWB025
5. Inspect the fluid pressure of rear wheel cylinder

while the fluid pressure of front wheel cylinder is
4,900 kPa {50 kgf/cm 2 , 711 psi} and 9,800 kPa
{100 kgf/cm 2 , 1,421 psi}.
If not as specified, adjust the LSPV.
REAR
PRESSURE
LOADED
-----------
---------~-.
__
--
: A PERSON IN
: DRIVER'S SEAT
,,,
,,
,
4,900 {50, 711} 9,800 {1 00, 1,421}

FRONT PRESSUREkPa {kgf/cm~ psi}
DBR411ZWB026
Load sensing proportioning valve (LSPV) fluid pressure

Type
4x2 (except HiRider)
Without 4W-ABS
With4W-ABS
Without 4W-ABS
Hi-Rider, 4x4
With4W-ABS
Front wheel cylinder fluid pressure

4,900 {50, 711}

9,800 {1 00, 1,421}
4,900 {50, 711}
9,800 {1 00, 1,421}
4,900 {50, 711}
9,800 {1 00, 1,421}
4,900 {50, 711}
9,800 {1 00, 1,421}
Rear wheel cylinder

2,250-2,850 {23-29,
3,130-3,930 {32-40,
2,910-3,710 {3D-37,
4,970-6,170 {51-62,
2,250-2,850 {23-29,
3,130-3,930 {32-40,
2,650-3,450 {28-35,
4,700-5,900 {48-60,
327-413}
454-569}
423-538}
721-894}
327-413}
454-569}
385-500}
682-855}
Note
When applying the specified pressure, the brake pedal must not be "double pumped" or released.
Read the rear pressure. After approx. 2 s elapse from setting the front wheel cylinder fluid pressure.
04-11-12

LOAD SENSING PROPORTIONING VALVE (LSPV) ADJUSTMENT
dcf041143903w02
1. Place the unloaded vehicle on level ground. Unloaded: Fuel tank is full. Engine coolant and tire, jack and tools
are in designated position.
Note
A change of 5 mm {O.20 in} in dimension L results in a change of the following.
Type
Change (kPa {kgf/cm 2 , psi})

850 {8.7, 123}
1,020 {10, 148}
1,060{11,154}
1,080 {11, 157}
without 4W-ABS
with 4W-ABS
without 4W-ABS
with 4W-ABS

Hi-Rider, 4x4
2. Adjust main spring dimension L between the LSPV and the adjustment link loosening and repositioning the
LSPV.
4x2 (EXCEPT Hi Rider)
Hi-Rider, 4x4
'X
MAIN SPRING
' '.
./
MAIN SPRING
''''"
ADJUSTMENT LINK
<
DCF411 ZWB004
Decrease dimension L if the fluid pressure is low.

Increase dimension L if the fluid pressure is high.
Specification
Dimension L
Type
Hi-Rider, 4x4
Dimension L (mm {in})

without 4W-ABS
with 4W-ABS
without 4W-ABS
with 4W-ABS
147.5-154.5 {5.808-6.082}
175.5-182.5 {6.910-7.185}
3. Tightening the nut.

Specification
18.6-25.4 Nm {1.90-2.59 kgf.m, 13.8-18.7 ft.lbf}
4. After adjustment, recheck the fluid pressure.
If not as specified, replace the LSPV as a component.
04-11-13

LOAD SENSING PROPORTIONING VALVE (LSPV) REMOVAUINSTALLATION
dcf041143903w03
Caution
Do not disassemble the load sensing proportioning valve (LSPV) or move nut A, otherwise the
LSPV may not function properly.
3. After installation, adjust the main spring dimension. (See 04-11-13 LOAD SENSING PROPORTIONING VALVE
(LSPV) ADJUSTMENT.)
mJ'
WITHOUT 4W-ABS
12.8-21.6 Nm
{131-220 kgfcm,
114-191 in.lbf}
Hi-Rider, 4x4
18.6-25.4
{1.9D-2.59, 13.8-18.7}
],.13.
18.6-25.4
mJ' 49 0259 770B
_18,7)
Nm {kgfm, ttlbf}
DCF411 ZWB005
Brake pipe
(See 04-11-14 Brake Pipe Installation Note)
Nut
Bolt
Load sensing proportioning valve (LSPV)
Brake Pipe Installation Note

1. Install the brake pipe to the LSPV and align yellow
painting on the brake pipe and LSPV.
YELLOW PAINTING
DBR411 ZWB029
04-11-14

FRONT BRAKE (DISC) INSPECTION
dcf04113398Ow01
Disc Pad Thickness Inspection

1. Jack up the front of the vehicle on level ground and support it with safety stands.
2. Remove the wheels.
3. Look through the caliper inspection hole and
verify the remaining thickness of the pad.
Minimum front disc pad thickness
2.0 mm {0.079 in} min.
DBR411 ZWB036
Disc Plate Thickness Inspection

1. Measure the thickness of the disc plate.
If the thickness is not within the specification,
replace the disc plate.
Caution
When it is necessary to machine the disc
plate, make sure the disc plate is not
removed from the vehicle when
machined, excessive runout may result.
Machine the disc plate with it installed on
the vehicle.
Standard front disc plate thickness
4x2 (except Hi-Rider): 24.0 mm {0.945 in}
Hi-Rider, 4x4: 28.0 mm {1.11 in}
L-------------------------------A~B~R6=9~12~WO~10~
Minimum front disc plate thickness

Hi-Rider, 4x4: 26.0 mm {1.03 in}
Minimum front disc plate thickness after machining using a brake lathe on-vehicle
Hi-Rider, 4x4: 26.8 mm {1.06 in}
Disc Plate Runout Inspection
1. Tighten the disc plate to the wheel hub using two
wheel nuts. When measuring runout, measure at
the outer edge of the disc plate surface.
Front disc plate runout limit
0.05 mm {0.002 in} max.
04-11-15

FRONT BRAKE (DISC) REMOVAUINSTALLATION [4x2 (EXCEPT Hi-Rider)]
dcf04113398Ow02
Note
Because the disc plate is installed to the front wheel hub, refer to WHEEL HUB, STEERING KNUCKLE
REMOVAL/INSTALLATION to remove it. (See 03-11-4 WHEEL HUB, STEERING KNUCKLE REMOVAL/
INSTALLATION [4x2 (EXCEPT Hi-Rider)].)
3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
108-127
,",'" H
'-'. ".7--03.6,
-~
iii
-!P.
II
C!
RUBBER GREASE
Nm {kgf.m, ft.lbf}
DBR411 ZWB030
2
3
4
5
Brake hose
Bolt
Guide pin
Dust boot
Caliper
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
04-11-16
Disc pad
(See 04-11-16 Disc Pad Installation Note)
7
8
9
Plate
Guide plate
Mounting support

FRONT BRAKE (DISC) REMOVAUINSTALLATION [Hi-Rider, 4x4]
dcf041133980w03
Caution

3. After installation, depress the pedal a few times, rotate the wheel by hand, and verify that the brake does not
drag.
6@
II
6@
II
RUBBER GREASE
10
BRAKE GREASE
Nm {kgf.m, ttlbf}
DBR411ZWB035
1
2
3
4
5
6
Brake hose
Caliper
Guide pin
Disc pad
Outer shim (cover shim)
(See 04-11-18 Outer Shim, Inner shim Installation
Note)
Outer shim (rubber coated shim)
Note)
Inner shim (cover shim)

Note)
Inner shim (rubber coated shim)

Note)
Guide plate
(See 04-11-18 Guide Plate Removal Note)
9
10
11
Mounting support
Dust boot
12
Disc plate
(See 04-11-18 Disc Plate Removal Note)
(See 04-11-18 Disc Plate Installation Note)
04-11-17

Guide Plate Removal Note
1. Pull up and at a slant on the supporting part of the
guide plate in the direction indicated by the arrow
(1) and (2) as shown in the figure, to remove the
guide plate from the mounting support.
Caution
If the guide plate is removed by pulling in
the direction indicated by the arrow as
shown in the figure, the stopper may be
deformed and not able to be reused. Do
not remove in this manner.
GUIOE PLATE
DBR411 ZWB054
Disc Plate Removal Note

1. Mark the wheel hub bolt and disc plate before
removal for reference during installation.
DBR411 ZWB021
Disc Plate Installation Note

1. Remove any rust or grime on the contact face of the disc plate and wheel hub.
2. Install the disc plate and align the marks made before removal.
Outer Shim, Inner shim Installation Note
1. Assemble the rubber coated shim to the back plate of the disc pad.
2. Apply brake grease to the rubber coated shim as
r-----------R-U-BB-E-R-C-O-A-T-E-O-S-H-IM----.
APPLICATION LOCATION
OF GREASE (3 PLACES)
DBR411 ZWB038
04-11-18

3. Assemble the cover-shim to the grease-applied
rubber coated shim.
Caution
Be careful not to get any grease on the
pad lining surface.
DBR411 ZWB048
Disc Pad Installation Note

1. Push the piston fully inward using the SST.
2. Install the disc pad.
DBR411 ZWB055
DISC PAD (FRONT) REPLACEMENT [4x2 (EXCEPT Hi-Rider)]
dcf041133630w01

1
2
3
Bolt
Caliper
Guide pin
Disc pad
(See 04-11-16 Disc Pad Installation Note.)
Plate
Guide plate
1m
28-34Nm
{2.9-3.4 kgfm.
21-25 ft.lbf}
mD
DBR411ZWB032
04-11-19

DISC PAD (FRONT) REPLACEMENT [Hi-Rider, 4x4]
dcf04113363Ow02

1
2
3
4
5
6
7
8
9
29-34
CD {3.0-3.4, 22-25}
Bolt
Caliper
Guide pin
Disc pad
Outer shim (cover shim)
Outer shim (rubber coated shim)

Inner shim (cover shim)
Inner shim (rubber coated shim)
Guide plate
(See 04-11-18 Guide Plate Removal Note)
-:-.!..@
I
-:-.!..@
I
RUBBER GREASE
BRAKE GREASE
Nm {kgfm, ftlbf}
DBR411 ZWB037
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY [4x2 (EXCEPT Hi-Rider)]
dcf04113399Ow01

1
Piston
(See 04-11-21 Piston Disassembly Note)
Dust seal
Piston seal
Bleeder cap
Bleeder screw
Caliper
3
4
5
6
-!i
!&I
RUBBER GREASE
mi' 49 0259 7708

DBR411 ZWB033
04-11-20

Piston Disassembly Note
Caution
The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1. Place the piece of wood in the caliper, then blow
compressed air through the hole to force the
piston out of the caliper.
DBR411ZWB034
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY [Hi-Rider, 4x4]
dcf041133990w02

1
2
3
4
5
6
Dust seal
Piston
(See 04-11-21 Piston Disassembly Note)
Piston seal
Bleeder cap
Bleeder screw
Caliper
mJ * 5.9-B.B Nm {51-B9 kgfcm, 53-77 inlbf}
DBR411 ZWB039
Piston Disassembly Note

Caution
The piston could be damaged if blown out with great force. Blow the compressed air slowly to
prevent the piston from suddenly popping out.
1. Place the SST in the caliper, then blow
compressed air through the hole to force the
piston out of the caliper.
04-11-21

REAR BRAKE (DRUM) INSPECTION
dcf04112625Ow01
Brake Lining Thickness Inspection

1. Remove the brake drum. (See 04-11-23 REAR BRAKE (DRUM) REMOVAL/INSTALLATION.)
2. Inspect the brake lining thickness.
If it less than the minimum specification,
replace the brake shoe. (See 04-11-23 REAR
BRAKE (DRUM) REMOVAL/INSTALLATION.)
Minimum rear brake lining thickness
1.0 mm {0.04 in}
DBR411 ZWB042
Brake Drum Inspection

1. Remove the brake drum. (See 04-11-23 REAR BRAKE (DRUM) REMOVAL/INSTALLATION.)
2. Inspect the inner diameter of the brake drum.
If t exceeds the maximum specification,
replace the brake drum. (See 04-11-23 REAR
BRAKE (DRUM) REMOVAL/INSTALLATION.)
Maximum rear brake drum diameter
Hi-Rider, 4x4: 296.5 mm {11.67 in}
i
I
DBR411ZWB041
3. Apply chalk to the inside of the brake drum, rub it

against the brake shoe, and then inspect for
scratches and uneven or abnormal wear inside
the drum.
If there is significant uneven wear of the brake
drum, repair it within the maximum brake
drum inner diameter or replace. (See 04-1123 REAR BRAKE (DRUM) REMOVAL/
INSTALLATION.)
4. After inspection, wipe the chalk off.
DBR411 ZWB050
04-11-22

REAR BRAKE (DRUM) REMOVAL/INSTALLATION
dcf041126250w02
Warning
When removing/installing the brake drum component parts, the spring could fly off and cause
injury. Remove/install the spring being careful not to allow the spring to fly off. Wear protective
equipment such as safety glasses if necessary.

3. After installation, pump the brake pedal a few times and inspect the following:
Parking brake lever stroke
Brake drag
11
-Y.
APPLY
TO SHADED AREA
mI'
49 0259 770B
Nm {kgfcm, inlbf}
DBR411ZWB040
1
2
3
4
5
6
Brake drum
(See 04-11-24 Brake Drum I nstallation Note.)
Pawl spring
Pawl lever
Lower return spring
10
11
Hold spring (trailing shoe side)

Hold pin (trailing shoe side)
12
Parking brake cable

Brake shoe (trailing shoe)
Upper return spring

(See 04-11-24 Upper Return Spring Removal Note.)
(See 04-11-24 Upper Return Spring Installation
Note.)
13
14
Hold spring (leading shoe side)
16
17
Hold pin (leading shoe side)

Adjust strut
Brake shoe (leading shoe)
15
18
U-ring
Operating lever
Brake pipe
Wheel cylinder
Gasket
04-11-23
KE SYSTEM
~~~~~~f
CONVENTIONALBR=A==______
al Note
S ring Remov . a flathead
Upper Return e
the hand, as
1. screwdriver
Remove. th w.hile supporting
It
.t
f
om
flying off.
to prevent I r
shown In the figure,
~eturn Spring.usl~gWith
II tion Note
S ring Insta ~
flathead
Upper Return
spring
the hand, as
1. Install
r hile supporting It .t f om flying off.
screwdriver w.
to prevent I r
shown In the figure,
t~e
et~rn
u~lng.awith
lIation Note
f the rear brake
Brake Drum Inslah component part 0 wn in the figure.
1. Verify t~at eacerly installed as s 0
(drum) IS prop
h
DBR411 ZWB056
04-11-24

2. Turn the adjuster on the adjustment strut to adjust
the brake shoe until the outer diameter (M) of the
brake shoe is as specified below.
Brake shoe adjustment value

4x2 (except Hi-Rider): 269.3-269.7 mm
{10.603-10.618 in}
Hi-Rider, 4x4: 294.3-294.7 mm {11.5910.60 in}
3. Install the brake drum.
4. Depress the brake pedal five times and operate
the auto adjuster.
5. Verify there is no brake drag.
If there is any brake drag, readjust the brake adjustment
DBR411 ZWB051
WHEEL CYLINDER DISASSEMBLY/ASSEMBLY
dcf041126610w01
Caution
Replace the wheel cylinder component if a problem is found.
1
2
3
4
5
6
7
Dust boot
Wheel cylinder piston
Piston cup
Wheel cylinder spring
Bleeder cap
Bleeder screw
Wheel cylinder body
IJ*
49 0259 770B
DBR411 ZWB045
04-11-25
04-12
PARKING BRAKE SYSTEM LOCATION

INDEX .....................
PARKING BRAKE LEVER
INSPECTION ...............
PARKING BRAKE LEVER
ADJUSTMENT .............
PARKING BRAKE LEVER REMOVAU
INSTALLATION .............
04-12-2
04-12-3
04-12-3
04-12-4
PARKING BRAKE CABLE REMOVAU

INSTALLATION [WL-3] ......... 04-12-5
INSTALLATION
[WL-C (EXCEPT Hi-Rider)] ..... 04-12-6
INSTALLATION
[WL-C (Hi-Rider), WE-C] ............ 04-12-7
PARKING BRAKE SWITCH
INSPECTION .......... 04-12-8
04-12-1

PARKING BRAKE SYSTEM LOCATION INDEX
dcf041200000w01
WL-3
WL-C (EXCEPT Hi-Rider)
WL-C (Hi-Rider), WE-C
DCF412ZWB001
Parking brake lever

(See 04-12-3 PARKING BRAKE LEVER
. INSPECTION.)
ADJUSTMENT.)
04-12-2
Parking brake cable

(See 04-12-5 PARKING BRAKE CABLE
REMOVAUINSTALLATION [WL-3].)
REMOVAUINSTALLATION [WL-C (EXCEPT HiRider)].)
REMOVAUINSTALLATION [WL-C (Hi-Rider), WEC].)

(See 04-12-8 PARKING BRAKE SWITCH
INSPECTION.)

PARKING BRAKE LEVER INSPECTION
dcf04124430Ow01
Parking Brake Lever Stroke Inspection

1. Pump the brake pedal a few times.
2. Pull the parking brake lever two to three times.
3. 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} .
If not within the specification, adjust the parking brake lever. (See 04-12-3 PARKING BRAKE LEVER
ADJUSTMENT.)
Parking brake lever stroke when pulled at 98 N {10 kgf, 22 Ibf}
1-7 notches
PARKING BRAKE LEVER ADJUSTMENT
dcf041244300w02
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.
_________~
~
Tightening torque
6.9-9.8 Nm {71-99 kgfcm, 62-86 in.lbf}
4. After adjustment, pull the parking brake lever one
notch and verify that the parking brake warning
light illuminates.
5. Verify that the rear brakes do not drag.
~ ~
rmnfil_I_~.O~=A
---~
DBR412ZWB002.
04-12-3

PARKING BRAKE LEVER REMOVAUINSTALLATION
1.
2.
3.
4.
dcf041244300w03
Remove the lower panel. (See 09-17-10 LOWER PANEL REMOVAUINSTALLATION.)

After installation, inspect the parking brake lever stroke. (See 04-12-3 PARKING BRAKE LEVER
INSPECTION.)
Nm { kgtm, ftlbf}
DBR412ZWB004
Parking brake switch connector
Clip
Front parking brake cable
(See 04-12-5 PARKING BRAKE CABLE REMOVAU
INSTALLATION [WL-3].)
INSTALLATION [WL-C (EXCEPT Hi-Rider)].)
INSTALLATION [WL-C (Hi-Rider), WE-C].)
Bolt and nut
Parking brake lever component
04-12-4
Clip and joint pin

Cable connector
8
9
10
Clip and joint pin

Clip and joint pin
11
Lever
12
Clip and joint pin
13
14
Spring
Ratchet pawl
I.

15
16
17
Stopper
Fork joint
Spring
18
19
IGuide
Rod
PARKING BRAKE CABLE REMOVAUINSTALLATION [WL-3]

1.
2.
3.
4.
5.
dcf04124441Ow01
Remove the fuel tank cover. (See 01-14A-S FUEL TANK REMOVAUINSTALLATION [WL-3].)
Remove the brake shoe (trailing shoe). (See 04-11-23 REAR BRAKE (DRUM) REMOVAUINSTALLATION.)
INSPECTION.)
15.68-21.54
{1.599-2.196,
11.57-15.88}
15.68-21.54
{1.599-2.196,
11.57-15.88}
--""::::::==:I;'l2::.....-- ~
Nm {kgfm, ttlbf}
DBR412ZWB005
1
2
3
4
Clip
Bolt
Spring
(See 04-12-6 Front Parking Brake Cable Removal
Note.)
Bolt
6
7
8
9
10
11
Bracket
Bolt
Clip
Rear parking brake cable (left)
Rear parking brake cable (right)
Grommet
04-12-5

Front Parking Brake Cable Removal Note
1. Slide the clip installed to the cable connector in
the direction shown by the arrow.
2. Remove the end of the front parking brake cable
from the cable connector.
CABLE
CONNECTER
\ 7 ' - - > , - - _ CLIP

DBR412ZWB008
PARKING BRAKE CABLE REMOVAL/INSTALLATION [WL-C 4x2 (EXCEPT Hi-Rider)]
1.
2.
3.
4.
5.
dcf041244410w02
Remove the fuel tank cover. (See 01-14B-4 FUEL TANK REMOVAUINSTALLATION [WL-C, WE-C].)
INSPECTION.)
15.68-21.54
{1.599-2.196,
11.57-15.88}
@ - - - -......
15.68-21.54
{1.599-2.196,
11.57-15.88}
~
~7
(Q
15.68-21.54
{1.599-2.196,
11.57-15.88}
Nm {kgf.m, fj.lbf}
DBR412ZWB006
Nut
Bolt
Bolt, nut
Clip
9
10

11
Grommet
Spring
Note.)
(See 04-12-7 Front Parking Brake Cable Installation
Note.)
Bolt
Bracket
04-12-6

Front Parking Brake Cable Installation Note
1. Install the front parking brake cable with the
spring installation area of the equalizer pointed
towards the inside of the vehicle.
"OF
INSIDE
VEHICLE
DBR412ZWB009
PARKING BRAKE CABLE REMOVAUINSTALLATION [WL-C (Hi-Rider, 4x4), WE-C]

1.
2.
3.
4.
5.
dcf041244410w03
Remove the fuel tank cover. (See 01-14B-4 FUEL TANK REMOVAL/INSTALLATION [WL-C, WE-C].)
INSPECTION.)
15.68-21.54
{1.599-2.196,
11.57-15.88}
15.68-21.54
{1.599-2.196,
11.57-15.88}
156H;)J(
"OF
{1.599-2.196,
INSIDE
15.68-21.54
{1.599-2.196,
11.57-15.88}
11.5,5.88}
VEHICLE
~7
~
1
~5
"OF
INSIDE
VEHICLE
15.68-21.54
{1.599-2.196,
11.57-15.88}
6.9-9.8 Nm
{71-99 kgfcm,
62-86 in.lbf}
Nm {kgfm, It.lbf}
DBR412ZWB007
Clip
Bolt
2
3
Bolt
Spring
8
9
Spring
Clip
Bolt
10
Bracket
Note.)
(See 04-12-8 Front Parking Brake Cable Installation
Note.)
11
12

Grommet
04-12-7

Front Parking Brake Cable Installation Note
1. Install the front parking brake cable with the
spring installation area of the equalizer pointed
towards the inside of the vehicle.
DBR412ZWB010
PARKING BRAKE SWITCH INSPECTION
dcf041266450w01
1. Disconnect the parking brake switch connector.

table.
parking brake switch.
0--0: Continuity
Terminal
Condition
Body
ground
Parking brake lever pulled
B3E0412W006
Parking brake lever released

CHU0412W003
04-12-8
04-13B ANTILOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK

ABS LOCATION INDEX [4W-ABS] .....
ABS HU/CM SYSTEM INSPECTION
[4W-ABS] . .......................
ABS HUlCM REMOVAUINSTALLATION
[4W-ABS] . .......................
ABS HUlCM INSPECTION
[4W-ABS] . .......................
FRONT ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION
[4W-ABS (4x2 (EXCEPT Hi-Rider))] ..
REMOVAUINSTALLATION
[4W-ABS (Hi-Rider, 4x4)] ...........
04-13B-1
04-13B-2
04-13B-3
04-13B-5
04-13B-7
04-13B-8

INSPECTION ..................... 04-13B-9
REAR ABS WHEEL-SPEED SENSOR
REMOVAUINSTALLATION
[4W-ABS (4x2 (EXCEPT Hi-Rider))] .. . 04-13B-10
REMOVAUINSTALLATION
[4W-ABS (Hi-Rider, 4x4)] . .......... . 04-13B-11
INSPECTION [4W-ABS] ............. 04-13B-11
G SENSOR REMOVAUINSTALLATION
[4W-ABS] ....................... . 04-13B-12
G SENSOR INSPECTION [4W-ABS] .... 04-13B-13
ABS LOCATION INDEX [4W-ABS]
dcf041300000w02
DBR413ZWB001
ABS HU/CM
(See 04-13B-2 ABS HU/CM SYSTEM INSPECTION
[4W-ABS])
(See 04-13B-3 ABS HUlCM REMOVAU
INSTALLATION [4W-ABS])
(See 04-13B-5 ABS HU/CM INSPECTION [4WABS])
Front ABS wheel-speed sensor
(See 04-13B-7 FRONT ABS WHEEL-SPEED
SENSOR REMOVAUINSTALLATION [4W-ABS (4x2
(EXCEPT Hi-Rider))])
(See 04-13B-8 FRONT ABS WHEEL-SPEED .
SENSOR REMOVAUINSTALLATION [4W-ABS (HiRider, 4x4)])
(See 04-13B-9 FRONT ABS WHEEL-SPEED
SENSOR INSPECTION)
Rear ABS wheel-speed sensor

(See 04-13B-10 REAR ABS WHEEL-SPEED
SENSOR REMOVAUINSTALLATION [4W-ABS (4x2
(EXCEPT Hi-Rider))])
SENSOR REMOVAUINSTALLATION [4W-ABS (HiRider, 4x4)])
SENSOR INSPECTION [4W-ABS])
G sensor (Hi-Rider, 4x4)

(See 04-13B-12 G SENSOR REMOVAU
INS1ALLATION [4W-ABS])
(See 04-13B-13 G SENSOR INSPECTION [4WABS])
04-138-1

ABS HUlCM SYSTEM INSPECTION [4W-ABS]
dcf041300000w03
ABS Hydraulic Unit On-vehicle Inspection

Preparation
2. Turn the ignition switch to the ON position and verify that the ABS warning light goes out after approx. 3.0 s.
3. Turn the ignition switch off.
4. Jack up the vehicle and support it evenly on safety stands.
5. Shift to neutral.
6. Release the parking brake.
7. Verify that all four wheels rotate.
8. Rotate the inspected wheels by hand and verify there is no brake drag.
If there is any brake drag, perform regular brake inspection.
If there is no brake drag, perform ABS HU/CM operation inspection.
Operation inspection
1. Perform "Preparation".
2. Connect the current diagnostic tool to the DLC-2
connector.
3. Set up an active command mode inspection
according to the combination of commands
below.
DBR402ZTB003
Operation condition
Brake pressure retention
Brake pressure reduction
PMP_MOTOR
OFF
ON
Command name
V_RF_OTL
OFF
ON
V_RF_INL
ON
ON
Command
transmission type
Manual
The chart above shows an example of a right front wheel inspection.

Caution
When operating the solenoid valve and pump motor using the active command mode, make sure
to keep the operation time within 10 s to prevent damaging the ABS HUICM.
Note
When working with two people, one should press on the brake pedal, the other should attempt to rotate
the wheel being inspected.
4. Send the command while depressing on the brake pedal and attempting to rotate the wheel being inspected.
5. Performing the inspection above determines the following:
The ABS HU/CM brake lines are normal.
The ABS HU/CM hydraulic system is not significantly abnormal (including inside ABS HU/CM).
The ABS HU/CM internal electrical parts (solenoid, motor and other parts) are normal.
The ABS HU/CM output system wiring harnesses (solenoid valve, relay system) are normal.
However, the following items cannot be verified.
Malfunction of ABS HU/CM input system wiring harnesses and parts
Extremely small leakage in the ABS HU/CM internal hydraulic system
Intermittent malfunction of the abov~ items
04-138-2
ANTILOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]

ABS HUlCM REMOVAL/INSTALLATION [4W-ABS]
dcf04134375OW05
Caution
The internal parts of the ABS HUlCM could be damaged if dropped. Be careful not to drop the ABS
HUICM. Replace the ABS HUlCM if it is subjected to an impact.

6-10
{62-101,54-88}
18.6-25.5
{1.9-2.6,
13.8-18.8}
16-22
{1.7-2.2,12-16}
~18.6-25.5
{1.9-2.6,
13.8-18.8}
Nm {kgfm, ftlbf}
mJ' 490259 770B
DBR413ZWB002
2
3
Connector
(See 04-13B-4 Connector Removal Note.)
(See 04-13B-4 Connector Installation Note.)
Brake pipe
(See 04-13B-4 Brake Pipe Removal Note.)
(See 04-13B-4 Brake Pipe Installation Note)
ABS HUlCM component
Nut
5
6
7
washer
Bushing (bracket side)

Bracket
ABS HU/CM
Bushing (ABS HU/CM side)
04-138-3

Connector Removal Note
1. Rotate the lock lever in the direction of the arrow,
and remove the ABS HUlCM connector.
Brake Pipe Removal Note

1. Place an alignment mark on the brake pipe and
ABS HU/CM.
2. Apply protective tape to the connector to prevent
brake fluid from entering.
3. Remove the brake pipe.
Brake Pipe Installation Note

1. When install the brake pipe, align the marks made
before removal with the ABS HU/CM as shown in
the figure.
2. Tighten the brake pipe to the specified torque
using the SST (49 0259 770B).
LF
RF
REAR
DBR413ZWB006
Connector Installation Note

1. After connecting the connector, rotate the lock
lever in the direction of the arrow to install the
ABS HU/CM connector.
DBR413ZWB004
04-138-4

ABS HUlCM INSPECTION [4W-ABS]
dcf041343750w06
1. Disconnect the ASS HU/CM connector.

3. Attach the tester lead to the ASS HU/CM harness side connector, then inspect voltage, continuity or resistance
according to the standard (reference value) on the table.
Standard (Reference Value)
ASS HUlCM WIRING HARNESS-SIDE CONNECTOR
DBR413ZWB017
Terminal
A
B
C
Signal name
Ground
(ABS motor)
Power supply
(ABS motor
operation)
Power supply
(solenoid)
Ground
(ABS system)
Connected to
Ground point
Measured
item
Measured terminal
(measured condition)
Continuity A-ground point
Standard
Inspection item(s)
Continuity
detected
Wiring harness (Aground point)
Battery
Voltage
Under any condition
B+
Wiring harness (Bbattery)
Battery
Voltage
Under any condition
B+
Wiring harness
(C--battery)
Wiring harness (Dground point)
Wiring harness (E-LF
ABS wheel-speed
sensor connector
terminal A)
Wiring harness (F-LF
ABS wheel-speed
sensor connector
terminal B)
Wiring harness (G-LR
ABS wheel-speed
sensor connector
terminal B)
Ground point
Continuity D-ground point
Continuity
detected
LF wheelspeed sensor
(single)
LF ABS wheelspeed sensor
E-LF ABS wheelContinuity speed sensor

connector terminal A
Continuity
detected
LF wheelspeed sensor
(ground)
LF ABS wheelspeed sensor
F-LF ABS wheelContinuity speed sensor

connector terminal B
Continuity
detected
LR wheelspeed sensor
(ground)
LR ABS wheelspeed sensor
G-LR ABS wheelContinuity speed sensor

Continuity
detected
LR wheelspeed sensor
(signal)
LR ABS wheelspeed sensor
Power supply
(system)
Ignition switch
I-LR ABS wheelContinuity speed sensor

Voltage
Continuity
detected
Ignition switch at ON
B+
Ignition switch is off.
1 V or less
RR wheelspeed sensor
(ground)
RR ABS wheelspeed sensor
K-RR ABS wheelContinuity speed sensor

Continuity
detected
RR wheelspeed sensor
(signal)
RR ABS wheelspeed sensor
L-RR ABS wheelContinuity speed sensor

Continuity
detected
RF wheelspeed sensor
(ground)
RF ABS wheelspeed sensor
M-RF ABS wheelContinuity speed sensor

Continuity
detected
Wiring harness (I-LR

ABS wheel-speed
sensor connector
terminal A)
Wiring harness (Jignition switch)
Wiring harness (K-RR

ABS wheel-speed
sensor connector
terminal B)
Wiring harness (L-RR
ABS wheel-speed
sensor connector
terminal A)
Wiring harness (M-RF
ABS wheel-speed
sensor connector
terminal B)
04-138-5

Terminal
Signal name
Brake switch
RFwheelspeed sensor
(signal)
p'
G sensor
(signal)
On-board
diagnostic
R
S
T
U
Brake switch
RF ABS wheelspeed sensor
G sensor
KLN terminal of
DLC-2
Measured
item
Voltage
Measured terminal
(measured condition)
N-brake switch
(Brake pedal
depressed)
V-brake switch
(Brake pedal not
depressed)
O-RF ABS wheelContinuity speed sensor

Standard
B+
1 V or less
Continuity
detected
Continuity
P-G sensor connector

terminal B
Continuity
detected
Continuity
Q-DLC-2 connector
terminal KLN
Continuity
detected
Wiring harness (O-RF

ABS wheel-speed
sensor connector
terminal A)
Wiring harness (P-G
sensor connector
terminal B)
Wiring harness (QDLC-2 connector
terminal KLN)
G sensor
Continuity
V-G sensor connector

terminal A
W'
G sensor
(ground)
G sensor
Continuity
W-G sensor
connector terminal C
: Hi-Rider, 4x4
014-138-6
Wiring harness (Nbrake switch)

Brake switch
G sensor
(power supply
V'
Inspection item(s)
Connected to
Continuity
detected
Wiring harness (V-G

sensor connector
terminal A)
Wiring harness (W-G
sensor connector
terminal C)

FRONT ABS WHEEL-SPEED SENSOR REMOVAUINSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider))]
dcf041343720w01
1. When removing the ABS wheel-speed sensor on the right side, remove the washer tank installation bolts and
the connector, then move the washer tank to a place out of the way. (See 09-19-5 WINDSHIELD WASHER
TANK REMOVAUINSTALLATION.)
VIEW FROM LEFT SIDE
INSERT CLIP SURELY
II
19-25
19-25
{2.0-2.5,
15-18}
2 {2.0-2.5, 15-18}
Nm {kgf.m, ftlbf}
DBR413ZWB008
IConnector
IFront ABS wheel-speed sensor
Bolt
04-138-7

FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)]
dcf041343720w02
1. When removing the ABS wheel-speed sensor on the right side, remove the washer tank installation bolts and
the connector, then move the washer tank to a place out of the way. (See 09-19-5 WINDSHIELD WASHER
TANK REMOVAL/INSTALLATION.)
VIEW FROM LEFT SIDE
INSERT CLIP SURELY
Nm {kgfm, ttlbf}
DBR413ZWB009
IConnector
Bolt
04-138-8
IFront ABS wheel-speed sensor
ANTI LOCK BRAKE SYSTEM [4-WHEEL ANTI LOCK BRAKE SYSTEM (4W-ABS)]
FRONT ABS WHEEL-SPEED SENSOR INSPECTION
dcf041343720w03
Visual Inspection
1. Remove the wheel and tire, and inspect the sensor for looseness and damage. Replace the sensor if
necessary.
Clearance Inspection
1. Inspect the clearance between the wheel-speed
sensor and the sensor rotor.
ASS WHEEL-SPEED SENSOR
Clearance
0.3-1.1 mm {0.012-0.043 in}
CLEARANCE
""Y~~
If not as specified, replace the defective

part(s). (ABS wheel-speed sensor, ABS
sensor rotor and steering knuckle etc.)
ASS SENSOR ROTOR

DBR413ZWB010
1. Disconnect the ABS wheel-speed sensor connector.
2. Inspect the resistance at the ABS wheel-speed sensor.
If not as specified, replace the ABS wheel-speed sensor.
Resistance
1.2-1.6 kilohm
Voltage Inspection
1. Jack up the vehicle on level ground and support it evenly on safety stands.
3. Inspect each sensor by rotating each wheel one revolution per second.
If not as specified, replace the ABS wheel-speed sensor.
Voltage
0.15-1.2 V (AC)
Voltage Pattern Inspection
3. Using an oscilloscope, inspect voltage pattern for
+
distortion and noise by rotating each wheel.
If there is distortion or noise, inspect the ABS
sensor rotor.
HIGH SPEED
LOW SPEED
DBR413ZWB011
04-138-9

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider))]
dcf041343710w03

7.8-10.8 Nm
{80-110 kgf.cm,
70-95 inlbf}
19-25
{1.9-2.6,
14-18}
{80-110 kgfcm,
70-95 inlbf}
Nm {kgf.m, ftlbf}
DBR413ZWB012
I Connector
2
Bolt
04-138-10
IRear ABS wheel-speed sensor

REAR ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)]
dcf04134371Ow04

19-25
{1.9-2.6,
14-18}
Nm {kgf.m, ftlbf}
DBR413ZWB013
IConnector
IRear ABS wheel-speed sensor
Bolt
REAR ABS WHEEL-SPEED SENSOR INSPECTION [4W-ABS]
dcf04134371OwOS
Visual Inspection
1. Inspect the sensor for looseness and damage. Replace the sensor if necessary.
Clearance Inspection
1. Remove the ASS wheel-speed sensor.
2. Measure the length A and S shown in the figure
using vernier calipers.
3. Subtract S from A then verify the clearance
between the wheel-speed sensor and the sensor
rotor.
Clearance
0.3-1.1 mm {0.012-0.043 in}
If not as specified, replace the defective

part(s}. (ASS wheel-speed sensor, ASS
sensor rotor, rear axle shaft and rear axle
housing etc.)
.rD=
~
ASS SENSOR ROTOR
DBR413ZWB014
04-138-11

1. Disconnect the ASS wheel-speed sensor connector.
2. Inspect the resistance at the ASS wheel-speed sensor.
If not as specified, replace the ASS wheel-speed sensor.
Resistance
1.2-1.6 kilohm
Voltage Inspection
1. On level ground, jack up the vehicle and support it evenly on safety stands.
3. Inspect each sensor by rotating each wheel one revolution per second.
If not as specified, replace the ASS wheel-speed sensor.
Voltage
0.15-1.2 V (AC)
Voltage Pattern Inspection
3. Using an oscilloscope, inspect voltage pattern for
+
distortion and noise by rotating each wheel.
If there is distortion or noise, inspect the ASS
sensor rotor.
HIGH SPEED
LOW SPEED
DBR413ZWB011
G SENSOR REMOVAUINSTALLATION [4W-ABS]
dcf041343770w01
Caution
Be careful and do not allow the combined sensor to fall. If by chance it is subjected to strong
impact, replace it.
1. Slide the RH front seat fully backward.
1
2
3
Connector
G sensor and bracket
G sensor
7.8-10.S Nm {SO-l10 kgf.cm, 70-95 inlbf}
4.2-S.2 Nm {43-S3 kgfcm, 3S-54 inlbf}

DBR,!13ZWB015
04-138-12

G SENSOR INSPECTION [4W-ABS]
dcf041343770w02
1. Connect the connector.

2. Turn ignition switch (engine switch) on, and verify the voltage between terminals A and B under the following
conditions.
If not within the specification, replace the G sensor.
(1) Horizontal
,---------::---------------,
Voltage
2.4-2.6 V
DBR413ZWB016
(2) Facing up (inclined 90 from horizontal)

0
Voltage
1.3-1.7 V
ABR6916W007.
(3) Facing down (declined 90 from horizontal)

0
Voltage
3.3-3.7 V
ABR6916W010
04-138-13
TECHNICAL DATA
04-50
TECHNICAL DATA
BRAKE TECHNICAL DATA .......... 04-50-1
BRAKE TECHNICAL DATA
dcf04500000OW01
Item
Brake fluid type
Brake pedal height
Standard pedal play
Standard pedal-to-floor clearance
Power brake unit fluid pressure when pedal depressed
at 200 N {20 kgf, 45 Ibf}
Power brake unit fluid pressure when pedal depressed

at 200 N {20 kgf, 45 Ibf}
Minimum front disc pad thickness
Minimum front disc plate thickness
Minimum front disc plate thickness after machining
using a brake lathe on-vehicle
Front disc plate runout limit
Minimum rear brake lining thickness
Maximum rear brake drum diameter
Specification
214-219 mm {8A3-8.62 in}
3.0-8.0 mm {0.12-0.31 in}
105 mm {4.14 in} or more
At 0 kPa {O mmHg, 0 inHg}: 593 kPa {6.1 kgf/cm 2, 87 psi} or more

At 67 kPa {500 mmHg, 20 inHg}: 6,950 kPa {71 kgf/cm2, 1,008 psi} or
more
2.0 mm {0.079 in} min.
Hi-Rider, 4x4: 26.0 mm {1.03 in}
Hi-Rider, 4x4: 26.8 mm {1.06 in}
0.05 mm {0.002 in} max.
1.0 mm {0.04 in}
4x2 (except Hi-Rider): 271.5 mm {1 0.68 in}
Hi-Rider, 4x4: 296.5 mm {11.67 in}
Parking brake lever stroke when pulled at 98 N {10

kgf,22Ibf}
1-7 notches
Load sensing proportioning valve (LSPV) fluid pressure

Type
4x2 (except HiRider)
Without 4W-ABS
With 4W-ABS
Without 4W-ABS
Hi-Rider, 4x4
With 4W-ABS
Front wheel cylinder fluid pressure

4,900 {50, 711}
9,800 {1 00, 1,421}
4,900 {50, 711}
9,800 {100, 1,421}
4,900 {50, 711}
9,800 {100, 1,421}
4,900 {50, 711}
9,800 {100, 1,421}
Rear wheel cylinder

2,250-2,850 {23-29, 327-413}
3,130-3,930 {32-40, 454-569}
2,910-3,710 {30-37, 423-538}
4,970-6,170 {51-62, 721-894}
2,250-2,850 {23-29, 327-413}
3,130-3,930 {32-40, 454-569}
2,650-3,450 {28-35, 385-500}
4,700-5,900 {48-60, 682-855}
04-50-1
SERVICE TOOLS
04-60
SERVICE TOOLS
BRAKES SST ..................... 04-60-1
BRAKES SST
dcf046000000w01
490259770B
49 U043 OAOA
49 U043 004A
Flare nut
wrench
Oil pressure
gauge set
Oil pressure.
gauge
(Part of 49
U0430AOA)
CI
CI
49 U043 005
49 U043 006
490221 600C
Joint
(Part of 49
U0430AOA)
Hose
(Part of 49
U0430AOA)
Disc brake
expand tool
49 T033 001A
WDS
Disc brake
piston stopper
~------~------~------~mI
04-60-1
ON-BOARD DIAGNOSTIC
[SRSSS] . . . . . . . . . . . . . . . . . OS-02
[SRSSS] . . . . . . . . . . . . . . . .. OS-03
[SRSSS] . . . . . . . . . . . . . . . . . OS-13
05-02
SHIFT MECHANISM ....... OS-14
TECHNICAL DATA[SRSSS] ... OS-SO
SERVICE TOOLS[SRSSS] .... OS-60
CONTROL SYSTEM
WIRING DIAGRAM [SRSSS] .........
FOREWORD [SRSSS] ...........
ON-BOARD DIAGNOSTIC
FUNCTION [SRSSS] ..........
[SRSSS] ....................
DTC TABLE [SRSSS] ............
DTC P06S7, P06S8 [SRSSS] ........
DTC P070S, P0708, P1702,
P1704, P170S [SRSSS] .. '.o
DTC P0711, P0712, P0713 [SRSSS] ..
DTC P071S, P0717, P0718 [SRSSS] .
DTC P0720, P0721 , P0722 [SRSSS] . . . .
DTC P0731 , P0732, P0733,
P0734, P073S [SRSSS] .......
DTC P0740, P0741 , P0742,
P0743, P0744 [SRSSS] .............
OS-02-2
OS-02-3
OS-02-3
OS-02-4
OS-02-S
OS-02-7
OS-02-9
OS-02-13
OS-02-1S
OS-02-17
OS-02-19
OS-02-20
DTC P074S, P0748, P0960,

P0962,P0963[SRSSS] ............. OS-02-22
DTC P07S0, P07S3 [SRSSS] ........ OS-02-24
DTC P07SS, P07S7, P07S8 [SRSSS] '" .OS-02-26
DTC P0760, P0762, P0763 [SRSSS] ... OS-02-28
DTC P076S, P0768 [SRSSS] ........ OS-02-30
DTC P077S, P0778, P0964,
P0966,P0967[SRSSS] ......... OS-02-32
DTC P0791, P0794 [SRSSS] ........ OS-02-34
DTC P079S, P0798, P0968,
P0970,P0971 [SRSSS] ............. OS-02-36
DTC P163S [SRSSS] ............. OS-02-38
DTC P1700 [SRSSS] ............... OS-02-38
DTC P1711 [SRSSS] ........ OS-02-39
DTC P1780 [SRSSS] ............. OS-02-40
DTC P1783 [SRSSS] .............. OS-02-42
DTC U0100, U0297 [SRSSS] ....... OS-02-43
PID/DATA MONITOR INSPECTION
[SRSSS] ..................... OS-02-4S
05-02-1

AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [SRSSS]
IG1
B+
id0502c1811000
B+
TCM
AT RELAY
TCC CONTROL SOLENOID
OTHER
MODULE
SHIFT SOLENOID A
SHIFT SOLENOID B
4x4
CONTROL
MODULE
SHIFT SOLENOID C
SHIFT SOLENOID D
IG1
J J-------'

MJ-------'
INSTRUMENT
CLUSTER
TR1
TR2
TR4
OSS SENSOR
ISS SENSOR
TSS SENSOR
arnffwOOOO 1941
05-02-2
ON-BOARD DIAGNOSTIC [5R55S1

FOREWORD [5R55S]
id0502c1800200
When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, OlD
OFF indicator light flashing, and TCM memory for diagnostic trouble code (DTC), then diagnose the
malfunction according to following flowchart.
If the DTC exists, diagnose the applicable DTC. (See 05-02-5 DTC TABLE [5R55S].)
If the DTC does not exist and the MIL does not illuminate, and the OlD OFF indicator light flashes, diagnose
the applicable symptom troubleshooting. (See05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
VALIDATE CONCERN
WARNING LIGHT'
ON IFLASHING
NO WARNING LIGHT'
WITH SYMPTOM
INSPECT FOR
PRIORITIZED DTC
INSPECT DTC
TEST
DTC
NODTC
DIAGNOSE BY DTC
DTCTABLE
DTC TROUBLESHOOTING FLOW
DIAGNOSE BY SYMPTOM
1. DIAGNOSTIC INDEX
3. SYMPTOM TROUBLESHOOTING
*: Malfunction Indicator Lamp (MIL), OlD OFF indicator light
AUTOMATIC TRANSMISSION ON-BOARD DIAGNOSTIC FUNCTION [5R55S]
id0502c1811100
DTC Reading Procedure

1. Perform necessary vehicle preparation and visual inspection.
2. Connect the IDS/PDS to the DLC-2.
,.---------------------,
items from the initial screen of the IDS/PDS.
When using the IDS (laptop PC)
3. Select "Modules".
4. Select "TCM".
When using the PDS (Pocket PC)
2. Select "TCM".
absggw00000987
screen.
5. After completion of repairs, clear all DTCs stored in the TCM. (See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
05-02-3

AFTER REPAIR PROCEDURE [5R55S]
id0502c1800400
Caution
After repairing a malfunction, perform this procedure to verify that the malfunction has been
corrected .
When this procedure is carried out, be sure to drive the vehicle at lawful speed and pay attention
to other vehicles.

items from the initial screen of the IDS/PDS .
4. Select "TCM".
2. Select "TCM".
absggw00000987
IDS/PDS screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
6. Verify that the ATF level is normal.
,7. Turn the OlD OFF switch on (OlD OFF indicator illuminates) and gradually accelerate vehicle speed to 64 kml
h {40 mph}.
Verify that the transmission shifts to 4GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
8. Turn the OlD OFF switch off (O/D OFF indicator turns off) and accelerate the vehicle speed to 80 'km/h {50
mph}.
Verify that the transmission shifts to 5GR, and maintain the vehicle speed and acceleration pedal opening
angle for 15 s or more.
9. Decelerate using light brake pedal force (Brake light illuminates). Maintain this condition for 5 s or more.
10. Stop the vehicle for approx. 20 s.
11. Repeat Steps 7-10 five times.
12. Gradually slow down and stop the vehicle.
13. Make sure that the repaired DTC does not recur.
05-02-4

DTC TABLE [5R55S]
Condition
DTC No.
P0657
P0658
P0705
P0708
id0502c1800500
Page
Solenoid valve power supply circuit open
(See 05-02-7 DTC P0657, P0658 [5R55S].)

(See 05-02-7 DTC P0657, P0658 [5R55S].)
Solenoid valve power supply circuit voltage low

Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
(invalid bit pattern)
P1705 [5R55S].)
Digital transmission range (TR) sensor circuit malfunction (See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1705 [5R55S].)
(TR3A circuit open)
P0711
Transmission fluid temperature (TFT) sensor malfunction

(ATF temperature no change)
(See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
P0712
Transmission fluid temperature (TFT) sensor circuit

malfunction (short to ground)
(See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)
P0713
Transmission fluid temperature (TFT) sensor circuit

malfunction (open circuit)
(See 05-02-13 DTC P0711, P0712, P0713 [5R55S].)

Turbine shaft speed (TSS) sensor signal is not input
(See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)

(See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)
(See 05-02-15 DTC P0715, P0717, P0718 [5R55S].)

(See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)
P0715
P0717
P0718
P0720
P0721
P0722

Output shaft speed (OSS) sensor signal is not input
P0731
Gear 1 incorrect
P0732
Gear 2 incorrect
P0733
Gear 3 incorrect
P0734
Gear 4 incorrect
P0735
Gear 5 incorrect
P0740
P0741
P0742
P0743
Torque converter clutch (TCC) control

malfunction (open circuit)
malfunction (stuck off)
malfunction (stuck on)
malfunction (open or short circuit)
solenoid circuit
solenoid circuit
solenoid circuit
solenoid circuit
P0744
Torque converter clutch (TCC) control solenoid circuit

malfunction (short to power)
P0745
P0748
P0750
P0753
P0755
P0757
P0758
P0760
P0762
P0763
P0765
Pressure control solenoid A circuit malfunction (nonoperation)

(See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)

(See 05-02-17 DTC P0720, P0721 , P0722 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55SJ.)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-19 DTC P0731 , P0732, P0733, P0734,
P0735 [5R55S].)
(See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0744 [5R55S].)
(See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0744 [5R55S].)
(See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0744 [5R55S].)
(See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0744 [5R55S].)
(See 05-02-20 DTC P0740, P0741 , P0742, P0743,
P0744 [5R55S].)
(See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0963 [5R55S].)
(See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0963 [5R55S].)
(See 05-02-24 DTC P0750, P0753 [5R55S].)
(See 05-02-24 DTC P0750, P0753 [5R55S].)
(See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
(See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
(See 05-02-26 DTC P0755, P0757, P0758 [5R55S].)
Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
(See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
Shift solenoid C circuit malfunction (open or short circuit) (See 05-02-28 DTC P0760, P0762, P0763 [5R55S].)
P0768
Shift solenoid 0 circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
Shift solenoid 0 circuit malfunction (open or short circuit) (See 05-02-30 DTC P0765, P0768 [5R55S].)
P0775
Pressure control solenoid B malfunction (low pressure)
P0778
P0791
Pressure control solenoid B circuit malfunction (nonoperation)

(See 05-02-32 DlC P0775 , P0778, P0964, P0966,

P0967 [5R55S].)
(See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0967 [5R55S].)
(See 05-02-34 DTC P0791 , P0794 [5R55S].)
05-02-5

DTC No.
P0794
P0795
P0798
P0960
P0962
P0963
P0964
P0966
P0967
P0968
P0970
P0971
P1635
P1700
P1702
P1704
P1705
P1711
P1780
P1783
U0100
U0294
Page
(See 05-02-34 DTC P0791 , P0794 [5R55S].)
(See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0971 [5R55S].)
(See 05-02-36 DTC P0795, P0798, P0968, P0970,
Pressure control solenoid C circuit malfunction (nonP0971 [5R55S].)
operation)
Pressure control solenoid A circuit malfunction (open
(See 05-02-22 DTC P0745, P0748, P0960, P0962,
circuit)
P0963 [5R55S].)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
P0963 [5R55S].)
ground)
Pressure control solenoid A circuit malfunction (short to (See 05-02-22 DTC P0745, P0748, P0960, P0962,
power supply)
P0963 [5R55S].)
(See 05-02-32 DTC P0775, P0778, P0964, P0966,
Pressure control solenoid B circuit malfunction (open
circuit)
P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
ground)
P0967 [5R55S].)
Pressure control solenoid B circuit malfunction (short to (See 05-02-32 DTC P0775, P0778, P0964, P0966,
P0967 [5R55S].)
power supply)
(See 05-02-36 DTC P0795, P0798, P0968, P0970,
Pressure control solenoid C circuit malfunction (open
P0971 [5R55S].)
circuit)
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
ground)
P0971 [5R55S].)
Pressure control solenoid C circuit malfunction (short to (See 05-02-36 DTC P0795, P0798, P0968, P0970,
P0971 [5R55S].)
power supply)
(See 05-02-38 DTC P1635 [5R55S].)
Tire/axle ratio out of acceptable range
(See 05-02-38 DTC P1700 [5R55S].)
(See 05-02-9 DTC P0705, P0708, P1702, P1704,
P1705 [5R55S].)
(See 05-02-9 DTC P0705, P0708, P1702, P1704,
Digital transmission range (TR) sensor circuit not
indicating P or N position during on-board diagnostic
P1705 [5R55S].)
(See 05-02-9 DTC P0705, P0708, P1702, P1704,
Digital transmission range (TR) sensor circuit not
P1705 [5R55S].)
indicating P or N position during on-board diagnostic
ATF temperature out of on-board diagnostic range
(See 05-02-39 DTC P1711 [5R55S].)
OlD OFF switch circuit malfunction (open or short circuit) (See 05-02-40DTC P1780 [5R55S].)
(See 05-02-42 DTC P1783 [5R55S].)
ATF overheating
(See 05-02-43 DTC U0100, U0297 [5R55S].)
(See 05-02-43 DTC U0100, U0297 [5R55S].)
Condition
i.
05-02-6

DTC P0657, P0658 [5R55S]
id0502c1814400
DTC P06S7 Solenoid valve power supply circuit open

DTC P06S8 Solenoid valve power supply circuit voltage low
DETECTION P0657: Open circuit in circuit between solenoid valve and TCM
CONDITION P0658: Short circuit in circuit between solenoid valve and TCM
Short to ground in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal
CK (wiring harness-side).
POSSIBLE
Open circuit in wiring harness between AT connector terminal I (wiring harness-side) and TCM terminal CK
CAUSE
(wiring harness-side).
Damaged connector between shift AT connector and TCM.
TCM malfunction.
@cv
i~
'--
AT CONNECTOR WIRING
AT
TCM
SOLENOID VALVE
TCM WIRING HARNESS-SIDE

CONNECTOR
A E I M
B F J N
C G K 0
0 H L P
U Y AC
R V Z AD
S W AA AE
T X AB AF
AG
AH
AI
AJ
AK AO AS AW
AL AP AT AX
AM AO AU AY
AN AR AV AZ
BA
BB
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM BO BU BY CC
BN BR BV BZ CD
BO BS BW CA CE
BP BT BX CB CF
CG
CH
CI
CJ
-,...-
CK CN
-rCLpO
-rPMCP
'--'--
05-02-7

INSPECTION
STEP
1
RECORDED
recorded?
2

AVAILABILITY
ACTION
Yes
No
Yes


INSPECT AT CONNECTOR FOR POOR
CONNECTION
No Repair or replace the connector and/or terminals, then go
Turn the engine switch to the LOCK position.
to Step 8.
Inspect AT connector connection.
Disconnect the AT connector.
Is the connection normal?
INSPECT POWER SUPPLY CIRCUIT
Yes
No
(engine off).
Inspect voltage at AT connector terminal H
Is
the voltage approx. 12 V?
INSPECT TCM CONNECTOR FOR POOR
Yes
CONNECTION
No
Disconnect the TCM connector.
Go to Step 8.

Repair or replace connector and/or terminals, then go to
Step 8.
INSPECT SOLENOID POWER SUPPLY CIRCUIT

FOR OPEN CIRCUIT
Inspect for continuity between the TCM
terminal CK (wiring harness-side) and the AT
connector terminal I (wiring harness-side).
Is there continuity between terminals?
Yes
No

INSPECT SOLENOID POWER SUPPLY CIRCUIT

FOR SHORT TO GROUND
Inspect continuity between AT connector
terminal H (wiring harness-side) and body
ground.
Yes
No
Repair or replace the wiring harness, then go to the Step 8.

Yes
Replace the TCM, then go to the next step.

(See 05-13-44 TCM REMOVAUINSTALLATION [5R55S].)
No
Yes

(See 05-02-5 DTC TABLE [5R55S].)
No

OR P0658 COMPLETED
Make sure to reconnect all the disconnected
connectors.
Clear the DTC from memory using the IDS/
PDS.
(See 05-02-4 AFTER REPAIR PROCEDURE
[5R55S].)
VERIFY DTCS
Are DTCs except for P0657 and P0658 output?
05-02-8

DTC P0705, P0708, P1702, P1704, P1705 [5R55S]
DTC P070S
DTC P070S
DTC P1702
DTC P1704
DTC P170S
Digital transmission range (TR) sensor circuit malfunction (invalid bit pattern)
Digital transmission range (TR) sensor circuit malfunction (TR3A circuit open)
Digital transmission range (TR) sensor circuit not indicating P or N position during on-board
diagnostic
diagnostic
P0705: Open circuit or short to ground in wiring harness between digital TR sensor terminal and TCM
terminal or in digital TR sensor internal circuit (invalid bit pattern)
P070S: Open circuit in wiring harness between digital TR sensor and TCM terminal or in digital TR sensor
internal circuit (TR3 circuit)
P1702: TCM cannot detect a signal from digital TR sensor
P1704: PID TR_D not indicating P or N position, digital TR sensor or selector cable misalignment
P1705: On-board diagnostic not performed in P or N position

Digital TR sensor or selector cable misadjustment
Short to ground in wiring harness between digital TR sensor terminal G and TCM terminal AX
Short to ground in wiring harness between digital TR sensor terminal E and TCM terminal BY
Short to ground in wiring harness between digital TR sensor terminal C and TCM terminal BU
Short to ground in wiring harness between digital TR sensor terminal A and TCM terminal CA
Short to ground in wiring harness between digital TR sensor terminal I and TCM terminal BH
Open circuit in wiring harness between digital TR sensor terminal G and TCM terminal AX
Open circuit in wiring harness between digital TR sensor terminal E and TCM terminal BY
Open circuit in wiring harness between digital TR sensor terminal C and TCM terminal BU
Open circuit in wiring harness between digital TR sensor terminal A and TCM terminal CA
Open circuit in wiring harness between digital TR sensor terminal I and TCM terminal BH
Short to power supply in wiring harness between digital TR sensor terminal G and TCM terminal AX
Short to power supply in wiring harness between digital TR sensor terminal E and TCM terminal BY
Short to power supply in wiring harness between digital TR sensor terminal C and TCM terminal BU
Short to power supply in wiring harness between digital TR sensor terminal A and TCM terminal CA
Short to power supply in wiring harness between digital TR sensor terminal I and TCM terminal BH
Damaged connectors between digital TR sensor and TCM
TCM malfunction
DETECTION
CONDITION
POSSIBLE
CAUSE
idOS02c1814S00
05-02-9

DTe P0705
DTe P0708
DTe P1702
DTe P1704
DTe P1705
Digital transmission
diagnostic
range
range
range
range
(TR)
(TR)
(TR)
(TR)
sensor
sensor
sensor
sensor
circuit malfunction (invalid bit pattern)

circuit malfunction (TR3A circuit open)
circuit intermittent
circuit not indicating P or N position during on-board
diagnostic
DIGITAL TR SENSOR
DIGITAL TR SENSOR WIRING

@ (J)
TCM
@!@
@
TR3A
@!@
@!@
AT CONNECTOR WIRING
@!@
@!@
~
-
05-02--10

CONNECTOR
A
M Q
Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG
Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH
W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
.....-CK CN
r-- CL CO
r-- -
X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ
'---
CM CP

INSPECTION
STEP
1
RECORDED
recorded?
Yes
No

AVAILABILITY
Yes
VERIFY DIGITAL TR SENSOR ALIGNMENT

Select the N position.
Disconnect the selector cable from the manual
lever.
Verify that the SST (307-351 (49 UN30 7351))
fits in the appropriate slots of digital TR sensor.
Is the digital TR sensor correctly adjusted?
VERIFY SELECTOR CABLE ADJUSTMENT
Verify that the selector cable is correctly
adjusted.
(See 05-14-2 SELECTOR CABLE
ADJUSTMENT.)
Is the selector cable is correctly adjusted?
INSPECT ELECTRICAL SYSTEM OPERATION
Connect the IDS/PDS to DLC-2.
Access TR_D and TR_V PIDs.
Move the selector lever into each range and
position (P, R, N, D, 3, 2, 1).
Observe the PIDs, TR D and TR V (vehicledependent) while wiggling wiring harness,
tapping on sensor or driving the vehicle.
- Use PIDs TR_D for DTCs P0705, P1704
and P1705.
- Use PIDs TR_V for DTC P0708.
Are the PIDs within the specification?
INSPECT DIGITAL TR SENSOR CONNECTOR
FOR POOR CONNECTION
Disconnect the digital TR sensor connector.
INSPECT DIGITAL TR SENSOR
Inspect the digital TR sensor.
(See 05-13-20 DIGITAL TRANSMISSION
RANGE (TR) SENSOR INSPECTION
[5R55S].)
Is digital TR sensor normal?
Yes
No
No
Yes
No
ACTION

Connect the selector cable to the manual lever, then go to
the next step.
Adjust the digital TR sensor, then go to Step 12.
(See 05-13-24 DIGITAL TRANSMISSION RANGE (TR)
SENSOR ADJUSTMENT [5R55S].)

Adjust the selector cable, then go to Step 12.
(See 05-14-2 SELECTOR CABLE ADJUSTMENT.)
Yes
Go to Step 12.
No
Yes
No
Yes
No

Replace the digital TR sensor, then go to Step 12.
SENSOR REMOVAUINSTALLATION [5R55S].)
Repair or replace connector and/or terminal, then go to

Step 12.

CONNECTION
to Step 12.
INSPECT DIGITAL TR SENSOR CIRCUIT FOR
Yes Repair or replace the wiring harness, then go to Step 12.
SHORT TO GROUND
Inspect continuity between digital TR sensor
terminals (wiring harness-side) and body
ground.
- G and body ground
- E and body ground
- C and body ground
- A and body ground
- I and body ground
05-02-11

INSPECTION
STEP
10
(engine off).
Inspect the voltage at digital TR sensor
terminals G, E, C, A and I (wiring harnessside).
Is the voltage 0 V?
11
OPEN CIRCUIT
Inspect the following digital TR sensor
terminals (wiring harness-side) and TCM
-G and AX
-E and BY
-C and BU
-Aand CA
- I and BH
VERIFY TROUBLESHOOTING OF DTC P0705,
12
P070S, P1702, P1704 OR P1705 COMPLETED
connectors.
Clear the DTC from the memory using the IDS/
PDS.
[5R55SJ.)
VERIFY DTCS
13
Are DTCs except for P0705, P0708, P1702,
P1704 and P1705 output?
05-02-12
ACTION
Yes
No

Yes
No

step.
Yes

(See 05-13-44 TCM REMOVAUI NSTALLATION [5R55S].)
No
Yes
No


DTC P0711, P0712, P0713 [5R55S]
DTC P0711
id0502c1814600
Transmission fluid temperature (TFT) sensor malfunction (ATF temperature no change)
DTC P0712
Transmission fluid temperature (TFT) sensor circuit malfunction (short to ground)
DTC P0713
Transmission fluid temperature (TFT) sensor circuit malfunction (open circuit)
DETECTION
CONDITION
POSSIBLE
CAUSE
P0711: ATF temperature signal continually reading cold or hot

P0712: TeM detects that ATF signal output from ATF sensor is 1570 C {315 F} or more
P0713: TeM detects ATF signal from ATF sensor is -40 C {-40 F} or less
TFT sensor malfunction

Short to ground in wiring harness between AT connector terminal K and TeM terminal AY
Short to ground in wiring harness between AT connector terminal Land TeM terminal BH
Open circuit supply in wiring harness between AT connector terminal K and TeM terminal AY
Open circuit supply in wiring harness between AT connector terminal Land TeM terminal BH
Damaged connectors between AT connector and TeM
TeM malfunction
AT CONNECTOR WIRING
TCM
AT
TFT SENSOR
@cv
' - - - - - - { L 17T------(E{):IHl

CONNECTOR
r--
I~
A
B
C
D
E
F
G
H
I
J
K
L
M Q U
N R V
0 S W
P T X
Y
Z
AA
AB
AC AG AK
AD AH AL
AE AI AM
AF AJ AN
AO
AP
AQ
AR
AS ~W
AT AX
AU AY
AV AZ
BA
BB
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM BQ BU BY
BN BR BV BZ
BO BS BW CA
BP BT BX CB
CC CG
CD CH
CE CI
CF CJ
-r--
CK CN
- rCL CO
- rCM CP
'--'--
'--
05-02-13

INSPECTION
STEP
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED
recorded?
2

AVAILABILITY
Yes
No
Yes
ACTION

CONNECTION
to Step 8.
Inspect the AT connector connection.
INSPECT TFT SENSOR
No Replace the TFT sensor, then go to Step 8.
Inspect the TFT sensor.
(See 05-13-26 TRANSMISSION FLUID
TEMPERATURE (TFT) SENSOR
INSPECTION [5R55S])
Is the digital TR sensor normal?
CONNECTION
to Step 8.
INSPECT TFT SENSOR CIRCUIT FOR SHORT
Yes Repair or replace the wiring harness, then go to Step 8.
TO GROUND
Inspect for continuity between the AT terminals
(wiring harness-side) and body ground.
- K and body ground
- L and body ground
INSPECT TFT SENSOR CIRCUIT FOR OPEN
CIRCUIT
No Repair or replace the wiring harness, then go to Step 8.
Inspect the following AT terminals (wiring
harness-side) and TCM terminals (wiring
harness-side):
-KandAY
-Land BH
Yes Replace the TCM, then go to the next step.
P0712 OR P0713 COMPLETED
Make
sure
to
reconnect
all
the
disconnected
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Are DTCs except for P0711, P0712 and P0713
output?
05-02-14

DTC P0715, P0717, P0718 [5R55S]
DTC P0715
DTC P0717
DTC P0718
DETECTION
CONDITION
POSSIBLE
CAUSE
id0502c1806200

Turbine shaft speed (TSS) sensor signal is not input.
P0715: TCM detects insufficient TSS sensor signal while driving
P0717: TCM detects that TSS sensor is not input while driving
P0718: TCM detects intermittent TSS sensor signal input while driving
TSS sensor malfunction.
Short to ground in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal
AP (wiring harness-side).
Open circuit in wiring harness between TSS sensor terminal A (wiring harness-side) and TCM terminal AP
Open circuit in wiring harness between TSS sensor terminal B (wiring harness-side) and TCM terminal AH
Damaged connectors between TSS sensor and TeM.
TCM malfunction.
TCM
TSS SENSOR WIRING
TSS SENSOR
@@

CONNECTOR
r---
A E I M Q
B F J N R
C G K 0 S
D H L P T
U
V
W
X
Y
Z
AA
AB
AC AG AK AO AS AW
AD AH AL AP AT AX
AE AI AM AQ AU AY
AF AJ AN AR AV AZ
BA BE
BB BF
BC BG
BD BH
BI BM BQ BU BY CC CG
BJ BN BR BV BZ CD CH
BK BO BS BW CA CE CI
BL BP BT BX CB CF CJ
-c--
CK CN
r--r-CL CO
r--r-CM CP
'--'--
05-02-15

INSPECTION
STEP
1
RECORDED
recorded?
2

AVAILABILITY
ACTION
Yes
No
Yes
No
INSPECT TSS SENSOR CONNECTOR FOR
Yes
POOR CONNECTION
No
Disconnect the TSS sensor connector.
INSPECT TSS SENSOR CIRCUIT FOR SHORT

TO GROUND
Inspect for continuity between TSS sensor
connector A (wiring harness-side) and body
ground.
Yes
No


Step 8.


CONNECTION
to Step 8.
INSPECT TSS SENSOR CIRCUIT FOR OPEN
CIRCUIT
Inspect the following TSS sensor terminals
(wiring harness-side) and TCM terminals
(wiring harness-side):
-AandAP
-B and AH
INSPECT TSS SENSOR
No Replace the TSS sensor, then go to the next step.
Inspect the TSS sensor.
(See 05-13-28 TURBINE SHAFT SPEED
(See 05-13-29 TURBINE SHAFT SPEED (TSS) SENSOR
(TSS) SENSOR INSPECTION [5R55S])
Is TSS sensor normal?
connectors.
PDS.
[5R55S].)
Are any DTCs p~esent?
VERIFY OTCS
output?
05-02-16

DTC P0720, P0721 , P0722 [5R55S]
id0502c1806300
DTC P0720
DTC P0721
DTC P0722

Output shaft speed (OSS) sensor signal is not input.
P0720: TCM detects insufficient ass sensor signal while driving
DETECTION
P0721: TCM detects intermittent ass sensor signal input while driving
CONDITION
P0722: TCM detects that ass sensor is not input while driving
POSSIBLE
CAUSE
ass sensor malfunction.

Short to ground in wiring harness between ass sensor terminal A (wiring harness-side) and TCM terminal
AG (wiring harness-side).
apen circuit in wiring harness between ass sensor terminal A (wiring harness-side) and TCM terminal AG
apen circuit in wiring harness between ass sensor terminal B (wiring harness-side) and TCM terminal AD
Damaged connectors between ass sensor and TCM.
TCM malfunction.
TCM
OSS SENSOR WIRING
OSS SENSOR
@@
L -_ _ _ _ _ _ _ _
I~~I
~@~6______~D

CONNECTOR
r--
It
A E I M 0
B F J N R
C G K 0 S
0 H L P T
U
V
W
X
Y
Z
AA
AB
AC AG AK AO AS AW BA BE
AD AH AL AP AT AX BB BF
AE AI AM AO AU AY BC BG
AF AJ AN AR AV AZ BD BH
BI BM BO BU BY CC CG , . . - CK CN
BJ BN BR BV BZ CD CH I-CL CO
BK BO BS BW CA CE CI
5i CP
BL BP BT BX CB CF CJ ' - - ' - -
'--
05-02-17

INSPECTION
STEP
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED
recorded?
2
AVAILABILITY
3
INSPECT OSS SENSOR CONNECTOR FOR

POOR CONNECTION
Disconnect the ass sensor connector.
INSPECT OSS SENSOR CIRCUIT FOR SHORT
TO GROUND
Inspect for continuity between ass sensor
ground.
CONNECTION
INSPECT OSS SENSOR CIRCUIT FOR OPEN
CIRCUIT
Inspect the following ass sensor terminals
-AandAG
-B and AD
INSPECT OSS SENSOR
Inspect the ass sensor.
(See 05-13-32 OUTPUT SHAFT SPEED
(aSS) SENSOR INSPECTION [5R55S])
Is ass sensor normal?
connectors.
PDS.
[5R55S].)
VERIFY DTCS
output?
05-02-18
Yes
No
Yes
No
Yes
No
ACTION
Step 9.
Yes
No

Yes
No

Repair or replace the connector and/or terminals, then go
to Step 9.
Yes
No

Yes
No

Replace the ass sensor, then go to the next step.
(See 05-13-33 OUTPUT SHAFT SPEED (aSS) SENSOR
Yes

No
Yes
No


DTe P0731 , P0732, P0733, P0734, P0735 [5R55S]
DTC
DTC
DTC
DTC
DTC
id0502c1814700
P0731
P0732
P0733
P0734
P0735
Gear 1 incorrect
Gear 2 incorrect
Gear 3 incorrect
Gear 4 incorrect
Gear 5 incorrect
P0731: Does not shift to 1st gear while driving
P0732: Does not shift to 2nd gear while driving
DETECTION
P0733: Does not shift to 3rd gear while driving
CONDITION
P0734: Does not shift to 4th gear while driving
P0735: Does not shift to 5th gear while driving
Shift solenoid A malfunction
Shift solenoid B malfunction
POSSIBLE
Shift solenoid C malfunction
CAUSE
Shift solenoid D malfunction
Transmission internal malfunction
TCM malfunction
STEP
INSPECTION
AVAILABILITY
VERIFY DTCS
Turn the engine switch to the LOCK position,
then to the ON position.
Verify the DTCs in the TCM memory.
Are DTCs except for P0731 , P0732, P0733,
SHIFT SOLENOID OPERATION INSPECTION
Drive in D range.
Connect the IDS/PDS to the DLC-2 and select
the following PIDs.
-SSA
-SSB
-SSC
-SSD
Using the IDS/PDS, verify the operation status
of shift solenoid A, B, C and D while driving.
- 1GR: SSA on, SSB off, SSC off, SSD on
- 2GR: SSA on, SSB off, SSC on, SSD on
- 3GR: SSA on, SSB on, SSC off, SSD on
- 4GR: SSA off, SSB off, SSC off, SSD on
- 5GR: SSA off, SSB off, SSC on, SSD on
Is the shift solenoid operation normal?
INSPECT ROAD TEST
Road-test the vehicle to verify the respective
shift points.
(See 05-13-8 ROAD TEST [5R55S].)
Are the shift points normal?
VERIFY TROUBLESHOOTING OF DTC P0731 ,
P0732, P0733, P0734 OR P0735 COMPLETED
connectors.
Clear the DTC using the IDS/PDS.
Start the engine.
[5R55S].)
VERIFY DTCS
Are DTCs except for P0731 , P0732, P0733,
Yes
No
Yes
No
ACTION

Yes
No

Replace the solenoid body component, then go to Step 5.
(See 05-13-35 SOLENOID BODY REMOVAU
Yes
No

Inspect the symptom troubleshooting, then go to the next
step.
(See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
TABLE [5R55S].)
Yes

No
Yes

No
05-02-19

DTC P0740, P0741 , P0742, P0743, P0744 [SRSSS]
DTC P0740
DTC P0741
DTC P0742
id0502c1814800
Torque converter clutch (TCC) control solenoid circuit malfunction (open circuit)
Torque converter clutch (TCC) control solenoid circuit malfunction (stuck off)
Torque converter clutch (TCC) control solenoid circuit malfunction (stuck on)
Torque converter clutch (TCC) control solenoid circuit malfunction (open or short circuit)
Torque converter clutch (TCC) control solenoid circuit malfunction (short to power)
PO?40: Open circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid internal
circuit.
PO?41: Torque converter clutch slipping indicating a mechanical or hydraulic concern.
PO?42: Short to ground in circuit between TCC control solenoid and TCM, or in TCC control solenoid
DETECTION
internal circuit.
CONDITION
PO?43: Open or short circuit in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
PO?44: Short to power supply in circuit between TCC control solenoid and TCM, or in TCC control solenoid
internal circuit.
DTC P0743
DTC P0744
TCC control solenoid malfunction.

Short to ground in wiring harness between AT connector terminal H (wiring harness-side) and TCM
terminal A (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal H (wiring harness-side) and TCM
terminal A (wiring harness-side).
Open circuit in wiring harness between AT connector terminal H (wiring harness-side) and TCM terminal A
Damaged connector between AT connector and TCM.
TCM malfunction.
POSSIBLE
CAUSE
TCM
C!S"
CV@
AT CONNECTOR WIRING
-=
AT
TCC CONTROL
SOLENOID
~IGIII~
"'-~
A""
~"
CV@
~O~)ruJ
~IHIJI~
//I"H'
"'r-'
I~~I

CONNECTOR
A E I M Q U Y AC AG AK AO
B F J N R V Z AD AH AL AP
C G K 0 S W AA AE AI AM AQ
D H L P T X AB AF AJ AN AR
AS W BA
AT AX BB
AU AY BC
AV AZ BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM BQ BU BY CC
BN BR BV BZ CD
BO BS BW CA CE
BP BT BX CB CF
CG ; - - ; - CK CN
CH I-I-CL CO
CI I-- I-CM CP
CJ ' - - ' - -
I~~I
STEP
1
INSPECTION
RECORDED
recorded?
05-02-20
Yes
No
ACTION

AVAILABILITY
10
11

CONNECTION
(engine off).
Inspect voltage at AT connector terminal I
INSPECT RESISTANCE
Inspect resistance between AT terminal I and H
(transmission case side).
Is resistance within 9-16 ohms?
(See 05-13-34 SOLENOID VALVE
INSPECTION [5R55S].)
CONNECTION
INSPECT TCC CONTROL SOLENOID CIRCUIT
FOR OPEN CIRCUIT
terminal (wiring harness-side) and the AT
connector terminal (wiring harness-side).
-CKand I
-Aand H
FOR SHORT TO GROUND
Inspect for continuity between AT connector
terminal (wiring harness-side) and body
ground.
- I and body ground
- H and body ground
(engine off).
Inspect voltage at AT connector terminal H
Is the voltage 0 V?
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Are DTCs except for P0740, P0741 , P0742,
Yes

If the vehicle is not repaired, go to the next

to Step 10.
No
Yes
Repair or replace the wiring harness, then go to the Step

10.
No

step.
Yes
No
Yes


05-02-21

DTCP0745,P0748,P0960,P0962,P0963[5R55S]
DTC
DTC
DTC
DTC
DTC
P0745
P0748
P0960
P0962
P0963
DETECTION
CONDITION
POSSIBLE
CAUSE
id0502c1815300

Pressure control solenoid A circuit malfunction (not operation)
Pressure control solenoid A circuit malfunction (open circuit)
Pressure control solenoid A circuit malfunction (short to ground)
Pressure control solenoid A circuit malfunction (short to power supply)
P0745: Incorrect shift pattern indicating mechanical or hydraulic failure in the transmission.
P0748: Possible slip in gear and/or 3GR ratio.
P0960: Open circuit in circuit between pressure control solenoid 0 and TCM, or in pressure control
solenoid A internal circuit.
P0962: Short to ground in circuit between pressure control solenoid A and TCM, or in pressure control
solenoid A internal circuit.
P0963: Short to power supply in circuit between pressure control solenoid A and TCM, or in pressure
control solenoid A internal circuit.
Pressure control solenoid A malfunction.
Short to ground in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM
terminal I (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM
terminal I (wiring harness-side).
Open circuit in wiring harness between AT connector terminal 0 (wiring harness-side) and TCM terminal I
TCM malfunction.
TCM
~
c;
cv
AT CONNECTOR WIRING
AT
PRESSURE CONTROL
SOLENOID A
"'\,,~
cv
I""'"
'/"
L~
frF'IBIEIGIIIKIMI~'
rr nltJ I
I[~ 0
~IHI*IOI<
P'
//I'ey
""r:'
I~~I

CONNECTOR
I~
M Q
Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG , - - - CK CN
Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH r-CL CO
W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI r-CM CP
X AB AF AJ AN AR AV AZ BD BH BL BP BT BX CB CF CJ ' - - U
'--
I~~I
STEP
INSPECTION
RECORDED
recorded?
05-02-22
ACTION
Yes
No


INSPECTION
STEP
VERIFY
RELATED
SERVICE
INFORMATION
2
AVAILABILITY
3
10
11

CONNECTION
(engine off).
INSPECT RESISTANCE
Inspect resistance between AT terminal I and 0
Is resistance within 3.3-7.5 ohms?
CONNECTION
INSPECT PRESSURE CONTROL SOLENOID A
-CKand I
- I andO
ground.
- I and body ground
- 0 and body ground
(engine off).
Inspect voltage at AT connector terminal 0
Is the voltage 0 V?
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Yes
No
Yes
No
ACTION
to Step 10.
Yes
No

Go to Step 6.
Yes
No

Replace the pressure control solenoid A, then go to Step
10.
Yes
No

Step 10.
Yes
No

Yes

10.
No
Yes
No

step.
Yes

(See 05-13-44TCM REMOVAUINSTALLATION [5R55S].)
No
Yes
No

05-02-23

DTC P0750, P0753 [5R55S]
id0502c1814900

P0750: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
circuit.
DETECTION
CONDITION P0753: Open or short circuit in circuit between shift solenoid A and TCM, or in shift solenoid A internal
circuit.
Shift
solenoid A malfunction.
Short to ground in wiring harness between AT connector terminal D (wiring harness-side) and TCM
terminal B (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal D (wiring harness-side) and TCM
POSSIBLE
terminal B (wiring harness-side).
CAUSE
Open circuit in wiring harness between AT connector terminal D (wiring harness-side) and TCM terminal B
TCM malfunction.
DTC P0750
DTC P0753
TCM
C.)';';
CV@
AT CONNECTOR WIRING
AT
SHIFT SOLENOID A
......,1,./
B'"
'/"
~
-
CV@
L~
~ 0 @J~
frrul BI EIGI I IKIMIl!: ~
///'.
...,,0,./
'~IDIFIHIJILlolr.:
I~~I
CONNECTOR
A E I M Q
B F J N R
C G K 0 S
0 H L P T
U
V
W
X
Y AC
Z AD
AA AE
AB AF
AG AK AO
AH AL AP
AI AM AQ
AJ AN AR
AS AW BA
AT AX BB
AU AY BC
AV AZ BD
BE
BF
BG
BH
BI BM BQ BU BY CC CG - BJ BN BR BV BZ CD CH -CK -CN
CL CO
BK BO BS BW CA CE CI - CM CP
BL BP BT BX CB CF CJ ' - - -
I~~I
INSPECTION
STEP
1
RECORDED.
recorded?
2
AVAILABILITY
05-02-24
ACTION
Yes
No

Yes

No

STEP
3
10
11
INSPECTION
ACTION

CONNECTION
to Step 10.
No Go to Step 6.
(engine off).
Inspect the voltage at AT connector terminal I
INSPECT RESISTANCE
No Replace the shift solenoid A, then go to Step 10.
Inspect resistance between AT terminal I and D
CONNECTION
INSPECT SHIFT SOLENOID A CIRCUIT FOR
OPEN CIRCUIT
-CKand I
- Band D
SHORT TO GROUND
ground.
- I and body ground
- D and body ground
(engine off).
Inspect voltage at AT connector terminal D
Is the voltage 0 V?
OR P0753 COMPLETED
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Yes
No
Yes
No
Yes
No

Step 10.


10.
Yes
No

step.
Yes

No
Yes

No
05-02-25

DTe P0755, P0757, P0758 [5R55S]
DTC P0755
id0502c1815000
DTC P0757

DTC P0758
DETECTION
CONDITION
POSSIBLE
CAUSE
P0755: Open or short circuit in circuit between shift solenoid Band TCM, or in shift solenoid B internal
circuit.
P0757: Shift solenoid B mechanically stuck on,
P0758: Open or short circuit in circuit between shift solenoid Band TCM, or in shift solenoid B internal
circuit.
Shift solenoid B malfunction.
Short to ground in wiring harness between AT connector terminal F (wiring harness-side) and TCM
terminal C (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal F (wiring harness-side) and TCM
terminal C (wiring harness-side).
Open circuit in wiring harness between AT connector terminal F (wiring harness-side) and TCM terminal C
TCM malfunction.
TCM
~
c;
CV@
AT CONNECTOR WIRING
AT
SHIFT SOLENOID B
",,1..1
~IBIEIGIIIKIMll!:
r[~ 0 ~ DIJI
CV@
~:
~"
~
-
~IHIJI~
/7
//1'
"",r:."
I~~I

CONNECTOR
A E I M
B F J N
C G K 0
0 H L P
Q
R
S
T
U
V
W
X
Y
Z
AA
AB
AC AG AK AO
AD AH AL AP
AE AI AM AQ
AF AJ AN AR
AS AW
AT AX
AU AY
AV AZ
BA
BB
BC
BD
I~~I
BE
BF
BG
BH
BI
BJ
BK
BL
BM BQ BU BY CC CG
BN BR BV BZ CD CH
BO BS BW CA CE CI
BP BT BX CB CF CJ
r--r--
CK CN
CL CO
r--CM
CP
r- r--
STEP
1
INSPECTION
RECORDED
recorded?
AVAILABILITY
05-02-26
ACTION
Yes
No

Yes

No

STEP
3
10
11
INSPECTION
ACTION
CONNECTION
to Step 10.
(engine off).
INSPECT RESISTANCE
Inspect resistance between AT terminal I and F
Yes
No
Go to Step 6.
Yes
No

Replace the shift solenoid B, then go to Step 10.

CONNECTION
No Repair or replace connector and/or terminals, then go to
Step 10.
INSPECT SHIFT SOLENOID B CIRCUIT FOR
OPEN CIRCUIT
-CKand I
-C and F
Yes Repair or replace the wiring harness, then go to the Step
10.
SHORT TO GROUND
ground.
- I and body ground
- F and body ground
(engine off).
Inspect voltage at AT connector terminal F
Is the voltage 0 V?

connectors.
PDS.
[5R55S].)
Are any DTCs pres ant?
VERIFY DTCS
output?
Yes
No

step.
Yes

No
Yes

No
05-02-27

DTC P0760, P0762, P0763 [SRSSS]
DTC P0760
DTC P0762
DTC P0763
DETECTION
CONDITION
POSSIBLE
CAUSE
id0502c1815100

P0760: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
P0762: Shift solenoid C mechanically stuck on.
P0763: Open or short circuit in circuit between shift solenoid C and TCM, or in shift solenoid C internal
circuit.
Shift solenoid C malfunction.
Short to ground in wiring harness between AT connector terminal B (wiring harness-side) and TCM
terminal F (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal B (wiring harness-side) and TCM
terminal F (wiring harness-side).
Open circuit in wiring harness between AT connector terminal B (wiring harness-side) and TCM terminal F
TCM malfunction.
TCM
CV@
C~
AT CONNECTOR WIRING
AT
SHIFT SOLENOID C
L~
",\..1..1
=-.:
CV@
F..IN
f~IBIEIGIIIKIMI\!:~
//("B
,,\.!
~ 0 ~ ~dbl
~IDIFIHIJILlolr.:
I~~I
CONNECTOR
,--
I~
M Q
Y AC AG AK AO AS f,W BA BE BI BM BQ BU BY CC CG
S W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
r--r--
CK CN
r--r-CL CO
r-f-CM CP
'--'--
'---
L~~I
INSPECTION
STEP
1
RECORDED
recorded?
2
AVAILABILITY
05-02-28
ACTION
Yes
No

Yes
Perform repair or diagnosis according to the avail8.ble

No

STEP
3
10
11
INSPECTION
ACTION

CONNECTION
to Step 10.
No Go to Step 6.
(engine off).
INSPECT RESISTANCE
No Replace the shift solenoid C, then go to Step 10.
Inspect the resistance between AT terminal I
and B (transmission case side).
CONNECTION
Step 10.
INSPECT SHIFT SOLENOID C CIRCUIT FOR
OPEN CIRCUIT
-CKand I
- F and B
10.
SHORT TO GROUND
Inspect
for
continuity
between
AT
connector
Go
to the next step.
No

ground.
- I and body ground
- B and body ground
No Repair or replace the wiring harness, then go to the next
step.
(engine off).
Inspect the voltage at AT connector terminal B
Is the voltage 0 V?
Make
sure
to
reconnect
all
the
disconnected
No
Go
to the next step.
connectors.
PDS.
[5R55S].)
VERIFY DTCS
output?
05-02-29

DTe P076S, P0768 [SRSSS]
DTC P0765
DTC P0768
id0502c1815200
Shift solenoid 0 circuit malfunction (open or short circuit)

Shift solenoid 0 circuit malfunction (open or short circuit)
DETECTION
CONDITION
P0765: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
circuit.
P0768: Open or short circuit in circuit between shift solenoid D and TCM, or in shift solenoid D internal
circuit.
Shift solenoid D malfunction.

Short to ground in wiring harness between AT connector terminal E (wiring harness-side) and TCM
terminal D (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal E (wiring harness-side) and TCM
terminal D (wiring harness-side).
Open circuit in wiring harness between AT connector terminal E (wiring harness-side) and TCM terminal D
TCM malfunction.
POSSIBLE
CAUSE
TCM
C~
cv
AT CONNECTOR WIRING
AT
SHIFT SOLENOID 0
",1./
~::!JIBIEIGIIIKIMI\!;)'
~ 0 ~ ~[1tJ1
6''-'?'"
~
-
cv
~ =:-.10 I F I HI J I LIolr. Ih
,/
//t'E''"
":/
I~~I

CONNECTOR
A
B
C
0
E
F
G
H
I
J
K
L
M Q U
N R V
0 S W
P T X
Y
Z
AA
AB
AC AG AK
AD AH AL
AE AI AM
AF AJ AN
AO AS AW BA
AP AT AX BB
AQ AU AY BC
AR AV AZ BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM BQ BU BY CC CG - BN BR BV BZ CD CH -CK -CN
CL CO
BO BS BW CA CE CI - CM CP
BP BT BX CB CF CJ ' - - -
I~~I
INSPECTION
STEP
1
ACTION

RECORDED
recorded?
Yes
No


AVAILABILITY
Yes

05-02-30
No

STEP
3
10
11
INSPECTION
ACTION

Yes
CONNECTION
to Step 10.
,
No Go to Step 6.
(engine off).
INSPECT RESISTANCE
No Replace the shift solenoid D, then go to Step 10.
Inspect resistance between AT terminal I and E
CONNECTION
Step 10.
INSPECT SHIFT SOLENOID D CIRCUIT FOR
OPEN CIRCUIT
-CKand I
-D and E
10.
SHORT TO GROUND
Inspect
for
continuity
between
AT
connector
No
Go
to the next step.

ground.
- I and body ground
- E and body ground
'No Repair or replace the wiring harness, then go to the next
step.
(engine off).
Inspect the voltage at AT connector terminal E
Is the voltage 0 V?
OR P0768 COMPLETED
Make
sure
to
reconnect
all
the
disconnected
Go
to the next step.
No
connectors.
PDS.
[5R55S].)
VERIFY DTCS
05-02-31

DTCP0775,P0778,P0964,P0966,P0967[5R55S]
DTC
DTC
DTC
DTC
DTC
P077S
P0778
P0964
P0966
P0967
DETECTION
CONDITION
POSSIBLE
CAUSE
Pressure
Pressure
Pressure
Pressure
control
control
control
control
solenoid
solenoid
solenoid
solenoid
B
B
B
B
id0502c1815400
malfunction (low pressure)

circuit malfunction (not operation)
circuit malfunction (open circuit)
circuit malfunction (short to ground)
Pressure control solenoid B circuit malfunction (short to power supply)

P0778: Incorrect gear ratio in 2GR and 5GR.
P0964: Open circuit in circuit between pressure control solenoid Band TCM, or in pressure control
solenoid B internal circuit.
P0966: Short to ground in circuit between pressure control solenoid Band TCM, or in pressure control
solenoid B internal circuit.
P0967: Short to power supply in circuit between pressure control solenoid Band TCM, or in pressure
control solenoid B internal circuit.
Pressure control solenoid B malfunction.
Short to ground in wiring harness between AT connector terminal M (wiring harness-side) and TCM
terminal J (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal M (wiring harness-side) and TCM
terminal J (wiring harness-side).
Open circuit in wiring harness between AT connector terminal M (wiring harness-side) and TCM terminal J
TCM malfunction.
TCM
CV@
c~
AT CONNECTOR WIRING
AT
PRESSURE CONTROL
SOLENOID B
""~
frrIBIEIGIIIKIMll!:
\,..,
CV@
'!,.IN
//I'M'
"\! 'Y
~OcrJ P" []]I
,7/
:::-IDIFIHIJILlolr.
I~~I

CONNECTOR
;--
M Q
Y AC AG AK AO AS AW BA BE BI BM BQ BU BY CC CG r - r CK CN
W AA AE AI AM AQ AU AY BC BG BK BO BS BW CA CE CI
O H
r- r-CL CO
SA s;-
'--'--
'---
I~~I
INSPECTION
STEP
1
RECORDED
recorded?
05-02-32
Yes
No
ACTION

INSPECTION
STEP
2
AVAILABILITY
3
10
11

CONNECTION
(engine off).
INSPECT RESISTANCE
Inspect resistance between AT terminal I and
M (transmission case side).
CONNECTION
INSPECT PRESSURE CONTROL SOLENOID B
-CKand I
- J and M
ground.
- I and body ground
- M and body ground
(engine off).
Inspect the voltage at AT connector terminal M
Is the voltage 0 V?
VERIFY TROUBLESHOOTING OF DTC P077S,
P077S, P0964, P0966 OR P0967 COMPLETED
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Are DTCs except for P0775, P077a, P0964,
Yes
No
Yes
No
ACTION
to Step 10.
Yes
No

Go to Step 6.
Yes
No

Replace the pressure control solenoid B, then go to Step
10.
Yes
No

Step 10.
Yes
No

Yes

10.
No
Yes
No

step.
Yes

No
Yes
No

05-02-33

DTC P0791 , P0794 [5R55S]
DTC P0791
DTC P0794
DETECTION
CONDITION
POSSIBLE
CAUSE
id0502c1814100

P0791: TCM detects insufficient ISS sensor signal while driving
P0794: TCM detects intermittent ISS sensor signal input while driving
ISS sensor malfunction.
Short to ground in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal
AS (wiring harness-side).
Open circuit in wiring harness between ISS sensor terminal A (wiring harness-side) and TCM terminal AS
Open circuit in wiring harness between ISS sensor terminal B (wiring harness-side) and TCM terminal AM
Damaged connectors between ISS sensor and TCM.
TCM malfunction.
TCM
ISS SENSOR WIRING
ISS SENSOR
', S
(j)
I~~I
//Q
"'9

CONNECTOR
r--
t
-
A E I M Q
B F J N R
C G K 0 S
0 H L P T
U
V
W
X
Y
Z
AA
AB
AC AG AK AO
AD AH AL AP
AE AI AM AQ
AF AJ AN AR
AS AW BA
AT AX BB
AU AY BC
AV AZ BO
I~~I
05-02-34
BE BI BM BQ BU BY CC
BF BJ BN BR BV BZ CD
BG BK BO BS ~W CA CE
BH BL BP BT BX CB CF
CG r--rCK CN
CH r-rCL CO
CI
--'--CJ '~

STEP
1
INSPECTION
RECORDED
recorded?
AVAILABILITY
Yes
No
INSPECT ISS SENSOR CONNECTOR FOR

POOR CONNECTION
Disconnect the ISS sensor connector.
INSPECT ISS SENSOR CIRCUIT FOR SHORT
TO GROUND
Inspect for continuity between ISS sensor
ground.
CONNECTION
INSPECT ISS SENSOR CIRCUIT FOR OPEN
CIRCUIT
Inspect the following ISS sensor terminals
-AandAS
- B and AM
Yes
Yes
No
No
ACTION

Step 8.
Yes
No
Yes
No

to Step 8.
Yes

No
INSPECT ISS SENSOR

Yes
No
Inspect the ISS sensor.
(See 05-13-30 INTERMEDIATE SHAFT
SPEED (ISS) SENSOR INSPECTION
[5R55S])
Is ISS sensor normal?
Yes
OR P0794 COMPLETED
No
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Yes
No

Replace the ISS sensor, then go to the next step.
(See 05-13-31 INTERMEDIATE SHAFT SPEED (ISS)

05-02-35

DTCP079S,P0798,P0968,P0970,P0971 [SRSSS]
DTC
DTC
DTC
DTC
DTC
P0795
P0798
P0968
P0970
P0971
DETECTION
CONDITION
POSSIBLE
CAUSE
id0502c1815500

Pressure control solenoid C circuit malfunction (not operation)
Pressure control solenoid C circuit malfunction (open circuit)
Pressure control solenoid C circuit malfunction (short to ground)
Pressure control solenoid C circuit malfunction (short to power supply)
P0798: Incorrect gear ratio in 4GR and 5GR.
P0968: Open circuit in circuit between pressure control solenoid C and TCM, or in pressure control
solenoid C internal circuit.
P0970: Short to ground in circuit between pressure control solenoid C and TCM, or in pressure control
solenoid C internal circuit.
P0971: Short to power supply in circuit between pressure control solenoid C and TCM, or in pressure
control solenoid C internal circuit.
Pressure control solenoid C malfunction.
Short to ground in wiring harness between AT connector terminal G (wiring harness-side) and TCM
terminal M (wiring harness-side).
Short to power supply in wiring harness between AT connector terminal G (wiring harness-side) and TCM
terminal M (wiring harness-side).
Open circuit in wiring harness between AT connector terminal G (wiring harness-side) and TCM terminal M
TCM malfunction.
TCM
~
c)>>
CV@
AT CONNECTOR WIRING
AT
PRESSURE CONTROL
SOLENOID C
",\.1..1
lruIBIEIGIIIKIMll!:
M""
;:to
cv
liE
~ 0 ~ D1J1
~ =-101 F I HI J I L I olr.:
F'"
~7
I~~I
//I'G""
",,;/

CONNECTOR
r--
I~
M 0
Y AC AG AK AO AS AW BA BE BI BM BO BU BY CC CG r - r CK CN
Z AD AH AL AP AT AX BB BF BJ BN BR BV BZ CD CH f-- f-CL CO
S W AA AE AI AM AO AU AY BC BG BK BO BS BW CA CE CI
T X AB AF AJ AN AR AV AZ BO BH BL BP BT BX CB CF CJ
SA s;-
'--'--
'--
I~~I
INSPECTION
STEP
1
RECORDED
recorded?
05-02-36
ACTION

STEP
2
10
11
INSPECTION
AVAILABILITY
Yes
No
Yes
CONNECTION
No
Yes
No
(engine off).
Yes
INSPECT RESISTANCE
No
Inspect resistance between AT terminal I and G
Yes
CONNECTION
No
INSPECT PRESSURE CONTROL SOLENOID C
Yes
No
-CKand I
-Mand G
Yes
Inspect for co'ntinuity between AT connector
No
ground.
- I and body ground
- G and body ground
(engine off).
Inspect the voltage at AT connector terminal G
Is the voltage 0 V?
connectors.
PDS.
[5R55S].)
VERIFY DTCS
ACTION

to Step 10.

Go to Step 6.

Replace the pressure control solenoid C, then go to Step
10.

Step 10.


10.
Yes
No
Yes

No
Yes

No

step.
05-02-37

DTC P1635 [5R55S]
id0502c1813800
DTC P1635 Tire/axle ratio out of acceptable range

DETECTION
Tire size or axle ratio message from the PCM corrupt or invalid.
CONDITION
CAN malfunction
POSSIBLE
PCM malfunction
CAUSE
TCM malfunction
INSPECTION
STEP
1

AVAILABILITY
VERIFY STORED DTe IN PCM AND ABS HUlCM

Verify stored DTCs in PCM and ABS HU/CM.
Are DTCs stored?
VERIFY DTCS
Are DTCs except for P1635 output?
ROAD TEST INSPECTION
Road-test the vehicle to verify the respective
shift points.
Are the shift points normal?

COMPLETED
connectors.
Clear the DTC using the IDS/PDS.
Start the engine.
[5R55S].)
VERIFY DTCS
Yes
No
Yes
No
Yes
No
DTC P1700

Inspect the symptom troubleshooting, then go to the next
step.
(See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
TABLE [5R55S].)
Yes
id0502c1805000
Note
Engine rpm limited to 4,000 rpm. Failed a NEUTRAL condition in 1GR, 3GR or 4GR in automatic mode .
Only 2GR and 5GR available.
Other DTCs that may set: P1700: P0745, P0750, P0755
Direct one-way clutch malfunction
Pressure control solenoid A malfunction
Transmission internal malfunction
TCM malfunction
05-02-38


Direct one-way clutch malfunction.
DETECTION
CONDITION
POSSIBLE
CAUSE

Yes
No
No
DTC P1700 [5R55S]
ACTION
(See 04-02-2 ON-BOARD DIAGNOSIS [4W-ABS
(EVEREST)].)

INSPECTION
STEP
1
AVAILABILITY
2
VERIFY DTCS
Are OTCs except for P1700 output?
VERIFY DTC P1700 OUTPUT
Drive in D range.
Verify the OTC in the TCM memory.
Are OTC P1700 output?
COMPLETED
connectors.
Clear the OTC using the IDS/PDS.
Start the engine.
[5R55Sj.)
VERIFY DTCS
Yes
ACTION
No
Yes

(See 05-02-5 OTC TABLE [5R55S].)
No
Yes
Inspect the direct one-way clutch, then go to the next step.

No
Yes

(See 05-13-44 TCM REMOVAUINSTALLATION [5R55Sj.)
No
Yes

No
DTC P1711 [5R55S]
id0502c1814200
DTC P1711 ATF temperature out of on-board diagnostic range

DETECTION
ATF temperature range too high or too low during on-board diagnostic.
CONDITION
POSSIBLE
TFT sensor malfunction.
CAUSE
TCM malfunction.
STEP
INSPECTION
VERIFY
FREEZE
FRAME
DATA HAS BEEN
1
RECORDED
recorded?
2
AVAILABILITY
3
ACTION
Yes
No

Yes

No
VERIFY DTCS
(See 05-02-5 OTC TABLE [5R55Sj.)
No Warm or cool vehicle to normal operating temperature, then
COMPLETED
(See 05-13-44 TCM REMOVAUINSTALLATION [5R55Sj.)
connectors.
PDS.
15R55Sj.)
VERIFY DTCS
(See 05-02-5 OTC TABLE [5R55Sj.)
No OTC troubleshooting completed.
05-02-39

DTC P1780 [5R55S]
id0502c1807600
OlD OFF switch circuit malfunction (open or short circuit)
DTC P1780
DETECTION
CONDITION
Open or short circuit in circuit between OlD OFF switch and TCM, or in OlD OFF switch internal circuit
OlD OFF switch malfunction.

Short to ground in wiring harness between engine switch and OlD OFF switch terminal C (wiring harnessside).
Open circuit in wiring harness between engine switch and OlD OFF switch terminal C (wiring harnessside).
Short to ground in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and TCM
terminal BM (wiring harness-side).
Open circuit in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and TCM terminal
BM (wiring harness-side).
Short to power supply in wiring harness between OlD OFF switch terminal 0 (wiring harness-side) and
TCM terminal BM (wiring harness-side).
Damaged connector between OlD OFF switch and TCM.
TCM malfunction.
POSSIBLE
CAUSE
SELECTOR LEVER
WIRING HARNESSSIDE CONNECTOR
BE
o
TCM
T@
IG1
I~~
010
OFF SWITCH
~-0-@7, CD@
//,6
@'Y
TCM WIRING HARNESS-SIDE CONNECTOR
A
B
C
D
E
F
G
H
I
J
K
L
M Q U
N R V
0 S W
P T X
Y
Z
AA
AB
AC
AD
AE
AF
AG AK
AH AL
AI AM
AJ AN
AO
AP
AQ
AR
AS AW
AT AX
AU AY
AV AZ
BA
BB
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
BM BQ BU BY
BN BR BV BZ
BO BS BW CA
BP BT BX CB
CC CG - CD CH -CK -CN
CL CO
CE CI - CM CP
CF CJ - -
I~~I
STEP
INSPECTION
RECORDED
recorded?
AVAILABILITY
Verify related'Service Information availability.
Is any related Service Infoqnation available?
INSPECT SELECTOR LEVER CONNECTOR
FOR POOR CONNECTION
Inspect the selector lever connector
connection.
~isconnect the selector lever connector.
Inspect for poor connection (such as damagedl
c
05-02-40
Yes
No
Yes
No
Yes
No
ACTION

Repair or replace the connector andlor terminals, then go
to Step 10.

STEP
4
10
11
INSPECTION
(engine off).
Inspect the voltage at OlD OFF switch terminal
C (wiring harness-side).
INSPECT 010 OFF SWITCH
Inspect the OlD OFF switch.
(See 05-13-19 OlD OFF SWITCH
Is the OlD OFF switch normal?
ACTION
Yes
No
Yes
No

Inspect the engine switch and wiring harness, then go to
Step 10.

Replace the selector lever, then go to Step 10.
(See 05-14-4 SELECTOR LEVER REMOVAU
INSTALLATION.)

Yes
CONNECTION
No
~isconnect the TCM connector.
Inspect for poor connection (such as damagedl
INSPECT 010 OFF SWITCH CIRCUIT FOR
Yes
OPEN CIRCUIT
No
terminal BM (wiring harness-side) and OlD
OFF switch terminal 0 (wiring harness-side).
Yes

10.
No

(engine off).
Inspect the voltage at OlD OFF switch terminal
o (wiring harness-side).
Is the voltage 0 V?
Yes

step.
VERIFY TROUBLESHOOTING OFDTC P1780

COMPLETED
connectors.
Clear the OTC from memory using the 10SI
POS.
[5R55S].)
Are any OTCs present?
VERIFY DTCS
Are OTCs except for P1780 output?
Yes
Re'):llace the TCM, then go to the next step.

No
Yes
Go to the applicable OTC inspection.

No

SHORT TO GROUND
Inspect for continuity between OlD OFF switch
. terminal 0 (wiring harness-side) and body
ground.
No
Repair or replace connector andlor terminals, then go to

Step 10.

05-02-41

DTC P1783 [5R55S]
id0502c1807700
DTC P1783 ATF overheating

DETECTION
ATF temperature signal is 1270 C {270 OF} or more
CONDITION
POSSIBLE
CAUSE
ATF level low

Deteriorated ATF
TFT sensor malfunction.
TCM malfunction.
INSPECTION
STEP
1
RECORDED
recorded?
2
AVAILABILITY
3
VERIFYDTCS
INSPECT ATF CONDITION
Inspect the ATF condition.
FLUID (ATF) INSPECTION [5R55S].)
Is it normal?
NSPECT ATF LEVELVE
Start the engine.
Warm up the AT.
Is the ATF level within the specification?
COMPLETED
connectors.
PDS.
[5R55S].)
VERIFYDTCS
05-02-42
ACTION
Yes
No

Yes

No
Yes

No
Go to SYMPTOM TROUBLESHOOTING, "NO.22

TRANSMISSION OVERHEATS", then go to the next step.
(See 05-03-24 NO.22 TRANSMISSION OVERHEATS
I
[5R55S].)
Yes
No
Yes
No
Yes
No
Replace the ATF, then go to Step 6.

(See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF)
.
.
Add ATF to the specified level, then go to the next step.
(See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF)
Yes

No

OTC U0100, U0297 [5R55S]
id0502c1815600

DTC U0297 Communication error to PCM
DETECTION
TCM cannot receive any signals from PCM.
CONDITION
Short to ground in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
Short to ground in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
Short to power supply in wiring harness between PCM terminal 195 (wiring harness-side) and TCM
terminal CB (wiring harness-side).
Short to power supply in wiring harness between PCM terminal 171 (wiring harness-side) and TCM
POSSIBLE
terminal CF (wiring harness-side).
CAUSE
Open circuit in wiring harness between PCM terminal 195 (wiring harness-side) and TCM terminal CB
Open circuit in wiring harness between PCM terminal 171 (wiring harness-side) and TCM terminal CF
Damaged connector between PCM and TCM.
PCM malfunction.
TCM malfunction.
DTC U0100
TCM
PCM
TCM WIRING HARNESS-SIDE CONNECTOR

r--
A E I M 0
B F J N R
C G K 0 S
0 H L P T
U
V
W
X
Y
Z
AA
AB
AC AG AK AO AS AW
AD AH AL AP AT AX
AE AI AM AO AU AY
AF AJ AN AR AV AZ
BA
BB
BC
BD
BE BI BM BO BU BY CC CG
BF BJ BN BR BV BZ CD CH
BG BK BO BS BW CA CE CI
BH BL BP BT BX CB CF CJ
-CK CN
-CLCO
PMCP
'--'--
PCM WIRING HARNESS-SIDE CONNECTOR

124 123 22 21 ~20 19 18 117 16 115 14 113 112 111 110 109 108 107 106 105 104 102 102 101
148 147 46 45 144 43 42 141 40 139 38 137 136 135 134 133 132 131 130 128 128 121 126 125
172 171 n70 69 168 67 66 165 64 ~63 62 161 160 159 158 157 156 155 154 152 152 151 150 149
196 195 n94 93 192 91 90 189 88 n87 86 185 184 183 182 181 180 179 178 17 176 175 174 173
05-02-43

STEP
1
INSPECTION
RECORDED
recorded?
ACTION
Yes
No


AVAILABILITY
Yes

INSPECT CAN CIRCUIT FOR SHORT TO

POWER SUPPLY
(engine off).
Inspect the voltage at TCM terminal CB and CF
Is the voltage 0 V?
VERIFY TROUBLESHOOTING OF DTC U0100
OR U0297 COMPLETED
connectors.
PDS.
[5R55S].)
VERIFY DTCS
Are DTCs except for U01 00 and U0297
output?
Yes

INSPECT PCM FOR POOR CONNECTION
to Step 8.
Inspect the PCM connection.
Disconnect the PCM.
CONNECTION
Step 8.
INSPECT CAN CIRCUIT FOR OPEN CIRCUIT
terminal (wiring harness-side) and the PCM
terminal (wiring harness-side).
- CB and 195
-CF and 171
INSPECT CAN CIRCUIT FOR SHORT TO
Yes Repair or replace the wiring harness, then go to the Step 8.
GROUND
Inspect for continuity between TCM terminal
(wiring harness-side) and body ground.
- CB and body ground
- CF and body ground
05-02-44
No

step.
Yes

No
Yes

No

PID/DATA MONITOR INSPECTION [SRSSS]
id0502c1805600

items from the initial screen of the IDS/PDS .
4. Select "TCM".
2. Select "TCM".
3. Select the PID from the PID table
4. Verify the PID data according to the directions on
the IDS/PDS screen.
absggw00000987
Note
Perform part inspection for the output device after TCM inspection .
The PID/DATA MONITOR function monitors the calculated value of the input/output signals in the TCM.
Therefore, if a monitored value of an output device is out of specification, it is necessary to inspect the
monitored value of the input device related to the output device control. Since an output device
malfunction is not directly indicated as a malfunction of the monitored value for the output device, it is
necessary to inspect the output device individually using the simulation function.
PID/DATA MONITOR AND RECORD function table
Monitor item
Definition
UniU
Condition
BPP
Brake switch
on/off
FIRM_ST
Firm shaft control (FSC)

status requested
0/1
GEAR
Calculated gear range in

TCM
1/2/3/4/5
GEAR_OSC
PID used to command

gear changes during
Simulation Function
1/2/3/4/5
rpm
rpm
RPM
ISS sensor
OSS sensor
Pressure control solenoid
A
B
C
Engine speed
SSA
Shift solenoid A
on/off
SSB
Shift solenoid B
on/off
SSC
Shift solenoid C
on/off
SSD
Shift solenoid D
on/off
TCC

Torque converter speed
ratio
ISS
OSS
PCA
PCB
PCC
TCCRAT
pis
pis
pis
rpm
ratio
Condition/Specification
Brake pedal depressed: on

Other: off
FSC not commanded by IDS/PDS PID output (off):
0
FSC commanded by IDS/PDS PID output (on): 1
1GR: 1
2GR: 2
3GR:3
4GR:4
5GR: 5
1GR: 1
2GR:2
3GR: 3
4GR:4
5GR:5
Indicates intermediate shaft speed
Indicates output shaft speed
Indicates pressure control solenoid A commanded
pressure
Indicates pressure control solenoid B commanded
pressure
Indicates pressure control solenoid C commanded
pressure
Indicates engine speed
Shift solenoid A operation: on
Shift solenoid A not operation: off
Shift solenoid B operation: on
Shift solenoid B not operation: off
Shift solenoid C operation: on
Shift solenoid C not operation: off
Shift solenoid D operation: on
Shift solenoid D not operation: off
Indicates TCC control solenoid operation
Indicates torque converter speed ratio (engine speed
compared with turbine shaft speed)
TCM
terminal
N/A
N/A
N/A
N/A
AM,AS
AD,AG
I,CK
J, CK
M,CK
N/A
B, CK
C,CK
F, CK
D,CK
A,CK
N/A
05-02-45

Definition
Monitor item
Unit!
Condition/Specification
Condition
C, of
Indicates ATF temperature
TFT
ATF temperature
TR_D
TR_V

voltage
TR1
TR1 switch
0/1
TR2
TR2 switch
0/1
TR3A
TR3 switch
0/1
TR4
TR4 switch
0/1
TSS
VSS
TSS sensor
Vehicle speed
rpm
mph
Indicates digital TR sensor signal

V
Indicates digital TR sensor signal voltage
TR1 switch open: 1

TR1 switch close: 0
TR2 switch open: 1
TR2 switch close: 0
TR3 switch open: 1
TR3 switch close: 0
TR4 switch open: 1
TR4 switch close: 0
Indicates turbine shaft speed
Indicates vehicle speed
TCM
terminal
AY, BH
AX, BU, BY,
CA
AX, BU, BY,
CA
BY
BU
AX
CA
AH,AP
AD,AG
Simulation Function Procedure

items from the initial screen of the IOS/POS.
4. Select "TCM".
When using the POS (Pocket PC)
2. Select "TCM".
3. Select the simulation items from the PIO table.
absggw00000987
If there is no operation sound from the solenoid after the simulation function inspection is performed, it is
possible that there is an open or short circuit in the wiring harness, or solenoid, or sticking and operation
malfunction.
Simulation item table
Simulation item
PCA
PCB
PCC
SSA
SSB
SSC
SSD
TCC
05-02-46
Shift solenoid A
Shift solenoid B
Shift solenoid C
Shift solenoid D
Unit
pis
pis
pis
on/off
on/off
on/off
on/off
%
TCM terminal
I, CK
J, CK
M,CK
B,CK
C,CK
F, CK
D, CK
A,CK
SYMPTOM TROUBLESHOOTING [5R55S]
05-03
CONTROL SYSTEM
WIRING DIAGRAM [5R55S] ........ 05-03-2
FOREWORD [5R55S] ......... 05-03-3
BASIC INSPECTION [5R55S] ....... 05-03-4
ITEM TABLE [5R55S] ......... 05-03-5
QUICK DIAGNOSIS CHART
[5R55S] ................. 05-03-7
NO.1 VEHICLE DOES NOT
MOVE IN D RANGE,
OR IN R POSITION [5R55S] ....... 05-03-9
NO.2 VEHICLE MOVES
IN N POSITION [5R55S] ........ 05-03-10
NO.3 VEHICLE MOVES IN P POSITION,
OR PARKING GEAR DOES NOT
DISENGAGE WHEN P IS DISENGAGED
[5R55S] ................. 05-03-10
NO.4 EXCESSIVE CREEP [5R55S] ... 05-03-11
NO.5 NO CREEP AT ALL [5R55S] .... 05-03-11
NO.6 LOW MAXIMUM SPEED AND
POOR ACCELERATION [5R55S] . 05-03-12
NO.7 NO SHIFTING [5R55S] ..... 05-03-13
NO.8 NO 2ND AND 5TH GEARS
(MANUAL 2ND IS OK) [5R55S] ...... 05-03-14
NO.9 ABNORMAL SHIFTING
[5R55S] ................ 05-03-14
NO.10 FREQUENT SHIFTING
[5R55S] ................. 05-03-15
NO.11 SHIFT POINT IS HIGH OR LOW
[5R55S] ................. 05-03-15
NO.12 TORQUE CONVERTER CLUTCH
(TCC) NON-OPERATION [5R55S] ... 05-03-16
NO.13 NO KICKDOWN [5R55S] ..... 05-03-17
NO.14 ENGINE FLARES UP OR SLIPS

WHEN UPSHIFTING OR DOWNSHIFTING
[5R55S] ................ 05-03-17
NO.15 ENGINE FLARES UP OR SLIPS
WHEN ACCELERATING VEHICLE
[5R55S] ................ 05-03-18
NO.16 JUDDER UPON TORQUE
CONVERTER CLUTCH (TCC)
OPERATION [5R55S] ........... 05-03-18
NO.17 EXCESSIVE SHIFT SHOCK
FROM N TO D OR N TO R
POSITION/RANGE [5R55S] ....... 05-03-19
NO.18 EXCESSIVE SHIFT SHOCK IS FELT
WHEN UPSHIFTING AND DOWNSHIFTING
[5R55S] ............. 05-03-20
NO.19 EXCESSIVE SHIFT SHOCK ON
TORQUE CONVERTER CLUTCH (TCC)
[5R55S] ......... : .... 05-03-21
NO.20 NOISENIBRATION FORWARD
OR REVERSE [5R55S] ............ 05-03-22
NO.21 NO ENGINE BRAKING IN
1GR POSITION OF MANUAL 1 RANGE
[5R55S] ................... 05-03-23
NO.22 TRANSMISSION OVERHEATS
[5R55S] .................... 05-03-24
NO.23 ENGINE STALLS WHEN
SHIFTED TO D RANGE, OR IN R POSITION
[5R55S] ...................... 05-03-25
NO.24 ENGINE STALLS WHEN DRIVING
AT SLOW SPEEDS OR STOPPING
[5R55S] ....................... 05-03-25
NO.25 STARTER DOES NOT WORK
[5R55S] .......... 05-03-25
05-03-1
SYMPTOM TROUBLESHOOTING [SRSSS]

AUTOMATIC TRANSMISSION CONTROL SYSTEM WIRING DIAGRAM [SRSSS]
IG1
B+
id0503c1809500
B+
TCM
AT RELAY
OTHER
MODULE
SHIFT SOLENOID A
SHIFT SOLENOID B
4x4
CONTROL
MODULE
4x4 HI
SHIFT SOLENOID C
4x4 LO
SHIFT SOLENOID D
IG1
J j-----'O

MI-----IO
INSTRUMENT
CLUSTER
TR1
TR2
TR4
OSSSENSOR
ISS SENSOR
TSS SENSOR
arnffw00001943
05-03-2

FOREWORD [5R55S]
idOS03c1800200
When the customer reports a vehicle malfunction, inspect the malfunction indicator lamp (MIL) indication, OlD
OFF indicator light flash, and diagnostic trouble code (DTC), then diagnose the malfunction according to the
following flowchart.
If a DTC exists, diagnose the applicable DTC inspection. (See 05-02-5 DTC TABLE [5R55S].)
If a DTC does not exist, the MIL does not illuminate and OlD OFF indicator light flash, diagnose the
applicable symptom troubleshooting. (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM TABLE
[5R55S].)
CUSTOMER ARRIVES
NO WARNING LIGHTWITH SYMPTOM
WARNING LIGHTON/FLASHING
CHECK FOR
PRIORITIZED DTC
DTC
CHECK DTC
TEST
WITHOUTDTC
DIAGNOSE BY DTC
DTCTABLE
DTC
TROUBLESHOOTING
FLOW
DIAGNOSE BY SYMPTOM
1. DIAGNOSTIC INDEX
3. SYMPTOM
TROUBLESHOOTING
*: Malfunction Indicator Lamp (MIL), OlD OFF indicator light.
05-03-3

BASIC INSPECTION [SRSSS]
INSPECTION
STEP
1
id0503c1800300
Perform the mechanical system test.

(See 05-13-4 MECHANICAL SYSTEM TEST
[5R55S].)
Is the mechanical system normal?
When the selector lever is moved, does the
selector illumination indicate a synchronized
position to the lever location? Also, when other
ranges are selected from N or P during idling,
does the vehicle move within 1-2 5?
Inspect the ATF color, condition and level.
Are the ATF color, odor and level normal?
ACTION
Yes
No
Repair or replace any malfunctioning parts according to the

inspection result.
Yes

Inspect the selector lever and digital TR sensor. Repair or
replace malfunctioning areas.
If the selector lever and digital TR sensor are normal, go to
the next step.
No
Yes
No
Perform the line pressure test.

[5R55S].)
Yes
No

[5R55S].)
Inspect the value at the following PCM and TCM
PIDs using the IDS/PDS.
(See 05-02-45 PID/DATA MONITOR
Yes
No
PCM PIDs:
APP1
APP2
ECT
RPM
VPWR
TCM PIDs:
TFT
TR_D
TR_V
TSS
ISS
OSS
Is the PID value normal?
05-03-4
Yes
No

inspection result.
Flush the AT and cooler line if necessary.
Adjust the accelerator cable if necessary.
inspection result.
Repair or replace any normal parts according to the
inspection result.
Perform the symptom troubleshooting and the follow
procedures.
inspection result.

SYMPTOM TROUBLESHOOTING ITEM TABLE [SRSSS]
id0503c1800400
Use the chart below to verify the trouble symptoms to diagnose the appropriate area.
No.
Vehicle does not move in D range, or
in R position
DESCRIPTION
Vehicle does not move when AP is
depressed.
Low maximum speed and poor

acceleration
Vehicle acceleration poor at start.

Delayed acceleration when accelerator
pedal depressed while driving.
No shifting
No 2nd and 5th gears (Manual 2nd is

OK)
Abnormal shifting
10
Frequent shifting
11
Shifts point is high or low
12
Torque converter clutch (TCC) nonoperation
13
No kickdown
14
Engine flares up or slips when

upshifting or downshifting
15
Engine flares up or slips when

accelerating vehicle
16
17
PAGE
(See 05-03-9 NO.1 VEHICLE
DOES NOT MOVE IN D
RANGE, OR IN R POSITION
[5R55S].)
Vehicle moves in N position
Vehicle creeps in N position.
(See 05-03-10 NO.2 VEHICLE
Vehicle creeps if brake pedal is not
MOVES IN N POSITION
depressed in N position.
[5R55S].)
Vehicle moves in P position, or parking Vehicle rolls when on a downward slope and (See 05-03-10 NO.3 VEHICLE
gear does not disengage when P
MOVES IN P POSITION, OR
tires do not lock in P position.
position is disengaged
Tires locked when P position is disengaged, PARKING GEAR DOES NOT
vehicle does not move in D range, and R
DISENGAGE WHEN P IS
position when AP is depressed, and engine DISENGAGED [5R55Sj.)
remains in stall condition.
Excessive creep
Vehicle accelerates in D range, and R
(See 05-03-11 NO.4
position without depressing accelerator
EXCESSIVE CREEP [5R55Sj.)
pedal.
No creep at all
(See 05-03-11 NO.5 NO
Vehicle does not move in D range, or R
CREEP AT ALL [5R55Sj.)
position when idling on flat, paved road.
(See 05-03-12 NO.6 LOW
MAXIMUM SPEED AND
POOR ACCELERATION
[5R55S].)
Single shift range only.
(See 05-03-13 NO.7 NO
Sometimes shifts correctly.
SHIFTING [5R55Sj.)
Vehicle dose not shift to 2nd or 5th gear.
(See 05-03-14 NO.8 NO 2ND
AND 5TH GEARS (MANUAL
2ND IS OK) [5R55Sj.)
Shifts incorrectly (incorrect shift pattern).
(See 05-03-14 NO.9
ABNORMAL SHIFTING
[5R55Sj.)
Downshifting occurs immediately even when (See 05-03-15 NO.10
the accelerator pedal is depressed slightly in FREQUENT SHIFTING
D range.
[5R55S].)
Shift point is considerably different from
(See 05-03-15 NO.11 SH IFT
automatic shift diagram.
POINT IS HIGH OR LOW
[5R55S].)
Shift delays when accelerating.
Shift occurs quickly when accelerating and
engine speed does not increase.
TCC does not operate when vehicle reaches (See 05-03-16 NO.12
TCC operation range.
TORQUE CONVERTER
CLUTCH (TCC) NONOPERATION [5R55Sj.)
(See 05-03-17 NO.13 NO
Does not downshift when accelerator pedal
is fully depressed within kickdown range.
KICKDOWN [5R55Sj.)
When accelerator pedal is depressed,
engine speed increases but vehicle speed
FLARES UP OR SLIPS WHEN
increases slowly.
UPSHIFTING OR
When accelerator pedal is depressed while DOWNSHIFTING [5R55Sj.)
driving, engine speed increases but vehicle
speed does not.
Engine flares up when accelerator pedal is

FLARES UP OR SLIPS WHEN
depressed for upshifting.
Engine flares up suddenly when accelerator ACCELERATING VEHICLE
pedal is depressed for downshifting.
[5R55Sj.)
Judder upon torque converter clutch
Vehicle jolts when TCC is engaged.
(See 05-03-18 NO.16
(TCC) operation
JUDDER UPON TORQUE
CONVERTER CLUTCH (TCC)
OPERATION [5R55Sj.)
Excessive shift shock from N to D or N Strong shock is felt when shifting from N to
(See 05-03-19 NO.17
to R position/range
D or N to R position/range at idle.
EXCESSIVE SHIFT SHOCK
FROM N TO D OR N TO R
POSITION/RANGE [5R55S].)
05-03-5

No.
18
Excessive shift shock is felt when

upshifting and downshifting
19
Excessive shift shock on torque

converter clutch (TCC)
Strong shock is felt when TCC is engaged.
(See 05-03-21 NO.19

EXCESSIVE SHIFT SHOCK
ON TORQUE CONVERTER
CLUTCH (TCC) [5R55S].)
20
Noise/vibration forward or reverse
Transmission noisy in all positions and

ranges.
(See 05-03-22 NO.20 NOISE/

VIBRATION FORWARD OR
REVERSE [5R55S].)
21
No engine braking in 1GR position of

manual 1 range
Engine speed drops to idle but vehicle

coasts when accelerator pedal is released
when in 1GR position of manual 1 range at
low vehicle speed.
22
Transmission overheats
Burnt smell emitted from transmission.

Smoke is emitted from transmission.
(See 05-03-23 NO.21 NO

ENGINE BRAKING IN 1GR
POSITION OF MANUAL 1
RANGE [5R55S].)
(See 05-03-24 NO.22
TRANSMISSION OVERHEATS
[5R55S].)
23
Engine stalls when shifted to D range,

or in R position
Engine stalls when shifting from N or P

position to D range or R position at idle.
24
Engine stalls when driving at slow

speeds or stopping
Engine stalls when brake pedal is

depressed while driving at low speed or
stopping.
25
Starter does not work
Starter does not work even when P or N

position is selected.
05-03-6
DESCRIPTION
Excessive shift shock is felt when
depressing accelerator pedal to accelerate
at upshifting.
During cruising, excessive shift shock is felt
when depressing accelerator pedal at
downshifting.
PAGE
(See 05-03-20 NO.18
EXCESSIVE SHIFT SHOCK IS
FELT WHEN UPSHIFTING
AND DOWNSHIFTING
[5R55S].)

STALLS WHEN SHIFTED TO
D RANGE, OR IN R POSITION
[5R55S].)
STALLS WHEN DRIVING AT
SLOW SPEEDS OR
STOPPING [5R55S].)
(See 05-03-25 NO.25
STARTER DOES NOT WORK
[5R55S].)

QUICK DIAGNOSIS CHART [5R55S]
id0503c1800500
X: Applied
1 Vehicle does not move in D range, or in R position
2 Vehicle moves in N position
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4 Excessive creep
5 No creep at all
6 Low maximum speed and poor acceleration
7 No shifting
8 No 2nd and 5th gears (Manual 2nd is OK)
9 Abnormal shifting
10 Frequent shifting
11 Shifts point is high or low
12 Torque converter clutch (Tee) non-operation
13 No kickdown
14 Engine flares up or slips when upshifting or
downshifting
15 Engine flares up or slip when accelerating vehicle
16 Judder upon torque converter clutch (Tee) operation
17 Excessive shift shock from N to D or N to R
position/range
18 Excessive shift shock is felt when upshifting and
downshifting
19 Excessive shift shock on torque converter
clutch (TeC)
20 Noise/vibration forward or reverse
21 No engine braking in 1GR position of manual 1 range
22 Transmission overheats
23 Engine stalls when shifted to D range, or in R position
24 Engine stalls when driving at slow speeds or stopping
25 Starter does not work
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
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
Electrical system components
Symptom item
AT outer parts
(;
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c
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Cause of trouble
a..
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arnffw00001948
05-03-7

X: Applied
1 Vehicle does not move in D range, or in R position
2 Vehicle moves in N position
3 Vehicle moves in P position, or parking gear does not
disengage when P is disengaged
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Excessive creep
No creep at all
Low maximum speed and poor acceleration
No shifting
No 2nd and 5th gears (Manual 2nd is OK)
Abnormal shifting
Frequent shifting
Shifts point is high or low
Torque converter clutch (Tee) non-operation
No kickdown
Engine flares up or slips when upshifting or downshifting
Engine flares up or slip when accelerating vehicle
Judder upon torque converter clutch (TeC) operation
Excessive shift shock from N to D or N to R position/range
Excessive shift shock is felt when upshifting and
downshifting
19
20
21
22
23
24
25
Excessive shift shock on torque converter clutch (Tee)

No engine braking in 1GR position of manual 1 range
Engine stalls when shifted to D range, or in R position
Engine stalls when driving at slow speeds or stopping
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
0en
r:::
en
r:::
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(!)
Cause of trouble
r:::
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X
X
X
X
X
X
Powertrain
system
~
c.
c.
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r:::
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0
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X
X
X
Hydraulic
system
components
U
t5 t5
r::: r::: r:::
t:i:
I-
X X
X X
X
X
X X
X
X
X
X
X
AT outer parts
r:::
X
X
X
X
X
X
X
Electrical system components
r:::
X
X
X
X
X X
X X
X X
"0
<ll
:I:::l
X X
X
X X
X
X X X X X
X
X
X
X X
X X X
X X
Symptom item
X X
X X X X X X X X X
X
X
E
r:::
Cl
r:::
~<ll
c.
t5<ll 00
c. r:::
~r::: -=en
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c.
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arnffw00001949
05-03-8

NO.1 VEHICLE DOES NOT MOVE IN D RANGE, OR IN R POSITION [5R55S]
1
DESCRIPTION
POSSIBLE
CAUSE
id0503c1800600
Vehicle does not move in D range, or in R position

Vehicle does not move when AP is depressed .
If the vehicle does not move in D range or R position, basically, the malfunction is in the AT. (Vehicle will
move even with a malfunction in the TCM.) Since a malfunction is in the sensor circuit or output circuit is
the cause of the malfunction in the AT, inspect the sensors, output circuit, and the related wiring
harnesses.
1. Clutch slipped, worn (D range-Forward clutch, R position-Direct clutch, Coast clutch, Reverse band)
Fluid pump malfunction
Pressure control solenoid B malfunction
Pressure control solenoid C malfunction
Body ground malfunction
Control valve body malfunction
2. Selector lever malfunction
3. Parking mechanism not operating properly
4. Torque converter malfunction
Note
Before the following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspections are conducted.
(See 05-03-4 BASIC INSPECTION [5R55S].)
STEP
ACTION
INSPECTION
When the vehicle is stopped on a flat, level road Yes Go to the next step.
i-:N-:-o-I-:C::':h-e-c.,.-k-,th:-e-pa-r-:-k-:-in--'g'-m-e-c""'h-a-n.,.-is-m-.-----------j
and the engine is off, does the vehicle move
when it is pushed? (In D range or N, R positions
and brake released)
Is the resistance between TCM ground terminal
No Repair the open ground circuit.
CO and body ground, and between TCM ground
terminal CL and body ground less than 5.0
ohms?
Yes Clean and inspect main control, if parts are damaged
Inspect the pressure control solenoid Band C.
replace main control.
If the problem remains, overhaul the transmission and repair
or replace any malfunctioning parts.
Is it normal?
No Repair or replace any malfunctioning parts.
- If the malfunction remains, inspect the related Service Information and perform repair or diagnosis.
If the vehicle repaired, the troubleshooting is completed.
If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM.
05-03-9

NO.2 VEHICLE MOVES IN N POSITION [5R55S]
2
DESCRIPTION
POSSIBLE
CAUSE
id0503c1800700
Vehicle moves in N position

Vehicle creeps in N position.
Vehicle creeps if brake pedal is not depressed in N position.
If the vehicle moves in N position, basically, the malfunction is in the AT. Since a malfunction in the
sensor circuit or output circuit is the cause of the malfunction in the AT, inspect the sensors, output
circuit, and the related wiring harnesses.
1. Clutch is burned (Forward clutch)
2. Selector lever position disparity. Although the selector indicator shows N position, the hydraulic
circuit shows D range or R position.
Incorrect fluid level
Shift control cables
Main control
Case and clutches
Note
STEP
1
INSPECTION
Does the vehicle creep when the selector lever is
moved slightly in the N position?
Yes
No
ACTION
Adjust the selector lever.
Repair the open ground circuit.
Reconnect the TCM.

Yes
No
ohms?
Inspect following items.
Fluid level
Fluid pump operation
Shift control cables
Main control
Case and clutches
Are they normal?
If the vehicle repaired, the troubleshooting is completed .
If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM .
NO.3 VEHICLE MOVES IN P POSITION, OR PARKING GEAR DOES NOT DISENGAGE WHEN P IS
DISENGAGED [5R55S]
3
DESCRIPTION
POSSIBLE
CAUSE
05-03-10
id0503c1800800
Vehicle moves in P position, or parking gear does not disengage when P is disengaged
Vehicle rolls on a downward slope in P position.
Tires are locked when P is disengaged. Vehicle does not move in D range, and R position when
accelerator pedal is depressed, and engine remains in stall condition.
1. Improper adjustment of selector lever
2. Transmission case damaged
3. Parking mechanism malfunction (May have effect on noise or shock from transmission)
4. If vehicle moves in N position, perform No.2 "VEHICLE MOVES IN N POSITION"

NO.4 EXCESSIVE CREEP [5R55S]
4
DESCRIPTION
POSSIBLE
CAUSE
id0503c1800900
Excessive creep
Vehicle accelerates in 0 range, and R position without depressing accelerator pedal.
1. Engine idle speed high (transmission system is not cause of problem)
2. Go to No.9 "FAST IDLE/RUNS ON"
NO.5 NO CREEP AT ALL [5R55S]

5
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801000
No creep at all
Vehicle does not move in 0 range and R position when idling on fiat, paved road.
Either transmission is stuck in 4GR or clutch slippage due to a stuck 3-4 clutch.
1. Clutch is burned
Line pressure low
Shift solenoid 0 malfunction
2. Transmission fixed in 4GR (Operation of fail-safe function)
Short or open circuit in wiring harness
Electronic parts of output and input system have malfunction
3. No engine torque
Low engine RPM
Torque converter malfunction
Note
STEP
INSPECTION
Does the vehicle creep in any range/position?
Yes
No
ACTION
Inspect or adjust the selector lever.
(See 05-14-2 SELECTOR LEVER INSPECTION.) (See 0514-2 SELECTOR CABLE ADJUSTMENT.)
Check the value at the following PCM PIDs using Yes Go to the next step.
the IDS/PDS.
i--N-o-l--,R'-e-p-a""-ir-o-r-r-ep-l-ac-e--'-an-y-m-a""lfu-n-c-ti-o-ni-n-g-p-a-rt-s-.- - - - - - 1
APP1
APP2
RPM
Are PID values normal?
No Repair the open ground circuit.
ohms?
Inspect the pressure control solenoid A.
Is it normal?
05-03-11

NO.6 LOW MAXIMUM SPEED AND POOR ACCELERATION [SRSSS]
6
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801100
Low maximum speed and poor acceleration

Vehicle acceleration is poor at start.
Delayed acceleration when accelerator pedal is depressed while driving.
If the clutch is stuck or does not stay in 4GR, the malfunction is in the engine control system.
1. Clutch slippage, burned
Line pressure low
Pressure control solenoid A, Band C malfunction
2. Signal malfunction
OSS sensor malfunction
Sensor ground malfunction
Accelerator pedal position sensor malfunction
TSS sensor malfunction
3. Transmission fixed in 4GR (Operation of fail-safe function)
Short or open circuit in wiring
Electronic parts of output and input system have malfunction
4. Insufficient starting torque (Suspected when in-gear condition, shift control and engine circuit are
normal)
Torque converter have malfunction (Poor operation, stuck)
TFT sensor malfunction (Short or open circuit)
5. Digital TR sensor adjustment incorrect
Note
STEP
INSPECTION
Go to No.12 "LACK/LOSS OF POWER1
ACCELERATION/CRUISE".
Is the CIS system normal?
2
Does the vehicle operate as follows?
Yes
No
Yes
No
D range: 4GR (fixed)

R position: Reverse
3
Drive the vehicle in D range.

Does the vehicle start from stop in first gear?
Check the value at the following TCM PIDs using
the IDS/PDS.
GR_CM
GEAR
Yes
No
ACTION
Repair or replace any malfunctioning parts.
Clean and inspect main control, if parts are damaged
Check the value at the following.
(See 05-02-45 PID/DATA MONITOR INSPECTION
[5R55S].)
PCM PIDs (using IDS/PDS):
APP1
APP2
VSS
TCM PIDs (using IDS/PDS):
TSS
ISS
OSS
TR_D
05-03-12

INSPECTION
STEP
4
Inspect the value at the following TCM PIDs

using the IDS/PDS.
SSA
SSB
SSC
SSD
Are the PID values normal?
ACTION
Yes
No
Inspect the shift solenoids for sticking.

If the shift solenoids are normal, go to the next step.
APP
OSS
ISS
TSS
TR_D

[5R55S].)
Yes
No

inspection results.
Reverify symptoms of malfunctioning.

Yes
No Overhaul the transmission and repair or replace any
[5R55S].)
NO.7 NO SHIFTING [5R55S]

7
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801200
No shifting
Single shift range only.

Sometimes it shifts correctly.
When the gear position is fixed in 4GR due to the fail-safe operation, the malfunction is in the AT.
Perform malfunction diagnosis according to No.6 "LOW MAXIMUM SPEED AND POOR
ACCELERATION".
Line pressure low
IAT sensor malfunction
VSS signal malfunction
3. Transmission fixed in 4GR (Operation in fail-safe function)
Short or open circuit in wiring harness
Disconnected shift solenoid connector
Poor ground of shift solenoid
Overdrive planetary malfunction
Center support malfunction
Direct clutch malfunction
Overdrive servo/band malfunction
05-03-13

NO.8 NO 2ND AND 5TH GEARS (MANUAL 2ND IS OK) [5R55S]
8
No 2nd and 5th gears (Manual 2nd is OK)
DESCRIPTION
Vehicle dose not shift to 2nd or 5th gear.

TCM malfunction
Main control malfunction
POSSIBLE
CAUSE
id0503c1814500
Note
Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
INSPECTION
STEP
1
ACTION
Verify that Manual 2nd is present and functions

correctly.
Is manual 2nd operating correctly?
Yes
No
Go to symptom troubleshooting NO.8 "ABNORMAL

SHIFTING".
Inspect the following solenoids.

Are they normal?
Yes

or replace any malfunction parts.
No
Repair or replace any malfunction parts.

NO.9 ABNORMAL SHIFTING [5R55S]

9
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801400
Abnormal shifting
Shifts incorrectly (incorrect shift pattern).
There is a malfunction in the signal circuit which controls shifting (accelerator pedal position sensor,
TSS sensor, OSS sensor), the control valve is stuck, the accumulator (forward or servo apply) is stuck,
or the clutch circuit is stuck.
Fluid level low
Line pressure low
3. Digital TR sensor malfunction
Selector lever adjustment incorrect
Digital TR sensor adjustment incorrect
Note
05-03-14

ACTION
INSPECTION
STEP
1
No Repair the open ground circuit. Reconnect the TCM
connector.
ohms?
2
APP
TSS
OSS
VSS
Are they normal?
3
NO.10 FREQUENT SHIFTING [SRSSS]

10
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801500
Frequent shifting
Downshifting occurs immediately even when the accelerator pedal is depressed slightly in D range.
The circuit which is the cause is basically the same as NO.9 "ABNORMAL SHIFTING". However, a
malfunction of the input signal to the accelerator pedal is position sensor, OSS sensor (including the
sensor ground, sensor harness and connector), or clutch slippage (clutch stuck, low pressure in line)
may also be the cause.
NO.11 SHIFT POINT IS HIGH OR LOW [SRSSS]

11
DESCRIPTION
POSSIBLE
CAUSE
Shift point is high or low

Shift point is considerably different from automatic shift diagram.
Shift delays when accelerating.
Shift occurs quickly when accelerating and engine speed does not increase.
If the transmission does not shift abnormally, there is a malfunction of the input signal to the accelerator
pedal position sensor, TSS sensor, or OSS sensor (including sensor ground).
If the engine speed is high or low, regardless of normal shifting, inspect the tachometer.
Verify that the output signal of the accelerator pedal position sensor change linearly.
Verify fluid level and conditions.
Verify main control operation.
05-03-15

NO.12 TORQUE CONVERTER CLUTCH (TCC) NON-OPERATION [5R55S]
12
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801700
Torque converter clutch (TCC) non-operation

TCC does not operate when vehicle reaches TCC operation range.
Basically, the TCC does not operate when the fail-safe is operating. Verify the DTC first.
Caution
If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. TCC is burned
(1) Input sensor system malfunction
ECT sensor
TFT sensor
Sensor ground
(2) Output solenoid valve system malfunction (Sticking)
TCC control solenoid malfunction
(3) Main control malfunction (Poor operation, stuck)
TCC hydraulic pressure system
Improper pressures
Converter malfunction
2. Accelerator pedal position sensor malfunction (Not operating linearly)
3. Brake switch malfunction (Always ON)
4. TCM malfunction
Note
INSPECTION
ACTION
STEP
value
at
the
following.
Go
to
the
next
step.
Check
the
1
Yes
APP
VSS
TFT
Are they normal?
2
No Repair the wiring harness.
ohms?
Measure the resistance between TCM terminal
3
A and AT connector terminal H, and between
No Repair the TCC control solenoid circuit. Reconnect the TCM
TCM terminal CK and AT connector terminal F.
connector.
Are the resistances less than 5.0 ohms?
Inspect the TCC control solenoid.
4
Yes Replace TCM.
No Replace TCC control solenoid.
Are the TCC control solenoids operating
properly?
5
05-03-16

NO.13 NO KICKDOWN [5R55S]
13
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801800
No kickdown
Does not downshift when accelerator pedal is fully depressed within kickdown range.
If the transmission does not downshift though shifting is normal, the malfunction is in accelerator pedal
position sensor circuit (including sensor ground, sensor harness and connector).
NO.14 ENGINE FLARES UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING [5R55S]

14
DESCRIPTION
POSSIBLE
CAUSE
id0503c1801900
Engine flares up or slips when upshifting or downshifting

When accelerator pedal is depressed for driving, engine speed increases but vehicle speed increases
slowly.
When accelerator pedal is depressed while driving, engine speed increases but vehicle speed does
not.
The clutch is slipping because it is stuck or it line pressure is low.
1. Clutch stuck, slippage (forward clutch, 3-4 clutch, 2-4 brake band, one-way clutch)
Line pressure low
3. Poor operation of mechanical pressure
Note
STEP
INSPECTION
Is the shift point normal?
ACTION
Yes
No

Go to symptom troubleshooting NO.9 "ABNORMAL
SHIFTING".
Check the value at the following PCM PIDs using Yes

theIDS/PDS.
~N70~~R~e-p-a~ir-o-r-re-p~la-c-e~a-n-y-m--a~lfu-n-c~ti-on~i-ng--p-a~rts-.----------~
APP
ACT
No Repair the wiring harness. Reconnect the TCM connector.
ohms?
Inspect PCA, PCB and PCC PIDs value.
Are the PCA, PCB and PCC PID values normal?
~~~~~----~----~~~~~----------------~
05-03-17

NO.15 ENGINE FLARES UP OR SLIPS WHEN ACCELERATING VEHICLE [5R55S]
15
DESCRIPTION
POSSIBLE
CAUSE
Engine flares up or slips when accelerating vehicle

Engine flares up when accelerator pedal is depressed for upshifting.
Engine flares up suddenly when accelerator pedal is depressed for downshifting.
The malfunction is basically the same as for No.14 "ENGINE FLARES UP OR SLIPS WHEN
UPSHIFTING OR DOWNSHIFTING". If conditions for No.14 worsen, the malfunction will develop to
No.15.
NO.16 JUDDER UPON TORQUE CONVERTER CLUTCH (TCC) OPERATION [5R55S]

16
DESCRIPTION
POSSIBLE
CAUSE
id0503c1802000
id0503c1802100
Judder upon torque converter clutch (TCC) operation

Vehicle jolts when TCC is engaged.
Poor TCC engagement due to either slippage because the TCC is stuck or the line pressure is low
Caution
If the TCC is stuck, inspect it. In addition, inspect the oil cooler for foreign particles which
may have mixed in with the ATF.
1. Torque converter clutch piston slipped, burned
Line pressure high
Note
STEP
1
INSPECTION
Disconnect TCM.
ohms?
Measure the resistance between the following
TCM and AT connector terminals.
TCM terminal A and AT connector terminal F
TCM terminal CK and AT connector terminal
H
Is the resistance less than 5.0 ohms?
Inspect the TCC control solenoid.
Is the solenoid valve operating properly?
Inspect the PCA, PCB and PCC PID values.
Yes
No
ACTION
Repair the wiring harness.
Yes
No

Repair the TCC control solenoid circuit.
Yes
No

Replace TCC control solenoid.
Replace the TCM.
Yes
No
5

- If the malfunction remains, inspect the related Service InforlT'ation and perform repair or diagnosis.
05-03-18

NO.17 EXCESSIVE SHIFT SHOCK FROM N TO D OR N TO R POSITION/RANGE [5R55S]
17
DESCRIPTION
POSSIBLE
CAUSE
id0503c1802200
Excessive shift shock from N to D or N to R position/range

Strong shock felt when shifting from N to 0 or N to R position/range.
Shift shock may worsen when the fail-safe is operating. If no DTC is output, the shift shock may worsen
due to poor operation of the control valve body or sticking of the clutch.
1. Clutch burned (N~D: Forward clutch, N~R: Reverse servo or Direct clutch)
Line pressure low, high
Pressure control solenoid A malfunction (N~D only)
Pressure control solenoid C malfunction (N~R only)
Main control malfunction
Digital TR sensor misadjustment or malfunction
2. Poor hydraulic operation (Malfunction in range change)
Forward clutch malfunction
Reverse servo malfunction
3. Idle speed high
4. Poor tightening torque of engine mount, exhaust mount
Note
INSPECTION
STEP
ACTION
Does the shift shock occur only when the engine Yes Go to the next step.
i-:-:--I--:=-0---'--to-S=-t:-e-p--=3:-.- - - ' - - - - - - - - - - - - - - - - 1
is cold?
N0 G
Yes Check the value at the following.
2
Is the resistance between the TCM ground
(See 05-02-45 PID/DATA MONITOR INSPECTION
terminal CO and body ground, and between
[5R55S].)
TCM ground terminal CL and body ground less
than 5.0 ohms?
APP
TFT
Is the pressure normal?
_
3
No Repair or replace any malfunctioning parts according to the
[5R55S].)
inspection results.
4
No Go to Step 5.
[5R55S].)
Is stall speed normal?
Inspect the voltage at the following TCM PID
5
using the IDS/PDS.
(See05-02-45 PID/DATA MONITOR
TR_D
Is the PID value normal?
Check the value at the following PCM PIDs using Yes Go to the next step.
6
theIDS/PDS.
I-:N-:-o-'I--:R=-e-p-a-:-ir-o-r-re-p--:l-ac-e--'-an-y-m-a~lfu-n-c--:ti-O--:ni:-n-g-p-a-rt-s.-------I
APP
7
ohms?
05-03-19

STEP
8
INSPECTION
Inspect the PCA and PCC PID values.
Are the PCA and PCC PID values normal?
Yes
ACTION
No
NO.18 EXCESSIVE SHIFT SHOCK IS FELT WHEN UPSHIFTING AND DOWNSHIFTING [5R55S]
18
DESCRIPTION
id0503c1804600
Excessive shift shock is felt when upshifting and downshifting

Excessive shift shock felt when depressing accelerator pedal to accelerate at upshifting. During
cruising, excessive shift shock is felt when depressing accelerator pedal at downshifting.
Shift shock may worsen when fail-safe is operating. The shift shock may worsen if the signal from the
accelerator pedal position sensor, TSS sensor, or OSS sensor has a malfunction.
1. Clutch slipped, burned
Line pressure low, high
Accelerator pedal position sensor misadjustment
ISS sensor malfunction
VSS signal malfunction
IAT sendor malfunction
3. Poor hydraulic operation (Malfunction in range change)
Low fluid pressure
4. Engine mounts installation
Loose attaching bolts
Worn parts
POSSIBLE
CAUSE
Note
05-03-20

STEP
1
INSPECTION
Inspect the engine mounts for loose tightening
bolts or worn parts.
Are all engine mounts normal?
[5R55S].)
Is stall speed normal?
Check the value at the following PCM PIDs using
the IDS/PDS.
APP
ohms?
Inspect the PCA, PCB and PCC PID values.
Yes
No
ACTION
Readjust, tighten or replace engine mounts.
Yes
No

Yes
No

Yes
No

Repair the wiring harness. Reconnect the TCM connector.
Yes

No
6

NO.19 EXCESSIVE SHIFT SHOCK ON TORQUE CONVERTER CLUTCH (TCC) [SRSSS]

19
DESCRIPTION
POSSIBLE
CAUSE
Excessive shift shock on torque converter clutch (TCC)

Strong shock is felt when TCC is engaged.
The troubleshooting flow is the same as No.16 "JUDDER UPON TORQUE CONVERTER CLUTCH
(TCC) OPERATION".
05-03-21

NO.20 NOISENIBRATION FORWARD OR REVERSE [SRSSS]
20
DESCRIPTION
POSSIBLE
CAUSE
id0503c1814600
Transmission noisy in all positions and ranges.

Improper fluid level
Transmission shift cable and bracket damaged or misadjusted.
Digital transmission range (TR) sensor damaged
Line pressure high/low
One-way clutch
Transmission oil cooler
Gear
Torque converter
Note
STEP
1
FLUID
Does the following problem exist?

Improper level.

Transmission shift cable and bracket
damaged or misadjusted. Digital
transmission range (TR) sensor damaged.
SHIFT LINKAGES (INTERNAL!

EXTERNAL)
IMPROPER PRESSURES

Transmission oil cooler lines fill tube
grounding.
GEAR

One-way clutch damaged, worn,
misassembled.
OTHER

Gear noise.
TORQUE CONVERTER CLUTCH

ASSEMBLY

Torque converter internal malfunction
preventing lockup piston application.
10
ACTION
Yes
Adjust to proper level.
No
Go to Step 2.
Yes
Inspect for damage. Readjust as required.

Repair all damaged components.
After repairing linkages, readjust the digital TR sensor.
Go to Step 3.
No
Yes
Perform line pressure and stall speed tests.

If pressure is high/low, check the pump assembly.
No
Go to Step 4.
Yes
Inspect and repair as required.

Tighten screws to specification.
No
Go to Step 5.
Yes
Repair one-way clutch.
No
Go to step 6.
Yes
Repair one-way clutch.
No
Go to Step 7.

One-way clutch damaged, worn,
misassembled.
REAR ONE-WAY CLUTCH ASSEMBLY
Do any of the following problems exist?

Internal leakage, cavitations.
Screws out of torque specification.

ASSEMBLY

Improper band/clutch application pressures,
line pressure high/low.
PUMP ASSEMBLY
INSPECTION
Before following the troubleshooting steps, make sure that the Automatic Transmission On-Board
Diagnostic and Automatic Transmission Basic Inspection are conducted.
Yes
Relocate transmission oil cooler lines or fill tube properly.
No
Go to Step 8.
Yes
Repair planetary gear assemblies.
No
Go to Step 9.
Yes
Go to symptom troubleshooting NO.16 "JUDDER UPON

TORQUE CONVERTER CLUTCH (TCC) OPERATION".
No
Go to symptom troubleshooting "SYMPTOM

TROUBLESHOOTING ITEM TABLE".

05-03-22

NO.21 NO ENGINE BRAKING IN 1 GR POSITION OF MANUAL 1 RANGE [5R55S]
21
DESCRIPTION
POSSIBLE
CAUSE
id0503c1814000
No engine braking in 1 GR position of manual 1 range
Engine speed drops to idle but vehicle coasts when accelerator pedal is released when in 1GR of
manual 1 range at low vehicle speed.

Line pressure low
Pressure control solenoid A and B malfunction
Reverse servo malfunction
Reverse band malfunction
Note
STEP
INSPECTION
Do the following symptoms concurrently
occur?
- Engine flares up or slips during
acceleration.
- Engine flares up or slips when shifting.
ACTION
Yes
No
Go to symptom troubleshooting NO.14 "ENGINE FLARES

UP OR SLIPS WHEN UPSHIFTING OR DOWNSHIFTING"
or NO.15 "ENGINE FLARES UP OR SLIPS WHEN
ACCELERATING VEHICLE".
Repeat the basic inspection and repair or replace any
malfunctioning parts according to the inspection result.

05-03-23

NO.22 TRANSMISSION OVERHEATS [5R55S]
22
DESCRIPTION
POSSIBLE
CAUSE
id0503c1814100
Burnt smell emitted from transmission.
Smoke emitted from transmission.
The malfunction maybe restriction in the cooling system. The technician needs to diagnose the
complete cooling system. Include coolers, line, and hoses. In addition, overheating of the transmission
may be caused by a malfunction of the TFT sensor.
1. Burning (TCC)
Line pressure
Improper fluid level
2. Oil cooler malfunction (Foreign material mixed ATF)
3. Excessive amount of ATF
Excessive tow load
Vehicle over load
Engine concern
Note
STEP
1
INSPECTION
Inspect oil cooler pipes for bending, damage,
corrosion or kinks.
Are the oil cooler pipes normal?
Yes
No
Is the line pressure normal.

[5R55S].)
Yes
No

[5R55S].)
Check the value at the following PCM PIDs using
the IDS/PDS.
TFT
TCC
PCA
PCB
PCC
ohms?
Inspect pressure control solenoid A, Band C.
Is it normal?
Yes
No

inspection results.
Yes
No

Yes
No

Reconnect the TCM connector.
Yes
Clean and inspect main control and the thermo static

bypass valve. If parts are damaged, replace main control.
ACTION
Replace any malfunctioning parts.
No
05-03-24

NO.23 ENGINE STALLS WHEN SHIFTED TO D RANGE, OR IN R POSITION [SRSSS]
23
DESCRIPTION
POSSIBLE
CAUSE
id0503c1814200
Engine stalls when shifted to D range, or in R position

Engine stalls when shifting from N or P position to D range or R position at idle.
The malfunction is on the engine control side (i.e. Electronic throttle control system). Otherwise, the
malfunction is in the TSS sensor (engine sometimes starts).
STEP
1
INSPECTION
Go to symptom troubleshooting No.10 "LOW
IDLE/STALLS DURING DECELERATION".
Is the engine control system normal?
Yes
No
AC,TION
Repeat basic inspection and repair or replace any
(See OS-03-4 BASIC INSPECTION [SRSSS].)
inspection results.

Ifthe vehicle repaired, the troubleshooting is completed .
If the vehicle the not repaired or additional diagnostic information is not available, replace the TCM ..
NO.24 ENGINE STALLS WHEN DRIVING AT SLOW SPEEDS OR STOPPING [SRSSS]

24
DESCRIPTION
. POSSIBLE
CAUSE
id0503c1814300
Engine stalls when driving at slow speeds or stopping

Engine stalls when brake pedal is depressed while driving at low speed or stopping.
The malfunction on engine control side (e.g. Fuel injection control, Electronic throttle control system)
Otherwise, the malfunction is in the control valve body, TCC control solenoid or TCC and one-way
clutch.
STEP
INSPECTION
Go to symptom troubleshooting No.1 0 "LOW
IDLE/STALLS DURING DECELERATION".
Go to symptom troubleshooting No.S "ENGINE
STALLS-AFTER START/AT IDLE".
Yes
No
Yes
No
3
ACTION
inspection results.
Repeat the basic inspection and repair or replace any
(See OS-03-4 BASIC INSPECTION [SRSSS].)
inspection results.

NO.2S STARTER DOES NOT WORK [SRSSS]
25
DESCRIPTION
POSSIBLE
CAUSE
id0503c1814400

Starter does not work even when in P or N position.
Selector lever misadjustment
Digital TR sensor misadjustment
Open or short circuit in digital TR sensor
TCM malfunction
Vehicle harnesses
Shift cable misadjustment
Fluid pump
Torque converter
05-03-25
CLUTCH .................. 05-10
MANUAL TRANSMISSION
[R15M-D] ................ 05-11A
05-10
MANUAL TRANSMISSION
[S15M-D, S15MX-D] ........ 05-118
SERVICE TOOLS ........... 05-60
CLUTCH
CLUTCH LOCATION INDEX .........

GENERAL PROCEDURES
(CLUTCH) ............
CLUTCH FLUID INSPECTION ......
CLUTCH FLUID AIR
BLEEDING/REPLACEMENT .......
CLUTCH PEDAL ADJUSTMENT ......
CLUTCH PEDAL
REMOVAUINSTALLATION ......
CLUTCH PEDAL
REMOVAUINSTALLATION ........
05-10-2 .
05-10-3
05-10-3
05-10-3
05-10-4
05-10-5
05-10-6
05-10-6
05-10-8

REMOVAUINSTALLATION ........ 05-10-10
DISASSEMBLY/ASSEMBLY ........ 05-10-11
CLUTCH UNIT
REMOVAUINSTALLATION ...... 05-10-12
CLUTCH COVER INSPECTION ...... 05-10-16
CLUTCH DISC INSPECTION ........ 05-10-17
CLUTCH RELEASE COLLAR
INSPECTION ............... 05-10-17
PILOT BEARING INSPECTION ..... 05-10-18
FLYWHEEL INSPECTION [R15M-D] .. 05-10-18
DUAL-MASS FLYWHEEL
INSPECTION [S15M-D, S15MX-D] ... 05-10-19
05-10-1
CLUTCH
CLUTCH LOCATION INDEX
dcf051016003w01
R15M-D
DBG510ZWB006
Clutch pipe
(See 05-10-3 GENERAL PROCEDURES
(CLUTCH).)
Brake fluid reservoir tank
(See 05-10-3 CLUTCH FLUID INSPECTION.)
(See 05-10-3 CLUTCH FLUID AIR BLEEDING/
REPLACEMENT.)
Clutch pedal
(See 05-10-4 CLUTCH PEDAL ADJUSTMENT.)
(See 05-10-5 CLUTCH PEDAL REMOVAU
INSTALLATION.)
Clutch master cylinder

(See 05-10-6 CLUTCH MASTER CYLINDER
(See 05-10-8 CLUTCH MASTER CYLINDER
Clutch release cylinder

(See 05-10-10 CLUTCH RELEASE CYLINDER
05-10-2
Clutch unit
(See 05-10-12 CLUTCH UNIT REMOVAU
INSTALLATION.)
Clutch cover
(See 05-10-16 CLUTCH COVER INSPECTION.)
Clutch disc
(See 05-10-17 CLUTCH DISC INSPECTION.)
Clutch release collar
(See 05-10-17 CLUTCH RELEASE COLLAR
INSPECTION.)
Pilot bearing
(See 05-10-18 PILOT BEARING INSPECTION.)
Flywheel [R15M-D] or dual-mass flywheel [S15M-D,
S15MX-D]
(See 05-10-18 FLYWHEEL INSPECTION [R15M-D].)
(See 05-10-19 DUAL-MASS FLYWHEEL
INSPECTION [S15M-D, S15MX-D].)
9
10
11
CLUTCH
GENERAL PROCEDURES (CLUTCH)
dcf051016003w02
Caution
Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid
does get on painted surfaces, wipe it off immediately.
Note
If any hydraulic related parts of the clutch system are removed during the procedure, add clutch fluid
(brake fluid), bleed air from the system and inspect for leakage after the procedure has been completed.
1. Remove the clutch pipe using the SST (4902597708).
2. Install the clutch pipe using a torque wrench and the SST (49 0259 7708).
CLUTCH FLUID INSPECTION
dcf051016010w01
1. Inspect whether the fluid level in the clutch fluid (brake fluid) reservoir tank is between MIN and MAX.
CLUTCH FLUID AIR BLEEDING/REPLACEMENT
dcf051016010w02
Caution
Fluid will damage painted surfaces. Be careful not to spill any on painted surfaces. If fluid does get
on painted surfaces, wipe it off immediately.
Keep the fluid level in the reserve tank at 3/4 full or more during air bleeding.
Note
When replacing the fluid, drain the old fluid, fill the reserve tank with new fluid and then perform Steps 17 below.
Specified fluid
1. Remove the bleeder cap from the clutch release cylinder, and connect a vinyl hose to the bleeder plug.
2. Place the other end of the vinyl tube in a clear container, and fill fluid in the container during air bleeding.
3. Working with two people, one should depress the clutch pedal a few times and then depress and hold the pedal
down.
4. While the clutch pedal is being held down, the other person should loosen the bleeder screw using the SST,
and bleed any fluid containing air bubbles. Once completed, tighten the bleeder screw.
5. Continue to perform Steps 3 and 4 until no air comes from the vinyl hose.
6. Tighten the bleeder screw using the SST.
,------;;;-----;;....,..----,--------------,
Tightening torque
5.9-8.8 Nm {61-89 kgfcm, 53-77 inlbf}
7. Fill the reserve tank to MAX with the
recommended fluid.
8. Perform the following inspections:
Clutch operation
Fluid leakage
Fluid level
DBG510ZWB002
05-10-3
CLUTCH
CLUTCH PEDAL ADJUSTMENT
dcf051 041 030w01
Clutch Pedal Stroke Inspection/Adjustment

1. Measure the clutch pedal stroke.
If there is any malfunction, loosen locknut A
and adjust the pedal stroke by clutch switch B.
Tighten locknut A after adjustment.
Clutch pedal stroke
152 mm {5.98 in}
1,,-_....
',I'
'/ I
I'
/ /'
1/ /
I ,I
/1 I
I"
/1 /
I 1/
1/ I
I /'
1/ I
1/
1/ I I / '
' J
~I
",
",
", ,,,
"
", ",
", ",
I
I I II
\
~ \
\.
\.\,'~"\.
\
,'....- '
\.
........
('ill.
' I III
',III
"i i ,
"1/
Nm
{kgfcm, inlbf}
DBG510ZWB013
Clutch Pedal Play Inspection/Adjustment

1. Lightly depress the clutch pedal by hand until
clutch resistance is felt and then measure the
pedal play.
Clutch pedal play
5-15 mm {0.20-0.59 in}
Clutch pedal push rod play (Reference value)

0.1-0.5 mm {0.004-0.020 in}
2. If it is not within the specification, loosen locknut
C and turn push rod D to adjust the pedal play.
3. Remeasure the pedal play and, if it is within the
specification, tighten locknut C.
11.76-16.66
{120.3-169.8,104.4-147.4}
Nm
{kgf.cm, inlbf}
DBG510ZWB014
05-10-4
CLUTCH
Clutch Disengagement Point Inspection
2. Without depressing the clutch pedal, move the shift lever slowly to the reverse position until gear noise is heard
and hold the lever in that position.
3. Slowly depress the clutch pedal and hold at the point where the gear noise stops (clutch disengagement point).
4. Measure distance A (from pedal not depressed to
clutch disengagement point) and verify that it is
Clutch disengagement stroke (Reference
value) [R15M-D]
A: 100-130 mm {3.94-5.11 in}
I
I
I
I
I
I
Clutch disengagement stroke (Reference

value) [S15M-D, S15MX-D]
A: 110-125 mm {4.34-4.92 in}
CHU0510W006
Clutch Switch Inspection

2. Disconnect the clutch switch connector.
3. Verify continuity as indicated in the table.
0---0 : Continuity
Condition
Terminal
A
Clutch pedal
depressed
Clutch pedal
released
DBG510ZWBOOl
CHU0510W007
If there is any malfunction, replace the clutch switch.
CLUTCH PEDAL REMOVAL/INSTALLATION
dcf051041030w02
1. The clutch pedal is mounted on the bracket integrated with the brake pedal and accelerator pedal. Refer to
section 01, INTAKE AIR SYSTEM, ACCELERATOR PEDAL REMOVAUINSTALLATION for the brake pedal
removal/installation. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL3].) (See 01-138-11 ACCELERATOR PEDAL COMPONENT REMOVAUINSTALLATION [WL-C, WE-C].)
05-10-5
CLUTCH
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY
dcf051 041 030w03
1. Remove the accelerator pedal component. (See 01-13A-9 ACCELERATOR PEDAL COMPONENT REMOVAL/
INSTALLATION [WL-3].) (See 01-13B-11 ACCELERATOR PEDAL COMPONENT REMOVAL/INSTALLATION
[WL-C, WE-C].)
4. Inspect and adjust the clutch pedal. (See 05-10-4 CLUTCH PEDAL ADJUSTMENT.)
7
11.76-16.66
{120.3-169.8,104.4-147.4}
Nm
{kgfcm, inlbf}
DBG510ZWB015
1
2
3
4
5
Clutch switch
Nut
Stopper rubber
Retaining ring
Pin
6
7
8
9
10
Bush
Nut
Push rod
Fork
Pedal pad
CLUTCH MASTER CYLINDER REMOVAUINSTALLATION
dcf051041990w01
Caution
Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If it is

3. Bleed the air from the system.
(See 05-10-3 CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)
4. Inspect and adjust the clutch pedal.
05-10-6
CLUTCH
R1SM-D
18.6-25.5 {1.90-2. 60 , 13.7-18.8}
------;-;---
16-22
16}
{1.7-2.2,12-
mJ*
Nm {kgfm, ftlbf}
*49 0259 770B
I
----I 1-=:::;~lrC:CYViirln~~de~r======~==
-----
S15M-D,
==---------
-3
4
ClutC.h master
. Packing
DBG510ZWB020
_ __
S1 SMX-D
18.6-25.5
37-18.8}
{1.9D-2.60, 1 .
5m
()fo~
&
j~-\
16--"
16)
{1.7-2.2,12-
mJ*
1m
Nm {kgf.m, ft.lbf}
*49 0259 770B
DBG510ZWB016
\,
1
2
3
IClutch
Hose clip
pipe
Nut
4
1 5
IClutc.h master cylinder

Packing
05-10-7
CLUTCH
CLUTCH MASTER CYLINDER DISASSEMBLY/ASSEMBLY
dcf051041990w02
1. Disassembre in the order indicated in the table.

R15M-D
...- 83.3-112.7 Nm
{8.5-11.4kgf.m,61.5-83.1 tt.lbf}
DBG510ZWB021
2
3
4
5
Snap ring
(See 05-10-9 Snap Ring Disassembly/Assembly
Note.)
Piston
Spacer
Primary cup
Return spring
Tank cap
05-10-8
7
8
9
10
11
12
13
14
Reservoir
Bushing
Joint bolt
Packing
One-way valve piston
Return spring
One-way valve pin
Clutch master cylinder body
CLUTCH
S1SM-D, S1SMX-D
83.3-112.7 Nm
{4.50-11.49 kgfm, 61.44-83.12 ftlbf}
iii
11 9
1110 0
~
iii
/~
1I1i1~
39.0-53.9 Nm
~
~
{3.98-5.49 kgfm, 28.8-39.7 ftlbf} ~
DBG510ZWB017
1
2
3
4
5
6
7
8
Hose clip
Reserve tank hose
Joint
Bushing
Clutch damper
Packing
Joint bolt
Packing
9
10
11
12
13
14
One-way valve piston

Return spring
One"way valve pin
Snap ring
(See 05-10-9 Snap Ring Disassembly/Assembly
Note.)
Piston component
Clutch master cylinder body
Snap Ring Disassembly/Assembly Note

1. While pressing the piston in with a cloth-wrapped
pin punch to protect the push rod contacting
surface, remove/install the snap ring.
CHU0510W003
05-10-9
CLUTCH
CLUTCH RELEASE CYLINDER REMOVAUINSTALLATION
dcf051041920w01
Caution
Fluid will damage painted surfaces. Be careful not to spill any fluid on painted surfaces. If fluid
does get on painted surfaces, wipe it off immediately.
(See 05-10-3 CLUTCH FLUID AIR BLEEDING/REPLACEMENT.)
4. Inspect and adjust the clutch pedal.
21.6-26.5 Nm
{2.21-2.70 kgfm,
16.0-19.5 It.lbf}
mJ'2
'49 0259 770B

DBG510ZWB003
Return spring (815M-D, 815MX-D)

Clutch hose
05-10-10
IClutch release cylinder
CLUTCH
CLUTCH RELEASE CYLINDER DISASSEMBLY/ASSEMBLY
dcf05104192Ow02

5.9-8.8 Nm {61-89 kgfcm, 53-77 inlbf}
DBG510ZWB004
2
3
4
Boot
Push rod
Piston, piston cup component
Return spring
5
6
7
Bleeder cap
Bleeder screw
Clutch release cylinder body
05-10-11
CLUTCH
CLUTCH UNIT REMOVAUINSTALLATION
dcf051016000w01

R15M-D:
96.1-102.9 {9.80-10.49, 70.88-75.89}
S15M-D, S15MX-D:
151.3-161.1 {15.43-16.42, 111.6-118.8}
R15M-D
mil
S15M-D, S15MX-D
':l)
R15M-D
>
~
Nm {kgf.m, ftlbf}
DBG510ZWB005
Return spring (S15M-D, S15MX-D)

Manual transmission
(See 05-11A-5 TRANSMISSION REMOVAU
INSTALLATION [R15M-Dj.)
(See 05-11 B-5 TRANSMISSION REMOVAIJ
INSTALLATION [S15M-Dj.)
(See 05-11 B-1 0 TRANSMISSION AND TRANSFER
REMOVAUINSTALLATION [S15MX-Dj.)
Boot
Clutch release collar
(See 05-10-17 CLUTCH RELEASE COLLAR
INSPECTION.)
Clutch release fork
Clutch cover
(See 05-10-13 Clutch Cover and Disc Removal
Note.)
(See 05-10-15 Clutch Cover Installation Note.)
05-10-12
Clutch disc
(See 05-10-13 Clutch Cover and Disc Removal
Note.) .
(See 05-10-15 Clutch Disc Installation Note.)
Pilot bearing [R15M-D]

(See 05-10-13 Pilot Bearing Removal Note [R15MD].)
(See 05-10-14 Pilot Bearing Installation Note
[R15M-D].)
10
Flywheel [R15M-D] or dual-mass flywheel [S15M-D,

S15MX-D]
(See 05-10-14 Flywheel [R 15M-D] or Dual-Mass
Flywheel [S15M-D, S15MX-D] Removal Note.)
(See 05-10-15 Flywheel [R15M-D] or Dual-Mass
Flywheel [S15M-D, S15MX-D] Installation Note.)
CLUTCH
Clutch Cover and Disc Removal Note
Caution
When replacing components, always replace as a complete set. [S15M-D, S15MX-D]
Due to the automatic adjustment function of clutch cover, if the old cover assembly is reused, it
must be reinstalled together with its original clutch disc. [S15M-D, S15MX-D]
1. Install the SSTs.

2. Loosen each bolt one turn at a time in a crisscross pattern until spring tension is released.
3. Remove the clutch cover and disc.
DBG510ZWB008
Pilot Bearing Removal Note [R15M-D]

Note
The pilot bearing does not need to be removed unless you are replacing it.
1. Use the SST to remove the pilot bearing.
ADJ4920W005
05-10-13
CLUTCH
Pilot Bearing Installation Note [R15M-D]
1. Use the SSTs to install the pilot bearing.
ENGINE SIDE
..
DBG510ZWB018
TRANSMISSION SIDE
PILOT BEARING
0-0.2 mm {0.0-0.0078 in}
DBG510ZWB019
Flywheel [R15M-D] or Dual-Mass Flywheel [S15M-D, S15MX-D] Removal Note

1. Hold the flywheel or dual-mass flywheel using the SST.
2. Remove the bolts evenly and gradually in a crisscross pattern.
3. Remove the flywheel or dual-mass flywheel.
,----------------------,
4. Inspect for oil leakage from the crankshaft rear oil
seal.
I
crankshaft rear oil seal.
(See 01-10A-17 REAR OIL SEAL
REPLACEMENT [WL-3].)
(See 01-108-18 REAR OIL SEAL
DBG510ZWB009
05-10-14
CLUTCH
Flywheel [R15M-D] or Dual-Mass Flywheel [S15M-D, S15MX-D] Installation Note
1. Clean the crankshaft thread holes.
2. Install the flywheel or dual-mass flywheel to the crankshaft.
3. Hand-tighten the flywheel lock bolts or dual-mass flywheel lock bolts.
4. Install the SST to the flywheel or dual-mass
,---------------------,
flywheel.
5. Gradually tighten the flywheel lock bolts or dualmass flywheel lock bolts in a crisscross pattern.
Tightening torque
R15M-D: 96.1-102.9 Nm {9.80-10.49
kgfm, 70.88-75.89 ft.lbf}
S15M-D, S15MX-D: 151.3-161.1 Nm
{15.43-16.42 kgfm, 111.6-118.8 ftlbf}
DBG510ZWB010
Clutch Disc Installation Note

1. Hold the clutch disc position using the SST.
ADJ4920W004
Clutch Cover Installation Note

1. Install the SSTs.
2. Tighten the bolts evenly and gradually in a
crisscross pattern.
Tightening torque
R15M-D: 17.6-26.5 Nm {1.80~2.70 kgfm,
13.0-19.5 ft.lbf}
S15M-D, S15MX-D: 25.0-33.0 Nm {2.553.36 kgf.m, 18.5-24.3 ft.lbf}
DBG510ZWB011
0510-15
CLUTCH
CLUTCH COVER INSPECTION
dcf051 01641 Ow01
1. Measure the wear of the diaphragm spring

fingers.
replace the clutch cover.
Clutch disc maximum depth
0.6 mm {0.024 in}
B3E0510W023
2. Measure the flatness of the pressure plate with a

straight edge and a feeler gauge.
Clutch cover maximum clearance
0.3 mm {0.012 in}
3. When checking the diaphragm spring fingers,

mount a dial indicator on the cylinder block.
B3E0510W024
4. Rotate the flywheel or dual-mass flywheel and

check for misaligned diaphragm spring fingers.
Clutch cover maximum height difference
1.0 mm {0.039 in}
DBG510ZWB012
05-10-16
CLUTCH
CLUTCH DISC INSPECTION
1.
2.
3.
4.
dcf05101646Ow01
Remove the clutch disc.

Inspect the lining surface for discoloration and grease/oil contamination.
Inspect the torsion spring for weakness and the rivet for looseness.
Using a vernier caliper, measure the depth
,-----------------------,
between the lining surface and the rivet head.
Clutch disc minimum depth
0.3 mm {0.012 in}

replace the clutch disc.
CHU0510W027
5. Measure the clutch disc runout using a dial

gauge.
Clutch disc maximum runout
0.7 mm {0.028 in}

replace the clutch disc.
6. Install the clutch disc.
CLUTCH RELEASE COLLAR INSPECTION

Caution
Do not clean the clutch release collar with cleaning fluids or a steam cleaner because it is filled
with grease.
1. Remove the clutch release collar.

2. Turn the collar while applying force in the axial
direction, and inspect for sticking, excessive
resistance, and an abnormal noise.
If there is any malfunction, replace the clutch
release collar.
3. Install the clutch release collar.
B3E0510W026
05-10-17
CLUTCH
PILOT BEARING INSPECTION
dcf051011501w01
1. Without removing the pilot bearing, turn the

bearing while applying force in the axial direction.
If there is any malfunction, replace the pilot
bearing.
DBG510ZWB023
FLYWHEEL INSPECTION [R15M-D]
dcf05101150Ow01
1. Remove the flywheel.

Note
using sandpaper.
contacts the clutch disc with the flywheel
installed to the crankshaft.
2. Inspect the surface that contacts the clutch disc
for scratches, nicks, and discoloration.
3. Inspectthe ring gear teeth for damage and wear.
4. Install the flywheel.
DBG510ZWB024
5. Measure the runout of the surface that contacts

the clutch disc using a dial gauge.
Flywheel maximum runout [R15M-D]
0.1 mm {0.004 in}
replace the flywheel.
05-10-18
CLUTCH
DUAL-MASS FLYWHEEL INSPECTION [S15M-D, S15MX-D]
dcf051011500w02
Caution
Do not rework the dual-mass flywheel if it is distorted.
Do not clean the dual-mass flywheel with any kind of fluid. Clean the dual-mass flywheel with a dry
cloth only.
Do not clean the gap between the primary and secondary mass. Only clean the bolt connection
surface and the clutch surface.
1. Remove the dual-mass flywheel.

Note
using sandpaper.
contacts the clutch disc with the dual-mass
flywheel installed to the crankshaft.
2. Inspect the dual-mass flywheel.

Cracks
Worn ring gear teeth
Chipped or cracked ring gear teeth
Surface that contacts the clutch disc for
scratches, nicks, and discoloration.
C3U0510W004
3. Verify that the center of the dual-mass flywheel

does not move.
.
(1) Rotate the dual-mass flywheel or attempt to
move it up and down, and left and right to
verify that the center of the dual-mass
flywheel does not move.
If there is any movement as indicated by
the arrows in the figure, replace the dualmass flywheel with a new one.
4. Verify that the secondary mass rotates by 15

teeth or more.
If it rotates by 15 teeth or more, replace the
dual-mass flywheel.
D3E510ZW8001
05-10-19
CLUTCH
5. Inspect for locating dowels touching the primary
mass of the dual-mass flywheel.
Caution
Make sure that the three locating dowels
are installed.
If the locating dowels are touching the primary

mass of the dual-mass flywheel, replace the
dual-mass flywheel with a new one.
6. Visually inspect the secondary mass.
flywheel.
7. Visually inspect the ring gear on the dual-mass
flywheel.
flywheel.
~-~------J--L-D7--=
~~~~~~~~~~~============~~=
-==--
1linnnnnnnnr
B3E0510W056
F.lING GEAR
D3E510ZW8002
8. Inspect the welded area of the dual-mass

flywheel for grease leakage.
If there is grease leakage, replace the dualmass flywheel.
9. Inspect the dual-mass flywheel runout.

Dual-mass flywheel maximum runout [S1SMD, S1SMX-D]
1.S mm {O.OS9 in}
If it is more than the maximum specification,

replace the dual-mass flywheel.
D3E510ZW8007
05-10-20
CLUTCH
10. Inspect the dual-mass flywheel for the amount of
guide pin projection.
dual-mass flywheel.
=1
11 mm {D.433D}
D3E510ZWB005
11. Rotate the secondary mass left and right and

verify that it rotates within a range of five teeth
without resistance.
12. Inspect the dual-mass flywheel for cracks.
If there are cracks, replace the dual-mass
flywheel.
D3E510ZWB006
05-10-21
05-118 MANUAL TRANSMISSION [S1SM-D, S1SMX-D]

MANUAL TRANSMISSION LOCATION
INDEX [S15M-D, S15MX-D] ........
NEUTRAL SWITCH
REMOVAUINSTALLATION
[S15M-D, S15MX-D] .......
TRANSMISSION OIL INSPECTION
[S15M-D, S15MX-D] ...........
TRANSMISSION OIL REPLACEMENT
[S15M-D, S15MX-D] .........
OIL SEAL (EXTENSION HOUSING)
REPLACEMENT [S15M-D] .....
REMOVAUINSTALLATION
[S15M-D] ...................
05-118-2
05-118-3
05-118-3
05-118-4
05-118-4
05-118-5

INSPECTION [S15M-D] .......... 05-118-5
TRANSMISSION
REMOVAUINSTALLATION
[S15M-D] ................... 05-118-5
TRANSMISSION AND TRANSFER
REMOVAUINSTALLATION
[S15MX-D] ................ 05-118-10
INSPECTION AFTER TRANSMISSION
INSTALLATION [S15M-D] ....... 05-118-12
AND TRANSFER INSTALLATION
[S15MX-D] ................. 05-118-12
05-118-1

MANUAL TRANSMISSION LOCATION INDEX [S15M-D, S15MX-D]
dcfOS110000OwOS
S15M-D
DBG511 BWB001
Transmission oil
(See 05-118-3 TRANSMISSION OIL INSPECTION
[S15M-D, S15MX-D].)
(See 05-118-4 TRANSMISSION OIL
REPLACEMENT [S15M-D, S15MX-D].)
05-118-2

(See 05-118-4 OIL SEAL (EXTENSION HOUSING)
REPLACEMENT [S15M-D].)
MANJJAL TRANSMISSION [S1SM-D, S1SMX-D]

3
Transmission
(See 05-11 B-5 TRANSMISSION REMOVAU
INSTALLATION [S15M-D].)
(See 05-11 B-1 0 TRANSMISSION AND TRANSFER
(See 05-11B-12 INSPECTION AFTER
TRANSMISSION INSTALLATION [S15M-DJ.)
(See 05-11 B-12 INSPECTION AFTER
TRANSMISSION AND TRANSFER INSTALLATION
[S15MX-D].)
Neutral switch
(See 05-118-3 NEUTRAL SWITCH REMOVAU
INSTALLATION [S15M-D, S15MX-D].)

REMOVAUINSTALLATION [S15M-D].)
(See 05-11 B-5 VEHICLE SPEED SENSOR (VSS)
INSPECTION [S15M-DJ.)
NEUTRAL SWITCH REMOVAUINSTALLATION [S15M-D, S15MX-D]

1.
2.
3.
4.
dcf051100000w06

Disconnect the neutral switch connector.
Remove the neutral switch.
Install the new neutral switch and a new packing
to the transmission case.
Tightening torque
25-34 Nm {2.6-3.4 kgf.m, 19-25 ft.lbf}
5. Connect the neutral switch connector.
S1SMX-O
DBG511 BWB002
TRANSMISSION OIL INSPECTION [S15M-D, S15MX-D]
dcf051127001w03

2. Remove oil filler plug.
If the oil is not near the brim of the plug port,
add the specified amount and type of oil.
Transmission case oil [S15M-D, S15MX-D]

4. Install oil filler plug and a new washer.
Tightening torque
40-59 Nm {4.1-6.0 kgfm, 30-43 ftlbf}
OIL FILLER PLUG

DBG511 BWB004
05-118-3

TRANSMISSION OIL REPLACEMENT [S15M-D, S15MX-D]
dcf05112?001w04

2. Remove oil filler plug and drain plug, and then
drain the oil.
3. Clean drain plug.
4. Install drain plug and a new washer.
Tightening torque
40-59 Nm {4.1-6.0 kgf.m, 30-43 ftlbf}
OIL DRAIN PLUG

DBG511 BWB005
5. Add the specified amount and type of oil through

the plug port for oil filler plug to near the brim of
the port.

Type: Mercon Multi-purpose AFT XT-2-QDX .
Capacity (approx. quantity): 3.55 L {3.75 US
qt, 3.12 Impqt}
DBG511 BWB006
6. Install oil filler plug and a new washer.
Tightening torque
40-59 Nm {4.1-6.0 kgf.m, 30-43 ft.lbf}
OIL FILLER PLUG

DBG511 BWBOO?
OIL SEAL (EXTENSION HOUSING) REPLACEMENT [S15M-D]
dcf05111?335w02

2. Drain the transmission oil.
(See 05-118-4 TRANSMISSION OIL REPLACEMENT [S15M-D, S15MX-D].)
3. Remove the propeller shaft.
(See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION.)
4. Remove the oil seal using a flathead screwdriver.
I----~~=i====:------l
DBG511 BMB003
05-118-4

6. Tap a new oil seal into the case using the SST.
8. Add transmission oil.
(See 05-118-4 TRANSMISSION OIL
REPLACEMENT [S15M-D, S15MX-D].)
VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S1SM-D]
dcf051117400w03
Caution
1.
2.
3.
4.

Disconnect the VSS connector.
Remove the VSS.
Apply the specified oil to a new O-ring and install
it on a VSS.
5. Install the VSS.
Tightening torque
7.8-11.0 Nm {80-112 kgfcm, 70-97
in.lbf}
6. Connect the VSS connector.
VEHICLE SPEED SENSOR (VSS) INSPECTION [S1SM-D]

1. Remove the VSS. (See 05-118-5 VEHICLE SPEED SENSOR (VSS) REMOVAL/INSTALLATION [S15M-D].)
2. Measure voltage between terminals of the VSS
while the gear is turning.
Vehicle speed sensor (VSS) voltage [S1SM-D]
S V or less
If the voltage is within the specification, the
VSS is normal. Repair the related wiring
harness.
If the voltage is not within the specification
(tester needle does not move), replace the
VSS.
3. Install the VSS. (See 05-118-5 VEHICLE SPEED
SENSOR (VSS) REMOVAL/INSTALLATION
[S15M-D].)
TRANSMISSION REMOVAL/INSTALLATION [S1SM-D]
DBG511 BWB009
dcf05110000OW07

2. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the front pipe and oxidation catalytic converter. (See 01-158-2 EXHAUST SYSTEM REMOVAU
6. Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no abnormality.
(See 05-118-12 INSPECTION AFTER TRANSMISSION INSTALLATION [S15M-D].)
05-118-5

Except Hi-Rider
REGULAR CAB
-!r.
7H10?~~
N
{80-112 kgfcm,
70-99 inlbf}
~ r=---
~
I
16
4Jr- 36.5-46.1
{3.73-4.70,
27.0-34.0}
Nm {kgfm, ftlbf}
DBG511 BWBOl 0
14
Back-up light switch connector
15
Vehicle speed sensor connector
16
Crossmember
(See 05-11 B-8 Cross member Removal Note [Except
Hi-Rider].)
Dust boot
17
Bolt
Change boot upper plate
18
Bolt
Transmission mount rubber .
(See 05-11 B-8 Transmission Removal/installation
Note.)
Shift lever knob

Console (regular cab) or boot panel (except regular
cab)
(See 09-17-12 CONSOLE REMOVAU
INSTALLATION.)
3
4
5
6
7
Boot
19
Dust boot
Gasket
Wave washer
9
10
Change bush
Shift lever
11
12
Change seat
13
20
Transmission mount bracket

Note.)
21
Transmission
Note.)
22
Front pipe bracket
05-118-6
(-

Hi-Rider
--&
7.>-11.0?~ ~
N
{80-112 kgfcm,
70-99 inlbf}
15.7-22.5
{1.61-2.29,
11.6--16.5}
31.4-46.1
{3.21-4.70,
23.2-34.0}
36.5-46.1
{3.73-4.70,
27.0-34.0}
Nm {kgfm, ftlbf}
DBG511BWB011
1
2
3
4
Shift lever knob
12
800t panel
INSTALLATION.)
13

14
15
8ack-up light switch connector

Vehicle speed sensor connector
16
Crossmember
(See 05-118-8 Transmission Removal/installation
Note.)
17
Transmission mount rubber

Note.)
Transmission
Note.)
Front pipe bracket
Dust boot
800t
6
7
Dust boot
Gasket
Wave washer
9
10
Change bush
Shift lever
11
Change seat
18
19
05-118-7

Crossmember Removal Note [Except Hi-Rider]
1. Remove the front parking brake cable as shown in
the figure. (See 04-12-6 PARKING BRAKE
CABLE REMOVAL/INSTALLATION [WL-C
2. Remove the crossmember.
Transmission Removal/installation Note

Warning
Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged
or cause injury.
Caution
When removing/installing the transmission, do not move it more than necessary so as to prevent
part interference with the body.
1. Support the transmission securely using a transmission jack.

2. Set the transmission jack attachment into the
,...--------------=::-----------,
concavity of the transmission to prevent the
transmission from falling when it is tilted.
3. Remove the following parts:
Crossmember. (Hi-Rider)
Transmission mount rubber.
- Transmission mount bracket. (except HiRider)
4. Remove the transmission installation bolt.
DBG511 BWB015
5. Remove the transmission.

(1) Move the transmission to the rear.
(2) Change the inclination of the transmission
jack to raise the extension housing side.
(3) Lower the transmission jack until the
transmission does not interfere with the
member.
(4) Repeat Steps (1) to (3) (After Step (3) is
completed, a space will be available between
the extension housing and member).
(5) Wind a rope around the transmission after it
has tilted enough.
05-118-8
DBG511 BWB012

Warning
Secure the transmission and
transmission jack properly using a rope,
otherwise the transmission could fall off,
causing damage or injury.
DBG511BWB013
(6) Move the transmission towards the engine

(After the inclination reaches a certain point,
the transmission can be moved towards
engine).
(7) Lower the transmission jack when the
extension housing moves to the position
where it does not interfere with the member.
DBG511BWB014
Shift Lever Component Installation Note

Note
If the extension housing has been removed or the transmission has been disassembled and inspected,
always add the specified type and amount of transmission oil.
1. Add the specified type and amount of oil to the
shift control case.
Shift control case oil [S15M-D]

Capacity (approx. quantity): 220-260 ml
{220-260 cc, 13.42-15.86 cu in}
DBG511AWB014
05-118-9

. TRANSMISSION AND TRANSFER REMOVAUINSTALLATION [S1SMX-D]
dcf05110000Ow08

2. Remove the front propeller shaft and rear propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAU
INSTALLATION.)
3. Remove the front pipe and oxidation catalytic converter. (See 01-158-2 EXHAUST SYSTEM REMOVAU
6. Perform the 'INSPECTION AFTER TRANSMISSION INSTALLATION', and verify that there is no abnormality.
(See 05-118-12 INSPECTION AFTER TRANSMISSION AND TRANSFER INSTALLATION [S15MX-D].)
7.8-11 Nm
14
36-S0
{3.7-S.0,
27-36}
31.4-46.1
{3.21-4.70, 23.2-34.0}
43-S4
{4.4-5.S,
32-39}
Nm {kgfm, ftlbf}
DBG511BWB018
Shift lever knob
Boot panel
INSTALLATION.)
3
4
Dust boot
05-118-10
5
6
7
8
9
10
Boot
Dust boot
Gasket
Wave washer
Change bush
Shift lever

11 Transfer shift lever
12 Change seat
13 Clutch release cylinder
14 Transfer under cover
15 Neutral switch connector
16 8ack-up light switch connector
17 4x4 indicator switch connector
18 Transfer neutral switch connector
19 Vehicle speed sensor connector
20
21
22
23
24
25
26
Crossmember
Note.)
Transmission
Note.)
Transmission mount component
Front pipe bracket
Transmission mount upper
Transmission rubber
Transmission mount lower
Transmission Removal/installation Note

Warning
Remove the transmission carefully, holding it steady. If the transmission falls it could be damaged
or cause injury.
Caution
When removing/installing the transmission, do not move it more than necessary so as to prevent
part interference with the body.
Note
Two transmission jacks are necessary for the transmission removal/installation.
1. Remove the front differential mount rubber. (See
03-14A-2 FRONT DIFFERENTIAL REMOVAL!

INSTALLATION.)
MOUNT RUBBER
DBG511BWB019
2. Support the transfer side securely using one

transmission jack.
DBG511 BWB020
05-118-11

4. Support the transmission securely using the other
transmission jack.
5. When removing/installing the transmission,
secure the transmission using the transmission
jack attachment to prevent it from tilting to the left
or right.
Caution
Do not allow the transmission jack to
interfere with the transmission mount
bracket bolts, otherwise the bolts could
be damaged.
6.
7.
8.
9.
Remove
Remove
Remove
Install in
the
the
the
the
DBG511 BWB021
first transmission jack.

transmission installation bolts.
transmission.
reverse order of removal.
INSPECTION AFTER TRANSMISSION INSTALLATION [S15M-D]
dcf05110000OW09
Note
Perform the following inspection only when the transmission has been overhauled.
1. Perform a road test and inspect the following items:
(1) No abnormal noise in each shift position.
(2) Smooth shift operation when shifting gears.
(3) No gear slipout after shifting gears.
(4) Back-up light switch operates correctly.
INSPECTION AFTER TRANSMISSION AND TRANSFER INSTALLATION [S15MX-D]
Note
Perform the following inspection only when the transmission or transfer has been overhauled.
1. Perform a road test and inspect the following items:
(1) No abnormal noise in each shift position.
(2) Smooth shift operation when shifting gears.
(3) No gear slipout after shifting gears.
(4) Back-up light switch operates correctly.
05-118-12
dcf05110000OW10
\.'
OS-13
LOCATION INDEX [5R55S] ....... 05-13-2
MECHANICAL SYSTEM TEST
[5R55S] ................. 05-13-4
ROAD TEST [5R55S] ............ 05-13-8
AIR PRESSURE TEST [5R55S] ..... 05-13-10
LEAKAGE INSPECTION [5R55S] .. 05-13-11
AUTOMATIC TRANSMISSION FLUID '
(ATF) INSPECTION [5R55S] ........ 05-13-13
AUTOMATIC TRANSMISSION FLUID
(AT F) REPLACEMENT [5R55S] .... 05-13-16
OlD OFF SWITCH INSPECTION
[5R55S] ................. 05-13-19
DIGITAL TRANSMISSION RANGE
(TR) SENSOR INSPECTION
[5R55S] ................. 05-13-20
[5R55S] ................. 05-13-22
(TR) SENSOR ADJUSTMENT
[5R55S] ................ 05-13-24
TRANSMISSION FLUID TEMPERATURE
(TFT) SENSOR INSPECTION
[5R55S] . . . . . . . . . . . . . . . . 05-13-26
TURBINE SHAFT SPEED (TSS)
SENSOR INSPECTION [5R55S] ... 05-13-28
TURBINE SHAFT SPEED (TSS)
SENSOR REMOVAUINSTALLATION
[5R55S] .............. 05-13-29
SENSOR INSPECTION [5R55S] ...... 05-13-30
[5R55S] ................... 05-13-31
OUTPUT SHAFT SPEED (OSS)
SENSOR INSPECTION [5R55S] ...... 05-13-32
OUTPUT SHAFT SPEED (OSS)

[5R55S] .................... 05-13-33
[5R55S] .................. 05-13-34
SOLENOID BODY
REMOVAUINSTALLATION
[5R55S] ..................... 05-13-35
AT RELAY LOCATION [5R55S] .... 05-13-38
AT RELAY INSPECTION [5R55S] .... 05-13-38
TCM INSPECTION [5R55S] .......... 05-13-39
TCM REMOVAUINSTALLATION
[5R55S] ..................... 05-13-44
REMOVAUINSTALLATION
[5R55S] ....................... 05-13-45
TORQUE CONVERTER INSPECTION
[5R55S] ....................... 05-13-54
TORQUE CONVERTER
REMOVAUINSTALLATION
[5R55S] ....................... 05-13-55
OIL SEAL (FLUID PUMP)
REPLACEMENT [5R55S] .......... 05-13-56
REPLACEMENT [5R55S] ......... 05-13-57
EXTENSION HOUSING GASKET
REPLACEMENT [5R55S] ........... 05-13-58
CONTROL VALVE BODY
REMOVAL [5R55S] ............. 05-13-61
CONTROL VALVE BODY
INSTALLATION [5R55S] ........ 05-13-63
OIL COOLER FLUSHING [5R55S] .... 05-13-67
OIL COOLER
REMOVAUINSTALLATION
[5R55S] ....................... 05~3-68
DRIVE PLATE
REMOVAUINSTALLATION
[5R55S] ................... 05-13-71
05-13-1

AUTOMATIC TRANSMISSION LOCATION INDEX [SRSSS]
id0513c1249000
absggw00001006
05-13-2

1
OlD OFF switch

(See 05-13-19 OlD OFF SWITCH INSPECTION
Automatic transmission fluid

FLUID (ATF) REPLACEMENT [5R55S].)
10
Transmission fluid temperature (TFT) sensor

(See 05-13-26 TRANSMISSION FLUID
TEMPERATURE (TFT) SENSOR INSPECTION
[5R55S].)
Solenoid valve
(See 05-13-34 SOLENOID VALVE INSPECTION
[5R55S].)
(See 05-13-35 SOLENOID BODY REMOVAU
Control valve body
(See 05-13-10 AIR PRESSURE TEST [5R55S].)
(See 05-13-61 CONTROL VALVE BODY REMOVAL
[5R55S].)
(See 05-13-63 CONTROL VALVE BODY
TCM
(See 05-13-39 TCM INSPECTION [5R55S].)
(See 05-13-44 TCM REMOVAUINSTALLATION
[5R55S].)
[5R55S].)
Drive plate
(See 05-13-71 DRIVE PLATE REMOVAU
Turbine shaft speed (TSS) sensor

(See 05-13-28 TURBINE SHAFT SPEED (TSS)
SENSOR INSPECTION [5R55S].)
(See 05-13-29 TURBINE SHAFT SPEED (TSS)
Intermediate shaft speed (ISS) sensor

(See 05-13-30 INTERMEDIATE SHAFT SPEED
(ISS) SENSOR INSPECTION [5R55S].)
(See 05-13-31 INTERMEDIATE SHAFT SPEED
(ISS) SENSOR REMOVAUINSTALLATION
[5R55S].)
Output shaft speed (OSS) sensor
(See 05-13-32 OUTPUT SHAFT SPEED (OSS)
(See 05-13-33 OUTPUT SHAFT SPEED (OSS)
(TR) SENSOR INSPECTION [5R55S].)
[5R55S].)
(TR) SENSOR ADJUSTMENT [5R55S].)
Automatic transmission
[5R55S].)
(See 05-13-11 LEAKAGE INSPECTION [5R55S].)
Oil cooler
(See 05-13-67 OIL COOLER FLUSHING [5R55S].)
(See 05-13-68 OIL COOLER REMOVAU
11
12
13
14
AT relay
(See 05-13-38 AT RELAY LOCATION [5R55S].)
(See 05-13-38 AT RELAY INSPECTION [5R55S].)
15
Torque converter
(See 05-13-54 TORQUE CONVERTER
(See 05-13-55 TORQUE CONVERTER REMOVAU
Oil seal (fluid pump)
(See 05-13-56 OIL SEAL (FLUID PUMP)
(See 05-13-57 OIL SEAL (EXTENSION HOUSING)
Extension housing gasket
(See 05-13-58 EXTENSION HOUSING GASKET
16
17
18
05-13-3

MECHANICAL SYSTEM TEST [5R55S]
id0513c1249100
Mechanical System Test Preparation

1. Engage the parking brake and use wheel chocks at the front and rear of the wheels.
2. Inspect the engine coolant level.
3. Inspect the engine oil level.
4. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
5. Inspect the idle speed.
Line Pressure Test (Pressure Control A, Pressure Control B)
Warning
Removing the plug when the ATF is hot is dangerous. Hot ATF can discharge from the opening
and cause severe burns. Before removing the line pressure tap, allow the AT and ATF to cool.
Caution
Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
Do not maintain WOT in any gear position for more than 5 s.
Note
Certain sensor failures may cause high pressure control, Failure Mode Effect Management (FMEM)
actions. Be sure that the self-test and electrical repairs have been carried out or test results may be
incorrect.
The line pressure tap is used to verify output pressure from pressure control A or pressure control B. Use
PC PIDs and take note which solenoid, pressure control A or pressure control B, is commanded higher.
Use the higher commanded PC x value when referencing the Line Pressure Charts A and B. The second
pressure tap is used to verify the output from the pressure control solenoid C.
Pressure control A, pressure control B
1. Remove the line pressure tap.
2. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
3. Connect the diagnostic scan tool and monitor the
PC A and PC B PIDs. Note which PID is
commanded higher. Use the higher commanded
PC x value when referencing the Line Pressure
Charts A and 8.
4. Start the engine and check the line pressure
reading from the gauge installed in Step 1. Refer
to the Line Pressure Chart for the correct shift
lever position.
If the line pressure is not within ranges given
in Line Charts A and B, refer to Line Pressure
Diagnosis Chart in this section for line pressure concern causes.
absggw00001756
Line pressure (pressure control A, pressure

control B)
Position/range
Line pressure (kPa {kgf/cm2, psi})

Idle
Stall
PIN
793 {B.09, 115}
793 {B.09, 115}
793 {B.09, 115}
2,13B {21.BO, 310}
D,3,2,1
793 {B.09, 115}
1,520 {15.47, 220}
05-13-4

kPa
PSI
2,758
400
2,413
350 -
2,068
300
1,724
250
r---_,r---_.-----.-----r----~----._--_,----_.----_r----._----._----r_--~
- - - PND Line Commanded
Min Line
-
Max Line
t-----t-----t-----t-----~--~r_--~----~----~----~----_+----_+----_+----~
::l
CJ)
CJ)
~
Il.
1,379
200
1,035
150
690
100
_ -
1-------
345
50
o
o
--
_ - -'
Q)
c
::J
---,---,
.............. ~
--1-
.............. I
-- -:-J
---; -
-,
, - , - '' - '
----I-- - '
.""..,.,
-,-'
_--
I....,..,.
- ' -'
-r------i
-,-'
-'...,.-----+-----+-----+-----1
'
- I - - ' -:.,-----+-----+-----+-----t-----t-----r_--~
.",....,
,-,-' - '
I~
-,
.......
--
-'.-----+-----t-----~----r_--~r_--~r_--~----~----_+----~
69
138
207
276
345
414
483
552
621
690
758
827
896
kPa
10
20
30
40
50
60
70
80
90
100
110
120
130
PSI
Commanded PCA or PCB

absggw00001757
kPa
PSI
2,758
400
2,413
350
R Line Commanded
r---
2,068
300
1,724
250
Min Rev Line

-
Max Rev Line
t-----t-----t-----~----r_--~r---~----~----~----~----_+----_+----_-~
.............. --;
::l
CJ)
CJ)
~
Il.
1,379
200
1,035
150 t-----+-----t-----t-----~----I-_------;
Q)
c
::J
690
100
345
50
+-__~----_+--_ _ -::::
'-------
..............
I
.
-'
_ ,;..
-,.,...,.,.
.............. ~
.
..",.,.",..,.",....
-- - ' ---+---i
..................... ,
~.,..,.."
..................... ,
. ..,.,.",.,
-,-'
- -::..... , / - - , --_+----_+----_+-----+----...,
,;.."""" - '
-'-_+----_+----_+----_+-----+-----+-----+-----l
..",..".
69
138
207
276
345
414
483
552
621
690
758
827
896
kPa
10
20
30
40
50
60
70
80
90
100
110
120
130
PSI
-'
.",.",.,.".
..................... ,
_-
Commanded PCA or PCB

f:bsggw00001758
5. Install the line pressure tap.

Tightening torque
10--15 Nm {102--152 kgfcm, 89-132 inlbf}
6. Go to the Pressure Control C Pressure Test in this section.
05-13-5

Pressure Control C
1. If not previously connected, install the scan tool.
2. Remove the line pressure tap.
3. Connect the pressure gauge (SST: 307-004) to
the line pressure tap.
4. Using the diagnostic scan tool, monitor the PC C
PID and note the commanded pressure.
5. Start the engine and check the PC C pressure.
If the gauge reading does not match within
103 kPa {1.05 kgflcm 2 , 15 psi} of the PID
value displayed for the PC C, inspect the
pressure control solenoid C. (See 05-13-34
SOLENOID VALVE INSPECTION [5R55S].)
If pressure control solenoid C operation is
normal, refer to the Line Pressure Diagnosis
Chart in this section for line pressure concern
causes.
Line pressure (pressure control C)
absggw00001759
Line pressure (kPa {kgf/cm 2 , psi})
Position/range
Idle
PIN
R
D,3,2,1
Stall
27 {O.28, 4}
o {O, O}
793 {8.09, 115}
793 {8.09, 115}
o {O, O}
. 27 {O.28, 4}
6. Install the line pressure tap.

Tightening torque
10-15 Nm {102-152 kgfcm, 89-132 inlbf}
Line pressure diagnosis chart
Test Results
High at Idle-All Ranges
Low at Idle-All Ranges
Low-All Forward Ranges

Low in P position Only
Low in R position Only
Low in N position Only
Low in D range
Low in D range Only (OlD OFF mode)
05-13-6
Possible Source
Wiring harnesses
PC C boost valve
Low fluid level
Fluid inlet filterlseal
Control valve body
Cross leaks
Gaskets
Pump
Separator plate
Forward Clutch
Main Control
Control valve body
Separator plate
Reverse servo piston, cover seal
Reverse clutch
Control valve body
Forward clutch
Control valve body
Forward clutch
Control valve body
Forward clutch
Control valve body

Test Results
Possible Source
Low in 1 range
Low in 2 range
Low in 3 range
Forward clutch
Control valve body
Forward clutch
Forward clutch
Stall Speed Test

Warning
Apply the parking brake firmly while performing each stall test. Failure to set the brakes can result
in death or severe injury.
Caution
Perform the line pressure test before performing the stall test. If the line pressure is low at stall
speed, do not perform the stall test or further transmission damage will occur.
The stall test should only be performed with the engine and transmission at normal operating
temperature.
Note
The stall speed test inspects the operation of the following:
Torque converter clutch
Forward clutch
Low/reverse one-way clutch
Low one-way clutch component
Engine driveability concerns
Overdrive one-way clutch component
1. Connect a tachometer to the engine.
Caution
Do not maintain WOT in any shift position for more than 5 s.
If the engine rpm recorded by the tachometer exceeds the maximum specified rpm, release the
accelerator pedal immediately. Otherwise, clutch or band slippage could occur.
Note
Prolonged use of this procedure may set DTC P0712 or P1783. After carrying out the Stall Speed Test,
run the OBD Test and clear DTCs from the memory.
2. Depress the accelerator pedal to the floor (WOT) in each shift position. Record the rpm reached in each shift
position.
Engine stall speed

Engine type
WL-C
WE-C
rpm
2,700
2,900
05-13-7

3. After testing the D, 3, 2, 1 range and R position, shift the selector lever to the N position and run the engine at
1,000 rpm for 15 s to allow the torque converter to cool before testing the next gear position.
If the stall speed is too high, refer to the stall speed diagnosis chart.
Stall speed diagnosis chart
Position/range
D, D (O/D OFF mode) and 1
D (O/D OFF mode), 2 and 1
D
D, D (O/D OFF mode), 2,1 and R
R
2
1
Stall speeds high

Rear one-way clutch
Forward clutch
Forward clutch
General pressure concerns
Forward clutch
High/reverse
High clutch
Low/reverse band/servo
Intermediate band/servo
Intermediate band/servo
Stall speeds low
Converter one-way clutch or engine

driveability concerns
-
4. If the stall speed is too low, inspect the idle speed.

If the idle speed is normal, remove the torque converter and inspect the torque converter one-way clutch for
slippage.
ROAD TEST [5R55S]
id0513c1248900
Warning
When performing a road test, be aware of other vehicles, people, and impediments to avoid an
accident.
Note
Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
When the legal speed limit must be exceeded, use a chassis dynamometer instead of performing a road
test.
Road Test Preparation
1. Inspect the engine coolant level.
2. Inspect the engine oil level.
3. Inspect the ATF level. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
4. Inspect the idle speed.
Shift Point Road Test
Note
This test verifies that the shift control system is operating correctly.
1. Bring up the engine and transmission to normal operating temperature.
2. Shift the selector lever to the D range.
3. Apply minimum throttle and observe speeds at which up-shift occurs and the torque converter engages.
Caution
Do not exceed posted speed limits when performing this test.
05-13--8

Shift speed (Reference) WL-C
Throttle position
Closed
Minimum monitor PIO minimum TP volt

1.25
Wide open
Gear position
5-4
4-1
1-2
2-3
3-4
4-5
1-2
2-3
3-4
4-5
Vehicle speed (kmlh {mph})

33-35 {20-22}
17-19 {10-12}
17-19 {10-12}
21-24 {13-15}
28-30 {17-19}
38-40 {23-25}
42-45 {26-28}
60-62 {37-39}
80-83 {49-52}
115-122 {71-76}
Gear position
5-4
4-1
1-2
2-3
3-4
4-5
1-2
2-3
3-4
4-5
Vehicle speed (km/h {mph})

44-46 {27-29}
17-19 {10-12}
17-19 {10-12}
26-29 {16-18}
31-33 {19-21}
52-54 {32-34}
42-45 {26-28}
61-66 {38-41}
84-91 {52-57}
107-119 {66-74}
Shift speed (Reference) WE-C

Throttle position
Closed
Minimum monitor PIO minimum TP volt

1.25
Wide open
4. Stop the vehicle.

5. Depress OlD OFF switch to activate D range and repeat Step 3.
6. The transmission will make all upshifts except 4-5, and the torque converter clutch application should occur
above 46 km/h {29 mph}.
7. Press the accelerator pedal to the floor, wide open throttle (WOT). The transmission should shift from 3GR to
2GR or 3GR to 1GR depending on vehicle speed, and the torque converter clutch should release.
8. With the vehicle speed above 48 km/h {30 mph}, move the transmission range selector lever from D range to 1
range and release the accelerator pedal. The transmission should immediately downshift to 3GR. When the
vehicle speed drops below 32 km/h {20 mph}, the transmission should downshift into 1st gear.
9. If the transmission fails to up-shift/down-shift or the torque converter does not apply and release, inspect
according to "SYMPTOM TROUBLESHOOTING". (See 05-03-5 SYMPTOM TROUBLESHOOTING ITEM
TABLE [5R55S].)
'05-13-9

AIR PRESSURE TEST [SRSSS]
id0513c1249500
Note
A no-drive or erratic shift condition may be due to inoperative bands and clutches. To diagnose these
conditions a series of checks can be made by substituting air pressure for fluid to determine the location of
the damaged or obstructed component.
Follow the procedure to determine the location of the inoperative clutch or band by substituting air
pressure into the various test plate passages.
Use only dry, regulated air pressure, 276 kPa {2.8 kgflcm 2 , 40 psi} maximum.
1. Remove the control valve body. (See 05-13-61 CONTROL VALVE BODY REMOVAL [5R55S].)
2. Install the transmission test plate and gasket (SST: 307-433-01, 307-433-02, 307-433-03).
Tightening torque
10 Nm {102 kgfm, 111.6-89 ft.lbf}
Note
Do not apply air to the test plate vent hole.
3. Apply air to the appropriate clutch or servo port.
Refer to the Air Pressure Test Diagnostic Chart
for conditions, possible causes and actions.
1
Reverse servo
2
3
4
5
6
7
Intermediate servo
Overdrive servo
Coast clutch
Forward clutch
Direct clutch
Reverse servo modulator
o
absggw00001755
4. After the testing is completed, remove the air test

plate and gasket (SST: 307-433-01,307-433-02,
307-433-03) and proceed with any repairs that are needed.
5. After the repairs are completed, install the control valve body. (See 05-13-63 CONTROL VALVE BODY
Air pressure test diagnostic chart
Condition
Dull thud heard or movement felt when
air is applied and released
No drive
Erratic shifts
No dull thud heard
No movement felt
Hissing sound heard
Servos do not operate
Multiple clutches are applied
05-13-10
Possible causes
Clutches, bands and fluid passages are
normal.
Actions
Concerns may not be in the
transmission. Check the powertrain
TCM, wiring harness and nontransmission related components.
Disassemble the transmission, clean and

inspect to locate area of concern.
Clutches and bands inoperative due to
incorrect pressures.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
be damaged or obstructed.
Clutches, bands and fluid passages may Disassemble the transmission, clean and
be damaged or obstructed.
Clutches and bands inoperative.
Clutch seals or check ball may be

damaged or leaking.
Seals and pistons may be damaged.
Supply and release ports may be
obstructed. Spring may be broken.
Fluid passages in center support or
clutch cylinders may be obstructed.

inspect to locate area of concern.Check
fluid passages in the center support for
obstructions.

LEAKAGE INSPECTION [5R55S]
id0513c1249600
Leak Check Test with a Black Light

Note
Automatic Transmission/Power Steering Dye (specifically formulated for ATF) is used to detect a
transmission fluid leak.
1. Add Automatic Transmission/Power Steering Dye to the transmission fluid. Use one 30.0 mL {30.0 cc, 1 ft oz}
of dye solution for every 3.8 L {4.0 US qt, 3.3 Imp qt} of transmission fluid.
2. Start and run the engine until the transmission reaches its normal operating temperature.
3. Observe the back of the cylinder block and top of the torque converter housing for evidence of fluid leakage.
4. Raise the vehicle on a hoist.
5. Run the engine at fast idle, then at engine idle, occasionally shifting to the D range and R position to increase
pressure within the transmission.
6. Observe the front of the flexplate, back of the cylinder block (in as far as possible), inside the torque converter
housing and the entire case until fluid leakage is evident and the probable source of leakage can be detemined.
Caution
Do not try to stop a fluid leak by increasing the torque beyond specifications. This may cause
damage to the transmission case threads.
External fluid leaks
Possible source
Leak path
Pan bolts not tightened to specification.

Case pan rail damaged.
Pan gasket damaged.
Cooler line(s), cooler line fitting(s) damaged.
Cooler line fittings-to-case union damaged.
Case damage at case fitting.
Fittings not tightened to specifications.
Fluid cooler line nut-to-case fittings leaking
Damaged or missing a-rings.

Fittings not tightened to specifications.
Leaks at the fluid cooler
Fluid cooler damage.

Fitting(s) damaged or not tightened to specifications.
Leaks at the external sensors
Damaged or missing a-rings.

Screw not tightened to specifications.
Leaks at the fluid pan-to-case
Fluid cooler lines or fittings leaking
Leaks at the manual control lever seal

Leaks at the solenoid body harness connector
Fluid leakage in the torque converter area
Damaged or missing lever seal.

Install a new solenoid body wiring harness connector 0ring seal. Either on the wiring harness end or the solenoid
body.
For possible sources refer to Fluid Leakage In Torque

Converter Area Chart.
05-13-11

Fluid Leakage in Torque Converter Area
In diagnosing and correcting fluid leaks in the front pump support and gear and torque converter area, use the
following procedures to locate the exact cause of the leakage.
Leakage at the front of the transmission, as evidenced by fluid around the torque converter housing, may have
several sources.
By careful observation it is possible, in many instances, to pinpoint the source of leak before removing the
transmission from the vehicle.
The paths which the fluid takes to reach the bottom of the torque converter housing are shown in the
illustration.
Leak path
1,2 and 4
1,2 and 4
1,2 and 4
1,2 and 4
1,2 and 4
3
3
5
5
5
5
05-13-12
Symptom
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak at front of
transmission
Leak between
engine and
transmission case
Possible source
Pump lip seal

Converter hub
weld
External pump
seal (large)
Pump-to-case
screws
Pump gasket
Torque converter
seal weld
Torque converter
stud
Engine oil leakrear main seal
Engine valve
cover
Oil galley
Engine oil
pressure sensor
Venting
absggw00001754

AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S]
id0513c1251100
Automatic Transmission Fluid (AT F) Condition Inspection

1. Hold the larger drain plug with a wrench and
r-----------------------,
remove the small (center) fluid level indicating
plug.
2. Check the ATF level.
3. Observe the color and the odor of the ATF.
Under normal circumstances the color should
be dark reddish, not brown or black.
4. Allow the ATF to drip onto a facial tissue and
examine the stain.
If evidence of solid material is found, the fluid
pan should be removed for further inspection.
If ATF contamination or transmission failure is
absggw00001022
confirmed by the sediment in the bottom of
the fluid pan, the transmission must be
disassembled and completely cleaned.
5. Install the small (center) fluid level indicating plug.
Tightening torque
Automatic Transmission Fluid (ATF) Level Inspection
1. Connect the M-MDS to the vehicle DLC-2 16-pin
connector.
2. Verify the ATF temperature using the PID/data
monitor "TFT".
3. Warm up the automatic transmission until the ATF
temperature is 27-49 C {80-120 OF}.
4. Move the range selector lever slowly through
each gear, stopping in each position and allowing
the transmission to engage.
5. Place the selector lever in the P position.

plug.
absggw00001022
7. Install the SST into the pan.

Note
Prior to filling the SST with clean ATF, make
sure that the canister is clean.
307-437
(49 UN30 7437)
arnffwOOOO 1950
05-13-13

8. Fill the SST with clean ATF.
9. Hang the SST under the vehicle. Position it

upright and close to the transmission.
10. Connect the SST.

Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan.
11. Apply a maxjmum of 206.85 kPa {2.11 kgf/cm 2 ,

30.0 pis} to the open end of the vacuum/pressure
hose from the rubber tip air nozzle. Fluid will
immediately start flowing out of the SST into the
fluid pan.
12. Add 0.5 L {0.5 US qt, 0.4 Imp qt} of ATF into the
fluid pan. Stop the process by releasing the air
pressure and removing the air nozzle from the
end of the hose.
13. Inspect the ATF level in the SST.
If the fluid drains back into the canister, the
transmission is full.
If no fluid drains back, more fluid will need to
be added. Repeat Steps 11 and 12.
05-13-14
206.85 kPa
{2.11 kgf/m 2 ,
30.0 pis}
arnffw00001954

14. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
15. Make sure that the ATF temperature is between
27-49 C {80-120 OF}.
16. Allow the ATF to drain.

When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029

Tightening torque
18. Check the operation of the transmission by
moving the selector lever slowly through each
gear, stopping in each position and allowing the
transmission to engage.
ATF
Type: Mercon V
05-13-15

AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SRSSS]
id0513c1251200
Draining
1. Place the selector lever in the P position.
2. Remove the drain plug (large plug) and allow the
ATF to drain.
absggw00001030
Refill
1. Install the drain plug (large plug).
Tightening torque
24-28 Nm {2.S-2.8 kgfm, 18-20 ft.lbf}
absggw00001030

plug.
I~
))QL2J
o(
o~ ~l'
tJ
@
~~L~v
0
absggw00001022
3. Install the SST into the pan.
Note
Prior to filling the SST with clean ATF, make
sure that the canister is clean.
arnffw00001950
05-13-16

4. Fill the SST with clean ATF.
5. Hang the SST under the vehicle. Position it

upright and close to the transmission.
6. Connect the SST.

Connect the open end of the fluid hose from
the SST (307-D465) to the SST (307-437) at
the bottom of the fluid pan.
7. Apply a maximum of 206.85 kPa {2.11 kgflcm 2 ,

30.0 pis} to the open end of the vacuum/pressure
hose from the rubber tip air nozzle. Fluid will
immediately start flowing out of the SST into the
fluid pan.
8. Add 1.89-2.83 L {2.00-2.99 US qt, 1.67-2.49
imp qt} of ATF into the fluid pan. Stop the
process by releasing the air pressure and
removing the air nozzle from the end of the hose.
206.85 kPa
{2.11 kgflm 2 ,
30.0 pis}
arnffw00001954
9. Connect the M-MDS to the vehicle DLC-2 16-pin

connector.
10. Verify the ATF temperature using the PID/data
monitor "TFT".
11. Warm up the automatic transmission until the ATF
temperature is 27-49 C {80-120 OF}.
12. Inspect the ATF level in the SST.
If the fluid drains back into the canister, the
transmission is full.
If no fluid drains back, more fluid will need to
be added. Repeat Steps 7 and 8.
absggw00000987
05-13-17

13. Once the transmission is full, place a hand
vacuum pump on the open end of the vacuum/
pressure hose on the SST and apply vacuum to
the system. This will pull out any extra fluid
trapped in the system and direct it into the
container.
14. Allow the ATF to drain .

When the ATF comes out as a thin stream or
drip, the ATF is at the correct level.
absggw00001029

Tightening torque
ATF
Type: Mercon V
Capacity (approx. quantity): 9.93 L {1 0.49 US
qt, 8.74 Imp qt}
I~
))Q~
r?l'
til~L--,-,v
o(
o~
absggw00001022
05-13-18

010 OFF SWITCH INSPECTION [SRSSS]
id0513c1254200
Operation Inspection
2. Verify that the OlD OFF indicator light is not illuminated. Press the OlD OFF switch and verify that the OlD OFF
indicator light illuminates.
If there is any malfunction, inspect the terminal voltage of the OlD OFF switch. (See 05-13-19 Voltage
Inspection.)
Voltage Inspection
2. Measure the voltage at the OlD OFF switch
connector.
If there is any malfunction, inspect for
continuity at the OlD OFF switch. (See 05-1319 Continuity Inspection.)
Connector terminal
Position
OFF (Normal)
ON (Depressed)
(V)
(V)
C
B+
absggw00001008
1. Disconnect the OlD OFF switch connector.
table.
If the switch is normal, inspect the wiring
harness. (OlD OFF switch-TCM, OlD OFF
switch-Body ground)
selector lever component. (See 05-14-4
SELECTOR LEVER REMOVAU
INSTALLATION.)
0-0 : Continuity
Switch
Terminal
ON (Normal)
OFF (Depressed)
()
-0
absggw00001858
05-13-19

DIGITAL TRANSMISSION RANGE (TR) SENSOR INSPECTION [5R55S]
id0513c1254700
Operating Inspection
1. Verify that the starter operates only when the engine switch is turned to the START position with the selector
lever in the P or N position.
If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
2. Verify that the back-up lights illuminate when shifted to the R position with the engine switch at the ON position.
If there is any malfunction, adjust the digital TR sensor. (See 05-13-24 DIGITAL TRANSMISSION RANGE
3. Verify that the positions of the selector lever and
the indicator are aligned.
If there is any malfunction, adjust the digital
TR sensor. (See 05-13-24 DIGITAL
TRANSMISSION RANGE (TR) SENSOR
ADJUSTMENT [5R55S].)
absggw00001014
Caution
2. Remove the digital TR sensor insulator.
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
3. Disconnect the digital TR sensor connector.
absggw00001812
05-13-20

table.
ADJUSTMENT [5R55SJ.)
0-0 : Continuity
Selector
position
Terminal
0 -0
-0
0
0
Q
-0
D
3
2
absggw00001017
-0
,......
,......
'-'
,......
'-'
0
-0
-0
absggw00001018
5. Reinspect for continuity at digital TR sensor.

If there is any malfunction, replace the digital TR sensor. (See 05-13-22 DIGITAL TRANSMISSION RANGE
(TR) SENSOR REMOVAUINSTALLATION [5R55SJ.)
6. Connect the digital TR sensor connector.
7. Install the digital TR sensor insulator.
Tightening torque
7.S-10.7 Nm {SO-10S kgf.cm, 69.1-94.7
in.lbf}
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
05-13-21

DIGITAL TRANSMISSION RANGE (TR) SENSOR REMOVAUINSTALLATION [5R55S]
id0513c1254800
Caution
DIGITAL TR
SENSOR
INSULATOR
absggw00001811

4. Remove the selector cable.
absggw00001813
5~ Set the adjustable wrench as shown in the figure

to hold the manual shaft lever.
6. Remove the manual shaft nut.
MANUAL SHAFT
LEVER
absggw00001032
8. Remove the digital TR sensor.
DIGITAL TR SENSOR
absggw00001814
05-13-22
/ .

9. Rotate the manual shaft to the torque converter
housing side fully and return two notches to set
the N position.
10. Install the digital TR sensor and loosely install the
screws.
Caution
Tightening one screw before tightening
the other may cause the digital TR sensor
to bind or become damaged.
MANUAL SHAFT
TORQUE
CONVERTER
HOUSING SIDE
Note
absggw00001034
11. Using the SST, align the digital TR sensor and

tighten the screws in an alternating sequence.
Tightening torque
6.5-9.5 Nm {67- 96 kgfcm, 58-84 in.lbf}
Caution
Do not use an impact wrench. Hold the
manual shaft lever when tightening the
manual shaft nut, otherwise the
transmission may be damaged.
12. Install the manual shaft lever.
Tightening torque
61-74 Nm {6.3- 7.5 kgfm, 45-54 ft.lbf}
13. Shift the selector lever to P position.
14. Turn the manual shaft lever to P position.
MANUAL SHAFT
LEVER
15. Install the selector cable.

DIGITAL TR SENSOR CD:::\

CONNECTOR
~
....
SELECTOR CABLE
absggw00001813
Tightening torque
7.8-10.7 Nm {80-108 kgfcm, 69.1-94.7
inlbf}
19. Inspect digital TR sensor operation. (See 05-1320 DIGITAL TRANSMISSION RANGE (TR)
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
05-13-23

DIGITAL TRANSMISSION RANGE (TR) SENSOR ADJUSTMENT [5R55S]
id0513c1254900
Caution
absggw00001811

4. Remove the selector cable.
5. Rotate the manual shaft to the N position.
Caution
manual shaft lever when removing the
DIGITAL TR SENSOR CCb

CONNECTOR
c.SJ
'-
absggw00001813
6. Set the adjustable wrench as shown in the figure

7. Remove the manual shaft nut.
absggw00001032
9. Loosen the digital TR sensor mounting bolts.

Caution
Tightening one screw before tightening
the other may cause the digital TR sensor
to bind or become damaged.
Note
DIGITAL TR SENSOR
absggw00001814
05-13-24

10. Using the SST, align the digital TR sensor and
tighten the screws in an alternating sequence.
Tightening torque
6.5-9.5 Nm {67- 96 kgfcm, 58-84 in.lbf}
u I ) ~/
-~
J
absggw00001035
11. Inspect for continuity between digital TR sensor

terminals A, E and I.
Caution
manual shaft lever when tightening the
absggw00001017
12. Install the manual shaft lever.
Tightening torque
61-74 Nm {6.3-7.5 kgfm, 45-54 ft.lbf}
13. Set the adjustable wrench as shown in the figure
14. Tighten the manual shaft nut using a torque
wrench.
MANUAL SHAFT
LEVER
Tightening torque
14-18 Nm {1.5-1.8 kgfm, 11-13 ft.lbf}
15. Shift the selector lever to P position.
16. Turn the manual shaft lever to P position.
17. Install the selector cable.
DIGITAL TR SENSOR a:::J::\

CONNECTOR
'- ~
SELECTOR CABLE
absggw00001813
Tightening torque
7.8-10.7 Nm {80-108 kgfcm, 69.1-94.7
in.lbf}
21. Inspect digital TR sensor operation. (See 05-1320 DIGITAL TRANSMISSION RANGE (TR)
DIGITAL TR
SENSOR
INSULATOR
absggw00001811
-05-13-25

TRANSMISSION FLUID TEMPERATURE (TFT) SENSOR INSPECTION [5R55S]
id0513c1710300
Caution
On-Vehicle Inspection
3. Remove the CKP sensor insulator.
4. Remove the insulator bracket.
5. Disconnect the AT connector.
absggw00001183
6. Measure resistance between the AT terminals K

and L.
If there is any malfunction, perform the offvehicle inspection for TFT sensor. (See 0513-27 Off-Vehicle Inspection.)
ATF temperature (OC ("F})
Resistance (kilohm)
-40--20 {-40--4}
284-967
-19--1 {-3-30}
100-284
0-20 {32-68}
37-100
21-40 {70-104}
16-37
41-70 {106-158}
5-16
2.7-5
71-90 {160-194}
91-110 {196-230}
1.5-2.7
111-130 {232-266}
0.8-1.5
131-150 {268-302}
0.54-0.8
absggw00001184
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAU
05-13-26

Off-Vehicle Inspection
Warning
A hot the transmission and ATF can cause severe burns. Turn off the engine and wait until they are
cool before replacing ATF.
1. Remove the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAUINSTALLATION [5R55S].)
2. Place the solenoid body and a thermometer in ATF as shown in the figure, and heat the ATF gradually.
3. Measure the resistance between the solenoid
body terminals K and L.
solenoid body. (See 05-13-35 SOLENOID
BODY REMOVAUINSTALLATION [5R55S].)

Resistance (kilohm)
ATF temperature eC ("F})
-40--20 {-40--4}
-19--1 {-3-30}
0-20 {32-68}
21-40 {70-104}
41-70 {106-158}
71-90 {160-194}
91-110 {196-230}
111-130 {232-266}
131-150 {268-302}
284--967
100-284
37-100
16-37
5-16
2.7-5
1.5-2.7
0.8-1.5
0.54--0.8
absggw00001185
4. Install the solenoid body. (See 05-13-35 SOLENOID BODY REMOVAUINSTALLATION [5R55S].)
05-13-27

TURBINE SHAFT SPEED (TSS) SENSOR INSPECTION [5R55S]
id0513c1252900
Caution
1.
2.
3.
4.

Remove the oxidation catalytic converter.
Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
6. Disconnect the TSS sensor connector.
Caution
Do not apply a shock in the TSS sensor.
absggw00001186
7. Measure the resistance between the TSS sensor

terminals.
If there is any malfunction, replace the TSS
sensor. (See 05-13-29 TURBINE SHAFT
SPEED (TSS) SENSOR REMOVAU
TSS sensor resistance

Resistance (ohm)
226-390
325-485
492-738
Temperature (OC eF})

-20 {4}
21 {70}
150 {302}
{I
I~~I
absggw00001189
. 8. Connect the TSS sensor connector.

9. Install the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
10. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
11. Install the oxidation catalytic converter.
05-13-28

TURBINE SHAFT SPEED (TSS) SENSOR REMOVAUINSTALLATION [5R55S]
id0513c1253000
Caution
Do not damage the TSS sensor.
1.
2.
3.
4.

6. Disconnect the TSS sensor connector.
7. Remove the TSS sensor.
Note
Inspect O-ring for damage. Install new 0ring if damaged. Lubricate the O-ring with
petroleum jelly to prevent damage to the 0ring.
8. Install the TSS sensor.
Tightening torque
8-12 Nm {82-122 kgfcm, 71-106 in.lbf}
absggw00001186
9. Connect the TSS sensor connector.

05-13-29

INTERMEDIATE SHAFT SPEED (ISS) SENSOR INSPECTION [5R55S]
id0513c1253400
Caution
1.
2.
3.
4.

Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
REMOVAL/INSTALLATION [5R55S].)
6. Disconnect the ISS sensor connector.
Caution
Do not apply a shock in the ISS sensor.
absggw00001187
7. Measure the resistance between the ISS sensor

terminals.
If there is any malfunction, replace the ISS
sensor. (See 05-13-31 INTERMEDIATE
SHAFT SPEED (ISS) SENSOR REMOVAL/
ISS sensor resistance

Resistance (ohm)
226-390
325-485
492-738
Temperature (OC eF})

-20 {4}
21 {70}
150 {302}
I)
I~~I
absggw00001189
8. Connect the ISS sensor connector.

10. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
05-13-30

INTERMEDIATE SHAFT SPEED (ISS) SENSOR REMOVAUINSTALLATION [SRSSS]
id0513c1253500
Caution
Do not damage the ISS sensor.
1.
2.
3.
4.

Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [SAT].)
6. Disconnect the ISS sensor connector.
7. Remove the ISS sensor.
Note
Tt---rc:"......::,,--_ISS SENSOR
CONNECTOR
8. Install the ISS sensor.
Tightening torque
8-12 Nm {82-122 kgf.cm, 71-106 in.lbf}
absggw00001187
9. Connect the ISS sensor connector.

11. Install the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
05-13-31

OUTPUT SHAFT SPEED (OSS) SENSOR INSPECTION [5R55S]
id0513c1254000
Caution
1.
2.
3.
4.

6. Disconnect the OSS sensor connector.
Caution
Do not apply a shock in the OSS sensor.
OSS SENSOR
CONNECTOR
~
~
'J/
OSS SENSOR
~-~
~
h
...........
--"-~
.--:;:::::::; I
~~
absggw00001188
7. Measure the resistance between the OSS sensor

terminals.
If there is any malfunction, replace the OSS
sensor. (See 05-13-33 OUTPUT SHAFT
SPEED (OSS) SENSOR REMOVAU
OSS sensor resistance

Resistance (ohm)
Temperature (Oe eF})
226-390
325-485
492-738
-20 {4}
21 {70}
150 {302}
absggw00001189
8. Connect the OSS sensor connector.

05-13-32

OUTPUT SHAFT SPEED (OSS) SENSOR REMOVAUINSTALLATION [SRSSS]
id0513c1254100
Caution
Do not damage the OSS sensor.
,1.
2.
3.
4.

6. Disconnect the OSS sensor connector.
7. Remove the OSS sensor.
Note
OSS SENSOR
8. Install the OSS sensor.
Tightening torque
12-16 Nm {123-163 kgfcm, 107-141
in.lbf}
absggw00001188
9. Connect the OSS sensor connector.

05-13-33

SOLENOID VALVE INSPECTION [5R55S]
id0513c1253200
Caution
1.
2.
3.
4.
5.

Remove the digital TR sensor insulator.
Remove the CKP sensor insulator.
Remove the insulator bracket.
absggw00001183
6. Measure the resistance between the following
terminals.
If there is any malfunction, inspect the coupler
component.
If the coupler component is normal, replace
the solenoid body. (See 05-13-35 SOLENOID
BODY REMOVAUINSTALLATION [5R55S].)
Solenoid valve resistance)

Terminals
Solenoid valve
D-I
F-I
8-1
E-I
Shift solenoid A
Shift solenoid 8
Shift solenoid e
Shift solenoid D
Pressure control
solenoid A
Pressure control
solenoid 8
Pressure control
solenoid e
Tee control
solenoid
0-1
M-I
G-I
H-I
Resistance
(ohm)
16-45
16-45
16-45
16-45
absggw00001184
3.3-7.5
3.3-7.5
3.3-7.5
9-16
7. Connect the AT connector.

8. Remove the insulator bracket. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
(
05-13-34

SOLENOID BODY REMOVAL/INSTALLATION [5R55S]
id0513c1254400
On-Vehicle Removal
Warning
A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
Caution
Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.
1.
2.
3.
4.
5.
6.

Drain the ATF. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].)
Note
reusable. Clean and inspect the gasket for
damage. If not damaged, the gasket should
be reused.
absggw00001183
7. Remove the screws, transmission fluid pan and

gasket.

Caution
pins.
o
b5r5za00000015
05-13-35

b5r5za00000018
On-Vehicle Installation
Caution
and not damaged. If damaged,
b5r5za00000272

sequence shown.
Tightening torque
7-9 Nm {72-91 kgf.cm, 62-79 inlbf}
Caution
damaged.
b5r5za00000273

fluid filter.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 inlbf}
Note
b5r5za00000275
05-13-36

4. Install the transmission fluid pan gasket on the
pan.
Note
reusable, clean and inspect for damage. If
GASKET
absggw00001562
5. Install the transmission fluid pump and gasket,

6. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5-11.5 Nm {97-117 kgfcm, 85-101
in.lbf}
Caution
Damage will occur to the solenoid body
component if the screw is tightened
above specification.
7. Install and lubricate new O-rings on the AT

connector and connect the connector.
Tightening torque
Note
Clean the area around connector to prevent
contamination of the AT connector.
Use petroleum jelly to lubricate the O-rings
to aid in the installation process.
8. Remove the insulator bracket. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL/
9. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION
[5R55S].)
10. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL!
12. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
13. Perform the mechanical system test. (See 05-13-4 MECHANICAL SYSTEM TEST [5R55S].)
14. Perform the road test. (See 05-13-8 ROAD TEST [5R55S].)
05-13-37

AT RELAY LOCATION [5R55S]
id0513c1254500
%.al~~""';--'---AT
RELAY
absggw00001809
AT RELAY INSPECTION [5R55S]
id0513c1254600

2. Remove the AT relay.
3. Verify the continuity between the relay terminals.
relay.
0-0 : Continuity
Step
1
2
Terminal
B+
GND
0
acxuuw00002119
acxuuw00002118
05-13-38

TCM INSPECTION [SRSSS]
id0513c1250700
Terminal Voltage/Resistance Table (Reference)

,.--
It
---
A
B
C
D
E
F
G
H
I M Q
J N R
K 0 S
L P T
U
V
W
X
Y AC AG
Z AD AH
AA AE AI
AB AF AJ
AK AO AS AW BA BE
AL AP AT AX BB BF
AM AQ AU AY BC BG
AN AR AV AZ BD BH
BI BM BQ BU BY CC CG
BJ BN BR BV BZ CD CH
BK BO BS ~W CA CE CI
BL BP BT BX CB CF CJ
-,--
-CKCL -CNCO
r-- -
CM CP
'---
absggw00001190
Terminal
Signal
Connected to
Test Condition.
Voltage!
Resistance
Action
TCC control
TCC control
solenoid control solenoid
Inspect resistance between TCM

terminals A and CK (wiring harnessside).
9-16 ohm

Shift solenoid A
Shift solenoid A terminals Band CK (wiring harness- 16-45 ohm
control
side).

Shift solenoid B
Shift solenoid B terminals C and CK (wiring harness- 16-45 ohm
control
side).
Shift solenoid 0
control

Shift solenoid 0 terminals 0 and CK (wiring harness- 16-45 ohm
side).
Engine switch ON
E
Instrument
indicator output cluster
B+
Below 1.0 V
OlD OFF
Engine switch OFF

Shift solenoid C
Shift solenoid C terminals F and CK (wiring harness- 16-45 ohm
control
side).
Selector
position
indicator signal
3
Instrument
cluster
Inspect continuity between TCM and

instrument cluster (wiring harnessside).
-
Continuity
Inspect the TCC control

solenoid
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the shift
solenoid A
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the shift
solenoid B
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the shift
solenoid 0
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the instrument
cluster
Inspect the related
wiring harness
Inspect the shift
solenoid C
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the related
wiring harness
05-13-39

Terminal
Signal
Connected to
Test Condition
Voltage!
Resistance
Action
Pressure
Pressure
control solenoid control solenoid terminals I and CK (wiring harnessA
side).
A control
3.3-7.5
ohm
Pressure
Pressure
control solenoid control solenoid terminals J and CK (wiring harnessB
B control
side).
Selector
position
indicator signal
1
Instrument
cluster
-

-
Pressure
Pressure
control solenoid control solenoid terminals M and CK (wiring harnessC control
C
side).
4x4 HI indicator Instrument

output
cluster
3.3-7.5
ohm
Continuity
Inspect the pressure

control solenoid A
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
control solenoid B
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the related

wiring harness

control solenoid C
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S])
Inspect the related
wiring harness
3.3-7.5
ohm
Engine switch ON
B+
Engine switch OFF
Below 1.0 V

cluster
Inspect the related
wiring harness
Selector
position
indicator signal
2
4x4 LO
Instrument
indicator output cluster
Instrument
cluster

Engine switch ON
S
T
Engine switch OFF
Continuity
Inspect the related

wiring harness
B+
Below 1.0 V

cluster
Inspect the related
wiring harness
Vehicle speed
output
Instrument
cluster

Continuity
Inspect the related

wiring harness
AA
AB
AC
AD
Output shaft
speed (+)
OSS sensor

terminals AD and AG (wiring
harness-side) .
325-485
ohm
Inspect the OSS sensor

(See 05-13-32
OUTPUT SHAFT
SPEED (OSS)
SENSOR INSPECTION
[5R55S])
Inspect the related
wiring harness
AE
AF
05-13-40

Terminal
Signal
Connected to
Test Condition
Voltage!
Resistance
Action
AG
Output shaft
speed (-)
OSS sensor

terminals AD and AG (wiring
harness-side) .
325-485
ohm
AH
Turbine shaft
speed (-)
TSS sensor

terminals AH and AP (wiring
harness-side).
325-485
ohm
Inspect the OSS sensor

(See 05-13-32
OUTPUT SHAFT
SPEED (OSS)
SENSOR INSPECTION
[5R55SJ)
Inspect the related
wiring harness
Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT
SPEED (TSS)
SENSOR INSPECTION
[5R55SJ)
Inspect the related
wiring harness
AI
AJ
AK
System GND
GND
Continuity
Under any condition
Inspect the related

wiring harness
Inspect the ISS sensor

(See 05-13-30
INTERMEDIATE
SHAFT SPEED (ISS)
SENSOR INSPECTION
[5R55SJ)
Inspect the related
wiring harness
AL
AM
Intermediate
shaft speed (-)
ISS sensor

terminals AM and AS (wiring
harness-side) .
325-485
ohm
AN
AO
System GND
GND
Under any condition
Continuity
AP
Turbine shaft
speed (+)
TSS sensor

terminals AH and AP (wiring
harness-side) .
325-485
ohm
Inspect the related

wiring harness
Inspect the TSS sensor
(See 05-13-28
TURBINE SHAFT
SPEED (TSS)
SENSOR INSPECTION
[5R55SJ)
Inspect the related
wiring harness
AQ
AR
AS
Intermediate
shaft speed (+)
ISS sensor

terminals AM and AS (wiring
harness-side).
325-485
ohm
Inspect the ISS sensor

(See 05-13-30
INTERMEDIATE
SHAFT SPEED (ISS)
SENSOR INSPECTION
[5R55SJ)
Inspect the related
wiring harness
AT
AU
AV
AW
AX
TR3A signal
Digital TR
sensor
Inspect continuity
between TCM
terminals AX and
BH (wiring
harness-side).
P position, 1,2
and 3 range
Continuity
Other
Not
continuity
Inspect the Digital TR

sensor
(See 05-13-20 DIGITAL
TRANSMISSION
RANGE (TR) SENSOR
INSPECTION [5R55SJ)
Inspect the related
wiring harness
05-13-41

Terminal
AY
Signal
ATF
temperature
Connected to
TFT sensor
Test Condition
Inspect resistance
between TCM
terminals AY and
BH (wiring
harness-side).
Voltage!
Resistance
ATF
temperature
-40--20C
{-4Q--4 OF}
284-967
kilohm
ATF
temperature
-19--1 C
{-3-30 OF}
100-284
kilohm
ATF
temperature
0-20C
{32-68 OF}
ATF
temperature
21-40C
{70-104 OF}
37-100
kilohm
16-37
kilohm
ATF
temperature
41-70C
{106-158 OF}
5-16
kilohm
ATF
temperature
71-90C
{160-194 OF}
2.7-5
kilohm
ATF
temperature
91-110C
{196-230 OF}
ATF
temperature
111-130C
{232-266 OF}
ATF
temperature
131-150C
{268 302 OF}
Action
Inspect the TFT sensor

(See 05-13-26
TRANSMISSION
FLUID TEMPERATURE
(TFT) SENSOR
INSPECTION [5R55S])
Inspect the related
wiring harness
1.5-2.7
kilohm
0.8-1.5
kilohm
0.54-0.8
kilohm
AZ
BA
4x4 HI mode
input
4x4 control
module

4x4 control module (wiring harnessside).
BB
4x4 LO mode
input
4x4 control
module

4x4 control module (wiring harnessside).
Sensor GND
Continuity
Continuity
Inspect the 4x4 control

module
Inspect the related
wiring harness
Inspect the 4x4 control
module
Inspect the related
wiring harness
BC
BD
BE
BF
BG
BH
BI
BJ
BK
BL
05-13-42
TFT sensor
Inspect the TCM terminals AX, AY BU BY and
Digital TR
".
CA.(wiring harness-side)
sensor
Inspect the related

wiring harness
(
\

Terminal
BM
Signal
OlD OFF
switch
Connected to
OlD OFF
switch
BN
BO
BP
Engine switch ON
BO
BR
BS
Test Condition
Voltage!
Resistance
OlD OFF
switch button
depressed
B+
OlD OFF
switch button
not depressed
Below 1.0 V
Action
Inspect the OlD OFF

switch
(See 05-13-19 OlD
OFF SWITCH
INSPECTION [5R55S])
Inspect the related
wiring harness
System GND
GND
Continuity
Inspect the related

wiring harness
P, R position
and 2 range
Continuity
Other
Not
continuity

sensor
TRANSMISSION
RANGE (TR) SENSOR
INSPECTION [5R55S])
Inspect the related
wiring harness
Under any condition
BT
BU
TR2 signal
Digital TR
sensor
Inspect continuity
between TCM
terminals BU and
BH (wiring
harness-side) .
BV
BW
BX
BY
TR1 signal
Digital TR
sensor
BZ
CA
CB
TR4 signal
CAN_H
Digital TR
sensor
PCM
CC
CD
CE
CF
CG
CH
CI
CJ
Inspect continuity
between TCM
terminals BY and
BH (wiring
harness-side).
P, R position
and 3 range
Continuity
Other
Not
continuity
Inspect continuity
between TCM
terminals CA and
BH (wiring
harness-side).
P, N position
and 1 range
Continuity
Other
Not
continuity
Because this terminal is for serial

communication, goodlno good
judgment by terminal voltage is not
possible. Carry out inspection
according to DTCs.

sensor
TRANSMISSION
RANGE (TR) SENSOR
INSPECTION [5R55S])
Inspect the related
wiring harness
sensor
TRANSMISSION
RANGE (TR) SENSOR
INSPECTION [5R55S])
Inspect the related
wiring harness
Inspect the related

wiring harness
Inspect the related

wiring harness
CAN_L
PCM
Because this terminal is for serial

communication, goodlno good
judgment by terminal voltage is not
possible. Carry out inspection
according to DTCs.
-
05-13-43

Signal
Terminal
Connected to
Test Condition
Voltagel
Resistance
Action
CK
Solenoid valve
power supply
Solenoid valve
Inspect the TCM terminals A, B, C, D, F, I, J and M.

CL
CM
System GND
CN
CO
CP
AT relay
IG
System GND
IG
Continuity
Engine switch ON
B+
Engine switch OFF
Below 1.0 V
Under any condition
GND
GND
AT relay
Inspect the solenoid

valve
(See 05-13-34
SOLENOID VALVE
INSPECTION [5R55S))
Inspect the related
wiring harness
Inspect the related
wiring harness
Inspect the AT relay
(See 05-13-38 AT
RELAY INSPECTION
[5R55S))
Inspect the related
wiring harness
-
Continuity
Inspect the related

wiring harness
Engine switch ON
B+
Engine switch OFF
Below 1.0 V
Inspect the AT relay

(See 05-13-38 AT
RELAY INSPECTION
[5R55S))
Inspect the related
wiring harness
Under any condition
TCM REMOVAUINSTALLATION [SRSSS]
id0513c1250800

1
2
3
4
Bracket
TCM connector
TCM
Wiring harness
AT relay
Bracket
Nm {kgfcm, in.lbf}
absggw00001526
05-13-44

AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SRSSS]
id0513c1249200

2. Drain the ATF. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].)
3. Remove the following parts.
(1) Under cover
(2) Front propeller shaft (4x4) (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
(3) Rear propeller shaft (See 03-15-2 PROPELLER SHAFT REMOVAUINSTALLATION [5AT].)
(4) Oxidation catalytic converter.
(5) Front pipe
6. Add ATF and, with the engine idling, inspect the ATF level and inspect for leakage. (See 05-13-16 AUTOMATIC
TRANSMISSION FLUID (ATF) REPLACEMENT [5R55S].) (See 05-13-13 AUTOMATIC TRANSMISSION
7. Inspect selector lever operation. (See 05-14-2 SELECTOR LEVER INSPECTION.)
8. Inspect for leakage of ATF from all connecting pOints.
Service item
Automatic transmission replacement
Automatic transmission overhaul
Control valve body replacement
Torque converter replacement
Fluid pump replacement
Clutch system replacement
Test item
Line pressure test
x
x
x
x
x
x
Stall speed test
x
x
x
05-13-45

4x2
27.3-3S.3}
40.0-54.5
{4.1-5.5,
29.6-40.1}
WE-C
WL-C
~
I I
'-..j
43.0-54.0
{4.4-5.5,
31.S-39.S}
31.4-46.1~
7S.0-9S.0
{S.0-9.9,
~7.6-72.2}
36.5-46.1
{3.S-4.7,
27.0-34.0}
31.4-46.1---4,
{3.3-4.7,
23.2-34.0}
{3.3-4.7,
23.2-34.0}
Nm {kgf.m, ttlbf}
arnffw00001939
1
2
3
4
5
Insulator
Insulator
Selector cable bracket
Selector cable
Cover
05-13-46
Torque converter installation nuts

(See 05-13-50 Torque Converter Installation Nuts
Removal Note.)
Installation Note.)
Crossmember
(See 05-13-51 Transmission Removal Note.)
Transmission mount rubber
CKP sensor connector
10
AT connector
Digital TR sensor connector
18
Transmission installation bolt and nut
TSS sensor connector
19
Transmission
(See 05-13-52 Transmission Installation Note.)
11
12
13
14
ISS sensor connector
ass sensor connector
15
16
Wiring harness
Insulator bracket
17
Oil pipe
(See 05-13-50 Oil Pipe Removal Note.)
(See 05-13-53 Oil Pipe Installation Note.)
l.
05-13-47

4x4
40.0-S4.S
{4.1-S.S,
29.6-40.1}
37.0-S2.0
{3.8-S.3,
27.3-38.3}
36-S0
{3.7-S.0,
27-36}
7.8-10.8 Nm 27.3-38.3}
{80-110 kgfcm,
69.1-9S.S inlbf}
43.0-S4.0
{4.4-S.S,
31.8-39.8}
{3.3-4.7,
23.2-34.0}
Nm {kgfm, ftlbf}
arnffw00001940
Insulator
2
3
Insulator
05-13-48
ISelector cable

6
7
8
9
10
11
12
13
14
15
Torque converter installation nuts

Removal Note.)
Installation Note.)
Transfer case under cover
Crossmember
Transmission mount component
Transmission mount upper
Transmission rubber
Transmission mount lower
Transfer case motor connector
16
AT connector
17
18
Digital TR sensor connector

TSS sensor connector
19
ISS sensor connector
20
21
OSS sensor connector

Wiring harness
22
23
Insulator bracket
24
25
Transfer case speed sensor connector

CKP sensor connector
Oil pipe
(See 05-13-50 Oil Pipe Removal Note.)
(See 05-13-53 Oil Pipe Installation Note.)
Transmission installation bolt and nut
Transmission and transfer case
(See 05-13-52 Transmission Installation Note.)
4x4
38.0-52.0 Nm
{3.9-5.3 kgfm,
28.1-38.3 ttlbf}
absggw00001540
26
ITransfer case
27
ITransmission
05-13-49

Torque Converter Installation Nuts Removal Note
1. Remove the cooling fan.
2. Hold the crankshaft pulley to prevent the drive
plate from rotating.
absggw00001804
3. Remove the torque converter nuts.
absggw00001805
Oil Pipe Removal Note

1. Remove the oil pipe installation bolt and nut.
NUT
absggw00001810
05-13-50

Transmission Removal Note
Warning
Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter.
1. Remove the front differential mount rubber.
MOUNT RUBBER
absggw00001541
2. Support the transfer case side securely using one

transmission jack.
Caution
Do not allow the transmission jack to
interfere with the transmission mount
bracket bolts, otherwise the bolts could
be damaged.
absggw00001806
4. Support the transmission securely using a

transmission jack.
5. Support the front side of engine securely using a
transmission jack.
absggw00001807
05-13-51

6. Remove the transmission installation bolt.
absggw00001542
7. Remove the transmission while setting it out of

the way so that it does not contact the differential.
absggw00001543
Transmission Installation Note

Warning
Verify that the transmission is securely supported by the jack. If the transmission falls, serious
injury or death and damage to the vehicle could result. Before removing the transmission make
sure that the jack is securely supporting the transmission.
Caution
To prevent the torque converter and transmission from separating, remove the transmission
without tilting it toward the torque converter
1. Support the front side of engine securely using a transmission jack.

2. Support the transmission and transfer case
,.-----------------------,
securely using a transmission jack.
absggw00001808
05-13-52

3. Install the transmission while setting it out of the
way so that it does not contact the differential.
absggw00001544
4. Tighten the transmission installation bolts and

nuts.
Tightening torque
37-52 Nm {3.8-5.3 kgfm, 28-38 ft.lbf}
absggw00001542
5. Install the front differential mount rubber.

Tightening torque
54.9-80.4 Nm {5.6-8.1 kgf.m, 41-59 ft.lbf}
MOUNT RUBBER
absggw00001541
Oil Pipe Installation Note

1. Install the oil pipe installation bolt and nut.
Tightening torque
7.8-10.7 Nm {80-109 kgfcm, 69.1-94.7

in.lbf}
NUT
absggw00001810
05-13-53

Torque Converter Installation Nuts Installation Note
1. Hold the crankshaft pulley to prevent the drive
plate from rotating.
Caution
Loosely and equally tighten the torque
converter nuts, then further tighten them
to the specified tightening torque.
absggw00001804
2. Tighten the new torque converter installation nuts.
Tightening torque
40.0-54.5 Nm {4.1-5.5 kgf.m, 29.6-40.1
ft.lbf}
absggw00001805
TORQUE CONVERTER INSPECTION [5R55S]
id0513c1711900
Caution
Do not use water-based cleaners or mineral spirits to clean or flush the torque converter or
transmission damage will occur. Use only clean ATF designated for the transmission and
converter being serviced.
The torque converter drain plug and seal are not reusable. If equipped, discard the drain plug and
seal, then install a new drain plug component.
If a new or remanufactured torque converter is not being installed, the following steps must be completed.
1. With the torque converter on a bench, pour a small ATF from the torque converter onto an absorbent white
tissue or through a paper filter and examine the ATF.
2. Observe the color and odor of the ATF. The ATF should be red, not brown or black. Odor may indicate an
overheating condition such as clutch disc or band failure.
3. Examine the stain on the tissue for evidence of particles (spec of any kind). Examine the fluid level indicator for
signs of antifreeze (gum or varniSh).
If particles are present in the fluid or there is evidence of engine coolant or water, a new torque converter
must be installed.
If there are no particles or contamination present, drain the remainder of the ATF from the torque converter.
4. Add 1.9 L {2.0 US qt, 1.7 Imp qt} of clean ATF into the converter and agitate by hand.
5. Thoroughly drain the fluid.
05-13-54

TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S]
id0513c171 01 00
Removal
1. Remove the transmission. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [5R55S].)
Caution
The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
Do not drop the torque converter.
Do not pinch fingers.
2. Using the SSTs, remove the torque
conv~rter.
Installation
Caution
Do not damage the fluid pump gear O-ring when installing torque converter.
Make sure the converter hub is fully engaged in the pump support and gear and rotates freely. Do
not damage the hub seal.
If the torque converter slides out, the hub seal may be damaged.
1. Lubricate the converter hub with clean ATF.
Warning
The torque converter can fall out if the
transmission is tipped. Failure to follow
these instructions may cause personal
injury.
b5r5za00000286
2. Using the SST, install the torque converter by

pushing and rotating.
3. Install the automatic transmission. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL!
4. Perform the mechanical system test. (See 05-134 MECHANICAL SYSTEM TEST [5R55S].)
05-13-55

OIL SEAL (FLUID PUMP) REPLACEMENT [5R55S]
id0513c1712000
Removal
Caution
The oil seal is easily damaged by the sharp edges of the torque converter splines. Do not let the
splines contact the oil seal.
Do not drop the torque converter.
Do not pinch fingers.
2. Remove the torque converter. (See 05-13-55 TORQUE CONVERTER REMOVAL/INSTALLATION [5R55S].)
Caution
Do not to damage the bushing on the fluid pump body.
3. Using the SST, remove the fluid pump seal.
b5r5za00000295
Installation
1. Install a new seal onto the SST.
Note
Check and make sure that the garter spring
in the seal has not popped off of the
converter hub seal.
arnffw00001959
2. Using the SST, install the converter hub seal.

3. Install the torque converter. (See 05-13-55
TORQUE CONVERTER REMOVAL!
4. Install the automatic transmission. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL/
5. Perform the mechanical system test. (See 05-134 MECHANICAL SYSTEM TEST [5R55S].)
arnffw00001960
05-13-56

OIL SEAL (EXTENSION HOUSING) REPLACEMENT [SRSSS]
id0513c1710000
Removal (4x2)
1. Remove the propeller shaft. (See 03-15-2 PROPELLER SHAFT REMOVAL/INSTALLATION [5AT].)
2. Using the SST, remove the extension housing
seal.
arnffv00000522
Removal (4x4)
1. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAL/INSTALLATION [5R55S].)
2. Using the SSTs, remove the extension housing
seal.
Installation (4x2)
1. Using the SST, install the extension housing seal.
Note
Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.
[5AT].)
3. I nspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF)
arnffv00000545
Installation (4x4)
1. Using the SST, install the extension housing seal.
Note
Make sure the extension housing seal is
correctly installed onto the SST and the
garter spring is in the correct position.
2. Install the transfer case. (See 03-16-7

TRANSFER CASE REMOVAL/INSTALLATION
[5R55S].)
3. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF)
b5r5za00000280
05-13-57

EXTENSION HOUSING GASKET REPLACEMENT [SRSSS]
id0513c1254300
Removal (4x2)
1. Remove the oxidation catalytic converter.
3. Remove the crossmember and transmission mount rubber. (See 05-13-45 AUTOMATIC TRANSMISSION
4. Lower the transmission.
Caution
The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
b5r5za00000011
6. Remove and discard the extension housing

gasket.
absggw00001629
Removal (4x4)
1. Remove the oxidation catalytic converter.
3. Remove the crossmember and Transmission mount component. (See 05-13-45 AUTOMATIC TRANSMISSION
4. Remove the transfer case. (See 03-16-7 TRANSFER CASE REMOVAUINSTALLATION [5R55S].)
Caution
The parking pawl, parking pawl return spring and parking pawl shaft could fall out during removal
of the extension housing.
5. Remove the extension housing.
05-13-58

6. Remove and discard the extension housing
gasket.
absggw00001630
Installation (4x2)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
Make sure the parking lever actuating rod
is correctly seated into the case parking
rod guide cup.
absggw00001629
3. Install the extension housing.
Tightening torque
28-32 Nm {2.9-3.2 kgf.m, 21-23 ft.lbf}
4. Install the crossmember and transmission mount
rubber. (See 05-13-45 AUTOMATIC
TRANSMISSION REMOVAUINSTALLATION
[5R55S])
PROPELLER SHAFT REMOVAUINSTALLATION
[5AT].)
7. Inspect the ATF level for leakage. (See 05-13-13
AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
Installation (4x4)
1. Clean the extension housing and install new
extension housing gasket.
2. Make sure that the park pawl is installed correctly.
Caution
Make sure the parking lever actuating rod
is correctly seated into the case parkin-g
rod guide cup.
absggw00001630
05-13-59

3. Install the extension housing.
Tightening torque
28-32 Nm {2.9-3.2 kgf.m, 21-23 ft.lbf}
4. Install the transfer case. (See 03-16-7
TRANSFER CASE REMOVAUINSTALLATION
[5R55S].)
5. Install the crossmember and Transmission mount
component. (See 05-13-45 AUTOMATIC
[5R55S])
[5AT].)
8. Inspect the ATF level for leakage. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
05-13-60

CONTROL VALVE BODY REMOVAL [5R55S]
id0513c1710600
On-Vehicle Removal
Warning
A hot transmission and ATF can cause severe burns. Turn off the engine and wait until they are
Caution
Clean the transmission exterior thoroughly with a stream cleaner or cleaning solvents before
removal.
1.
2.
3.
4.
5.
6.

absggw00001183

o
b5r5za00000015
8. Remove the detent spring.
05-13-61

9. Remove the low/reverse brake servo component.
Caution
pins.
b5r5za00000017

b5r5za00000018
11. Remove the control valve body.
b5r5za00000019
05-13-62

CONTROL VALVE BODY INSTALLATION [5R55S]
id0513c1710700
On-Vehicle Installation
2. Using the SSTs, Install the control valve body and

loosely install the bolts.
(1) Install the short bolt.
(2) Install the bolt with the larger head.
(3) Install the remaining bolts.
3. Remove the SSTs and loosely install the screw.

4. Tighten the bolts in the sequence shown.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 in.lbf}
05-13-63
b5r5za00000270
5. Install the detent spring.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 in.lbf}

Caution
and not damaged. If damaged, a
b5r5za00000272
05-13-64

sequence shown.
Tightening torque
7-9 Nm {72-91 kgfcm, 62-79 in.lbf}
b5r5za00000273
8. Install the reverse servo. Tighten the bolts in the

sequence shown in 2 stages.
Tightening torque
Stage 1: 5 Nm {51 kgfcm, 44 inlbf}
Stage 2: 10-12 Nm {102-122 kgf.cm, 89106 inlbf}
Caution
damaged.
b5r5za00000274

fluid filter.
Tightening torque
9-11 Nm {92-112 kgfcm, 80-97 inlbf}
Note
0'----0
10. Install the transmission fluid pan gasket on the

pan.
Note
reusable, clean and inspect for damage. If
GASKET
absggw00001562
11. Install the transmission fluid pump and gasket,

12. Tighten the bolts in a crisscross sequence.
Tightening torque
9.5-11.5 Nm {97-117 kgfcm, 85-101
inlbf}
Caution
Damage will occur to the solenoid body
component if the screw is tightened
above specification.
05-13-65

13. Install and lubricate new O-rings on the AT
connector and connect the connector.
Tightening torque
Note
Clean the area around connector to prevent
contamination of the AT connector.
Use petroleum jelly to lubricate the O-rings
to aid in the installation process.
absggw00001183
14. Remove the insulator bracket. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAU
15. Remove the CKP sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAUINSTALLATION
[5R55S].)
16. Remove the digital TR sensor insulator. (See 05-13-45 AUTOMATIC TRANSMISSION REMOVAL/
18. Add ATF and, with the engine idling, inspect the ATF level and for leakage. (See 05-13-13 AUTOMATIC
TRANSMISSION FLUID (ATF) INSPECTION [5R55S].)
05-13-66

OIL COOLER FLUSHING [5R55S]
id0513c1710900
Note
If the automatic transaxle is replaced, flush and inspect the oil cooler.
When replacing the automatic transaxle, inspect the oil cooler together with flushing it using the following
procedure, and with the oil cooler hose removed.
1.
2.
3.
4.
5.
6.
7.
8.
Remove the oil cooler. (See 05-13-68 OIL COOLER REMOVAUINSTALLATION [5R55S].)
Disconnect the oil cooler hose.
Set a clean fluid pan up to the oil cooler hose inlet.
Blow 491-882 kPa {5-9 kgf/cm 2 , 72-127 psi} of compressed air from the oil cooler hose outlet to drain
.
remaining oil.
Add new ATF from the oil cooler hose outlet and blow 491-882 kPa {5-9 kgf/cm 2 , 72-127 psi} of
compressed air to flush. (Repeat 2 or 3 times)
Verify that none of the following foreign material is mixed in with the drained ATF:
Large metal fragments of ~ 0.5 mm {0.02 mm} or more that cannot pass through the oil strainer
Fibrous clutch facing
Repeat the procedures from Step 3 to 4 and flush the inside of the oil cooler.
If foreign material such as metal fragments or clutch facing remains even after the oil cooler is flushed
repeatedly, replace the oil cooler (radiator).
OIL COOLER
(RADIATOR)
OIL PAN
t~~
......... COMPRESSED
AIR
'*
FRONT
FRONT
COMPRESSED AIR
~~gJ
COMPRESSED AIR
05-13-67

OIL COOLER REMOVAL/INSTALLATION [5R55S]
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
id0513c1248700

Drain the engine coolant.
Remove the following parts.
(1) Splash shield
(2) Under cover
(3) Front bumper
Add the engine coolant.
Add ATF to the specified level. (See 05-13-16 AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT
[5R55S].)
Inspect for oil leakage from the oil pipes and oil hoses.
Inspect for coolant from the hoses.
Inspect for engine coolant leakage.
Inspect the ATF level and condition. (See 05-13-13 AUTOMATIC TRANSMISSION FLUID (ATF) INSPECTION
[5R55S].)
05-13-68
FRONT
FRONT
.#f
FRONT
{90-129 kgfcm,
77.9-112.4 inlbf}
Nm {kgfm, ftlbf}
arnffw00001945
Oil pipe
(See 05-13-70 Oil Pipe, Hose clamp, Oil hose
Installation Note.)
Hose clamp
Installation Note.)
05-13-69

3
Oil hose
Installation Note.)
Cover
Oil cooler
Braket
Radiator (in tank oil cooler)

(See 05-13-70 Radiator (In Tank Oil Cooler)
Installation Note.)
Radiator (In Tank Oil Cooler) Irlstallation Note

1. The automatic transmission oil cooler flushing must be performed whenever a transmission is removed for
service because the existing fluid may be contaminated, and to prevent contamination of new fluid.
Note
Flushing must be performed after installation of the overhauled or replaced transmission.
2. Follow the instructions in the manufacturer's publication for flushing operation.

Oil Pipe, Hose clamp, Oil hose Installation Note
1. Apply compressed air to cooler-side opening, and
blow any remaining grime and foreign material
from the cooler pipes. Compressed air should be
applied for more than 1 min.
acxuuw00000609
2. Align the marks, and slide the oil hose onto the oil
pipe until it is fully seated as shown.
3. Install the hose clamp onto the hose.
OIL
HOSE
arnffwOOOO 1946
Note
If reusing the hose, install the new hose
clamp exactly on the mark left by the
previous hose clamp. Then apply force to the
hose clamp in the direction of the arrow in
order to fit the clamp in place.
4. Verify that the hose clamp does not interfere with

any other components.
absggw00001709
05-13-70

DRIVE PLATE REMOVAUINSTALLATION [5R55S)
id0513c1250200

1
2
3
Backing plate
Drive plate
(See 05-13-71 Drive Plate Removal Note.)
(See 05-13-71 Drive Plate Installation Note.)
Plate
Spacer
absggw00001705
Drive Plate Removal Note

1. Set the SST or equivalent against the drive plate.
2. Remove the bolts and the drive plate.
absggw00001706
Drive Plate Installation Note

1. Remove the sealant from the bolt holes in the crankshaft.
2. Install the drive plate.
3. Install the backing plate.
4. Set the SST or equivalent against the drive plate.
5. Tighten the drive plate mounting bolts in two or
three steps in the order as shown in the figure.
Tightening torque
151.3-161.1 Nm
{15.5-16.4 kgfm, 111.6-118.8 ft.lbf}
6. Install the transmission. (See 05-13-45
AUTOMATIC TRANSMISSION REMOVAL!
absggw00001707
05-13-71
05-14
SHIFT MECHANISM
LOCATION INDEX ................. 05-14-1
SELECTOR LEVER INSPECTION ..... 05-14-2
SELECTOR CABLE
ADJUSTMENT .................... 05-14-2
SELECTOR CABLE
SELECTOR LEVER
AUTOMATIC TRANSMISSION SHIFT MECHANISM LOCATION INDEX
id051400254000
absggw00001005
Selector lever
(See 05-14-2 SELECTOR LEVER INSPECTION.)
(See 05-14-4 SELECTOR LEVER REMOVAU
INSTALLATION.)
Selector cable
(See 05-14-3 SELECTOR CABLE REMOVAU
INSTALLATION.)
05-14-1

SELECTOR LEVER INSPECTION
id051400255500
1. Turn the engine switch to the ON position (engine off).

2. With the brake pedal depressed, verify that there
is a "click" at each range when shifted.
3. Verify that the selector lever can be shifted.
4. Verify that there is a "click" at each position when
shifted from the P position to the 1 range.
BUTTON MUST BE
DEPRESSED
r-"-... BUTTON NEED NOT

Y
BE DEPRESSED
arnffw00001928
5. Verify that the positions of the selector lever and

the indicator are aligned.
ADJUSTMENT [5R55S].)
6. Verify that the vehicle operates in each selected
range.
absggw00001014
SELECTOR CABLE ADJUSTMENT

1.
2.
3.
4.
5.
id051400256100
Remove the console.

Shift the selector lever to the N position.
Loosen the nut at approx. 90.
Adjustment the end of the selector cable position.
Tighten the nut.
Tightening torque
9.8-18.2 Nm {100-185 kgf.cm, 87-161

inlbf}
6. Install the console.

NUT
absggw00001019
\.
05-14-2

SELECTOR CABLE REMOVAUINSTALLATION
1.
2.
3.
4.
5.
id051400256200

Remove the console.
Shift the selector lever to the P position.
7.8-10.7
{80-109,
69.1-94.7}
7.8-10.7
{80-109,
69.1-94.7}
Nm {kgfcm, in.lbf}
Digital TR sensor insulator
Selector cable
(See 05-14-3 Selector Cable Installation Note.)
Selector Cable Installation Note

1. Shift the selector lever to the N position.
2. Loosen the nut at approx. 90
3. Adjustment the end of the selector cable position.
4. Tighten the nut.
0
Tightening torque
9.8-18.2 Nm {100-185 kgfcm, 87-161
in.lbf}
NUT
absggw00001019
05-14-3

SELECTOR LEVER REMOVAL/INSTALLATION
1.
2.
3.
4.
id051400255700

Remove the console.
Shift the selector lever to the P position.
Connector
Selector cable
(See 05-14-4 Selector Cable Installation Note.)
Selector lever
Bulb
Selector lever bracket
9.8-14.7
{10o-149,
'7' '.')
I
Nm {kgfcm, in.lbf}
arnffw00001930
Selector Cable Installation Note

1. Shift the selector lever to the N position.
2. Loosen the nut at approx. 90.
3. Adjustment the end of the selector cable position.
4. Tighten the nut.
Tightening torque
9.8-18.2 Nm {100-185 kgfcm, 87-161
inlbf}
NUT
absggw00001019
05-14-4
TECHNICAL DATA
05-50
TECHNICAL DATA
......................... . 05-50-1
TRANSMISSIONfTRANSAXLE [5R55S]
id0550h1800400
Specification
Item
Type: Mercon V
ATF
Line pressure (pressure control A, pressure control B)

Positionlrange
PIN
R
D, 3, 2,1
Idle
Stall
793 {8.09, 115}

793 {8.09, 115}
793 {8.09, 115}
793 {8.09, 115}

2,138 {21.80, 310}
1,520 {15.47, 220}
Line pressure (pressure control C)

Position/range
27 {0.28, 4}
793 {8.09, 115}
27 {0.28, 4}
D, 3, 2,1
IEnglne stall speed
Stall
Idle
PIN
Engine type
WL-C
WE-C
o {O, O}
793 {8.09, 115}
o {O, O}
rpm
2,700
2,900

ATF temperature
eC eF})
-40--20 {-40--4}
-19--1 {-3-30}
0-20 {32-68}
21-40 {70-104}
41-70 {106-158}
71-90 {160-194}
91-110 {196-230}
111-130 {232-266}
131-150 {268-302}
Resistance (kilohm)
284-967
100-284
37-100
16-37
5-16
2.7-5
1.5-2.7
0.8-1.5
0.54-0.8
TSS sensor resistance

Resistance (ohm)
226-390
325-485
492-738
Temperature
ISS sensor resistance

Resistance (ohm)
226-390
325-485
492-738
eC eF})
-20 {4}
21 {70}
150 {302}
Temperature
eC eF})
-20 {4}
21 {70}
150 {302}
05-50-1
TECHNICAL DATA
ass sensor resistance

Temperature (Oe eF})
-20 {4}
Resistance (ohm)
226-390
325-485
492-738
21 FO}
150 {302}
Solenoid valve resistance)

Terminals
D-I'
F-I
8-1
E-I
0-1
M-I
G-I
H-I
Solenoid valve
Shift solenoid A
Shift solenoid 8
Shift solenoid C
Shift solenoid D
Pressure control solenoid 8
Resistance (ohm)
16-45
16-45
16-45
16-45
3.3-7.5
3.3-7.5
3.3-7.5
9-16
Clutch
Item
Specified fluid
Clutch pedal stroke
Clutch pedal play
Clutch pedal push rod play (Reference value)
Clutch disengagement stroke (Reference value)
[R15M-D]
Clutch disengagement stroke (Reference value)
[S15M-D, S15MX-D]
Clutch disc maximum depth
Clutch cover maximum clearance
Clutch cover maximum height difference
Clutch disc minimum depth
Clutch disc maximum runout
Flywheel maximum runout [R15M-D]
Dual-mass flywheel maximum runout [S15M-D,
S15MX-D]
Specification
SAE J 1703, FMVSS 116 DOT-3
152 mm {5.98 in}
5-15 mm {0.20-0.59 in}
0.1-0.5 mm {0.004-0.020 in}
A: 100-130 mm {3.94-5.11 in}

A: 110-125 mm {4.34-4.92 in}
0.6 mm {0.024 in}
0.3 mm {0.012 in}
1.0 mm {0.039 in}
0.3 mm {0.012 in}
0.7 mm {0.028 in}
0.1 mm {0.004 in}
1.5 mm {0.059 in}
Manual Transmission [S15M-O, S15MX-O]

Item

Vehicle speed sensor (VSS) voltage [S15M-D]
Shift control case oil [S15M-D]
05-50-2
Specification
5 Vor less
Capacity (approx. quantity): 220-260 ml {220-260 cc, 13.42-15.86
cu in}
SERVICE TOOLS
05-60
SERVICE TOOLS
TRANSMISSION SST ............... 05-60-1
TRANSMISSION SST
dcf05600000Ow01
49 S120 440
49 G030 797
49 E011 1AO
Mainshaft
holder
Handle
Ring gear brake

set
(fIP
490259770B
49 SE01 310A
49 1285071
Flare nut
wrench
Clutch disc
centering tool
Bearing puller
49 F028202
49 G030 795
49 G028 203
Bush Installer
Oil seal Installer
Support
a::::):::l:Bj I
05-60-1
SERVICE TOOLS
TRANSMISSION SST [5R55S]
id0560h1500200
1: Mazda SST number

Example
1:49 UN2O. 50.72
2:20.5-0.72
Holding Tool
1:2:10.0.-0.0.1
1:2:1o'o'-DO.O.9
1 :2:30.7-0.0.4
Slide Hammer
Rubber Tip Air

Nozzle
1:2:30.7-0.91
1:2:30.7-30.9
Pressure
Gauge,
Transmission
Fluid
1 :2:30.7-334
Handle, Torque
Converter
u)
u)
))
Remover,
Torque
Converter Fluid
Seal
Aligner, Valve
Body (2
required)
1:2:30.7-349
1:49 UN3O. 7351

2:30.7-351
Installer, Torque
Converter Fluid
Seal
Alignment
Gauge, TR
Sensor
1:2:30.7-433-0.1,
30.7 -433-0.2,
30.7-433-0.3
1:2:30.7-435
1:49 UN3O. 7437

2:30.7-437
Installer,
Transmission
Extension
Housing Fluid
Seal
Adapter, Fluid
Level and Fill
Plug
1:2:30.8-0.0.2
1 :2:30.8-375
1:2:416-Do'o'2
Installer,
Transmission
Extension
Housing Oil
Seal
Remover, Input
Shaft Oil Seal
Vacuum Pump
Kit
1:49 Eo'11 1Ao'

2:Brake Set, Ring
Gear
05-60-2
))
Transmission
Test Plate and
Gasket
1:49 UN3O.
7D465O.
2:3o'7-D465
Fluid
Transporter/
Evacuator/
Injector
STEERING
GENERAL PROCEDURES ... 06-10
POWER STEERING ......... 06-14
06-10

SERVICE TOOLS ........... 06-60
GENERAL PROCEDURES
GENERAL PRECAUTION
(STEERING) ..................... 06-10-1
GENERAL PRECAUTION (STEERING)
dcf06100000Ow01
Wheels and Tire Installation

torque.
Tightening torque
88.2-117.6 Nm {9.00-11.99 kgf.m, 65.06-86.73 ft.lbf}
1. Disconnect the negative battery cable before performing any work that requires handling of connectors. (See
01-17-2 BATTERY REMOVAUINSTALLATION.)
Power Steering Components Removal/Installation

1. If any power steering fluid line has been disconnected anytime during the procedure, add ATF M-III or
equivalent (e.g. Dexron@II), bleed the fluid lines, and inspect for leakage after the procedure has been
completed.
II
06-10-1
POWER STEERING
06-14
POWER STEERING
STEERING LOCATION INDEX ......

AIR BLEEDING ..............
POWER STEERING FLUID
INSPECTION ..............
STEERING WHEEL AND COLUMN
INSPECTION ...........
REMOVAUINSTALLATION .........
STEERING SHAFT INSPECTION .....
06-14-2
06-14-3
06-14-3
06-14-5
06-14-6
06-14-9

REMOVAUINSTALLATION .......... 06-14-10
DiSASSEMBLy/ASSEMBLy ....... 06-14-11
INSPECTION ............ 06-14-13
REMOVAUINSTALLATION ........ 06-14-14
DISASSEMBLy/ASSEMBLy ....... 06-14-15
06-14-1
POWER STEERING
STEERING LOCATION INDEX
dcf061400000w01
DBR614ZWB001
Power steering fluid tank

(See 06-14-3 AIR BLEEDING.)
(See 06-14-3 POWER STEERING FLUID
INSPECTION.)
Steering wheel and column

(See 06-14-5 STEERING WHEEL AND COLUMN
INSPECTION.)
(See 06-14-6 STEERING WHEEL AND COLUMN
Steering shaft
(See 06-14-9 STEERING SHAFT INSPECTION.)
06-14-2
Steering gear and linkage

INSPECTION.)
Power steering oil pump

(See 06-14-14 POWER STEERING OIL PUMP
(See 06-14-15 POWER STEERING OIL PUMP
POWER STEERING
AIR BLEEDING
dcf061400000w02
Caution
Do not turn the steering wheel during the fluid level inspection, otherwise the fluid level changes
and cannot be inspected correctly.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Inspect the fluid level. (See06-14-3 POWER STEERING FLUID INSPECTION.)

Jack up the front of the vehicle and support it on safety stands.
Turn the steering wheel fully to the left and right several times with the engine not running.
Reinspect the fluid level.
If it has dropped, add fluid.
Repeat Steps 3 and 4 until the fluid level stabilizes.
Lower the vehicle.
Start the engine and let it idle.
Turn the steering wheel fully to the left and right several times.
Verify that the fluid is not foamy and that the fluid level has not dropped.
If the fluid level has dropped, add fluid as necessary and repeat Steps 8 and 9.
POWER STEERING FLUID INSPECTION
dcf06143204Ow01
Fluid Level Inspection

1. Inspect the power steering fluid level.
Add fluid to the specified level as necessary.
Power steering fluid type
ATF M-III or equivalent (e.g. DexronlI)
Power steering fluid capacity (approx. quantity)
1.1 L {1.2 US qt, 1.0 Imp qt}
Fluid Leakage Inspection
1. Start the engine and let it idle.
2. Turn the steering wheel fully to the left and right to apply fluid pressure.
Caution
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.
3. Inspect for fluid leakage at the points indicated in

the figure.
If fluid leakage is found, replace related parts.
DBR614ZWB999
06-14-3
POWER STEERING
Fluid Pressure Inspection
1. Assemble the SSTs as shown in the figure.
2. Mark both hose connections to ensure that the
hose is reinstalled in its original position.
3. Disconnect the pressure pipe from the oil pump,
and connect the SSTs.
Tightening torque
29.4-44.1 Nm {3.00-4.49 kgfm, 21.7-32.5
ft.lbf}
A6E0612W101
4. Connect the SSTs (49 1232 670B and 49 H002

671) to the SST (49 G032 3A4A)
5. Bleed the air from the system. (See 06-14-3 AIR
BLEEDING.)
6. Open the gauge valve fully.
7. Start the engine and turn the steering wheel fully
left and right to raise the fluid temperature to 5060 DC {122-140 OF}.
Caution
If the valve is left closed for more than 5
s, the fluid temperature will increase
excessively and adversely affect the oil
pump.
8. Close the gauge valve completely. Increase the
engine speed to 1,000-1,500 rpm and measure
the fluid pressure generated by the oil pump. If
the pressure is not within the specification, repair
or replace the oil pump component.
THERMOMETER
50-60C {122-140F}
Oil pump fluid pressure

9.3-9.8 MPa {94.8-99.9 kgf/cm 2 , 13481421 psi}
Caution
If the steering wheel is kept in the fully
turned position for more than 5 s, the
fluid temperature will rise excessively
and adversely affect the oil pump.
9. Open the gauge valve fully and increase the engine speed to 1,000-1,500 rpm
10. Turn the steering wheel fully to left and right and
.--------------------------,
measure the fluid pressure generated at the gear
5dH~~~?~~T~~00F}
housing. If the pressure is not within the
specification, repair or replace the steering gear
OPEN VALVE _~~
component.
Gear housing fluid pressure
9.30-9.79 MPa {94.8-99.8 kgf/cm 2 , 13481419psi}
11. Remove the SSTs. Install and tighten the
pressure pipe to the specified torque.
Tightening torque
31.4-47.0 Nm {3.21-4.79 kgfm, 23.2-34. ft.lbf}
06-14-4
COMPLETELY
r~~~-*-r,
DBR614ZWB604
POWER STEERING
STEERING WHEEL AND COLUMN INSPECTION
dcf061432010w01
Steering Wheel Play Inspection

1. With the wheels in the straight-ahead position, gently turn the steering wheel to the left and right and verify that
the play is within the specification.
If the play exceeds the specification, either the steering joints are worn or the backlash of the steering gear
is excessive. Correct as necessary.
Steering wheel play
0-30 mm {0-1.18 in}
Steering Wheel Looseness Inspection
1. Move the steering wheel as shown in the figure to
inspect for column bearing wear, steering shaft
joint play, steering wheel looseness, and column
looseness.
Repair or replace as necessary.
DBR614ZW301
Steering Wheel Effort Inspection

1. Inspect the following points:
Tire size and tire pressure
Fluid level
2. With the vehicle on a hard, level surface, put the wheels in the straight-ahead position.
3. Remove the air bag module.
Warning
Handling the air bag module improperly can accidentally deploy the air bag module, which may
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
4. Start the engine and warm the power steering fluid to 50-60 DC {122-140 OF}.
5. Measure the steering wheel effort using a torque
,----------------------,
wrench.
If not within the specification, verify the
_
following:
No air in steering system
- No fluid leakage at hose or connectors
Function of oil pump and steering gear
'-'!I
Steering wheel effort

7.8 Nm {80 kgfcm, 58 in.lbf} max.
Note
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.
The steering wheel effort varies with'conditions as shown below.
Road conditions, such as dry or wet, and asphalt or concrete.
- Tire conditions, such as brand, wear, and tire pressure.
DBR614ZW302
06-14-5
POWER STEERING
STEERING WHEEL AND COLUMN REMOVAUINSTALLATION
dcf06143201Ow02
Warning
seriously injure you. Read AIR BAG SYSTEM WARNINGS before handling the air bag module. (See
08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)

7.9-11.7 Nm
{81-119 kgfcm,
WITHOUT AIR BAG SYSTEM
1
15.7-22.5
{1.60-2.29,
11.6-16.6}
:"
19.6-26.5
2'O0-2'70'
14.5--19.5}
18-25
{1.8-2.5,
13-18}
~~
19.6-26.5
{2.00-2.70,
14.5-19.5}
Nm {kgfm, ftlbf}
DBR614ZWB101
Lower panel
(See 09-17-10 LOWER PANEL REMOVAU
INSTALLATION.)
Steering wheel
(See 06-14-7 Steering Wheel Removal Note.)
(See 06-14-8 Steering Wheel Installation Note.)
2
3
Horn cap
Air bag module
(See 08-10-4 DRIVER-SIDE AIR BAG MODULE
Locknut
Column cover
(See 09-17-8 COLUMN COVER REMOVAU
INSTALLATION. )
Clock spring
(See 08-10-7 CLOCK SPRING REMOVAU
INSTALLATION.)
06-14-6
POWER STEERING
8
Combination switch
(See 09-18-9 COMBINATION SWITCH REMOVAU
INSTALLATION.)
Steering shaft
(See 06-14-8 Steering Shaft Installation Note.)
10
Universal joint
Boot
11
12
Intermediate shaft
13
14
15
Steering lock mounting bolts

(See 06-14-7 Steering Lock Mounting Bolts
Removal Note.)
(See 06-14-8 Steering Lock Mounting Bolts
Installation Note.)
Steering lock component
Outer cylinder
(See 06-14-7 Outer Cylinder Removal Note.)
Steering Wheel Removal Note

Caution
Do not try to remove the steering wheel by hitting the shaft with a hammer. The column will
collapse.
1. Set the vehicle in the straight-ahead position.

2. Remove the steering wheel using a suitable puller.
Steering Lock Mounting Bolts Removal Note
1. Make a groove in the heads of the steering lock
mounting bolts using a chisel and a hammer.
2. Remove the bolts using a flathead screwdriver.
3. Disassemble the steering lock component.
DBR614ZWB601
Outer Cylinder Removal Note

1. Turn the key to the ACC position.
2. Push the pin and remove the outer cylinder.
~---m
PIN
DBR614ZWB606
06-14-7
POWER STEERING
Steering Lock Mounting Bolts Installation Note
1. Assemble the steering lock component to the steering shaft.
2. Verify that the lock operates correctly.
3. Install new steering lock mounting bolts.
4. Tighten the bolts until the heads break off.
DBR614ZWB602
Steering Shaft Installation Note

Caution
Do not apply a shock in the axial direction of the shaft.
1. Lock the tilt lever. (Equiped with tilt mechanism)
2. Tighten nut A.
3. Tighten bolt B.
Tightening torque
15.7-22.5 Nm {1.60-2.29 kgfm, 11.6-16.5
ft.lbf}
DBR614ZWB002
Steering Wheel Installation Note

1. Make sure the wheels in the straight-ahead position, and install the steering wheel.
06-14-8
POWER STEERING
STEERING SHAFT INSPECTION
dcf06143210Ow01
1. Inspect the following.

(1) Column bearing for damage
(2) Steering shaft length
Steering shaft length

789.9-792.9 mm {31.1 0-31.22 in}
(3) Dust boot damage
Replace the steering shaft component as
necessary.
DBR614ZWB504
2. Inspect the tilt operation. (Equiped with tilt

mechanism)
(1) Verify that the tilt lever moves smoothly from
unlock position to lock position.
(2) Verify that the steering shaft is fixed firmly
when the tilt lever is locked.
Replace the steering shaft component as
necessary.
TILT LEVER
UNLOCKED
DBR614ZW555
06-14-9
POWER STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
dcf061432960w01
Caution
place where the sensor will not be pulled by mistake while servicing the vehicle.
1. Remove the front ABS wheel-speed sensor. (with 4W-ABS) (See 04-13B-7 FRONT ABS WHEEL-SPEED
SENSOR REMOVAL/INSTALLATION [4W-ABS (4x2 (EXCEPT Hi-Rider].) (See 04-13B-8 FRONT ABS
WHEEL-SPEED SENSOR REMOVAL/INSTALLATION [4W-ABS (Hi-Rider, 4x4)].)
4. After installation, adjust the total toe-in. (See 02-11-3 FRONT WHEEL ALIGNMENT [4x2].) (See 02-11-5 .
FRONT WHEEL ALIGNMENT [4x4].)
@~
~@~
51.5-68.6
{5.25-7.00,
38.0-50.5}
<D
~Al
-'~
44.1-58.8
{4.50-6.00,
1iI 32.5-43.3}
r -----
~
@--t
~@)~
A
0
a~
78.4-156.8
/ {7.99-15.99,57.82-115.6}
Al
1iI~
mD
3
43.5-64.7
~~~~;~~'
44.1-58.8
{4.50-6.00,
32.5-43.3}
44.1-58.8
{4.50-6.00,
32.5-43.3}
~
o,!".
iii
{4.50-6.00,
32.5-43.3}
DBR614ZWB502
1
2
3
4
5
6
7
Cotter pin
Locknut
Ball joint
(See 06-14-11 Ball Joint, Idler Arm, Steering Gear
and Pitman Arm Removal Note.)
Tie rod
Locknut
Center link
Idler arm
06-14-10
9
10
11
12
13
14
15
16
Bushing
Washer
Bolt, Nut, washer
Idler arm bracket
Pressure pipe
Return pipe
Bolt
Bolt, Nut, Washer
Steering gear and pitman arm
POWER STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman Arm Removal Note
1. Remove the ball joint from the knuckle and center
,-------------------:;;----,
link, the idler arm from the center link, and
"
I
steering gear and pitman arm from the center link
using the SST.
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY
dcf061432960w02

3. After assembly, adjust the steering gear backlash. (See 06-14-13 Steering Gear Backlash Adjustment.)
f-----{4
<O>----1iI
@--------@ iii
{5.7-6.5,42-47}
~ ~
-~o
1lI1
~ ~'----
iii
. 147-167
------cD {15.Q-17.0,
10B-123}
Nm {kgfm, ft-lbf}
DBR614ZWB503
1
2
Nut
Pitman arm
(See 06-14-12 Pitman Arm Disassembly Note.)
Locknut
(See 06-14-12 Locknut, Sector Shaft Disassembly
Note.)
Sector shaft
(See 06-14-12 Locknut, Sector Shaft Disassembly
Note.)
Side cover
6
7
O-ring
Back up ring
Y packing
06-14-11
POWER STEERING
9
Oil seal
13
O-ring
10
11
Y packing
14
15
Seal ring
Gear housing
12
Back up ring
Valve and piston component
(See 06-14-12 Valve and Piston Component
Assembly Note.)
Pitman Arm Disassembly Note

1. Separate the pitman arm from the steering gear
using the SST.
DBR614ZWB008
Locknut, 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.
DBR614ZWB009
Valve and Piston Component Assembly Note

Caution
Do not scratch the seal ring and a-ring on the piston against the entrance to the housing
Insert the piston by slightly turning to the left and right so as not to create flection at the a-ring
and seal ring.
1. Insert the valve and piston component to the gear
housing.
06-14--12
POWER STEERING
2. Inspect the worm shaft preload using the SST.
Steering gear worm shaft preload

0.64-1.23 Nm {6.6-12.5 kgfcm, 5.7-10.8
in.lbf}
[Pull scale reading: 6.4-12.3 N {0.66-1.25
kgf, 1.44-2.76 Ibf}]
If not within specification, replace the valve and
piston component.
DBR614ZWB898
STEERING GEAR AND LINKAGE INSPECTION
dcf06143296Ow03
Tie-rod End Inspection

1. Inspect the tie-rod end for damage and excessive play.
If there are any cracks, replace the tie-rod end.
2. Inspect the boot for cracks.
If there is any malfunction, replace the tie-rod end boot.
3. Rotate the ball joint 5 times.
If there is any malfunction, replace the tie-rod end boot.
4. Measure the rotational torque of the tie-rod end
,--------------------,
using the SST and a pull scale.
If not within the specification, replace the tierod end.
Tie-rod end rotational torque
0.49-1.18 Nm {5-12 kgfcm, 4.4-10.4
inlbf}
[Pull scale reading: 4.9-11.8 Nm {0.5-1.2
kgf,1.11-2.65Ibf}]
A6E6316W100
Steering Gear Backlash Adjustment

Caution
Adjust the backlash while keeping the steering gear in the center position. Otherwise, the
backlash becomes excessively small and gears,m_a_y_b_e_d_a_m_ag_e_d_._ _-=________-----,
1. Turn the adjusting screw to adjust steering gear
backlash.
Steering gear backlash

o mm {O in}
06-14-13
POWER STEERING
POWER STEERING OIL PUMP REMOVAUINSTALLATION
1.
2.
3.
4.
Remove
Remove
Remove
Install in
dcf061432650w01
the battery and battery tray. (See 01-17~2 BATTERY REMOVAL/INSTALLATION.)

the clip shown in the figure.
in the order indicated in the table.
the reverse order of removal.
CLIP
DBR614ZWB020
~29.4-44.1
{3.0D-4.49,21.7-32.5}
i~---..
-~
--
18.6-25.5
{1.90-2.60,
13.8-18.8}
------....,~
18.6-25.5
{1.90-2.60,
13.8-18.8}
4
Nm {kgfm, ftlbl}
DBR614ZWB121
Bracket (except WL-3)
Pressure pipe
Return hose
06-14-14
4
5
6
Bolt and nut

Power steering oil pump
O-ring
POWER STEERING
POWER STEERING OIL PUMP DISASSEMBLY/ASSEMBLY
dcf061432650w02
Note
The following procedure is for replacement of the O-ring and oil seal only. Replace the pump component if
other repairs are necessary.
.

3. After installing the PIS pump. flush the power steering system according to the following procedures.
(1) Add ATF until it reaches the MAX level of the PIS fluid tank.
(2) Start the engine and turn the steering wheel fully to the left and right several times to circulate the ATE
If the fluid level is dropped. add ATF
(3) Drain the ATE
(4) Add the new ATF to the MAX level of the PIS fluid tank, and repeat Step (1) and (2) a few times.
mJ
2
22-26
~ {2.2-2.6, 16-19}
V
7.S-12Nm
{S0-122 kgfcm,
69.0-106 inlbf}
~
II
7.S-11.S Nm
{S0-123 kgf.cm,
70-105 inlbf}
Stud
(See 06-14-16 Stud Disassembly Note.)
(See 06-14-19 Stud Assembly Note.)
3
4
Power steering oil pump component

(See 06-14-16 Power Steering Oil Pump
Component Disassembly Note.)
6
7
{5.0-7.0,
36-50}
Nm {kgfm, ftlbf}
DBR6HZW901
Suction pipe
O-ring
Connector
O-ring
Control valve
06-14-15
POWER STEERING
8
9
10
11
12
13
Spring
Rear pump body
(See 06-14-18 Rear Pump
a-ring
Cam ring
(See 06-14-18 Rotor, Cam
Note.)
Rotor
Note.)
Vane
Note.)
14
Body Assembly Note.)
Ring, Vane, Assembly
15
16
17
18
Side plate
(See 06-14-18 Side Plate Assembly Note.)
a-rings
Front pump body
Gear shaft component
(See 06-14-16 Gear Shaft Component Disassembly
Note.)
(See 06-14-17 Gear Shaft Component Assembly
Note.)
Oil seal
(See 06-14-17 Oil Seal Disassembly Note.)
Stud Disassembly Note

1. Tighten 2 nuts against each other on the stud,
and then remove it.
DBR614ZWB201
Power Steering Oil Pump Component Disassembly Note

1. Secure the power steering oil pump using the
SST.
Caution
Use the SST to prevent damage to the
pump when securing it in a vise.
DBR614ZWB202
Gear Shaft Component Disassembly Note

1. Remove the snap ring to front body shown in the
figure.
SNAP RING
DBR614ZWB888
06-14-16
POWER STEERING
2. Tap the gear shaft from the shaft side using a
plastic hammer to remove it.

1. Tap the oil seal out using a flathead screwdriver.
Caution
To prevent damaging the power steering
oil pump body when tapping it out, wrap
a clean rag on the end of the flathead
screwdriver. If the power steering oil
pump body is damaged, replace it
together with the power steering oil
pump component.
DBR614ZWB204

1. Press fit the oil seal using a proper pipe.
Caution
Install it so that the side with narrow
groove points outwards.
~------------------------------~D~BR~6-14~ZW~B~20~,1!J!II
Gear Shaft Component Assembly Note
1. Set a proper pipe into the gear depression and
press fit the gear shaft.
DBR614ZWB207
06-14-17
POWER STEERING
2. Install the snap ring to front body shown in the
figure.
SNAP RING
DBR614ZWB888
Side Plate Assembly Note

1. Install the side plate in the front pump body
shown in the figure
DBR614ZWB500
Rotor, Cam Ring, Vane, Assembly Note

1. Install the rotor in the front pump body shown in the figure.
2. Install the cam ring in the front pump body shown
r------------------------,
in the figure.
3. Install the vane in the rotor.
DBR614ZWB206
Rear Pump Body Assembly Note

1. Install a new O-ring and the side plate to the front body.
2. Position the side plate using the rear pump body.
3. Install the rear body to the rear pump body.
DBR614ZWB208
06-14-18
POWER STEERING
Stud Assembly Note
1. Tighten 2 nuts against each other on the stud,
and then install it so that the stud projection is
within the following specification.
DBR614ZWB201
06-14-19
TECHNICAL DATA
06-50
TECHNICAL DATA
STEERING TECHNICAL DATA . ....... 06-50-1
STEERING TECHNICAL DATA

Item
Steering wheel play

Steering wheel effort
Steering shaft length
Steering gear worm shaft preload
Tie-rod end rotational torque
Steering gear backlash
Power steering fluid type
Power steering fluid capacity (approx. quantity)
Oil pump fluid pressure
Gear housing fluid pressure
dcf06500000Ow01
Specification
0-30 mm {0-U8 in}
7.8 Nm {80 kgfcm, 58 inlbf} max.
789.9-792.9 mm {31.10-31.22 in}
0.64-1.23 Nm {6.6-12.5 kgfcm, 5.7-10.8 inlbf}
[Pull scale reading: 6.4-12.3 N {O.66-1.25 kgf, 1.44-2.76Ibt}]
0.49-1.18 Nm {5-12 kgfcm, 4.4-10.4 inlbt}
[Pull scale reading: 4.9-11.8 Nm {0.5-1.2 kgf, 1.11-2.65 Ibt}]
Omm
ATF M-III or equivalent (e.g. DexronlI)

1.1 L {1.2 US qt, 1.0 Imp qt}
9.3-9.8 MPa {94.8-99.9 kgf/cm 2 , 1348-1421 psi}
9.30-9.79 MPa {94.8-99.8 kgf/cm 2 , 1348-1419psi}
06-50-1
SERVICE TOOLS
06-60
SERVICE TOOLS
STEERING SST .................... 06-60-1
STEERING SST
dcf06600000Ow01
491232670B
49 H002 671
Power steering
gauge set
Adapter
49 G032 3A4A
~C'=:::::::=IHJ:I' Power steering
flirT
gauge adapter
iCfDI
set
49 T028 3AO
49 U032 3AO
490180510B
Ball joint puller

set
Pitman arm
Preload
measuring
attachment
49 F032 301
49 B032 304
49 G032 354
Power Steering
Pump Hanger
Adapter
Adjusting
Wrench
06-60-1

AIR CONDITIONING (HVAC)
07
SECTION
CONTROL SYSTEM ......... 07-40

SERVICE TOOLS ........... 07-60
SYMPTOM
TROUBLESHOOTING ...... 07-03
REFRIGERANT SYSTEM .... 07-10
BASIC SYSTEM ............ 07-11
07-03
FOREWORD ....................
TROUBLESHOOTING INDEX .........
NO.1 INSUFFICIENT AIR (OR NO AIR)
BLOWN FROM VENTS .........
NO.2 AMOUNT OF AIR BLOWN FROM
VENTS DOES NOT CHANGE .....
07-03-1
07-03-1
NO.3 NO TEMPERATURE CONTROL

WITH CLIMATE CONTROL UNIT ..... 07-03-3
NO.4 AIR FROM VENTS COLD
ENOUGH ................ 07-03-4
NO.5 NO COOL AIR ............. 07-03-6
NO.6 NOISE WHILE OPERATING AlC
SYSTEM .................. 07-03-8
07-03-1
07-03-2
FOREWORD
dcf07030000Ow01
The areas for inspection (steps) are given according to various circuit malfunctions. Use the following chart to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
dcf070300000w02
Insufficient air (or no air) blown from vents.
Amount of air blown from vents does not change.
No temperature control with climate control unit.
Air from vents not cold enough.
5
6
No cool air.
Noise while operating
No.
1
2
3
Ale system.
DESCRIPTION
Problem with each vent and/or duct.
Malfunction in blower system.
Malfunction in air outlet duct and/or climate control
unit air mix system.
Magnetic clutch operates but Ale system
malfunctions.
Magnetic clutch does not operate.
Noise from magnetic clutch, Ale compressor, hose
or refrigerant line.
NO.1 INSUFFICIENT AIR (OR NO AIR) BLOWN FROM VENTS
1
DESCRIPTION
POSSIBLE
CAUSE
Insufficient air (or no air) blown from vents.
Problem with each vent and/or duct.

Malfunction in VENT mode system (Steps 1-4)
Malfunction in HEAT mode system (Step 5)
Malfunction in DEFROSTER mode system (Steps 6-8)
Step
1
2
3
Inspection
INSPECT TO SEE WHETHER MALFUNCTION
IS IN VENT MODE OR OTHER MODES
Does air blowout when in VENT mode?
INSPECT VENT
Is vent clogged?
. VERIFY THAT DUCT IN DASHBOARD IS
INSTALLED
Is duct in dashboard properly installed?
Inspection item (s)

Yes
No
Go to Step 4.
Go to next step.
Yes
No
Yes
Remove obstruction, then go to Step 8.

Inspect duct for clogging, deformity and air leakage, then go
to Step 8.
Install duct securely in the proper position, then go to Step
8.
No
07-03-1
Step
4
5
6
Inspection
IS IN HEAT MODE OR DEFROSTER MODE
Does air blowout when in HEAT mode?
INSPECT DEFROSTER MODE
Does air blowout when in DEFROSTER
mode?
Inspection item (s)

Yes
No
Inspect vent for clogging, then go to Step 8.
Yes
Operation is normal. Recheck malfunction symptoms.
No
INSPECT VENT
Is vent clogged?
Yes
No
VERIFY THAT DEFROSTER DUCT IS

INSTALLED
Is defroster duct properly installed?
Yes
Inspect duct for clogging, deformity, and air leakage, then

No
CONFIRM THAT MALFUNCTION SYMPTOMS

DO NOT RECUR AFTER REPAIR
Does air blowout?
Yes
Install duct securely in proper position, then go to the next

step.
Explain repairs to customer.
No
Recheck malfunction symptoms, then repeat from Step 1 if

malfunction recurs.
NO.2 AMOUNT OF AIR BLOWN FROM VENTS DOES NOT CHANGE

2
DESCRIPTION
POSSIBLE
CAUSE
dcf070300000w04
Amount of air blown from vents does not change.
Malfunction in blower system.

Blower relay, blower motor, resistor, fan switch malfunction (Step 1)
Blower unit malfunction (Steps 2-4)
Step
1
Inspection
INSPECT BLOWER SYSTEM
Inspect the following systems and electrical
parts.
- Blower relay
- Blower motor
- Resistor
- Fan switch
- Related wiring harnesses
Are they normal?
CHECK TO SEE WHETHER MALFUNCTION
IS IN BLOWER UNIT OR ELSEWHERE
Turn engine switch to ON position.
Turn fan switch on.
Recirculate air inside vehicle.
Does fan in blower unit rotate smoothly?
Inspection item (s)

Yes
No
Repair or replace malfunctioning part, then go to Step 5.
Yes
Go to Step 4.
No
INSPECT BLOWER UNIT

Inspect fan in blower unit.
- Is fan free of interference from blower unit
case?
- Is fan free of foreign material and
obstructions?
Is fan normal?
Yes
No

Remove obstruction, repair or replace fan and blower unit
case, then go to Step 5.
INSPECT BLOWER UNIT INTAKE VENT

Is blower unit intake vent clogged?
Yes
Remove obstruction, then go to the next step.
No
Inspect if there are any obstructions in passage _between

blower unit and air outlet duct, then go to the next step.
VERIFY THAT MALFUNCTION SYMPTOM

OCCURS AFTER REPAIR
Does air blowout?
Yes
No

malfunction recurs.
07-03-2
NO.3 NO TEMPERATURE CONTROL WITH CLIMATE CONTROL UNIT
3
DESCRIPTION
POSSIBLE
CAUSE
dcf070300000w05
No temperature control with climate control unit.
Malfunction in air outlet duct and/or climate control unit air mix system.
Air outlet duct air mix link, air mix crank, air mix rod, air mix wire, wire clamp malfunction (Steps 2, 3)
Climate control unit rack-and-pinion, air mix wire malfunction (Step 4)
Air outlet duct air mix door malfunction (Steps 5, 6)
Heater piping malfunction (Step 7)
Step
Inspection
INSPECT COOLANT TEMPERATURE

Is coolant sufficiently warmed up?
INSPECT AIR OUTLET DUCT AIR MIX

SYSTEM
Inspect air outlet duct air mix links, air mix
cranks, air mix rods or wire clamp.
- Is there grease on links and cranks?
- Are links, cranks, and rods. securely
installed in their proper positions?
- Is wire clamp free of deformation?
Are above items normal?
VERIFY THAT AIR MIX WIRE FROM AIR
OUTLET DUCT IS POSITIONED SECURELY
AND CORRECTLY (IF AVAILABLE)
Is air mix wire securely installed in the
correct position in relation to air outlet duct
air mix links?
INSPECT CLIMATE CONTROL UNIT
Inspect climate control unit as follows.
- Is bevel gear set properly engaged?
- Is air mix wire properly installed in correct
position in relation to bevel gear?
- Is wire clamp free of deformation?
Are above items okay?
INSPECT AIR OUTLET DUCT
Is there any foreign material or obstruction in
air outlet duct air mix doors?
INSPECT AIR OUTLET DUCT AIR MIX
DOORS
Is air outlet duct air mix door securely and
properly installed?
5
6
INSPECT HEATER LINES

Inspect heater lines.
- Is heater piping free of damage and
cracks?
- Are heater piping connections free of
engine coolant leakage?
- Are heater piping connections securely
tightened?
- Are heater piping installation points on air
outlet duct free of engine coolant
leakage?
OCCURS AFTER REPAIR
Does unit operate in every temperature
setting?
Inspection item (s)

Yes
No
Yes
Warm engine up, then go to Step 8.

No
Apply grease or install links, cranks, and rods securely in

their proper positions, repair or replace wire clamp, then go
to Step 8.
Yes

Adjust air mix wire or install securely in correct position, then
go to Step 8.
No
Yes
No

Properly engage bevel gear or install air mix wire in correct
position, repair or replace wire clamp, then go to Step 8.
Yes
No
Yes
Inspect air mix door for cracks or damage, then go to the

next step.
Install air mix door securely in proper position, then go to the
next step.
Operation is normal. Recheck malfunction symptoms.
No
Yes
No
If heater piping connections is loosed, tighten connections

with specified torque.
Repair or replace heater piping, then go to the next step.
Yes
No

malfunction recurs.
07-03-3
NO.4 AIR FROM VENTS COLD ENOUGH
4
DESCRIPTION
POSSIBLE
CAUSE
dcf070300000w06
Air from vents not cold enough.

Magnetic clutch operates but AlC system malfunctions.
Drive belt malfunction (Step 2)
Malfunction in blower unit or condenser (Steps 4, 5)
Malfunction in receiver/drier or expansion valve (valve closes too much) (Steps 8, 9)
Malfunction in refrigerant lines (Steps 10, 11)
AlC compressor system malfunction, insufficient compressor oil (Steps 15, 16)
Over filling of compressor oil, malfunction in expansion valve or air outlet duct air mix link system (Steps
17-19)
Step
1
Inspection
INSPECT DRIVE BELT
Inspect drive belt.
(See 01-10A-3 DRIVE BELT INSPECTION
[WL-3].) (See 01-10B-3 DRIVE BELT
Is it normal?
INSPECT REFRIGERANT SYSTEM
PERFORMANCE
Perform refrigerant system performance test.
(See 07-10-2 REFRIGERANT SYSTEM
PERFORMANCE TEST.)
Is operation normal?
IS IN BLOWER UNIT INTAKE AND
CONDENSER OR ELSEWHERE
Are refrigerant high-pressure and lowpressure values both high?
INSPECT BLOWER UNIT INTAKE
Is blower unit intake clogged?
INSPECT CONDENSER
Inspect condenser.
(See 07-11-8 CONDENSER INSPECTION.)
Is it normal?
IS IN EXPANSION VALVE, RECEIVER/DRIER
AND REFRIGERANT LINES OR ELSEWHERE
Are refrigerant high-pressure and lowpressure values low?
IS IN EXPANSION VALVE AND RECEIVER!
DRIER OR ELSEWHERE
Immediately after AlC compressor operates,
does refrigerant high-pressure value
momentarily rise to correct value, then fall
and stay below it? (Is there negative
pressure on low-pressure side?)
IS IN EXPANSION VALVE OR RECEIVER!
DRIER
Turn AlC switch off and let air conditioner
stop for 10 min.
Start engine.
Turn both AlC switch and fan switch on.
Does malfunction occur after AlC
compressor turns on?
07-03-4
Yes
No
Inspection item (s)

Adjust or replace drive belt, then go to Step 20.
Yes
No
Operation is normal. (Recheck malfunction symptoms.)
Yes

Go to Step 6.
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Remove obstruction, then go to Step 20. (If air does not

reach evaporator within cooling unit, heat exchange does
not occur and refrigerant pressure becomes high.
Therefore, removal of obstruction is necessary.)
Adjust refrigerant to specified amount, then go to Step 20.
(Excessive amount of refrigerant.)
Replace condenser, or repair and clean condenser fins,
then go to Step 20.
Go to Step 14.

Go to Step 10.

Replace condenser and vacuum refrigerant line 30 min or
more by vacuum pump, add refrigerant to specified level,
then go to Step 20. (Since water has intermixed in receiver/
drier and it is saturated, replacement is necessary.)
Step
9
10
11
12
13
14
15
16
17
Inspection
VERIFY THAT EXPANSION VALVE HEATSENSING TUBE WITHIN COOLING UNIT IS
POSITIONED SECURELY AND CORRECTLY
Is expansion valve heat-sensing tube within
cooling unit securely installed in proper
position?
Inspection item (s)

Yes
Replace expansion valve, then go to Step 20. (Since valve

closes too much, replacement is necessary.)
No
Install heat-sensing tube securely in proper position, then go

to Step 20.
INSPECT REFRIGERANT LINES

Inspect refrigerant lines.
- Is piping free of damage and cracks?
- Are piping connections free of oil grime?
(Visual inspection)
- Are piping connections free of gas
leakage?
- Are piping installation points on
condenser free of gas leakage?
- Are piping installation points on receiver/
drier free of gas leakage?
- Are piping installation points on AlC
compressor free of gas leakage?
- Are piping installation points on cooling
unit free of gas leakage?
- Perform gas leak inspection using gas
leak tester.
INSPECT EVAPORATOR PIPING
CONNECTIONS IN COOLING UNIT FOR GAS
LEAKAGE
Are piping connections for evaporator in
cooling unit free of gas leakage?
Yes
No
If piping or AlC component (s) are damaged or cracked,

replace them.
Then go to Step 20.
If there is no damage, go to Step 13.
Yes

CONNECTIONS IN COOLING UNIT FOR
LOOSE
cooling unit loose?
Yes
INSPECT PIPING CONNECTIONS FOR

LOOSE
Are piping connections loose?
Yes
If the vane makes a noise, add 10 ml {10 ee, 0.34 fl oz} of

compressor oil to the AlC compressor. Verify that the noise
is no longer heard.
Adjust refrigerant to specified amount, then go to Step 20.
If piping is damaged or cracked, replace it.
Then go to Step 20.
If there is no damage,go to the next step.
Tighten connections with specified torque, adjust both
compressor oil and refrigerant to specified amount, then go
to Step 20.
is no longer heard.
Replace a-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.
Tighten connections with specified torque, adjust both
compressor oil and refrigerant to specified amount, then go
to Step 20.
is no longer heard.
Replace a-ring on piping, adjust refrigerant to specified
amount, then go to Step 20.

IS IN EXPANSION VALVE, AIR MIX
ACTUATOR AND COMPRESSOR OIL OR
ELSEWHERE
Does refrigerant high-pressure value hardly
increase?
Yes
No
Go to the next step. (Pressure hardly increases.)

Go to Step 17.

IS IN COMPRESSOR OIL AMOUNT AND AlC
COMPRESSOR OR ELSEWHERE
When engine is racing, does high-pressure
value increase?
Yes
Return to Step 3.
No

IS IN COMPRESSOR OIL AMOUNT OR AlC
COMPRESSOR
After compressor oil is replenished each 10
ml {10 ee, 0.34 fl oz}, does high-pressure
value increase?
Yes
Troubleshooting completed. (Explain to customer that cause

was insufficient compressor oil.)
No
Replace AlC compressor, then go to Step 20. (Cause is

defective AlC compressor.)

IS IN EXPANSION VALVE OR ELSEWHERE
Is only refrigerant low-pressure value high?
Yes
Go to Step 19.
No
No
No
No
07-03-5
Step
18
Inspection
VERIFY THAT AIR MIX IS INSTALLED
SECURELY AND PROPERLY
Are air outlet duct air mix links, air mix
cranks, and air mix rods securely and
properly installed?
Yes
No
19
20
VERIFY THAT EXPANSION VALVE HEATSENSING TUBE WITHIN COOLING UNIT IS

POSITIONED SECURELY AND CORRECTLY
Is expansion valve heat-sensing tube within
cooling unit securely installed in proper
position?
OCCURS AFTER REPAIR
Does cool air blowout? (Are results of
refrigerant system performance test
normal?)
Yes
No
Yes
No
Inspection item (s)

Set fan switch to 4th position.
Turn AlC switch on.
Set FRESH mode.
Set temperature control to MAX COLD.
Set VENT mode.
(1 )Start and run the engine at 1,500 rpm for 10 min.
(2)Run the engine at idle for 1 min.
(3)Within 12 s, idle -? 4,000 rpm -? idle. Perform cycle 5
times.
(4) Run the engine at idle for 30 s.
(5)Drain the compressor oil completely from the AlC
compressor and verify the amount.
If there is approx. 90 ml {90 cc, 3.0 fl oz} of
compressor oil, go to Step 20.
If there is more than 90 ml {90 cc, 3.0 fl oz} of
compressor oil, remove surplus oil and fill AlC
compressor with 90 ml {90 cc, 3.0 fl oz} of
compressor oil. Repeat Steps (1) to (5).
(Cause is excessive amount of compressor oil.)
Repair or install links, cranks and rods securely in proper
position, then go to Step 20.
Replace expansion valve, then go to the next step. (Since
valve opens too much, replacement is necessary.)
Install heat-sensing tube securely in proper position, then go
to the next step.
malfunction recurs.
NO.5 NO COOL AIR

5
DESCRIPTION
POSSIBLE
CAUSE
dcf070300000w07
No cool air
Malfunction in PCM AlC cut control system (Step 3)
Malfunction in climate control unit (Step 4)
Malfunction in refrigerant pressure switch (Steps 5, 7-9)
Malfunction in PCM (AiC signal) (Step 6)
Malfunction in PCM (IG1 signal) (Steps 10,11)
Malfunction in AlC compressor (Step 12)
Malfunction in AlC relay (Steps 13-15)
Malfunction in evaporator temperature sensor (Step 16)
When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing 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.
Step
1
2
Inspection
INSPECT AIR BLOW OUT
Does air blowout?
INSPECT AlC COMPRESSOR OPERATION
Start engine.
Turn AlC switch and fan switch on.
Does AlC compressor operate?
INSPECT FOR DTC IN PCM
Inspect for DTCs related to the PCM onboard diagnostic system.
07-03-6
No
Inspection item (s)

Go to Step 1 of troubleshooting index No.1.
Go to Step 1 of troubleshooting index No.4.
Yes
No
Go to appropriate inspection procedure.

Yes
No
Yes
Step
5*
6*
8*
10
11*
12*
13
Inspection
IS IN CLIMATE CONTROL UNIT OR
ELSEWHERE
Does cool air blowout when terminal 38 of
climate control unit connector (3-pin, AlC
signal) is grounded?
IS IN AlC SIGNAL CIRCUIT (BETWEEN
REFRIGERANT PRESSURE SWITCH AND
PCM) OR ELSEWHERE
Test voltage at following terminal of
- Terminal 8 (AiC signal)
Is voltage approx. 12 V?
(LACK OF CONTINUITY) IS IN WIRING
HARNESS (BETWEEN REFRIGERANT
PRESSURE SWITCH AND PCM) OR PCM
Test voltage at AlC signal terminal of PCM.
IS IN REFRIGERANT PRESSURE SWITCH,
REFRIGERANT AMOUNT, OR ELSEWHERE
Does cool air blowout when terminals A and
8 of refrigerant pressure switch connector
are shorted?
IS IN WIRING HARNESS (BETWEEN
REFRIGERANT PRESSURE SWITCH AND
CLIMATE CONTROL UNIT) OR ELSEWHERE
Test voltage at following terminal of climate
control unit. (3-pin)
- Terminal 38 (3-pin, AlC signal)

IS IN REFRIGERANT PRESSURE SWITCH OR
REFRIGERANT AMOUNT
Inspect refrigerant pressure switch.
Is it normal?
(LACK OF CONTINUITY) IS IN AlC CONTROL
SIGNAL CIRCUIT (BETWEEN AlC RELAY
AND PCM) OR ELSEWHERE
Does cool air blowout when terminal E of AI
C relay connector (AiC control signal) is
grounded?
(LACK OF CONTINUITY) IS IN PCM OR
WIRING HARNESS (BETWEEN AlC RELAY
AND PCM)
Test voltage at the AlC relay control signal
terminal of PCM.
IS IN MAGNETIC CLUTCH OR ELSEWHERE
Test voltage at the following terminal of
magnetic clutch.
- Terminal A (magnetic clutch operation
signal)
INSPECT FUSE
Are AlC relay power supply fuses normal?
Inspection item (s)

Yes
No
Yes
No
Replace climate control unit, then go to Step 17.

Release short, then go to the next step.
Go to Step 7.
.
Yes
Repair wiring harness between PCM and refrigerant

pressure switch, then go to Step 17.
No
Inspect PCM, then go to Step 17.
Yes
Go to Step 9.
No
Yes
No
Yes
No
Go to Step 10.
Repair wiring harness between refrigerant pressure switch
and climate control unit, then go to Step 17.
If refrigerant amount is empty, replace condenser, vacuum

refrigerant line 30 min or more by vacuum pump, and add
refrigerant to specified level, then go to Step 17.
Replace refrigerant pressure switch, then go to Step 17.
Yes
No
Release short, then go to the next step.
Yes
No

Repair wiring harness between AlC relay and PCM, then go
to Step 17.
Yes
Inspect magnetic clutch, then go to Step 17.
No
Yes
NO
Go to Step 12.
Replace fuse, then go to Step 17. If fuse burns out

immediately, go to the next step.
07-03-7
14
15
16
17
Inspection item (s)
Inspection
Step
INSPECT WIRING HARNESS BETWEEN

FUSE BLOCK AND AlC RELAY FOR LACK
OF CONTINUITY
Test voltages at following terminals of AlC
relay.
- Terminal A (AiC relay control signal)
- Terminal C (AiC control signal) ,
Are voltages approx. 12 V?
IS IN AlC RELAY OR WIRING HARNESS
(BETWEEN AlC RELAY AND MAGNETIC
CLUTCH) AND EVAPORATOR
TEMPERATURE SENSOR
Test voltage at the following terminal of AlC
relay.
- Terminal D (magnetic clutch operation
signal)
INSPECT EVAPORATOR TEMPERATURE
SENSOR
Inspect evaporator temperature sensor.
Is it normal?
Does cool air blowout? (Are the results of
refrigerant system performance test
normal?)
07-03-8
Yes
No
Repair wiring harness between fuse block and AlC relay,

then go to Step 17.
Yes
Inspect wiring harness between AlC relay and magnetic

clutch.
If above wiring harness is normal, go to the next step.
If above wiring harness malfunctions, repair wiring
harness, then go to Step 17.
No
Replace AlC relay, then go to Step 17.
Yes

Replace evaporator temperature sensor, then go to the next
step.
No
Yes
No

malfunction recurs.
NO.7 NO COOL AIR.[SRSSS]
7
DESCRIPTION
POSSIBLE
CAUSE
id070300804804
No cool air
?
?
?
?
?
?
?
?
?
?

AlC compressor system malfunction (Step 2)
Incorrect amount of refrigerant (Step 3)
AlC switch indicator light malfunction (Steps 4-6)
PCM AlC cut-off control system (WL, WLT-1, WLT-2: Step 18) (G6: Step 7)
PCM (IG1 signal) system malfunction (WL, WLT-1, WLT-2: Steps 8,9) (G6: Step 20)
Themoswitch, AlC switch malfunction (WL,WLT-1, WLT-2: Steps 11,12,14,15) (G6: Step 10-14)
PCM (AiC signal) system malfunction (WL, WLT-1, WLT-2: Steps 17) (G6: Step 16, 17)
Refrigerant pressure switch malfunction (WL, WLT-1, WLT-2: Step 26) (G6: Step19)
AlC relay malfunction (WL, WLT-1, WLT-2: Steps 22-25) (G6: Step 22-24)
? 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.
STEP
1
2
INSPECTION
INSPECT AIR BLOW OUT
? Does air blowout?
INSPECT AlC COMPRESOR OPERATION
? Start engine.
? Turn both AlC switch and front fan switch on.
? Does AlC compressor operate?
INSPECT REFRIGERANT AMOUNT
? Inspect refrigerant amount.
? Is it okay?
INSPECT AlC SWITCH INDICATOR LIGHT

? Does AlC switch indicator light illuminate?
*5

FUSE BLOCK AND FRONT CLIMATE
CONTROL UNIT FOR CONTINUITY
? Turn ignition switch to ON position.
? Remove airflow mode wire and air mix wire
and pull out front climate control unit.
? Test voltage at front climate control unit
terminal C (IG2 signal).
? Is voltage approximately 12 V?
*6
*8
*9
INSPECT AlC SWITCH

? Inspect AlC switch.
? Is it okay?
CHECK FOR DTCS IN PCM
? Check the DTC for the ON-BOARD
DIAGNOSTIC (ENGINE CONTROL).
? Are the following DTCs displayed?
-DTC 0120
MAGNETIC CLUTCH SYSTEM OR
ELSEWHERE
? Does magnetic clutch operate when AlC
relay connector terminal B (IG2 signal) is
grounded?
VERIFY WHETHER MALFUNCTION IS IN AlC
RELAY SYSTEM (COIL-SIDE) OR
ELSEWHERE
? Turn AlC switch off.
? Test voltage at PCM connector terminal
L(IG1 signal).
ACTION
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Go to next step.
Go to Step 1 of troubleshooting indexes No.1, 2.
Go to Step 1 of troubleshooting index NO.6.
Go to next step.
Go to next step.
Add or subtract refrigerant to specified level, then go to Step
27.
WL or WL-T1, WLT-2: Go to Step 8.
G6: Go to Step 7.
Go to next step.
Go to next step.
Repair wiring harness between fuse block and AlC switch,
then go to Step 27.
Yes
Inspect wiring harness between AlC switch and resistor,

then go to Step 27.
No
Yes
Replace AlC switch, then go to Step 27.
No
Go to appropriate inspection procedure. (The throttle

position sensor (DTC 0120), which sends the PCM's AlC cut
off control input signal, may be the cause of the trouble.)
Go to Step 10.
Yes
Go to next step.
No
Go to Step 21.
Yes
No
Go to Step 11.
Repair wiring harness between AlC relay and PCM, then go
to Step 27.
07-03-8a
STEP
*10
*11
*12
*13
*14
INSPECTION
ACTION

THEMOSWITCH SYSTEM OR ELSEWHERE
? Turn ignition switch to LOCK position.
? Remove radiator grille.
? Disconnect refrigerant pressure switch
connector.
? Set front fan switch at first speed.
? Test voltage at the following refrigerant
pressure switch connector terminal B (AiC
signal) on wiring harness side.
? Is voltage approximately 12 V when AlC
switch is off and 0 V when it is on?
Yes

EVAPORATOR TEMPERATURE SENSOR
AND WIRING HARNESS (BETWEEN FUSE
BLOCK AND EVAPORATOR TEMPERATURE
SENSOR FOR CONTINUITY) OR
ELSEWHERE
? Remove glove compartment.
? Disconnect evaporator temperature sensor
connector.
? Start engine.
? When evaporator temperature sensor
connector terminals Band C (on wiring
harness side) are shorted, does cool air blow
out?
EVAPORATOR TEMPERATURE SENSOR OR
WIRING HARNESS (BETWEEN FUSE BLOCK
AND THEMOSWITCH FOR CONTINUITY)
? Test voltage at evaporator temperature
sensor connector terminal A (IG2 signal).
AND REFRIGERANT PRESSURE SWITCH
FOR CONTINUITY
? Inspect for continuity between evaporator
temperature sensor connector terminal B (AI
C signal) and refrigerant pressure switch
connector terminal B.
? Is there continuity?
AND WIRING HARNESS (BETWEEN
AND AlC SWITCH FOR CONTINUITY) OR
ELSEWHERE
? Turn AlC switch ON.
? Turn fan switch ON.
? Test voltage at AlC switch connector terminal
A (AiC signal).
Yes
07-03-8b
No
No
Go to Step 16.
Reconnect refrigerant pressure switch connector, then go to
next step.
Undo short, then go to next step.

WL or WL-T1, WLT-2: Undo short, then go to Step 14.
G6: Undo short, then go to Step 13.
Yes
No
Inspect evaporator temperature sensor, then go to Step 27.

Repair wiring harness between fuse block and evaporator
temperature sensor, then go to Step 27.
Yes
Go to next step.
No

and evaporator temperature sensor, then go to Step 27.
Yes
WL or WL-T1, WLT-2: Go to next step.

G6: Inspect wiring harness between evaporator temperature
sensor and AlC switch, then go to Step 27.
No
Inspect AlC switch, then go to Step 27.
STEP
*15
*16
*17
*18
*19
*20
*21
22
INSPECTION
ACTION

AND WIRING HARNESS (BETWEEN
AND AlC SWITCH FOR CONTINUITY) OR
ELSEWHERE
? Test voltage at evaporator temperature
sensor connector terminal C (AiC signal).
Yes
VERIFY WHETHER MALFUNCTION IS IN PCM

AND WIRING HARNESS (BETWEEN PCM
AND REFRIGERANT PRESSURE SWITCH
FOR CONTINUITY) OR ELSEWHERE
? Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (AiC signal).
Yes
No
Go to Step 19.

OR WIRING HARNESS (BETWEEN PCM AND
REFRIGERANT PRESSURE SWITCH FOR
CONTINUITY)
? Test voltage at the following PCM connector
terminals (AiC signal).
- Terminal G (WL or WL-T1, WLT-2)
- Terminal Q (G6)
AND WIRING HARNESS (BETWEEN PCM
AND EVAPORATOR TEMPERATURE
SENSOR FOR CONTINUITY) OR
ELSEWHERE
? Inspect the following input signal
components:
- Engine coolant temperature sensor,
including PCM wiring harness (AiC cut-off
control)
? Are they okay?
Yes

G6: Inspect wiring harness between PCM and refrigerant
No
Yes
Repair wiring harness between PCM and evaporator

temperature sensor, then go to Step 27.
Replace input signal components, then go to Step 27.

REFRIGERANT PRESSURE SWITCH OR
ELSEWHERE
? When the following refrigerant pressure
switch connector terminal A and S (on wiring
harness side) are shorted, does cool air blow
out?
IS IN AlC RELAY OR ELSEWHERE
? Does magnetic clutch operate when terminal
S (IG2 signal) of AlC relay connector is
grounded?
MAGNETIC CLUTCH OR WIRING HARNESS
CLUTCH FOR CONTINUITY)
? Test voltage at magnetic clutch connector
terminal A (AiC control signal).
Yes
No
Inspect refrigerant pressure switch, then go to Step 27.

Undo short, reconnect refrigerant pressure switch, then go
to next step.
Yes
Inspect wiring harness between AlC relay and PCM, then

go to Step 27.
No
Go to next step.
Yes
Inspect magnetic clutch, then go to Step 27.
No
Go to next step.
INSPECT AlC RELAY (SWITCH-SIDE) POWER

SUPPLY FUSE
? Are AlC relay power supply fuses okay?
Yes
Go to next step.
No
Inspect for a short to ground on blown fues's circuit. Repair

or replace as necessary.
Install appropriate amperage fuse.
No
No
Go to Step 17.
Repair wiring harness between evaporator temperature
sensor and AlC switch, then go to Step 27.
Go to next step.
07-03-8c
INSPECTION
STEP
*23
*24
*25
*26
27
ACTION

FUSE BLOCK AND AlC RELAY
(SWITCH-SIDE) FOR CONTINUITY
? Test voltage at the following AlC relay
connector terminals:
- Terminal A (IG2 signal)
- Terminal C (AIC control signal)
Yes

MAGNETIC CLUTCH OR WIRING HARNESS
CLUTCH FOR CONTINUITY)
? Test voltage at AlC relay connector terminal
D (AIC control signal).
Yes

G6: Repair wiring harness between AlC relay and magnetic
clutch, then go to Step 27.
No
Inspect AlC relay, then go to Step 27.

FUSE BLOCK AND AlC RELAY
(SWITCH-SIDE) FOR CONTINUITY
? Test voltage at refrigerant pressure switch
connector (on wiring harness side) terminal
A (AIC control signal)
Yes. Go to next step.

No
Repair wiring harness between AlC relay and refrigerant


REFRIGERANT PRESSURE SWITCH OR
ELSEWHERE
? When refrigerant pressure switch connector
terminal A and B (on wiring harness side) are
shorted, does cool air blowout?
Yes
Inspect refrigerant pressure switch, then go to next step.
No

and magnetic clutch, then go to next step.

OCCURS AFTER REPAIR
? Does cool air blowout? (Is refrigerant system
performance test result correct?)
Yes
No

malfunction recurs.
07-03-8d
No
Go to next step.
Repair wiring harness between fuse block and AlC relay,
then go to Step 27.
NO.6 NOISE WHILE OPERATING Ale SYSTEM
6
DESCRIPTION
POSSIBLE
CAUSE
dcf070300000w08
Noise while operating AlC system.
Noise from magnetic clutch, AlC compressor, hose or refrigerant line.

Magnetic clutch operation noise (Step 4)
AlC compressor vane noise (Steps 5-13)
AlC compressor slippage noise (Steps 14-17)
Hose or refrigerant line interference noise (Step 18)
Step
1
Inspection
CHECK AlC COMPRESSOR VANE NOISE
Is there a jingling, popping, beeping, or
buzzing sound (AiC compressor vane
noise)?
Inspection item (s)

Yes
Go to Step 5.
No
INSPECT AlC COMPRESSOR SLIPPAGE

NOISE
Is there a squeaking or whirling sound (AiC
compressor slippage noise)?
Yes
Go to Step 14.
No
INSPECT AlC COMPRESSOR

INTERFERENCE NOISE
Is there a rattling or vibrating sound
(interference noise)?
INSPECT MAGNETIC CLUTCH OPERATION
NOISE
Is there a clicking sound (magnetic clutch
operation noise)?
Yes
Go to Step 18.
INSPECT AlC COMPRESSOR NOISE TIME

Is noise heard continuously for 3 s or more
after AlC compressor comes on?
INSPECT IDLE SPEED

Inspect idle speed.
(See 01-10A-20 ENGINE TUNE-UP [WL-3].)
(See 01-108-21 ENGINE TUNE-UP [WL-C,
WE-C).)
Is it normal?
07-03-8e
No
Yes
Adjust clearance between pressure plate of magnetic clutch

and AlC compressor pulley, then go to Step 19.
(See 07-40-4 MAGNETIC CLUTCH ADJUSTMENT.)
No
Yes
No
Condition is normal. (Recheck malfunction symptoms.)
Yes

Follow the repair instruction described in section F, then go
to Step 19.
No

Condition is normal. (Noise occurs for 2-3 S immediately
after AlC compressor turns on.)
Step
7
10
11
12
13
14
15
16
17
Inspection
INSPECT REFRIGERANT AMOUNT
Inspect refrigerant amount.
Is it normal?
INSPECT REFRIGERANT LINES
Inspect refrigerant lines.
- Is piping free of damage and cracks?
- Are piping connections free of oil grime?
(Visual inspection)
- Are piping connections free of gas
leakage?
- Are piping installation points on
condenser free of gas leakage?
- Are piping installation points on receiver/
drier free of gas leakage?
- Are piping installation points on AlC
compressor free of gas leakage?
- Are piping installation points on cooling
unit free of gas leakage
- Perform gas leak inspection using gas
leak tester.
CONNECTIONS IN COOLING UNIT FOR GAS
LEAKAGE
cooling unit free of gas leakage?
IS IN COMPRESSOR OIL OR ELSEWHERE
Add 20 ml {20 cc, 0.8 fl oz} of compressor
oil.
Is noise heard when racing engine?
IS IN AlC COMPRESSOR OR ELSEWHERE
Drain compressor oil.
Is it contaminated with metal particles?
IS SOMEWHERE IN AlC SYSTEM OR
ELSEWHERE
Is compressor oil whitish and mixed with
water?
INSPECT AlC COMPRESSOR OIL
Is compressor oil darker than normal and
contaminated with aluminum chips?

IS IN AlC COMPRESSOR OR ELSEWHERE
Is noise heard immediately after AlC
compressor is stopped?
INSPECT DRIVE BELT
Inspect drive belt.
(See OHOA-3 DRIVE BELT INSPECTION
[WL-3].) (See 01-10B-3 DRIVE BELT
Is it normal?
INSPECT DRIVE BELT CONDITION
Is drive belt worn?
Does it have foreign material imbedded in it,
or have oil on it?
INSPECT MAGNETIC CLUTCH
Inspect magnetic clutch.
(See 07-40-5 MAGNETIC CLUTCH
INSPECTION.)
Is it normal?
Inspection item (s)

Yes
No
Go to Step 10.
Yes
No

If piping or AlC component (s) is damaged or cracked,
replace then go to Step 19.
If there is gas leakage, repair or replace connection and
replace condenser*, then go to Step 19.
Yes
Adjust refrigerant amount to specified level, then go to Step

19.
If piping is damaged or cracked, replace then go to Step 19.
If there is gas leakage, repair or replace connection and
replace condenser*, then go to Step 19.
Explain repair to customer.
No
Yes
No
/"
Yes
No

Replace AlC compressor, then go to Step 19.
Yes
Replace entire AlC system (excluding heater), then go to

Step 19.
No
Yes
No
Replace AlC compressor and condenser, then go to Step

19. (Since AlC compressor may be worn and receiver/drier
may be clogged, replacement of receiver/drier is
necessary.)
Condition is normal. Recheck malfunction symptoms.
Replace AlC compressor, then go to Step 19. (AiC
compressor discharge valve left open)
Yes
No

Adjust or replace drive belt, then go to Step 19.
Yes
Remove obstruction, remove oil, or replace drive belt, then

go to Step 19.
No
Yes
No
Yes
No
..
Replace AlC compressor (excluding pressure plate, AlC

compressor pulley, and stator), then go to Step 19.
Replace magnetic clutch, then go to Step 19.
07-03-9
Step
J.18
"
19
Inspection
IS IN AlC COMPRESSOR OR REFRIGERANT
LINES
Is noise emitted from Ale compressor?
OCCURS AFTER REPAIR
Has Ale compressor noise stopped?
Yes
No
Yes
No
Inspection item (s)

Visually inspect Ale compressor, replace appropriate parts
if necessary, then go to the next step.
If noise is due to refrigerant lines, repair detached or
missing clips, tighten loose bolts, then go to the next step.
malfunction recurs.
: If there is gas leakage, air enters into the Ale system. The desiccant within the receiver/drier absorbs the
moisture from the air and becomes saturated. If the Ale system is used in this condition, the inside of the Ale
compressor will begin to rust due to this moisture, which may cause lock up or noise to occur. Therefore,
replacement of the receiver/drier is necessary.
07-03-10
REFRIGERANT SYSTEM
07-10
REFRIGERANT SYSTEM
REFRIGERANT SYSTEM SERVICE

WARNINGS ...................... 07-10-1
CAUTIONS ...................... 07-10-1
REFRIGERANT SYSTEM GENERAL
PROCEDURES ................... 07-10-2
REFRIGERANT SYSTEM SERVICE WARNINGS
REFRIGERANT SYSTEM
PERFORMANCE TEST ............. 07-10-2
REFRIGERANT PRESSURE
CHECK .......................... 07-10-3
RECOVERy ....................... 07-10-3
REFRIGERANT CHARGING .......... 07-10-3
dcf071000000w01
Handling Refrigerant
Avoid breathing air conditioning refrigerant or lubricant vapor. Exposure may irritate eyes, nose and
throat. Also, due to environmental concerns, the use of recovery/recycling/recharging equipment is
mandatory when draining R-134a from the air conditioning system. If accidental system discharge
occurs, ventilate work area before resuming service.
Do not perform pressure test or leak test for R-134a service equipment and/or vehicle air conditioning
system using 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.
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.
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
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 40C {104 OF}.
REFRIGERANT SYSTEM SERVICE CAUTIONS
dcf071000000w02
Handling Insufficient Refrigerant Level

If an insufficient refrigerant level is detected at troubleshooting, do not charge (add) the refrigerant.
Because an accurate amount of refrigerant cannot be determined from the pressure indicated on the
manifold gauge, never charge the refrigerant. If there is too much or too little refrigerant from the
refilling, there may be secondary problems such as damage to the refrigerant cycle parts, or a decrease
of cooling performance. Therefore, if it is determined that the refrigerant level is insufficient,
completely remove refrigerant from the refrigerant cycle and refill with refrigerant to the specified
amount.
Handling AlC Related Parts
There will be no effect on either performance or quality of AlC-related parts, including but not limited to
the piping, etc., provided that said parts are serviced/repaired in accordance with standard procedure.
When serviced/repaired AlC units in locations where there is a considerable risk of contamination from
dirt or dust, plug up the openings on the parts to prevent dust/dirt from entering.
When using adhesive material to cover openings on AlC parts, make sure that the adhesive side of the
material does not come in contact with the connectors on the parts.
When the system is opened to atmosphere, there is no need to replace the condenser, or the receiver
dryer when it is housed within the condenser, provided that the unit is plugged accordingly.
07-10-1
REFRIGERANT SYSTEM
Handling Compressor Oil
Use only FD46XG compressor oil for this
FD46XG COMPRESSOR OIL
vehicle. Using a PAG oil other than FD46XG
z
o
compressor oil can damage the AlC
I
compressor.
ti:
I
a:
I
Do not spill FD46XG compressor oil on the
I
o
I
C/)
I
vehicle. A drop of compressor oil on the
co
I
I
vehicle surface can eat away at the paint. If oil
I
w
I
a:
I
gets on the vehicle, wipe it off immediately.
:::>
I
FD46XG compressor oil (PAG oil) has a higher
:MINERAL OIL
tn
moisture absorption efficiency than the
5
previously used mineral oil. If moisture mixes
:2 0 ~~~~===~~==;::=
TIME
with the compressor oil, the refrigerant
DBG710ZWB001
system could be damaged. Therefore, install
caps immediately after using the compressor
oil or removing refrigerant system parts to prevent moisture absorption.
REFRIGERANT SYSTEM GENERAL PROCEDURES
1. Fully close the valves of the SST (49 C061 001 A).
2. Connect the SSTs (49 C061 002,49 C061 003)
to the high- and low-pressure side joints of the
SST (49 C061 001A).
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.
dcf071000000w03
'J'
.. em,;",..
~.
l~:!'~
I.
II
I I
I.
:A'
II. '
CAP
~HARGING
CAP~
CHARGING VALVE OF
LOW-PRESSURE SIDE
~_~ALVEOF
HIGH-PRESSURE
SIDE
----
BHE0710W001
REFRIGERANT SYSTEM PERFORMANCE TEST
dcf071000000w04
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Inspect the refrigerant pressure. (See 07-10-3 REFRIGERANT PRESSURE CHECK.)

Place a dry-bulb thermometer in the driver-side center ventilator outlet.
Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
Set the fan speed to MAX HI.
Set to RECIRCULATE mode.
Set the temperature control to MAX COLD.
Set to VENT mode.
Close all the doors and windows.
Wait until the air conditioner output temperature stabilizes.
Stabilized condition
The AIC compressor repeatedly turns on and off at regular intervals.
11. After the blower air is stabilized, read the dry-bulb thermometer.
12. Verify the ambient temperature.
13. Verify that the temperature reading is in the
C {OF}
a:
shaded zone.
o
6 {43}r
If the there is any malfunction, inspect the
~
-w
refrigerant system according to the
~
f-a: 5
4 {41}f{39} ftroubleshooting chart.
m:::> 3 {37} f>!;:(
a: a: 2 {36}r
ww 1 {34} ff-a.
Z:2
Ww
Of-
o {32} L...-~-II():)'----!-:X-~'-..o.....o...,.l:C....J:o:...x-:.:><::..~c.J
..
20
25
30
35
{68}
{77}
{85}
{95}
40C
{104} {OF}
AMBIENTTEMPF.RATURE
DBG710ZWB003
07-10-2
"
REFRIGERANT SYSTEM
REFRIGERANT PRESSURE CHECK
dcf071078834w01
1. Install the SSTs (49 C061 OAOS).

2. Start the engine and after it is warmed up, run it at a constant 1,500 rpm.
3. Set the fan speed MAX HI.
4. Turn the AlC switch on.
5. Set to RECIRCULATE mode.
6. Set the temperature control to MAX COLD.
7. Set to VENT mode.
8. Close all the doors and all the windows.
9. Measure the ambient temperature and high- and low- pressure side reading of the SST (49 C061 001 A).
10. Verify that the intersection of the pressure reading
of the SST (49 C061 001 A) and ambient
MPa
{kgf/cm 2 , psi}
temperature is in the shaded zone.
HIGH-PRESSURE SIDE
If there is any malfunction, inspect the
~ 2.0
~ {21, 299}
refrigerant system according to the
C9
troubleshooting chart.
Cl 1.5
B {15,213}
LL
:2
1.0
{10, 142}
LL
oC9
z
is
0.2
{2.0,28}
LOW-PRESSURE SIDE
II: 0.1
~ {1.0,14}
::l
(f)
(f)
1____~__~~__
-
I
20
{68}
I
25
{77}
~ ~
L __ _
I
I __ I
30
35
40C
{85}
{95} {104} {OF}
AMBIENT TEMPERATURE
DBG710ZWB002
RECOVERY
dcf071078834w02
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.
REFRIGERANT CHARGING
dcf071078834w03
Caution
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.
Charging Recycled R-134a Refrigerant
1. Connect an R-134a recovery/recycling/recharging device to the vehicle and follow the device manufacturer's
instructions.
07-10-3
REFRIGERANT SYSTEM
Charging Preparation
1. Install the SSTs (49 C061 OAOS).
2. Connect the tap pin side of the SST (49 C061 004) to the air purge valve of the SST (49C061 001).
3. Connect the SST (49 C061 005) to the center joint of the SST (49 C061 001A).
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.
r---TA-P-P-I-N-S-IDn-E-7-~A-;-;:_IR.:-;:P::7"~.;-;::;R""G-;:::-;-;-=-;-;-;-;:::---,-,-.-,- - , - - '
Regular amount of refrigerant (approx.
quantity)
475 g {16.8 oz}
Ck'INa"!.u
REFRIGER:gNT
TANK
.
SCALE
r:=:.=e:"
" .,
~f~~~~=~
@}- : ---::
@8
VACUUM PUMP
BHE0710W004
Evacuation
1. Open all the valves of the SST (49 C061 001 A).
Caution
Close the SST (49 C061 001 A) 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.
2. Start the vacuum pump and let it operate for 15
min.
:4'
I.
II
j,
CLOSE
BHE0710W005
3. Verify that high- and low-pressure side readings

of the SST (49 C061 001A) are at -101 kPa {760 mmHg, -29.9 inHg}. Close each valve of the
SST (49 C061 001A).
BHE0710W002
Airtightness Check
1. Stop the vacuum pump and wait for 5 min.
2. Check the high- and low-pressure side readings of the SST (49 C061 001A) .
If the reading has changed, inspect for leakage and go to Evacuation. (See 07-10-4 Evacuation.)
If the reading has not changed, go to Charging New R-134a Refrigerant. (See 07-10-5 Charging New R134a Refrigerant.)
07-10-4
REFRIGERANT SYSTEM
Charging New R-134a Refrigerant
1. Open the valve of the refrigerant tank.
2. Weigh the refrigerant tank to charge the suitable amount of refrigerant.
Warning
If the refrigerant system is charged with a large amount of refrigerant when inspecting 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 inspecting for gas leakage.
If charging the system with refrigerant using service cans, running the engine with the highpressure 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.
Caution
Always being charging of refrigerant from the high-pressure side. If changing is begun from the
low-pressure side, the vanes of the AlC compressor will not be released and abnormal noise may
result.
3. Open the low-pressure side valve of the SST (49
C061 001A).
4. When the high-pressure side reading increases to

0.098 MPa {1.0 kgf/cm 2 , 14 psi}, close the
low-pressure side valve of the SST (49 C061
001A).
5. Inspect for leakage from the cooler pipe/hose
connections using the SST (49 C061 013).
If there is no leakage, go to Step 7.
If leakage is found at a loose joint, tighten the
joint, then go to next step.
6. Inspect for leakage again.
If there is no leakage after tightening the joint,
go to next step.
If there is still a leakage at the same joint,
discharge the refrigerant and then repair the
joint. Repeat the charging procedure from evacuation.
,.
I.
II
Warning
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.
07-10-5
REFRIGERANT SYSTEM
C061 001 A) and charge with refrigerant until the
weight of refrigerant tank has decreased 250 g
{8.83 oz} from the amount in Step 2.
OPEN
8. Close the low-pressure side valve of the SST (49

C061 001A).
Warning
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.
9. Start the engine and actuate the A/C compressor.

C061 001 A) and charge with refrigerant until the
weight of the refrigerant tank has decreased
regular amount from the amount in Step 2.
11. Close the low-pressure side valve of the SST (49
C061 001 A) and the valve of the refrigerant tank.
12. Stop the engine and A/C compressor.
BHE0710W002
OPEN
BHE0710W007
Leak Test
1. Inspect for leakage using the SST (49 C061 013).
If there is no leakage, go to Step 3.
If leakage is found at a loose joint, tighten the joint, then go to next step.
2. Inspect for leakage again.
If there is no leakage after tightening the joint, go to next step.
If there is still leakage at the same joint, discharge the refrigerant and then repair the joint. Repeat the
charging procedure from evacuation.
3. Disconhect the SSTs (49 C061 006A, 49 C061 007) from the charging valves.
4. Install the caps to the charging valves.
,-----~--;-;---------------,
CHU0710W006
07-10-6
BASIC SYSTEM
07-11
BASIC SYSTEM
HVAC BASIC SYSTEM

LOCATION INDEX . ................
BLOWER UNIT
REMOVAUINSTALLATION ..........
BLOWER UNIT
DISASSEMBLY/ASSEMBLY . ........
COOLING UNIT
COOLING UNIT
DISASSEMBLY/ASSEMBLY . ........
EVAPORATOR INSPECTION . ........
07-11-1
07-11-2
07-11-2
07-11-3
07-11-4
07-11-5
AIR OUTLET DUCT

AIR OUTLET DUCT
DISASSEMBLY/ASSEMBLY . ....... . 07-11-6
AlC COMPRESSOR
CONDENSER
CONDENSER INSPECTION ......... . 07-11-8
REFRIGERANT LINES
HVAC BASIC SYSTEM LOCATION INDEX
arnffw00000449
1
2
Heater unit
Cooling unit
(See 07-11-2 COOLING UNIT REMOVAU
INSTALLATION.)
(See 07-11-4 COOLING UNIT DISASSEMBLY/
ASSEMBLY.)
Refrigerant line
(See 07-11-8 REFRIGERANT LINES REMOVAU
INSTALLATION.)
Heater hose
Blower unit
(See 07-11-5 BLOWER UNIT DISASSEMBLY/
ASSEMBLY.)
Condenser
AlC compressor
(See 07-11-6 AlC COMPRESSOR REMOVAU
INSTALLATION. )
07-11-1
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
1.
2.
3.
4.
dcf07116114OW01

Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAL/INSTALLATION.)
Remove the cooling unit. (See 07-11 ~3 COOLING UNIT REMOVAL/INSTALLATION.)
Connector
2
3
Nut
Blower unit
DBG711 ZWB002
BLOWER UNIT DISASSEMBLY/ASSEMBLY
dcfD7116114OW02

Caution
Apply only the specified grease to the link. Otherwise abnormal noise or improper operation may
result.
1
2
Blower motor
3
4
Resistor
Blower wiring harness
Air intake link
Air intake crank
6
7
8
9
10
11
Polyurethane protector
Blower case (1)
Blower case (2)
Air interke door
Blower case (3)
Blower case (4)
07-11-2
BASIC SYSTEM
COOLING UNIT REMOVAUINSTALLATION
1.
2.
3.
4.
dcf071161520w01

Discharge the refrigerant from the system. (See 07-10-3 REFRIGERANT CHARGING.)
Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAUINSTALLATION.)
Disconnect the air intake wire from the blower unit. (See 07-40-8 CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
Caution
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.
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1
Cooler hose (LO)

(See 07-11-9 Refrigerant Line Removal Note.)
(See 07-11-9 Refrigerant Line Installation Note.)
Cooler pipe
Cooling unit
(See 07-11-3 Cooling Unit Installation Note.)

7. Perform the refrigerant system performance test.
PERFORMANCE TEST.)
9.81~19.61 Nm
{100-200 kgfcm,
86.8-173.5 inlbf}
DBG711ZWB018
DBG711 ZWB025
Cooling Unit Installation Note

1. When installing a new cooling unit (evaporator), add FD46XG compressor oil into the refrigerant cycle.
Supplemental amount (approx. quantity)
40 ml {40 cc, 1.4 fl oz}
07-11-3
BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY
dcf07116152Ow02
Caution

1
Polyurethane protector
Cooler case (1)

Cooler case (2)
Thermistor
(See 07-11-5 Thermistor Assembly Note.)
Evaporator
Expansion valve
(See 07-11-4 Expansion Valve assembly Note.)
High pressure pipe
3
4
5
6
7
DBG711 ZWB020
Expansion Valve assembly Note

Replace the O-rings at the expansion valve joints and apply compressor oil to the O-rings and connect the
joints.
Tighten the joint to the specified torque using two open-end wrenches.
Assemble the heat-sensing tube as shown in the
r--=-2::-0-~2::-:4-:-N:-.m-------------------'
figure.
{2.0-2.5 kgfm,
15-18 ftlbf}
11.8-14.7 Nm
HEAT-SENSING TUBE
DBG711 ZWB009
07-11-4
BASIC SYSTEM
Thermistor Assembly Note
1. Assemble the thermistor as shown in the figure.
EVAPORATOR
.,
40mm
Ir
1{1.6 in}
4 LINE
arnffw00000020
EVAPORATOR INSPECTION
1.
2.
3.
4.
dcf07116181Ow01
Remove the cooling unit. (See 07-11-3 COOLING UNIT REMOVAL/INSTALLATION.)

Remove the evaporator from the cooling unit.
Check for cracks, damage, and oil leakage. If an problems found, replace the evaporator.
Check for bent fins. in they are bent, use a flat-head screwdriver to straighten them.
AIR OUTLET DUCT REMOVAUINSTALLATION
dcf07116012Ow01

2. Remove the dashboard. (See 09-17-4 DASHBOARD REMOVAL/INSTALLATION.)
3. Remove as indicated in the table.
,----------------------,
I ~ I~i~toutlet duct
DBG711ZWB012
07-11-5
BASIC SYSTEM
AIR OUTLET DUCT DISASSEMBLY/ASSEMBLY
dcf07116012Ow02
DBG740ZWB033
2
3
4
Airflow mode main link

Airflow mode link
Airflow mode link set
Case (1)
5
6
7
Case (2)
Case (3)
Airflow mode door

AlC COMPRESSOR REMOVAL/INSTALLATION
1.
2.
3.
4.
dcf07116145Ow01

Remove the drive belt.
Loosen the AIC compressor bolts, then slide the AIC compressor.
Caution
07-11-6
BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
1
2
3
4
Cooler hose (HI)

Cooler hose (LO)
Magnetic connector
AlC compressor
(See 07-11-7 AlC Compressor Installation Note.)

7. Adjust the drive belt. (See 01-10A-4 DRIVE BELT
ADJUSTMENT [WL-3].) (See 01-10B-4 DRIVE
BELT ADJUSTMENT [WL-C, WE-C].)
PERFORMANCE TEST.)
A: 15-21 Nm {1.6-2.1 kgfm, 12-15 ftlbf}

B: 24-35 Nm {2.4-3.6 kgf.m, 18-26 ftlbf}
c: 17.6-26.5 N;m {1.80-2.70 kgfm, 13.0-19.5 ftlbf}
DBG711 ZWB024
AlC Compressor Installation Note

Caution
Due to the high moisture-absorption characteristics of the compressor oil, it may absorb moisture
if left over a long period of time thereby negatively affecting AlC operation. Drain the compressor
oil and refill within 10 min. of each other.
1. Rotate new AlC compressor shaft six to eight revolutions while collecting refrigerant oil in a clean measuring
device. Use this refrigerant oil to refill new compressor. Do not allow refrigerant oil to become contaminated.
2. Rotate old A/C compressor shaft six to eight revolutions while collecting refrigerant oil in a separate, clean
measuring device.
3. Compare those oil amounts. The amount of the oil drained from the new AlC compressor should be greater
than the old one.
4. Pour the same amount oil of drained from the old
NEW AlC COMPRESSOR
OLD AlC COMPRESSOR
AlC compressor back into the new AlC
compressor.
AlC compressor oil type

FD46XG
AlC compressor oil sealed volume (approx.
quantity)
180 ml {180 cc, 6.08 fl oz}
SAME
AMOUNT
DBG711ZWB016
07-11-7
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
dcf07116148Ow01
1.
2.
3.
4.

Remove the radiator grill. (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
Remove the charge air cooler. (See 01-13A-2 INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-3].) (See
01-13B-3INTAKE-AIR SYSTEM REMOVAUINSTALLATION [WL-C, WE-C].)
5. Disconnect the cooler hose (HI) and cooler pipe. Do not allow remaining compressor oil in the refrigerant line to
spill.
Caution
abnormal noise or other malfunction could occur. Always plug open fittings immediately after
removing any refrigeration cycle parts.
1
2
Nut
Condenser
(See 07-11-8 Condenser Installation Note.)

PERFORMANCE TEST.)
DBG711 ZWB029
Condenser Installation Note

1. After replacing the condenser, add compressor oil to the refrigeration cycle.
Supplemental oil amount (approx. quantity)
20 ml {20 cc, 0.7 fl oz}
CONDENSER INSPECTION
dcf07116148Ow02
1. Inspect the condenser for cracks, damage, and oil. leakage.

If there is any malfunction, replace the condenser.
2. Visually inspect the fins for clogging of foreign material.
If any fins are clogged, remove the foreign material.
3. Visually inspect the fins for bending.
If there is any bending, use the end of a flathead screwdriver to straighten fins.
REFRIGERANT LINES REMOVAL/INSTALLATION
dcf07116146Ow01

2. Discharge the refrigerant from the system. (See 07-10-3 RECOVERY.) (See 07-10-3 REFRIGERANT
CHARGING.)
Caution
3. Remove the radiator grille. (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
07-11-8
BASIC SYSTEM
4. Remove in the order indicated in the table. Do not allow compressor oil to spill.
A: 6.85-9.80 Nm {70-100 kgfcm, 60.8-86.7 in.lbf}

B: 15-21 N'm {1.5-2.2 kgfm, 11-15 ftlbf}
C: 20-29 N'm {2.0-3.0 kgfm, 15-21 ftlbf}
D: 9.81-19.61 Nm {100-200 kgfcm, 86.8-173.5 inlbf}
E: 24-35 N'm {2.4-3.6 kgfm, 18-26 ftlbf}
DBG711 ZWB028
Cooler hose (LO)

(See 07-11-9 Cooler Hose Removal Note.)
Cooler hose (HI)

(See 07-11-9 Cooler Hose Removal Note.)
Cooler pipe

6. Perform the refrigerant system performance test. (See 07-10-2 REFRIGERANT SYSTEM PERFORMANCE
TEST.)
Cooler Hose Removal Note

WL-3 only
Loosen the A/C compressor bolts, then slide the A/C compressor, and remove the cooler hose bolt from the AI
C compressor.
Refrigerant Line Removal Note
Loosen the nut by using two spanners, then remove the cooler pipe or hose.
Refrigerant Line Installation Note
1. When installing a new cooler pipe or hose, add FD46XG compressor oil into the refrigeration cycle.
Supplemental amount
Cooler hose (LO): 8 ml {8 ee, 0.3 fl oz}
Cooler hose (HI): 5 ml {5 ee, 0.2 fl oz}
Cooler pipe: 3 ml {3 ee, Q.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.
07-11-9
CONTROL SYSTEM
07-40
CONTROL SYSTEM
HVAC CONTROL SYSTEM LOCATION

INDEX ..........................
BLOWER MOTOR
BLOWER MOTOR INSPECTION ......
RESISTOR
RESISTOR INSPECTION ............
MAGNETIC CLUTCH
DISASSEMBLY/ASSEMBLY .........
MAGNETIC CLUTCH ADJUSTMENT ...
MAGNETIC CLUTCH INSPECTION ....
THERMISTOR
THERMISTOR INSPECTION .........
07-40-1
07-40-2
07-40-2
07-40-3
07-40-3
07-40-3
07-40-4
07-40-5
07-40-5
07-40-5

INSPECTION ..................... 07-40-6
REMOVAL. ....................... 07-40-7
INSTALLATION .................... 07-40-7
DISASSEMBLY/ASSEMBLY ......... 07-40-8
CLIMATE CONTROL UNIT WIRE
ADJUSTMENT .................... 07-40-8
AlC AMPLIFIER INSPECTION ......... 07-40-9
AlCSWITCH
AlC SWITCH INSPECTION ........... 07-40-10
FAN SWITCH INSPECTION ........... 07-40-10
HVAC CONTROL SYSTEM LOCATION INDEX
dcfO?400000OW01
DBG740ZWB001
Blower motor
(See 07-40-2 BLOWER MOTOR REMOVAU
INSTALLATION.)
(See 07-40-2 BLOWER MOTOR INSPECTION.)
Resistor
(See 07-40-3 RESISTOR REMOVAU
INSTALLATION.)
(See 07-40-3 RESISTOR INSPECTION.)
Thermistor
(See 07-40-5 THERMISTOR REMOVAU
INSTALLATION.)
(See 07-40-5 THERMISTOR INSPECTION.)
Magnetic clutch
ADJUSTMENT.)
(See 07-40-5 MAGNETIC CLUTCH INSPECTION.)
Refrigerant pressure switch

(See 07-40-6 REFRIGERANT PRESSURE
SWITCH REMOVAUINSTALLATION.)
(See 07-40-6 REFRIGERANT PRESSURE
SWITCH INSPECTION.)
07-40-1
CONTROL SYSTEM
6
Climate control unit

(See 07-40-7 CLIMATE CONTROL UNIT
REMOVAL.)
INSTALLATION.)
(See 07-40-8 CLIMATE CONTROL UNIT WIRE
ADJUSTMENT.)
BLOWER MOTOR REMOVAL/INSTALLATION
lAIC relay
dcf074061020w01
1. Disconnect negative battery cable.

1
2
Blower motor connector

Screw
Blower motor
l
DBG740ZWB016
BLOWER MOTOR INSPECTION
dcf074061020w02
Connect battery positive voltage to blower motor terminal A, connect terminal B to ground, and then verify its
operation.
If there is any malfunction, replace the blower
motor.
ADJ8540W108
07-40-2
CONTROL SYSTEM
RESISTOR REMOVAUINSTALLATION
dcf074061015w01

1
2
3
Resistor connector
Screw
Resistor
l
DBG740ZWB018
RESISTOR INSPECTION
dcf074061015w02
1. Verify that the resistance between the resistor

terminals is as shown in the table.
I
If th ere IS any ma If unctl~n, repie
t he
resistor.
Terminal
Resistance (ohm)
1A-1B (2A)
1A-1C
1C-1D
R1: 0.43-0.47
R2: 1.04-1.16
R3: 1.47-1.63
R3
R2
R1
DBG740ZWB019
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
dcf074061010w01

1
2
3
4
5
6
7
8
9
Bolt
(See 07-40-4 Bolt Removal/Installation Note.)
Pressure plate
(See 07-40-4 Pressure Plate Installation Note.)
Shim
Snap ring
AlC compressor pulley
Screw
Stator
(See 07-40-4 Stator Removal Note.)
(See 07-40-4 Stator Installation Note.)
Snap ring
AlC compressor body

3. Adjust the magnetic clutch clearance. (See 07-404 MAGNETIC CLUTCH ADJUSTMENT.)
07-40-3
CONTROL SYSTEM
Bolt Removal/Installation Note
1. When removing or installing the bolt, hold the
pressure plate in place as shown in the figure.
2. When installing a new Ale compressor body,
replace the recommended bolt.
DBG740ZWB006
Stator Removal Note

1. Set a straight-socket (17 mm {0.67 in}) on the shaft of the Ale compressor to protect it.
2. Remove the stator using a pulley puller as shown
in the figure.
STRAIGHT-SOKET
(17mm {O.67 in})
DBG740ZWB028
Stator Installation Note

1. Install the stator perpendicularly using the SST
(49 H061 005) and a pulley puller as shown in the
figure.
tpl:ltI$I.r,~
PULLEY PULLER
o~
DBG740ZWB029
Pressure Plate Installation Note

1. When installing the pressure plate, carry out magnetic clutch clearance adjustment.
MAGNETIC CLUTCH ADJUSTMENT
1. Set the Ale compressor on a level block.
2. Turn on the magnetic clutch by connecting the battery
voltage to the magnetic clutch connector terminal and
the ground to the Ale compressor body.
3. Fix a dial gauge on a magnetic base and set the
measuring probe onto point A on the pressure
plate surface.
4. Turn off the magnetic clutch by disconnecting the
ground from the Ale compressor body, then
measure the dial gauge readings.
07-40-4
MEASURING
PROBE
MAGNETIC
BASE
LEVEL BLOCK
T===========~'/
. arnffw00000025
CONTROL SYSTEM
5. Measure the clearance for point Band C on the
pressure plate surface by repeating the above
steps 2 through 4.
MEASURING POINT
A
Clearance
0.35-0.75 mm {0.014-0.029 in}
arnffwOOOOO026
6. If the clearance is not as specified, adjust it by

changing the shim.
Note
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.
:>-SHIM
~~II~~~Ii~I!~NCCOMPRESSOR
arnffw00000027
07-40-4a
CONTROL SYSTEM
MAGNETIC CLUTCH INSPECTION
dcfO?406101Ow03
1. Connect battery positive voltage to terminal A of

magnetic clutch and the ground to AlC
compressor body.
2. Verify that the magnetic clutch operates .
If there is any malfunction, replace the stator.
DBG?40ZWB007
THERMISTOR REMOVAUINSTALLATION
dcfO?4061 022w01
1. Remove the thermistor from the cooling unit. (See 07-11-4 COOLING UNIT DISASSEMBLY/ASSEMBLY.)
THERMISTOR INSPECTION
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
dcfO? 4061 022w02

Remove the cooling unit. (See 07-11-3 COOLING UNIT REMOVAUINSTALLATION.)
Remove the thermistor. (See 07-11-4 COOLING UNIT DISASSEMBLY/ASSEMBLY.)
Connect the thermistor connector to the wiring harness connector.
Turn the ignition switch to on position.
Turn the fan switch on.
Immerse the sensor part of thermistor in a container of ice water.
Verify that magnetic clutch operate as shown below.
If not as specified, replace the thermistor.
Water temperature
Differential
0-3C
{32-37F}
13-17C
{34-62F}
3-5C
{38-41 OF}
2-6C
{36-42F}
Magnetic
clutch
OFF
OFF
07-40-5
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH REMOVAUINSTALLATION
dcf074061503w01

~. Discharge the refrigerant from the system. (See 07-10-3 RECOVERY.) (See 07-10-3 REFRIGERANT
CHARGING.)
Caution
Refrigerant pressure switch connector
Refrigerant pressure switch

PERFORMANCE TEST.)
DBG740ZWB010
Refrigerant Pressure Switch Installation Note

1. Apply compressor oil to O-ring and connect the joint.
REFRIGERANT PRESSURE SWITCH INSPECTION
1. Install the SST (gas charging set).
2. Disconnect the refrigerant pressure switch connector.
3. Verify the high-pressure side reading of the SST
(manifold gauge) and continuity between the
refrigerant pressure switch terminals.
dcf074061503w02
0.176-0.216
{1.795-2.202, 25.53~31.31}
ON
OFF
2.94-3.34
{30.0-34.0, 427-4B3}
-----r
- 1
i. .L------1 t
nmnn,
I
i
0.02
{0.20,2.B4}
or less
0.39-0.79
{3.9B-B.05,57-114}
MPa {kgf/cm2, psi}
DBG740ZWB011
07-40-6
CONTROL SYSTEM
CLIMATE CONTROL UNIT REMOVAL
dcf074061190w01

2. Remove the glove compartment. (See 09-17-9 GLOVE COMPARTMENT REMOVAUINSTALLATION.)
t ..
3. Remove the center panel module or audio unit. (See 09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO UNIT REMOVAUINSTALLATION [TYPE 8].)
4. Disconnect the connector A.
5. Disconnect the air intake wire from the blower unit.
6. Disconnect the airflow mode wire from the air outlet duct.
7. Release the left and right tabs and remove in the
b;::;~~~=====::::~~/-/~=::::::~~I
order indicated in the table.
IConnector B
-;
DBG740ZWB03lf tff
CLIMATE CONTROL UNIT INSTALLATION
dcf074061190w02
1. Connect the climate control unit connectors.

2. Insert the climate control unit until each clip clicks.
3. Adjust the climate control unit wire. (See 07-40-8
ADJUSTMENT.)
4. Install the center panel module or audio unit. (See
09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO
UNIT REMOVAUINSTALLATION [TYPE 8].)
5. Install the glove compartment. (See 09-17-9
GLOVE COMPARTMENT REMOVAU
INSTALLATION.)
DBG740ZWBO
07-40-7
CONTROL SYSTEM
CLIMATE CONTROL UNIT DISASSEMBLY/ASSEMBLY
dcf07406119OW03

1
2
3
4
5
6
7
8
Panel
Airflow mode wire
Air intake wire
AlC amplifier
Fan switch
Climate control unit harness
Illumination bulb
Body
DBG740ZWB037
CLIMATE CONTROL UNIT WIRE ADJUSTMENT

Air
1.
. ,2.
.
,,'
3.
4.
5.
Intake Wire
Set the REC/FRESH lever at REC .
Set the air intake link to REC in the direction of
the arrow and insert a screwdriver into the set
hole.
Connect the air intake wire to the air intake link.
Clamp the air intake wire to wire clamp.
Verify that the REC/FRESH lever moves its full
stroke.
dcf07406119OW04
SET HOLE
DBG740ZWB041
Airflow Mode Wire

1. Set the airflow mode control dial at DEFROSTER.
2. Set the airflow mode link to DEFROSTER in the
direction of the arrow and insert a screwdriver into
the set hole.
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.
07-40-8
CONTROL SYSTEM
AlC AMPLIFIER INSPECTION
delO?4061190w05
1.
2.
3.
4.
Connect the AlC amplifier connector.

f
Connect the negative (-) lead of the tester to body ground.
By inserting the positive (+) lead of the tester into each AlC amplifier terminal, measure the voltage according
to the terminal voltage table .
If there is any malfunction, inspect the parts under "Inspection item (s)".
- If the parts under "Inspection item (s)", replace the AlC amplifier.
Terminal Voltage Table
DBG740ZWB699
Term
inal
1A
Signal
name
IG2
Connected to
AlC2 10 A fuse
Measurement
condition
Engine switch at ON
position
Engine switch at LOCK
position
1B
1C
AlC
GND
Voltage (V)
B+
Below 1.0
AlC switch OFF
B+
AlC switch ON
Below 1.0
Under any condition
Below 1.0
AlC relay
Ground
Inspection item (s)

Inspect for continuity or short circuit (AI
C amplifier-AlC2 10 A fuse:1A-AlC2
10 A fuse
Inspect AlC2 10 A fuse
Inspect short circuit (AIC amplifier-AI
C210 A fuse: 1A-AlC2 10 A fuse)
Inspect or continuity or short circuit (AIC
amplifier-AIC relay: 1B-Inspect AlC
relay
Inspect terminal voltage of AlC amplifier
(1A)
Inspect for continuity (AIC amplifierground:1 C-GND)
Thermistor Side
1. Connect the thermistor connector.
3. Turn the fan switch ON.
4. Turn the AlC switch ON.
5. Connect the positive (+) and negative (-) probes
of the voltmeter to terminal 2A and terminal 2B of
the thermistor respectively. (The wiring harness
connector must be connected to the thermistor
connector.)
6. If there is any malfunction, replace the AlC
amplifier.
DBG740ZWB600
,.~
07-40-9
CONTROL SYSTEM
AlC SWITCH REMOVAUINSTALLATION
dcf07406119Ow06

!. Remove the center panel module or audio unit. (See 09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].) (See 09-20-5 AUDIO UNIT REMOVAUINSTALLATION [TYPE 8].)
3. Disconnect the AlC switch connector.
4. Release the left and right tabs and remove the AI
C switch as shown in the figure.
DBG740ZWB045
AlC SWITCH INSPECTION
dcf07406119Ow07
1. Inspect for continuity between the AIC switch

terminals using a tester.
o---O : Bulb 0--0: Continuity

Switch
position
OFF
ON
Terminal
C
0
0
D
D
-0
DBG740ZWB044
2. Connect battery positive voltage to terminal D and

ground to the terminal C.
3. Turn the AlC switch on.
4. Verify that the LED illuminates.
If there is any malfunction, replace the AlC switch.
FAN SWITCH INSPECTION
DBG740ZWB043
dclO74061050w01
1. Remove the climate control unit. (See 07-40-7 CLIMATE CONTROL UNIT REMOVAL.) (See 07-40-7 CLIMATE
CONTROL UNIT INSTALLATION.)
2. Verify that the continuity between the fan switch terminals is as indicated in the table.
If there is any malfunction, replace the fan
switch.
0--0: Continuity
Switch
position
Terminal
A
[ilill]
0
1
3
4
D
D
~ f--o
-0- f---O
DBG740ZWB025
07-40-10
DBG740ZWB026
TECHNICAL DATA
07-50
TECHNICAL DATA
HVAC TECHNICAL DATA . ........... 07-50-1
HVAC TECHNICAL DATA
dcf07500000Ow01
Specification
Item
REFRIGERANT SYSTEM
Type
Refrigerant
Regular amount (approx. quantity)
(g {oz})
R-134a
550 {19.4}
BASIC SYSTEM
AlC compressor
CONTROL SYSTEM
AlC compressor
Type
Lubrication oil Sealed volume
, (approx.
quantity)
Magnetic clutch clearance
FD46XG
(ml {cc, fl oz})
(mm {in})
1BO {1BO, 6.0B}
0.35-0.75 {0.014-0.029}
07-50-1
SERVICE TOOLS
07-60
SERVICE TOOLS

AIR CONDITIONING (HVAC) SST . ... 07-60-1
HEATER, VENTILATION & AIR CONDITIONING (HVAC) SST

49 C061 OAOB
Gas Charge Set
dcf076000000w01
49 C061 012
49 C061 013
Anti-back flow
valve
Gas Leak
Tester
~~
dd~
49 H061 005
Attachment
07-60-1
RESTRAINTS
ON-BOARD DIAGNOSTIC. . . . 08-02
SYMPTOM
TROUBLESHOOTING ...... 08-03
08-02
AIR BAG SYSTEM .......... 08-10

SEAT BELT ................ 08-11
SERVICE TOOLS ........... 08-60
ON-BOARD DIAGNOSTIC
FOREWORD ......................
AIR 8AG SYSTEM WIRING DIAGRAM
(ON-80ARD DIAGNOSTiC) .........
DTC DiSPLAy .....................
CLEARING DTC ...................
DTC TA8LE . ......................
PID/DATA'MONITOR DISPLAY . .......
PID/DATA MONITOR TA8LE .........
DTC 81231 .......................
DTC 81317, 81318 ... ..............
DTC 81342 .......................
08-02-1
08-02-1
08-02-2
08-02-2
08-02-3
08-02-5
08-02-6
08-02-8
08-02-8
08-02-9
DTC 81869, 81870 .................. 08-02-10

DTC 81877, 81878, 81879, 81885 ..... 08-02-12
DTC 81881, 81882, 81883, 81886 ..... 08-02-14
DTC 81913, 81916, 81932, 81934 . ... . 08-02-16
DTC 81913, 81925, 81933, 81935 . ... . 08-02-18
DTC 81992, 81993, 81994, 81995 ..... 08-02-20
DTC 81996, 81997, 81998, 81999 ..... 08-02-22
DTC82444,U2017 .................. 08-02-24
DTC 82445, U2018 . ................. 08-02-25
DTC 82867 ........................ 08-02-27
FOREWORD
dcf080200000w01
Outline
The OBD (on-board diagnostic) system has the following functions:
Malfunction detection function: Detects malfunctions in the air bag system and outputs DTCs.
Data monitor function: Reads out specific input/output signals and the system status.
Diagnostic DTCs can be read/cleared using the current diagnostic tool.
AIR 8AG SYSTEM WIRING DIAGRAM (ON-80ARD DIAGNOSTIC)
POOR CONNECTION
DETECTOR BAR
dcf080200000w02
}-----{1
k---Fi;;;::j--tW~~;:-' DRIVER-SIDE
}------{l~-E~~C::::~
I------f.i\k::::;-i
AIR BAG
SYSTEM
WARNING
LIGHT
.;t-----<~+----I
SAS
CONTROL
MODULE
r----i,.C=::::J

BELT
1-----1.C==-.J
AIR BAG MODULE
i----l'ii:k::::;--,
TWISTED PAIR
DRIVER-SIDE
SIDE AIR BAG
SENSOR
PASSENGER-SIDE A
SIDE AIR BAG
SENSOR
B
AIR BAG
MODULE
1-----1!?.C==-.J
DRIVER-SIDE SIDE
PASSENGER-SIDE
PRE-TENSIONER SEAT
BELT
1- ............ ..
1 ................ -
.- ............ ..
1 ................. -
TWISTED PAIR
r----i..C~
PASSENGER-SIDE SIDE
AIR BAG MODULE
POOR CONNECTION
DETECTOR BAR
DCF810ZWB001
08-02-1
ON-BOARD DIAGNOSTIC
DTC DISPLAY
UsingWDS
2. Retrieve DTC using the WDS.
dcf080200000w03
DCF802ZWB003
Using IDS/PDS
PDS.
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
DCF802ZWB003
screen.
4. After completion of repairs, clear all DTCs stored in the SAS control module. (See 08-02-2 CLEARING DTC.)
CLEARING DTC
dcf080200000w04
Using WDS
1. After repairs have been made, perform the DTCs reading procedure.
2. Erase DTC using the WDS.
3. Ensure that the customer's concern has been resolved.
Using IDS/PDS
PDS.
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
screen.
4. Press the clear button on the DTC screen to clear the DTC.
5. Verify that no DTCs are displayed.
08-02-2
DCF802ZWB003
ON-BOARD DIAGNOSTIC
DTCTABLE
dcf080200000w05
OTCs are common for present and past malfunction diagnosis.

Note
When OTCs not shown in the OTC table are displayed, replace the SAS control module.
If the air bag system warning light does not illuminate or remains illuminated when the engine switch is
turned to the ON position, inspect and repair the air bag system warning light circuit, and then confirm that
the air bag system warning light is operational.
The air bag system warning light flashes the OTC pattern for five cycles, and then remains illuminated
until the engine switch is turned to the LOCK position.
OTC
Current
diagnostic
tool display
Flashing pattern
Priority
ranking
81231
13
UJULJ
81317

the time
81318

the time
12
JLJllLJ

the time

the time
Air bag system warning light dose not

illuminate

the time
33
JUlUlJLJ
10
81342
81869
81870
81879
81881
81882
34
IJUlJUU
81883
81885
33
JUlUlJLJ
SAS control module

activation (deployment)
control freeze
The SAS control module
power supply voltage
increases (16.1 V or more)
The SAS control module
power supply voltage
decreases (less than 9 V)
81877
81878
System malfunction
location
10
Page
(See 08-02-8 DTC

81231.)
(See 08-02-8 DTC
81317,81318.)
(See 08-02-8 DTC
81317, 81318.)
SAS control module

SAS control module (air
bag system warning light
DTC 12 is displayed)
Air bag system warning
light system circuit open
light system circuit short to
ground
light system circuit short to
power supply
Driver-side pre-tensioner
seat belt circuit resistance
high
seat belt circuit short to
power supply
seat belt circuit short to
ground
Passenger-side pretensioner seat belt circuit
resistance high
short to ground.
seat belt circuit resistance
low
(See 08-02-9 DTC

81342.)
(See 08-02-10 DTC

81869, 81870.)
(Se~ 08-02-12 DTC

81877,81878,
81879,81885.)
(See 08-02-14 DTC

81881,81882,
81883,81886.)
(See 08-02-12 DTC

81877, 81878,
81879,81885.)
08-02-3
ON-BOARD DIAGNOSTIC
DTC
Current
diagnostic
tool display
Flashing pattern
Priority
ranking
System malfunction
location
Page

resistance low
JlJlflJU1illl11
(See 08-02-16 DTC

81913,81916,
circuit short to body ground
81932,81934.)
21
Passenger-side air bag

(See 08-02-18 DTC
module circuit short to body 81913,81925,
ground
81933,81935.)
81916
19
JlJlflJU1illl11

circuit short to power
supply
(See 08-02-16 DTC

81913,81916,
81932,81934.)
81925
21

module circuit short to
power supply
(See 08-02-18 DTC

81913,81925,
81933,81935.)
81932
19
JlJlflJU1illl11

circuit resistance high
(See 08-02-16 DTC

81913,81916,
81932,81934.)
81933
21

module circuit resistance
high
(See 08-02-18 DTC

81913,81925,
81933,81935.)
81934
19
JlJlflJU1illl11

circuit resistance low
(See 08-02-16 DTC

81913,81916,
81932,81934.)
81935
21

low
(See 08-02-18 DTC

81913,81925,
81933,81935.)
34
81886
19
81913
JU1JLJ1JU1J1
81992
81993
22
JULJULJ
12
23
JULJUULJ
11
81994
81995
81996
81997
81998
81999
82444
08-02-4
43
1DUJU1
Driver-side side air bag

power supply
ground
high
low
Passenger-side side air bag
power supply
ground
high
low
sensor system (internal
circuit disabled}
(See 08-02-14 DTC

81881,81882,
81883,81886.)
(See 08-02-20 DTC

81992, 81993,
81994,81995.)
(See 08-02-22 DTC

81996,81997,
81998,81999.)
(See 08-02-24 DTC

82444, U2017.)
ON-BOARD DIAGNOSTIC
DTC
Current
diagnostic
tool display
B2445
Flashing pattern
44
B2867
U2017
43
U2018
Priority
ranking
System malfunction
location
Page

(See 08-02-25 DTe
sensor system (internal
B2445, U2018.)
circuit disabled)
Poor connection of any

SAS control module
connectors
(See 08-02-27 DTe

B2867.)

sensor (communication
error)
(See 08-02-24 DTe

B2444, U2017.)
Passenger-side side air bag (See 08-02-25 DTe

sensor (communication
B2445, U2018.)
error)
PID/DATA MONITOR DISPLAY
dcf08020000Dw06
Using WDS
2. Access and monitor PIDs using the WOS.
DCF802ZWB003
Using IDS/PDS
1. Connect the 10S/POS to the OLC-2 connector.
POS .
3. Select "Module".
4. Select "RCM".
2. Select "RCM".
3. Select the applicable PIO from the PIO table.
4. Verify the PIO data according to the directions on the screen.
Note
The PIO data screen function is used for monitoring the calculated value. Therefore, if the monitored value
of the output parts is not within the specification, inspection of the monitored value of input parts
corresponding to applicable output part control is necessary. In addition, because the system does not
display output part malfunction as abnormality in the monitored value, it is necessary to inspect the output
part individually.
08-02-5
ON-BOARD DIAGNOSTIC
PID/DATA MONITOR TABLE
CONT_RCM
(Number of continuous DTC)
CRSH_ST_D1
CRSH_ST_D2
circuit state)
CRSH_ST_P1
sensor communication state)
CRSH_ST_P2
D_PTENSFLT
belt circuit state)
DABAGR
resistance)
DR_PTENS
belt resistance)
DS_AB
module resistance)
DS_AB_ST
DS1_STAT
circuit state)
DSB_P_ST
(On demand driver-side pretensioner seat belt circuit
state)
IG_V_2
(System IG1 voltage value)
OD_CRST_D1
air bag sensor communication
state)
OD_CRST_D2
air bag sensor circuit state)
OD_CRST_P1
side air bag sensor
OD_CRST_P2
state)
08-02-6
dcf080200000w07
Unit/condition
-
OK!
FAULT
DTC is detected: 1-255
DTC is not detected: 0
terminal
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2B,2C
OK!
FAULT
Sensor normal: OK
2B,2C
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal

Related wiring harness circuit resistance high: OPEN
2P,2S
ohm
Under any condition: 1.5-3.7 ohms
1S,1V
ohm
2P,2S
ohm
2M, 20
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal
V

Related wiring harness short to ground: SHRT GND
Related wiring harness short to power supply: SHRT B+
Engine switch to ON position: B+
2M,20
1S,1V
2P,2S
1W
OK!
FAULT
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2Z,2AA
OK!
FAULT
Sensor normal: OK
2B,2C
OK!
FAULT
Sensor normal: OK
2B,2C
ON-BOARD DIAGNOSTIC
PID name (definition)
OD_DAB1_ST
(On demand driver-side air
bag module circuit state)
OD_DSAB_ST
air bag circuit state)
OD_PAB1_ST
air bag module circuit state)
OD_PSAB_ST
state)
P_PTENSFLT
seat belt circuit state)
Unit/condition
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal
terminal
1S,1V
2M,20
1M,1P

21,2L

2G,2J
PABAGR
module resistance)
ohm
1M,1P
PS_AB
module resistance)
ohm
21,2L
PS_AB_ST
SHRT_B+
SHRT_GND
OPEN
SQ_LOWRES
Normal
PS_PTENS
seat belt resistance)
PS1_STAT
PSB_P_ST
pre-tensioner seat belt circuit
state)
ohm
SHRT_GND
SHRT_B+
OPEN
SQ_LOWRES
Normal
SQ_LOWRES
OPEN
SHRT_B+
SHRT_GND
Normal

21,2L
2G,2J

1M,1P

2G,2J
08-02-7
ON-BOARD DIAGNOSTIC
DTC 81231
DTC B1231
DETECTION
CONDITION
dcf080200000w08
SAS control module activation (deployment) control freeze

Warning
Detection conditions are for understanding the DTC outline before performing an inspection .
Performing an inspection with only detection conditions may cause injury due to an
operating error, or damage the system. When performing an inspection, always follow the
inspection procedure.
SAS control module determined collision
ACTION
Replace the SAS control module.
(See 08-10-6 SAS CONTROL MODULE REMOVAUINSTALLATION.)
DTC 81317, 81318

DTC
I
I
B1317
B1318
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf080200000w09
SAS control module power supply voltage increases (16.1 V or more)

SAS control module power supply voltage decreases (less than 9 V)
Warning
Detection conditions are for understanding the DTC outline before performing an inspection.
When the SAS control module power supply voltage is not within 9-16 V.
Open or short circuit in wiring harness between battery and SAS control module
ENGINE 15 A fuse malfunction
Battery malfunction
SAS control module malfunction
FUSE BLOCK
SAS CONTROL MODULE WIRING
~mlxtdABI
~O
L~J
1vI1S11Pl1MI1J 11GI1011A
1wIH 110 1
1XI1UI1RI
oom
G3TI~BI ~
~
~
11HI1EI1B
11111FI1C
I~~
W
W
AE
W IAAbdAGl1
Step
1
Inspection
INSPECT FUSE
Remove the ENGINE 15 A fuse.
Is the fuse normal?
INSPECT BATTERY
Measure the battery positive voltage.
Is the voltage 9 V-16 V?
BATTERY AND FUSE BLOCK
Measure the fuse block terminal W voltage.
08-02-8
Action
Yes
No

Replace the fuse.
Yes
No

The battery has a malfunction.
Inspect the charge/discharge system.
Install the fuse, then go to the next step.
Repair the wiring harness between the fuse block and
engine switch.
Yes
No
ON-BOARD DIAGNOSTIC
Step
4
Inspection
INSPECT FUSE BLOCK
Warning
Handling the air bag system
components improperly can
accidentally deploy the air bag
modules and pre-tensioner seat belts,
which may seriously injure you. Read
the service warnings and cautions
before handling the air bag system
components.
(See 08-10-2 SERVICE WARNINGS.)
(See 08-10-3 SERVICE CAUTIONS.)
Yes
No
Action
(See 08-10-6 SAS CONTROL MODULE REMOVAU
INSTALLATION.)
Repair the wiring harness between the fuse block and SAS
control module.

Disconnect the negative battery cable and
wait for 1 min or more.
Remove the column cover.
Disconnect the clock spring connector.
Remove the glove compartment. (Vehicles
with passenger-side air bag)
Disconnect the passenger-side air bag
module connector. (Vehicles with passengerside air bag)
Disconnect the driver and passenger-side
seat connectors; (Vehicles with side air bag)
pre-tensioner seat belt connectors. (Vehicle
Remove the console.
Disconnect the all SAS control module
connectors.
Measure the SAS control module terminal
1W voltage.
DTC 81342
DTC B1342
DETECTION
CONDITION
dcf080200000w10
SAS control module

Warning
Malfunction in the SAS control module internal circuit
POSSIBLE
CAUSE
ACTION
(See 08-10-6 SAS CONTROL MODULE REMOVAUINSTALLATION.)
08-02-9
ON-BOARD DIAGNOSTIC
DTC 81869, 81870
DTC
I
I
B1869
B1870
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf080200000w11
Air bag system warning light system circuit open or short to ground
Air bag system warning light system circuit short to power supply
Warning
Malfunction in air bag system warning light circuit
METER 15 A fuse malfunction
Malfunction of connectors between instrument cluster and SAS control module
Open or short circuit in wiring harness between METER 15 A fuse and instrument cluster
Open or short circuit in wiring harness between instrument cluster and SAS control module
INSTRUMENT CLUSTER
101
SAS CONTROL MODULE

J 1m
10 1M 11K 11 11G 1E 11C 1A

1P iN 11L 1J 11H iF 110 1B
"'"
\:;
rr
;:::::><::
2wl2U 12S 20120 2MI2K 2112G 2EI2CI2A
2X 12V 12T 2RI2P 2NI2L 2J 12H 2FI2DI2B
I~~
I'"'::::::-:::::J
1V 11S11PI1MI1JI1GI1011A
1wl1T 110 I
1xl1Ul1RI
11HI1EI1B
11111FI1C
I~~
STEP
INSPECTION
INSPECT METER 15 A FUSE
1
Turn engine switch to LOCK position.
Remove the METER 15 A fuse.
Is fuse normal?
2
METER 15 A FUSE AND INSTRUMENT
CLUSTER
Measure voltage at instrument cluster
connector terminal 2C.
Is voltage 9 V or more?
08-02-10
Yes
No
ACTION
Reinstall the METER 15 A fuse, then go to the next step.
Replace the METER 15 A fuse.
Yes
No

ON-BOARD DIAGNOSTIC
STEP
INSPECTION
Yes
INSTRUMENT CLUSTER AND SAS CONTROL
No
MODULE
Warning
components.
Turn the engine switch to LOCK position.
Remove the glove compartment. (Vehicles
with passenger-side air bag)
seat connectors. (Vehicles with side air bag)
Remove the console.
connectors.
Disconnect the instrument cluster.
Inspect following wiring harness between
SAS control module and instrument cluster
terminals for short to ground, short to power
supply, and open circuit:
-H-1H
Is wiring harness normal?
INSPECT AIR BAG SYSTEM WARNING LIGHT Yes
No
Connect instrument cluster.
Turn the engine switch to ON position.
Is air bag system warning light illuminated?
y
INSPECT AIR BAG SYSTEM WARNING LIGHT

Using a jumper wire, cause a short circuit
between instrument cluster terminal 1Hand
ground.
Does air bag system warning light go out?
Connect the all SAS control module
connectors.
Connect the driver and passenger-side pretensioner seat belt connectors. (Vehicle with
pre-tensioner seat belt)
Connect the driver and passenger-side seat
connectors. (Vehicles with side air bag)
Connect the passenger-side air bag module
connector. (Vehicles with passenger-side air
bag)
Connect the clock spring connector.
Verify that the air bag system warning light
turns off approx. 2 5 after illuminating for
approx. 6 s.
Is the result normal?
Yes
No
Yes
ACTION
Replace the air bag wiring harness.

Replace the instrument cluster.
INSTALLATION.)
INSTALLATION. )
The system is normal at present. (Clear the malfunction
from the memory.)
No, Replace the SAS control module.

INSTALLATION.)
08-02-11
ON-BOARD DIAGNOSTIC
DTCB1877,B1878,B1879,B1885
DTC
B1877
B1878
B1879
B1885
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf080200000w12
Driver-side pre-tensioner seat belt system resistance high

Driver-side pre-tensioner seat belt system circuit short to power supply
Driver-side pre-tensioner seat belt system circuit short to ground
Driver-side pre-tensioner seat belt system resistance low
Warning
Resistance other than 1.5-3.1 ohms detected in driver-side pre-tensioner seat belt circuit
Malfunction in the wiring harness between driver-side pre-tensioner seat belt and SAS control module
Open or short circuit in wiring harness between driver-side pre-tensioner seat belt and SAS control
module
Driver-side pre-tensioner seat belt malfunction

/n
2Y 2V
DRIVER-SIDE PRE-TENSIONER SEAT BELT

I
I
~
I 2S I 2P I 2M I 2J I 2G I 20 I 2A
2Z 2WI2T 1
2AA 2X 2U 2R 20
12H 1 2E 12B
I 2L I 21 I 2F I 2C
I~~
I~~
STEP
INSPECTION
INSPECT DRIVER-SIDE PRE-TENSIONER
1
SEAT BELT
Using the current diagnostic tool, verify the
following PID/DATA monitor.
(See 08-02-6 PID/DATA MONITOR TABLE.)
-DR_PTENS
Is the resistance of the driver-side pretensioner seat belt normal?
- Resistance: 1.5-3.1 ohms
INSPECT DRIVER-SIDE PRE-TENSIONER
2
SEAT BELT CONNECTOR
Warning
components.

Disconnect the driver-side pre-tensioner seat
belt connector.
Is there any malfunction of the driver-side
pre-tensioner seat belt connector?
08-02-12
No
ACTION
INSTALLATION.)
Yes
No

Yes
ON-BOARD DIAGNOSTIC
STEP
ACTION
INSPECTION
OR RELATED WIRING HARNESS
Connect leads of SST (Fuel and
thermometer checker) or apply 2-ohm
resistor to driver-side pre-tensioner seat belt
connector terminal A and B.
Set resistance of SST (Fuel and
thermometer checker) to the 2-ohm position.
Are DTCs B1877, B1878, B1879, and/or
B1885 indicated?
MODULE AND SAS CONTROL MODULE
belt connector.
Remove the console.
Disconnect the SAS control module
connectors.
Inspect the wiring harness between SAS
control module terminal 2S and driver-side
pre-tensioner seat belt terminal A, SAS
control module terminal 2P and driver-side
pre-tensioner seat belt terminal B for the
following:
- Short to ground
- Short to power supply
- Open circuit
Is the wiring harness normal?

connectors.
Connect the driver and passenger-side pretensioner seat belt connectors.
B1885 indicated?
Yes
No
Yes
No
Yes

INSTALLATION.)
from the memory.)
No
Replace the driver-side pre-tensioner seat belt.

(See 08-10-5 SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
08-02-13
ON-BOARD DIAGNOSTIC
DTCB1881,B1882,B1883,B1886
DTC
B1881
B1882
B1883
B1886
dcf080200000w13
Passenger-side pre-tensioner seat belt circuit resistance high

Passenger-side pre-tensioner seat belt circuit short to power supply
Passenger-side pre-tensioner seat belt circuit short to body ground
Passenger-side pre-tensioner seat belt circuit resistance low
Warning
Performing an inspection according to only the detection conditions may cause injury due to
an operating error, or damage the system. When performing an inspection, always follow the
DETECTION
CONDITION
POSSIBLE
CAUSE
Resistance other than 1.5-3.1 ohms detected in passenger-side pre-tensioner seat belt circuit
Malfunction in wiring harness between passenger-side pre-tensioner seat belt and SAS control module
Open or short circuit in wiring harness between passenger-side pre-tensioner seat belt and SAS control
module
Passenger-side pre-tensioner seat belt malfunction

HARNESSSIDE CONNECTOR
/n
2Y
2V 1 2S 1 2P 12M 1 2J
PASSENGER-SIDE PRE-TENSIONER SEAT BELT

I 2G I 20 I 2A
2Z 2wI2T 1
12H 12E 12B
2AA 2X I 2U I 2R I 20 I 2L I 21 I 2F I 2C
I~~
I~~I
STEP
1
INSPECTION
INSPECT PASSENGER-SIDE PRETENSIONER SEAT BELT
-PS_PTENS
Is the resistance of the passenger-side pretensioner seat belt normal?
INSPECT PASSENGER-SIDE PRETENSIONER SEAT BELT CONNECTOR
Warning
- components.
Disconnect the passenger-side pre-tensioner
seat belt connector.
Is there any malfunction of the passengerside pre-tensioner seat belt connector?
08-02-14
ACTION
Yes

INSTALLATION.)
No
Yes

No
ON-BOARD DIAGNOSTIC
STEP
3
INSPECTION
ACTION

PASSENGER-SIDE PRE-TENSIONER SEAT
BELT OR RELATED WIRING HARNESS
Connect the leads of the SST (Fuel and
thermometer checker} or apply 2-ohm
resistance to passenger-side pre-tensioner
seat belt connector terminals A and B.
Set the resistance of the SST (Fuel and
Are DTCs B 1881, B 1882, B 1883, and/or
B 1886 indicated?
PASSENGER-SIDE PRE-TENSIONER SEAT
BELT MODULE AND SAS CONTROL
MODULE
connector.
Remove the console.
connectors.
control module terminal 2J and passengerside pre-tensioner seat belt terminal A, SAS
control module terminal 2G and passengerside pre-tensioner seat belt terminal B for the
following:
- Short to ground
- Open circuit
Yes
No
Replace the passenger-side pre-tensioner seat belt.

INSTALLATION.)
Yes
No


connectors.
Connect the driver and passenger-side pretensioner seat belt connectors.
Are DTCs B 1881, B 1882, B 1883, and/or
B 1886 indicated?
Yes

INSTALLATION.)
from the memory.)
No
08-02-15
ON-BOARD DIAGNOSTIC
DTCB1913,B1916,B1932,B1934
Driver-side
Driver-side
Driver-side
Driver-side
B1913
B1916
B1932
B1934
DTC
air bag
air bag
air bag
air bag
module
module
module
module
system
system
system
system
circuit short to ground

circuit short to power supply
resistance high
resistance low
Warning
DETECTION
CONDITION
POSSIBLE
CAUSE
resistance other than 1.5-3.7 ohms detected in driver-side air bag module circuit
Malfunction in wiring harness between driver-side air bag module and SAS control module
Open or short circuit in wiring harness between clock spring and SAS control module
Clock spring malfunction
Driver-side air bag module malfunction

I n
dcf080200000w14
CLOCK SPRING WIRING

I~J ~
S~[B
1vI1S11P 1MI1JI1GI1DI1A
1WIH 110
1xI1UI1R
11HI1EI1B
11111FI1C
I~'
DRIVER-SIDE AIR BAG MODULE WIRING

(CLOCK SPRING)
I~'I
~
I~' I
STEP
1
INSPECTION
INSPECT DRIVER-SIDE AIR BAG MODULE
-DABAGR
Is the resistance of the driver-side air bag
module normal?
INSPECT DRIVER-SIDE AIR BAG MODULE
CONNECTOR (CLOCK SPRING)
Warning
components.
Disconr,ect the negative battery cable and
Remove the driver-side air bag module.
Is there any malfunction of the driver-side air
bag module connector?
08-02-16
ACTION
Yes

INSTALLATION.)
No
Yes
Replace the air bag wiring harness and/or clock spring.
No
ON-BOARD DIAGNOSTIC
STEP
INSPECTION
ACTION
Replace the driver-side air bag module.
(See 08-10-4 DRIVER-SIDE AIR 8AG MODULE

DRIVER-SIDE AIR BAG MODULE OR
RELATED WIRING HARNESS
Connect the leads of SST (Fuel and
resistance to driver-side air bag module
connector terminals 3A and 38.
Set the resistance of SST (Fuel and
thermometer checker) to 2-ohm position.
Are DTCs 81913,81916,81932 and/or
81934?
Yes
No
INSPECT CLOCK SPRING

Inspect the clock spring.
(See 08-10-8 CLOCK SPRING
INSPECTION.)
Is the clock spring normal?
Yes
No

Replace the clock spring.
(See 08-10-7 CLOCK SPRING REMOVAUINSTALLATION.)
Yes
No

Yes

INSTALLATION.)
from the memory.)

CLOCK SPRING AND SAS CONTROL
MODULE
Remove the glove compartment.
Remove the console.
connectors.
control module terminal 1S and clock spring
terminal1A, SAS control module terminal1V
and clock spring terminal 18 for the
following:
- Short to ground
- Open circuit

connectors.
Connect the driver and passenger-side pretensioner seat belt connectors. (Vehicle with
connectors. (Vehicles with side air bag)
connector. (Vehicles with passenger-side air
bag)
Are DTCs 81913,81916,81932 and/or
81934?
No
08-02-17
ON-BOARD DIAGNOSTIC
DTCB1913,B1925,B1933,B1935
DTC
B1913
B1925
B1933
B1935
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf080200000w15
Passenger-side air bag module circuit short to ground

Passenger-side air bag module circuit short to power supply
Passenger-side air bag module circuit resistance high
Passenger-side air bag module circuit resistance low
Warning
Resistance other than 1.4-2.9 ohms detected in passenger-side air bag module circuit
Malfunction in wiring harness between passenger-side air bag module and SAS control module
Open or short circuit in wiring harness between passenger-side air bag module and SAS control
module
Passenger-side air bag module malfunction
I n
PASSENGER-SIDE AIR BAG MODULE WIRING

I "::::><::: I~
1vl1S11PI1MI1J 11GI1DI1A
1wlnl1Q1
1xl1U11RI
~mij
11HI1EI1B
11111FI1C
I~~
I~~I
STEP
1
INSPECTION
INSPECT PASSENGER-SIDE AIR BAG
MODULE
-PABAGR
Is the resistance of the passenger-side air
bag module normal?
INSPECT PASSENGER-SIDE AIR BAG
MODULE CONNECTOR
Warning
components.
Turn the engine switch to the LOCI( position.
module connector.
Is there any malfunction of the passengerside air bag module connector?
08-02-18
No
ACTION
INSTALLATION.)
Yes
No

Yes
ON-BOARD DIAGNOSTIC
STEP
3
INSPECTION
ACTION

PASSENGER-SIDE AIR BAG MODULE OR
No Replace the passenger-side air bag module.
(See 08-10-5 PASSENGER-SIDE AIR BAG MODULE
resistance to passenger-side air bag module
Are DTCs B1913, B1925, B1933 and/or
B 1935 indicated?
PASSENGER-SIDE AIR BAG MODULE AND
No Replace the air bag wiring harness.
SAS CONTROL MODULE
module connector.
Remove the console.
connectors.
control module terminal 1P and passengerside air bag module terminal A, SAS control
module terminal 1M and passenger-side air
bag module terminal B for the following:
- Short to ground
- Open circuit
INSPECT AIR BAG SYSTEM WARNING LIGHT Yes Replace the SAS control module.
INSTALLATION.)
connectors.
Connect the passenger-side air bag module No The system is normal at present. (Clear the malfunction
connector.
from the memory.)
B1935 indicated?
08-02-19
ON-BOARD DIAGNOSTIC
DTCB1992,B1993,B1994,B1995
B1992
DTC
dcf080200000w16
Driver-side side air bag module circuit short to power supply

Driver-side side air bag module circuit short to ground
B1993
B1994
Driver-side side air bag module circuit resistance high
B1995
Driver-side side air bag module circuit resistance low

Warning
DETECTION
CONDITION
POSSIBLE
CAUSE
Resistance other than 1.4-3.2 ohms detected in driver-side side air bag module circuit
Malfunction in wiring harness between driver-side side air bag module and SAS control module
Open or short circuit in wiring harness between driver-side side air bag module and SAS control
module
Driver-side side air bag module malfunction
/n
DRIVER-SIDE SIDE AIR BAG MODULE

2Y 2V 12S 1 2P 12M-I 2J 12G 120 12A
~
I~~
2Z 2wI2TI
12H 12E 12B
2AA 2X 1 2U 1 2R 1 20 1 2L 1 21 1 2F 1 2C
I~~
STEP
1
INSPECTION
INSPECT DRIVER-SIDE SIDE AIR BAG
MODULE
-DS_AB
Is the resistance of the driver-side side air
bag module normal?
MODULE CONNECTOR
Warning
components.

Remove the driver-side side air bag module.
Disconnect the driver-side side air bag
module connector.
side air bag module connector?
08-02-20
ACTION
Yes

INSTALLATION.)
No
Yes
No
ON-BOARD DIAGNOSTIC
STEP
INSPECTION

Yes
DRIVER-SIDE SIDE AIR BAG MODULE OR
No
thermometer checker} or apply 2-ohm
resistance to driver-side side air bag module
B1995 indicated?
Yes
DRIVER-SIDE SIDE AIR BAG MODULE AND
No
SAS CONTROL MODULE
module connector.
Remove the console.
connectors.
control module terminal 2M and driver-side
side air bag module terminal A, SAS control
module terminal 20 and driver-side side air
bag module terminal B for the following:
- Short to ground
- Open circuit
INSPECT AIR BAG SYSTEM WARNING LIGHT Yes
connectors.
Connect the driver-side side air bag module No
connector.
B1995 indicated?
ACTION
Replace the driver-side side air bag module.
INSTALLATION.)


INSTALLATION.)
from the memory.)
08-02-21
ON-BOARD DIAGNOSTIC
DTCB1996,B1997,B1998,B1999
DTC
B1996
B1997
B1998
B1999
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf080200000w17
Passenger-side side air bag module circuit short to power supply

Passenger-side side air bag module circuit short to ground
Passenger-side side air bag module circuit resistance high
Passenger-side side air bag module circuit resistance low
Warning
Detection conditions are for understanding the DTC outline before performing an inspection
Resistance other than 1.4-3.2 ohms detected in passenger-side side air bag module circuit
Malfunction in wiring harness between passenger-side side air bag module and SAS control module
Open or short circuit in wiring harness between passenger-side side air bag module and SAS control
module
Passenger-side side air bag module malfunction
/n
PASSENGER-SIDE SIDE AIR BAG MODULE

J)~
2Y 2V I 2S 12P 12M I 2J I 2G I 20 I 2A
2Z 2wI2T I
12H 12E 12B
2AA 2X I 2U I 2R I 20 I 2L I 21 I 2F I 2C
IGt, I
I~'I
STEP
1
INSPECTION
INSPECT PASSENGER-SIDE SIDE AIR BAG
MODULE
-PS_AB
Is the resistance of the passenger-side side
air bag module normal?
MODULE CONNECTOR
Warning
components.
Remove the passenger-side side air bag
module.
Disconnect the passenger-side side air bag
module connector.
Is there any malfunction of the passengerside side air bag moduie connector?
08-02-22
No
ACTION
INSTALLATION.)
Yes
No

Yes
ON-BOARD DIAGNOSTIC
STEP
INSPECTION
OR RELATED WIRING HARNESS
resistance to passenger-side side air bag
module connector terminals A and B.
B 1999 indicated?
AND SAS CONTROL MODULE
module connector.
Remove the console.
connectors.
control module terminal 2L and passengerside side air bag module terminal A, SAS
control module terminal 21 and passengerside side air bag module terminal B for the
following:
- Short to ground
- Open circuit

connectors.
Connect the passenger-side side air bag
module connector.
B1999 indicated?
ACTION
Yes
No
Replace the passenger-side side air bag module.

INSTALLATION.)
Yes

No
Yes
No

INSTALLATION.)
from the memory.)
08-02-23
ON-BOARD DIAGNOSTIC
DTC 82444, U2017
B2444
U2017
dcf080200000w18
Driver-side side air bag sensor system internal circuit disabled

Driver-side side air bag sensor system communication error
Warning
DTC~~~-+~-----~_____~~~~----------~~---------------~~----------------------------------------------------------------------~
DETECTION
CONDITION
POSSIBLE
CAUSE
Malfunction in wiring harness between driver-side side air bag sensor and SAS control module
Malfunction in driver-side side air bag sensor circuit
Open or short circuit in wiring harness between driver-side side air bag sensor and SAS control module
Driver-side side air bag sensor malfunction

DRIVER-SIDE SIDE AIR BAG SENSOR

STEP
INSPECTION
SENSOR CONNECTOR
Warning
components.
sensor connector.
side air bag sensor connector?
08-02-24
Yes
No
ACTION
ON-BOARD DIAGNOSTIC
STEP
2
INSPECTION
DRIVER-SIDE SIDE AIR BAG SENSOR AND
SAS CONTROL MODULE
Remove the console.
connector.
sensor connector.
Inspect the wiring harnesses between SAS
control module terminal 2AA and driver-side
side air bag sensor terminal A, SAS control
module terminal 2Z and driver-side side air
bag sensor terminal B for the following:
- Short to ground
- Open circuit
INSPECT SAS CONTROL MODULE
Connect the SAS control module connector.
Connect the driver-side side air bag sensor
connector.
Are DTCs B2444, U2017 indicated?
Yes
No
Yes
No
ACTION
Replace the driver-side side air bag sensor, then go to the
next step.
(See 08-10-6 SIDE AIR BAG SENSOR REMOVAU
INSTALLATION.)

INSTALLATION.)
DTC 82445, U2018

B2445
U2018
dcf080200000w19
Passenger-side side air bag sensor system internal circuit disabled

Passenger-side side air bag sensor system communication error
Warning
DTC~~~~~--~~~~~~~----~~------~~------------------------~
DETECTION
CONDITION
POSSIBLE
CAUSE
Malfunction in wiring harness between passenger-side side air bag sensor and SAS control module
Malfunction in passenger-side side air bag sensor circuit
Open or short circuit in wiring harness between passenger-side side air bag sensor and SAS control
module
Passenger-side side air bag sensor malfunction
PASSENGER-SIDE SIDE AIR BAG SENSOR

08-02-25
ON-BOARD DIAGNOSTIC
STEP
1
INSPECTION
SENSOR CONNECTOR
Yes
No
ACTION
Warning
components.

sensor connector.
Is there any malfunction of the passengerside side air bag sensor connector?
AND SAS CONTROL MODULE
Remove the console.
connector.
sensor connector.
Inspect the wiring harnesses between SAS
control module terminal 2C and passengerside side air bag sensor terminal A, SAS
control module terminal 28 and passengerside side air bag sensor terminal 8 for the
following:
- Short to ground
- Open circuit
Connect the SAS control module connector.
Connect the passenger-side side air bag
sensor connector.
Are DTCs 82445, U2018 indicated?
08-02-26
Yes
No
Yes
No
Replace the passenger-side side air bag sensor, then go

to the next step.
(See 08-10-6 SIDE AIR 8AG SENSOR REMOVAU
INSTALLATION.)

INSTALLATION.)
ON-BOARD DIAGNOSTIC
DTC 82867
dcfOB020000Ow20
DTC B2867
DETECTION
CONDITION
POSSIBLE
CAUSE
SAS control module connector poor connection

Warning
There is no continuity between poor connection detector bar terminals of SAS control module.
Poor connection of any SAS control module connectors
Malfunction of any SAS control module connectors
I n
/n
1wln 11Q 1
1XI1UI1RI
11HI1EI1B
1 11 11FI1C
I~~
L >< J
2Y 2vI2S12PI2MI2JI2GI2DI2A
1V 11S11Pl1MI1J 11GI1DI1A
2Z 2wI2TI
12HI2EI2B
2M 2X 12U 12R 1201 2L 1 21 12F 12C
I~~I
STEP
INSPECTION
VERIFY THAT ALL SAS CONTROL MODULE
CONNECTORS ARE CONNECTED WITH SAS
CONTROL MODULE
Yes
No
ACTION
Reconnect connector properly.
Warning
components.
Remove the console.
Are all SAS control module connectors
securely connected?
08-02-27
ON-BOARD DIAGNOSTIC
STEP
INSPECTION
INSPECT ALL SAS CONTROL MODULE
CONNECTORS
module connector.
side air bag module connectors. (Vehicles
with side air bag)
Remove the console.
connectors.
Are poor connection detector bars of all SAS
control module connectors normal?
08-02-28
ACTION
Yes

INSTALLATION.)
No
Replace wiring harnesses.
08-03
AIR BAG SYSTEM ................. 08-03-1

(SYMPTOM TROUBLESHOOTING) ... 08-03-1
NO.1 AIR BAG SYSTEM WARNING

LIGHT DOES NOT ILLUMINATE ...... 08-03-1
NO.2 AIR BAG SYSTEM WARNING
LIGHT ILLUMINATES
CONSTANTLY .................... 08-03-3
AIR BAG SYSTEM
dcf080300000w01
Troubleshooting Index
Use the chart below verify the symptoms of the trouble in order to diagnose the appropriate area.
No.
Air bag system warning light does not

illuminate.
Air bag system warning light is

illuminated constantly.
Description
Malfunction in air bag system warning
light circuit (short to ground).
Malfunction in air bag system warning
light circuit (open circuit or short to
power supply).
Page
(See 08-03-1 NO.1 AI R BAG SYSTEM
WARNING LIGHT DOES NOT
ILLUMINATE)
(See 08-03-3 NO.2 AIR BAG SYSTEM
WARNING LIGHT ILLUMINATES
CONSTANTLY)
AIR BAG SYSTEM WIRING DIAGRAM (SYMPTOM TROUBLESHOOTING)
dcf080300000w02
CLOCK SPRING
POOR CONNECTION
DETECTOR BAR
1-----f1
k---t~~6.fi(R=:::;-J DRIVER-SIDE
AIR BAG
1----{1~-t=~~~::::::..J MODULE
l----ro;;=::::;-l
AIR BAG
SYSTEM
WARNING
LIGHT
..;t---~-+----I

r----I.~:::::::J BELT
SAS
CONTROL
MODULE
TWISTED PAIR
DRIVER-SIDE
SIDE AIR BAG
SENSOR
A
B
PASSENGER-SIDE A
SIDE AIR BAG
SENSOR
B
DRIVER-SIDE SIDE
t----Wl=:::J
AIR BAG MODULE
r----I.!?C:::::::J
PASSENGER-SIDE
PRE-TENSIONER SEAT
BELT
,--------
I ............... ..
r---1..C=~
PASSENGER-SIDE SIDE
AIR BAG MODULE
,--------
1 .................. -
TWISTED PAIR
POOR CONNECTION
DETECTOR BAR
DCF810ZWB001
NO.1 AIR BAG SYSTEM WARNING LIGHT DOES NOT ILLUMINATE

1
DETECTION
CONDITION
POSSIBLE
CAUSE
dcf08030000OW03
Air bag system warning light does not illuminate.

Malfunction in air bag system warning light circuit (short to ground)

Instrument cluster (circuit board) malfunction
Short to ground circuit in wiring harness between instrument cluster and SAS control module
08-03-1
When performing an asterisked (*) troubleshooting inspection, slightly shake the wiring harness and
connectors while performing the inspection to discover whether poor contact points are the cause of any
intermittent malfunction. If there is a problem, verify that connectors, terminals and wiring harness are
STEP
1
*3
INSPECTION
INSPECT OTHER WARNING AND INDICATOR
LIGHTS CIRCUIT IN INSTRUMENT CLUSTER
Do other warning and indicator lights
illuminate?
Warning
the air bag system service warnings
and cautions before handling the air
bag system components.
module connector.
seat connectors.
Disconnect the driver- and passenger-side
pre-tensioner seat belt connectors.
Remove the console.
Disconnect all SAS control module
connectors.
Does the air bag system warning light
illuminate?
INSPECT WIRING HARNESS BETWEEN SAS
CONTROL MODULE AND INSTRUMENT
CLUSTER FOR SHORT TO GROUND
Is there continuity between terminal 1H of
the instrument cluster connector and
ground?
Connect all SAS control module connectors.
Connect the driver and passenger-side
connectors.
connector.
operate properly?
08-03-2
Yes
No
Yes
No
ACTION
Turn the engine switch to the LOCK position, then go to the
next step.
Inspect instrument cluster power supply system and ground
system the, then go to Step 4.
Replace the SAS control module, then go to Step 4.
INSTALLATION.)
Yes
No
Replace the wiring harness, then go to Step 4.

Replace the instrument cluster, then go to the next step.
INSTALLATION. )
Yes
No
Complete troubleshooting, then explain repairs to customer.

malfunction recurs.
NO.2 AIR BAG SYSTEM WARNING LIGHT ILLUMINATES CONSTANTLY
2
DETECTION
CONDITION
Air bag system warning light is illuminated constantly.

Malfunction in air bag system warning light circuit (open circuit or short to power supply).
.POSSIBLE
CAUSE
dcf08030000Ow04
Weak battery
Instrument cluster (circuit board) malfunction
No connection in SAS control module connector
Poor contact in instrument cluster connector (16-pin)
Open or short to power supply circuit in wiring harness between instrument cluster and SAS control
module
Poor contact at terminals 1X and/or 1W of SAS control module connector
Poor contact in wiring harness between terminal 1X of SAS control module connector and ground
Poor contact in wiring harness between battery and terminal 1W of SAS control module
When performing an asterisked (*) troubleshooting inspection, slightly shake the wiring harness and
connectors while performing the inspection to discover whether poor contact points are the cause of any
intermittent malfunction. If there is a problem, verify that connectors, terminals and wiring harness are
STEP
INSPECTION
INSPECT BATTERY
Measure the voltage of battery.
Is the voltage 9 V or more?
Yes
No
VERIFY THAT SAS CONTROL MODULE

CONNECTOR IS CONNECTED
Yes
No
ACTION
Battery is weak.
Inspect charge/discharge system, then go to Step 9.
Reconnect the connector properly, then go to Step 9.
Yes
No

Warning
the air bag system service warnings
and cautions before handling the air
*3

Remove the console.
Are all SAS control module connectors
securely connected?
CLUSTER FOR CONTINUITY
module connector.
seat connectors.
Disconnect the driver- and passenger-side
Remove the console.
Disconnect all SAS control module
connectors.
Is there continuity between SAS control
module connector (20-pin) terminal 1T and
instrument cluster connector terminal 1H?
08-03-3
STEP
*4
INSPECTION
CLUSTER FOR SHORT TO POWER SUPPLY
Measure the voltage at instrument cluster
connector terminal 1H.
IS IN AIR BAG SYSTEM WARNING LIGHT IN
INSTRUMENT CLUSTER
Connect instrument cluster connector
terminal 1H to ground, then reconnect the
connector
illuminate with engine switch ON?
INSPECT POWER SUPPLY CIRCUIT OF SAS
CONTROL MODULE (TERMINAL (20-pin) 1W)
connectors.
connector.
Inspect the voltage for PID/DATA monitor
"IG_V_2" item using current diagnostic tool.
Is the voltage of at least one terminal 9 V or
more?
BATTERY AND FUSE BLOCK
Measure the voltage at instrument cluster
connector terminal 2A.
VERIFY THAT SAS CONTROL MODULE
CONNECTOR TERMINAL 1X IS GROUND
module connector.
side air bag module connectors.
Remove the console.
Disconnect all SAS control module control
model connectors.
control module connector (20-pin) terminal
1X and ground for the following:
- Open circuit
08-03-4
ACTION
Yes
No
Yes
Replace the instrument cluster, then go to Step 9.

INSTALLATION.)
No
Yes
No
Go to the Step 8.
Yes
No

Repair the wiring harnesses, then go to Step 9.
Yes
Replace the SAS control module, then go to the next step.

INSTALLATION.)
Replace the wiring harnesses, then go to the next step.
No
STEP
INSPECTION
connectors.
connector.
Connect the instrument cluster connector.
operate properly?
ACTION
Yes
No
Complete troubleshooting, then explain repairs to customer.

malfunction recurs.
08-03-5
AIR BAG SYSTEM
08-10
AIR BAG SYSTEM
LOCATION INDEX ..................

SERVICE WARNINGS ...............
SERVICE CAUTIONS . ..............
REMOVAUINSTALLATION . .........
SIDE AIR BAG MODULE
SAS CONTROL MODULE REMOVAU
INSTALLATION ...................
SIDE AIR BAG SENSOR
08-10-1
08-10-2
08-10-3
08-10-4
08-10-5
08-10-5
08-10-6
CLOCK SPRING
CLOCK SPRING ADJUSTMENT ....... 08-10-7
CLOCK SPRING INSPECTION ........ 08-10-8
AIR BAG MODULE AND
DEPLOYMENT PROCEDURES . ..... . 08-10-9
AIR BAG MODULE AND
DISPOSAL PROCEDURES .......... 08-10-18
INSPECTION OF SST
(DEPLOYMENT TOOL) ............ . 08-10-19
08-10-6
LOCATION INDEX
dcf081000000w01
DCF810ZWB100

(See 08-10-4 DRIVER-SIDE AIR BAG MODULE
(See 08-10-9 AIR BAG MODULE AND
PRE-TENSIONER SEAT BELT DEPLOYMENT
PROCEDURES.)
(See 08-10-5 PASSENGER-SIDE AIR BAG
MODULE REMOVAUINSTALLATION.)
PROCEDURES.)
Side air bag module
(See 08-10-5 SIDE AIR BAG MODuLE REMOVAU
INSTALLATION.)
PROCEDURES.)
Pre-tensioner seat belt

PROCEDURES.)
SAS control module
(See 08-10-6 SAS CONTROL MODULE
Side air bag sensor
(See 08-10-6 SIDE AIR BAG SENSOR REMOVAU
INSTALLATION.)
Clock spring
(See 08-10-7 CLOCK SPRING REMOVAU
INSTALLATION.)
(See 08-10-8 CLOCK SPRING INSPECTION.)
(See 08-10-7 CLOCK SPRING ADJUSTMENT.)
08-10-1
AIR BAG SYSTEM

SERVICE WARNINGS
dcf081000000w02
Air Bag Module Inspection

Inspecting an air bag module using a tester
can operate (deploy) the air bag module,
which may cause serious injury. Do not use a
tester to inspect an air bag module. Always
use the on-board diagnostic function to
diagnose the air bag module for malfunctions.
NO GOOD
DPE810ZW1002
Air Bag Module Handling

Before removing the air bag module or disconnecting the air bag module connector, always turn the
ignition switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or
more to allow the backup power supply of the SAS control module to deplete its stored power.
Handling a live (undeployed) air bag module
that is pOinted toward your body could result
in serious injury if the air bag module were to
accidentally operate (deploy). When carrying
a live (undeployed) air bag module, point the
deployment surface away from your body to
lessen the chance of injury in case it operates
(deploys).
GOOD
NO GOOD
DPE810ZW1003
A live (undeployed) air bag module placed

with its deployment surface to ground is
dangerous. If the air bag module were to
accidentally operate (deploy), it could cause
serious injury. Always place a live
(undeployed) air bag module with its
deployment surface up.
GOOD
NO GOOD
DPE81 OZW1 004
Side Air Bag Module Handling

When a side air bag module operates (deploys) due to a collision, the interior of the seat back (pad,
frame, trim) may become damaged. If a side air bag does not operate (deploy) normally from a seat
back that has been reused, a serious accident may result. After a side air bag has operated (deployed),
always replace both the side air bag module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring harness is not caught.
SAS control module Handling
Removing the SAS control module or disconnecting the SAS control module connector with the
ignition switch at the ON position can activate the sensor in the SAS control module and operate
(deploy) the air bags and pre-tensioner seat belts, which may cause serious injury. Before removing the
SAS control module or disconnecting the SAS control module connector, always turn the ignition
switch to the LOCK position, disconnect the negative battery cable, and then wait for 1 min or more to
allow the backup power supply of the SAS control module to deplete its stored power.
Connecting the SAS control module connector with the SAS control module not securely fixed to the
vehicle is dangerous. The sensor in the SAS control module could send an electrical signal to the air
bag modules and pre-tensioner seat belts. This will operate (deploy) the air bags and pre-tensioner
seat belts, which may result in serious injury. Therefore, before connecting the connector, securely fix
the SAS control module to 'the vehicle.
08-10-2
AIR BAG SYSTEM

Because a sensor is built into the SAS control module, once the air bags and pre-tensioner seat belts
have operated (deployed) due to a collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible external damage or deformation. The
used SAS control module may have been damaged internally which may cause improper operation. If
the SAS control module is reused, the air bags and pre-tensioner seat belts may not operate (deploy)
normally, which could result in a serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or self-checked.
Side Air Bag Sensor Handling
Removing the side air bag sensor or disconnecting the side air bag sensor connector with the ignition
switch at the ON position can activate the side air bag sensor and operate (j:leploy) the side air bag,
which may cause serious injury. Before removing the side air bag sensor or disconnecting the side air
bag sensor connector, always turn the ignition switch to the LOCK position, disconnect the negative
battery cable, and then wait for 1 min or more to allow the backup power supply of the SAS control
module to deplete its stored power.
If the side air bag sensor is subjected to shock or the sensor is disassembled, the side air bag may
accidentally operate (deploy) and cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or disassemble the sensor.
Because a sensor is built into the side air bag sensor, once the air bag has operated (deployed) due to
a collision or other causes, the side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the side air bag sensor is reused, the
side air bag may not operate (deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag sensor cannot be bench-checked or
self-checked.
Pre-tensioner Seat Belt Inspection
Inspecting a pre-tensioner seat belt using a
tester can operate (deploy) the pre-tensioner
seat belt, which may cause serious injury. Do
not use a tester to inspect a pre-tensioner
seat belt. Always use the on-board diagnostic
function to diagnose the pre-tensioner seat
belt for malfunctions.
NO GOOD
E5U810ZW5005
SERVICE CAUTIONS
dcf081000000w03
Air Bag System Component Disassembly

Disassembling the air bag system
components could cause it to not operate
(deploy) normally. Never disassemble any air
DPE81 OZW1 005
l.
08-10-3
AIR BAG SYSTEM

Air Bag Module, Pre-tensioner Seat Belt Handling
Oil, grease, or water on the air bag modules may cause the air bags and pre-tensioner seat belts to fail
to operate (deploy) in an accident. Never allow oil, grease, or water to get on the air bag modules or
pre-tensioner seat belts.
Inserting a screwdriver or similar object into
the connector of an air bag module or a pretensioner seat belt may damage the connector
and cause the air bag module or the pretensioner seat belt to operate (deploy)
improperly, which may cause serious injury.
Never insert any foreign objects into the air
bag module or seat belt connectors.
NO GOOD
NO GOOD
DCF810ZWB002
Air Bag Module, Pre-tensioner Seat Belt Reuse

Even if an air bag module or a pre-tensioner seat belt does not operate (deploy) in a collision and does
not have any external signs of damage, it may have been damaged internally, which may cause
improper operation. Before reusing a live (undeployed) air bag module and the pre-tensioner seat belts,
always use the on-board diagnostic to diagnose the air bag module and the pre-tensioner seat belts to
verify that they have no malfunction.
Air Bag Wiring Harness Repair
Incorrectly repairing an air bag wiring harness
can accidentally operate (deploy) the air bag
module and pre-tensioner seat belts. If a
problem is found in the air bag wiring
harness, always replace the wiring harness
with a new one.
NO GOOD
CHU0810W606
DRIVER-SIDE AIR BAG MODULE REMOVAUINSTALLATION
dcf081 05701 OwOl
Warning
seriously injure you. Read the service warnings and cautions before handling the air bag module.
(See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
1. Turn the engine switch to the LOCK position.
2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL!
INSTALLATION.)
1
Bolt
Connector
(See 08-10-5 Connector Removal Note.)

6. Verify that the air bag system warning light
illuminates for approx. 6 s and goes out.
If the air bag system warning light does not
operate, refer to the on-board diagnostic
system (air bag system) and perform \
inspection of the system.
08-10-4
DCF8l0ZWB012
AIR BAG SYSTEM

Connector Removal Note
1. Using a flathead screwdriver, pry out the
connector stopper plate.
2. Disconnect the connector.
PASSENGER-SIDE AIR BAG MODULE REMOVAUINSTALLATION
CHU0810W003
dcf081057050w01
Warning
seriously injure you. Read the service warnings and cautions before handling the air bag module.
(See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)

2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAU
INSTALLATION.)
1
2
3
Connector
Bolt
5. Install in the reserve order of removal.

system (air bag system) and perform
SIDE AIR BAG MODULE REMOVAUINSTALLATION
DCF810ZWB013
dcf081000147w01
Warning
Handling the air bag module improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the service warnings and cautions before handling the air
bag module. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
If the side air bag module is installed with debris in the seat back, the foreign material may be
scattered when the side air bag module operates (deploys), causing injury. Verify that there is no
foreign material in the seat back before installing the side air bag module.

INSTALLATION.)
. 3. Remove in the order indicated in the table.
2
3
Cup
Bolt
Side air bag module
Connector

DCF810ZWB014
08-10-5
AIR BAG SYSTEM

SAS CONTROL MODULE REMOVAUINSTALLATION
dcf081057030w01
Warning
Handling the SAS control module improperly can accidentally deploy the air bag modules and pretensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the air bag module. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE
CAUTIONS.)
2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL/
INSTALLATION.)
3. Remove the console. (See 09-17-12 CONSOLE REMOVAL/INSTALLATION.)
. - - - - - - 3 - - - - - - - 2 - 6 - . 9 - - 9 . - 8-N.-m-------,
1
2
3
Connector
Bolt
{70-99 kgf.cm,
61-86 inlbf}
SAS control module

SIDE AIR BAG SENSOR REMOVAUINSTALLATION
DCF810ZWB015
dcf081000146w01
Warning
Handling the side air bag sensor improperly can accidentally operate (deploy) the air bag module,
which may seriously injure you. Read the service warnings and cautions before handling the side
air bag sensor. (See 08-10-2 SERVICE WARNINGS.) (See 08-10-3 SERVICE CAUTIONS.)
2. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL/
INSTALLATION.)
1
2
3
4
5
Bolt A
Cover
Connector
Bolt B
Side air bag sensor

5. Turn the engine switch to the ON position and
hold for 5 s or more.
DCF810ZWB016
operate, refer to the on-board diagnostic system (air bag system) and perform inspection of the system.
08-10-6
AIR BAG SYSTEM

CLOCK SPRING REMOVAL/INSTALLATION
dcf081066123w01
INSTALLATION.)
2. Remove the driver-side air bag module. (See OS-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
3. Remove the steering wheel. (See 06-14-6 STEERING WHEEL AND COLUMN REMOVAUINSTALLATION.)
4. Remove the column cover. (See 09-17-S COLUMN COVER REMOVAUINSTALLATION.)
~
1
2
3
Screw
Connector
Clock spring
(See 08-10-7 Clock Spring Installation Note.)

7. Turn the ignition switch to the ON position.
S. Verify that the air bag system warning light
DCF81 OZWB01 0
Clock Spring Installation Note

Caution
If the clock spring is not adjusted, the spring wire in the clock spring could over-wind and break
when the steering wheel is turned. Always adjust the clock spring after installing it.
1. Adjust the clock spring after installing it. (See OS-10-7 CLOCK SPRING ADJUSTMENT.)
CLOCK SPRING ADJUSTMENT
dcf081066123w02
Note
The adjustment procedure is also specified on the caution label of the clock spring.
1. Set the front tires straight-ahead.
Caution
The clock spring will break if over-wound. Do not forcibly turn the clock spring.
2. Turn the clock spring clockwise until it stops.
08-10-7
AIR BAG SYSTEM

3. From the stopped position, turn the clock spring
counterclockwise 2 3/4 turns.
4. Align the mark on the clock spring with the mark

on the outer housing.
CLOCK SPRING INSPECTION
dcf081066123w03
1. Verify that the continuity is as indicated in the table.

If not as indicated in the table, replace the clock spring.
Note
When the vehicle-side connector for the clock spring is disconnected, terminals 1A and 1B are shorted to
prevent unexpected operation (deployment) of the air bag module.
0-0 : Continuity
Terminal
Test condition
Under any
condition
1A 18 20
3A 38 40
'-0
0
0
DCF810ZWB006
VEHICLE-SIDE CONNECTOR
AlB
+
AlB
HORN
s~s I ~2~=ctT! ~ I
I~~I
AIR BAG MODULE-SIDE CONNECTOR
~ IH4~rt?HI
I~~I
DCF810ZWB007
08-10-8
AIR BAG SYSTEM

AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DEPLOYMENT PROCEDURES
dcf08105700Ow01
Warning
A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Do not dispose of a live (undeployed) air bag
module and pre-tensioner seat belt. If the SSTs (Deployment tool and Adapter harness) are not
available, consult the nearest Mazda representative for assistance.
Caution
Deploying the air bag modules and pre-tensioner seat belts inside the vehicle may cause damage
to the vehicle interior. When the vehicle is not to be scrapped, always deploy the air bag modules
and pre-tensioner seat belts outside the vehicle.
If the vehicle is to be scrapped, or when disposing of any air bag modules or pre-tensioner seat belts, operate
(deploy) them inside the vehicle by following the deployment procedure below and using the SST (Deployment
tool) .
When disposing of an operated (deployed) air bag module and pre-tensioner seat belt, refer to "AIR BAG
MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES".
Deployment Procedure for Inside of Vehicle
1. Inspect the SST (Deployment tool). (See 08-10-19 INSPECTION OF SST (DEPLOYMENT TOOL).)
2. Move the vehicle to an open space, away from strong winds, and close all of the vehicle doors and windows.
INSTALLATION.)
5. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.
Driver-side Air Bag Module
1. Remove the driver-side air bag module. (See 08-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
2. Connect the SST (Adapter harness) to the driverside air bag module as shown in the figure.
3. Install the driver-side air bag module. (See 08-104 DRIVER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
DCF810ZWB017
4. Connect the SST (Deployment tool) to the SST

(Adapter harness).
5. Connect both SST (Deployment tool) to the
battery. Connect the power supply red clip to the
positive battery terminal, and the black clip to the
negative battery terminal.
6. Verify that the red lamp on both SST (Deployment
tool) is illuminated.
7. Verify that all persons are standing at least 6 m
{20 ft} away from the vehicle.
~.
, I I
CPJ810ZWB032
08-10-9
AIR BAG SYSTEM

8. Press the activation switch on the SST
(Deployment tool) to operate (deploy) the driverside air bag module.
~.
I I I
ACTIVATION
SWITCH
Warning
The air bag module is very hot
immediately after it is operated
(deployed). You can get burned. Do not
touch the air bag module for at least 15
min after deployment.
9. Disconnect the SST (Deployment tool) from the
SST (Adapter harness).
A6E8130W028
Passenger-side Air Bag Module

2. Disconnect the passenger-side air bag module connector.
3. Connect the SST (Adapter harness) to the
I--------============::::;;;:::~::J
passenger-side air bag module as shown in the
figure.
PASSENGER-SIDE AIR
BAG MODULE
CONNECTOR

(Adapter harness).
5. Connect the SST (Deployment tool) to the battery.
Connect the power supply red clip to the positive
battery terminal, and the black clip to the negative
battery terminal.
DCF810ZWB008

(Deployment tool) to operate (deploy) the
passenger-side air bag module.
Warning
immediately after. it is operated
(deployed). You can be burned. Do not
08-10-10
:I'
I II
ACTIVATION
SWITCH
A6E8130W028
AIR BAG SYSTEM

Side Air Bag Module
1. Disconnect the seat connector.
2. Connect the SST (Adapter harness) to the side
air bag module as shown in the figure.
DCF810ZWB019

(Adapter harness).
battery terminal.
5. Verify that the red lamp on the SST (Deployment
DCF810ZWB008

(Deployment tool) to operate (deploy) the side air
bag module.
Warning
ACTIVATION
SWITCH
A6E8130W028
Pre-tensioner Seat Belt

1. Remove the pre-tensioner seat belt and connect
the SST (Adapter harness) as shown in the
figure. (See 08-11-1 SEAT BELT REMOVAL!
INSTALLATION.)
2. Install the pre-tensioner seat belt.
E5U810ZW5026
08-10-11
AIR BAG SYSTEM

(Adapter harness).
battery terminal.
~.
I I I
B3E0810W027

(Deployment tool) to operate (deploy) the pretensioner seat belt.
Warning
~.
I I I
ACTIVATION
SWITCH

A6E8130W028
Deployment Procedure for Outside of Vehicle

1. Inspect the SST (Deployment tool).
(See 08-10-19 INSPECTION OF SST (DEPLOYMENT TOOL).)
3. Disconnect the negative battery cable and wait for 1 min or more. (See 01-17-2 BATTERY REMOVAL!
INSTALLATION.)
4. Follow the procedure below for operating (deploying) the applicable air bag module or pre-tensioner seat belt.
Driver-side Air Bag Module
1. Remove the driver-side air bag module. (See 08-10-4 DRIVER-SIDE AIR BAG MODULE REMOVAL!
INSTALLATION.)
2. Connect the SST (Adapter harness) to the driverside air bag module as shown in the figure.
DCF810ZWB017
3. Place the driver-side air bag module on the center

of the tire wheel with the padded surface facing
up. To secure the air bag module to the tire wheel,
wrap a wire (cross section 1.25 mm 2 {O.002 in 2 }
or more) through the wheel and the bolt
installation holes of the air bag module at least 4
times.
Warning
If the air bag module is not properly
installed to the tire wheel, serious injury
may occur when the module is operated
(deployed). When installing the air bag
module to the tire wheel, make sure the
padded surface is facing up.
08-10-12
WIRE
DCF810ZWB020
AIR BAG SYSTEM

4. Stack three tires without wheels on top of the tire
with the driver-side air bag module, and then
stack another tire with a wheel on the very top.
TIRE WITH
WHEEL
TIRE
WITHOUT
WHEEL
TIRE WITH
DRIVER-SIDE
AIR BAG
MODULE
DPE81 OZWl 036
5. Secure the tires with wire.
A6E8130W034

(Adapter harness).
CPJ810ZWB034

(Deployment tool) to operate (deploy) the driverside air bag module.
Warning
:I.
I ' I
ACTIVATION
SWITCH

08-10-13
AIR BAG SYSTEM

Passenger-side Air Bag Module
1. Remove the passenger-side air bag module. (See 08-10-5 PASSENGER-SIDE AIR BAG MODULE REMOVAU
INSTALLATION.)
2. Place the padded surface of the passenger-side
air bag module facing the center of the tire as
shown in the figure. To secure the air bag module
to the tire wheel, wrap a wire (cross section 1.25
mm 2 {O.002 in 2 } or more) through the tire and
the bolt installation holes of the air bag module at
least 4 times.
TIRE
Warning
secured to the tire, the tires may fall over
by the impact of operation (deployment)
and cause serious injury. To prevent this,
secure the air bag module properly with
the padded surface facing the center of the tire.
PASSENGER-SIDE
AIR BAG MODULE
DCF810ZWB021
3. Connect the SST (Adapter harness) to the

passenger-side air bag module as shown in the
figure.
DCF810ZWB022
4. Stack the tire with the passenger-side air bag

module on top of two tires without wheels. Stack a
tire without a wheelan top of the tire with the
passenger-side air bag module, and then stack
another tire with a wheelan the very top.
TIRE WITH
WHEEL
TIRE WITH
PASSENGER-SIDE
AIR BAG MODULE
TIRE
WITHHOUT
WHEEL
DCF810ZWB023
A6E8130W034
08-10-14
AIR BAG SYSTEM

(Adapter harness).
DCF810ZWB024

(Deployment tool) to operate (deploy) the
passenger-side air bag module.
Warning

~.
I I t
ACTIVATION
SWITCH
A6E8130W028
Side Air Bag Module
1. Remove the side air bag module. (See 08-10-5 SIDE AIR BAG MODULE REMOVAUINSTALLATION.)
2. Connect the SST (Adapter harness) to the side
air bag module as shown in the figure.
SIDE AIR BAG

MODULE
DCF810ZWB025
3. Place the padded surface of the side air bag

module facing the center of the tire as shown in
the figure. To secure the air bag module to the tire
wheel, wrap a wire (cross section 1.25 mm 2
{O.002 in 2 } or more) through the tire and around
the bracket at least 4 times.
Warning
secured to the tire, the tires may fall over
by the impact of operation (deployment)
and cause serious injury. To prevent this,
secure the air bag module properly with
the padded surface facing the center of the tire.
DCF810ZWB026
08-10-15
AIR BAG SYSTEM

4. Stack the tire with the side air bag module on top
of two tires without wheels. Stack a tire without a
wheel on top of the tire with the side air bag
module, and then stack another tire with a wheel
on the very top.
TIRE WITH
SIDE AIR BAG
MODULE
TIRE
WITHOUT
WHEEL
DPE810ZW1037
A6E8130W034

(Adapter harness).
battery terminal.
l~
B3E0810W027

(Deployment tool) to operate (deploy) the side air
.
bag module.
Warning
08-10-16
~.
I I t
ACTIVATION
SWITCH
A6E8130W028
AIR BAG SYSTEM

Pre-tensioner Seat Belt
1. Remove the pre-tensioner seat belt. (See 08-11-1 SEAT BELT REMOVAUINSTALLATION.)
2. Connect the SST (Adapter harness) to the pretensioner seat belt as shown in the figure.
:..
, .. 'I
E5U810ZW5026
3. Put the pre-tensioner seat belt inside the tire and

secure it to the tire by wrapping a wire (cross
section of 1.25 mm2 {O.002 in 2 } or more)
through the tire and the bolt installation holes at
least 4 times.
Warning
If the pre-tensioner seat belt is not
properly secured to the tire, serious
injury may occur when the pre-tensioner
part is deployed. When installing the pretensioner seat belt to the tire, make sure
the pre-tensioner part is inside the tire.
4. Stack the tire with the pre-tensioner seat belt on

top of two tires without wheels. Stack a tire
without a wheelan top of the tire with the pretensioner seat belt, and then stack another tire
with a wheelan the very top.
PRE-TENSIONER
SEAT BELT
DPE81 OZW1 033
TIRE
WITHOUT
WHEEL
TIRE WITH
WHEEL
TIRE WITH
PRE-TENSIONER
SEAT BELT
DPE810ZW1034
A6E8130W034
08-10-17
AIR BAG SYSTEM

(Adapter harness).
battery terminal.
DPE81 OZW1 035

(Deployment tool) to operate (deploy) the pretensioner seat belt.
~.
I I
Warning
AIR BAG MODULE AND PRE-TENSIONER SEAT BELT DISPOSAL PROCEDURES
ACTIVATION
SWITCH
A6E8130W028
dcf081057000w02
Warning
A live (undeployed) air bag module or pre-tensioner seat belt may accidentally operate (deploy)
when it is disposed of and cause serious injury. Always refer to the "AIR BAG MODULE AND PRETENSIONER SEAT BELT DEPLOYMENT PROCEDURES" and dispose of air bag modules and pretensioner seat belts in a deployed condition.
The air bag modules and the pre-tensioner seat belts are very hot immediately after they are
deployed. You can be burned. Do not touch an air bag module and pre-tensioner seat belt for at
least 15 min after deployment.
Pouring water on the deployed air bag module and pre-tensioner seat belt is dangerous. The water
will mix with the residual gases to form a gas that can make breathing difficult. Do not pour water
on the deployed air bag module and pre-tensioner seat belt.
The deployed air bag module or pre-tensioner seat belt may contain deposits of sodium
hydroxide, a caustic byproduct of the gas-generated combustion. If this substance gets into your
eyes or on your hands, it can cause irritation and itching. When handling the deployed air bag
module and pre-tensioner seat belt, wear gloves and safety glasses.
1. Remove the deployed air bag module or pre-tensioner seat belt.
2. Put the air bag module or pre-tensioner seat belt
,.-,-----------=--=::---------------,
in a plastic bag, seal the bag, and then dispose of
it.
BHJ0810W023
08-10-18
AIR BAG SYSTEM

INSPECTION OF SST (DEPLOYMENT TOOL)
dcf081 001 o78w01
1. Before using the SST (49 H066 002), inspect its

operation.
Inspection Procedure
1. Follow the steps below to inspect the SST (49 H066 002) .
If not as indicated in the table, replace the SST (49 H066 002) because it has a malfunction.
Warning
Do not use a malfunctioning SST (49 HOGG 002), otherwise it could cause the air bag module or
pre-tensioner seat belt to accidentally operate (deploy).
Caution
Because the permissible voltage for the SST (49 HOGG 002) is 12 V, do not connect a 24 V power
source because it will damage the SST. Always connect only a 12 V power source.
Inspection procedure
Step
2
3
Connect the power supply

red clip to the positive
battery terminal, and the
black clip to the negative
battery terminal.
Connect connectors A and
Light condition
Green
Red
On
Off
B.
Off
On
Press the activation switch.
On
Off
BLACK CLIP
ACTIVATION
SWITCH
CONNECTOR B
08-10-19
SEAT BELT
08-11
SEAT BELT
LOCATION INDEX .................. 08-11-1

SEAT BELT
ADJUSTER ANCHOR
SEAT BELT INSPECTION ............ 08-11-6
BUCKLE REMOVAUINSTALLATION ... 08-11-7
LOCATION INDEX
dcf081157000w01
BENCH SEAT
DCF811ZWB100
Seat belt
(See 08-11-1 SEAT BELT REMOVAU
INSTALLATION.)
(See 08-11-5 ADJUSTER ANCHOR REMOVAU
INSTALLATION. )
(See 08-11-6 SEAT BELT INSPECTION.)
SEAT BELT REMOVAUINSTALLATION
2
3
Center seat belt

(See 08-11-1 SEAT BELT REMOVAU
INSTALLATION.)
Buckle
(See 08-11-7 BUCKLE REMOVAUINSTALLATION.)
dcf081157630w01
Warning
Handling the seat belt (pre-tensioner seat belt) improperly can accidentally deploy the pretensioner seat belt, which may seriously injure you. Read the service warnings and cautions
before handling the seat belt (pre-tensioner seat belt). (See 08-10-2 SERVICE WARNINGS.) (See 0810-3 SERVICE CAUTIONS.)
Caution
The ELR (emergency locking retractor) has a spring that will unwind if the retractor 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.
06-11-1
SEAT BELT
Regular Cab (Driver-side and passenger-side)
1. Turn the engine switch to the LOCK position. (vehicle with pre-tensioner seat belt)
2. Disconnect the negative battery cable and wait for 1 min or more. (vehicle with pre-tensioner seat belt) (See
01-17-2 BATTERY REMOVAL/INSTALLATION.)
3. Remove the anchor cover.
1
2
3
Connector (vehicle with pre-tensioner seat belt)

(See 08-11-2 Connector removal note.)
Bolt
Seat belt
4. Remove the upper anchor bolt.

5. Remove the B-pillar trim. (See 09-17-15 BPILLAR TRIM REMOVAL/INSTALLATION.)
(vehicle with pre-tensioner seat belt)
illuminates for approx. 6 s and goes out. (vehicle
ANCHOR COVER
UPPER ANCHOR
BOLT
39-78 {3.9-8.0,
29-57}
DCF811ZWB001
Connector removal note

1. Using a screwdriver, pry out the pre-tensioner
seat belt connector stopper plate.
E5U811ZW5003
Regular Cab (center)

IBolt
~ 39-78 {3.9-8.0,
29-57}
Nm {kgfm, ttlbf}
DCF811 ZWB002
08-11-2
SEAT BELT
Stretch Cab (with rear access system)
01-17 -2 BATTERY REMOVAUINSTALLATION.)
3. Remove the bezel.
ANCHOR
4. Remove the anchor cover.
COVER
5. Remove the upper anchor bolt and lower anchor
bolt.
UPPER
6. Remove the Rear access panel trim. (See 09-17ANCHOR
BOLT
18 REAR ACCESS PANEL TRIM REMOVAU
39-79
INSTALLATION.)
{3.9-8.0,
REAR
7. Remove the seat belt through the seat belt hole.
29-57}
ACCESS
PANEL
SEAT BELT
BEZEL
ANCHOR
COVER
LOWER ANCHOR BOLT ~..:-::;~><:::===s>
39-79 {3.9-8.0, 29-57}
Nm {kgf.m, ft.lbf}
DCF811 ZWB006

seat belt connector stopper plate. (vehicle with
9. Remove the bolts from the retractor.
10. Remove the retractor.

7.8-10.8 Nm
{0.8-1.1 kgfcm,
5.9-7.9 inlbf}
BOLT __
~f"'"
RETRACTOR
BOLT
SEAT BELT
Nm {kgfm, ftlbf}
DCF811 ZWB007
08-11-3
SEAT BELT
Double Cab
Front
01-17-2 BATTERY REMOVAL/INSTALLATION.)
(1) Rear scuff plate (See 09-17-21 REAR SCUFF PLATE REMOVAUINSTALLATION.)
(2) Rea'r seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor installation bolt (See 08-11-5 Rear)
(4) Remove the C-pillar trim (See 09-17-17 C-PILLAR TRIM REMOVAUINSTALLATION.)
(5) Front scuff plate (See 09-17-20 FRONT SCUFF PLATE REMOVAUINSTALLATION.)
(6) Remove the B-pillar lower trim (See 09-17-16 B-PILLAR LOWER TRIM REMOVAUINSTALLATION.)
(7) Front seat belt upper anchor cover
(8) Front seat belt upper anchor installation bolt
(9) Remove the B-pillar upper trim (See 09-17-16 B-PILLAR UPPER TRIM REMOVAUINSTALLATION.)
UPPER ANCHOR BOLT
1
2
3
4
Lower anchor cover

Connector (vehicle with pre-tensioner seat belt)
(See 08-11-2 Connector removal note.)
Bolt
Seat belt
II
39-78 {3.9-8.0, ' \ .

29-57}
UPPERANCHOR~~ ~\~
-""
COVER

(vehicle with pre-tensioner seat belt)
illuminates for approx. 6 s and goes out. (vehicle
DBG811 ZWBA02
Connector removal note

seat belt connector stopper plate.
08-11-4
SEAT BELT
Rear
(2) Rear seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor cover
(4) Rear seat belt upper anchor installation bolt
IBolt
ANCHOR COVER
7.8~10.8~
{O.8-1.1 kgfcm,
5.9-7.9 inlbf}
DBG811ZWBA01
ADJUSTER ANCHOR REMOVAL/INSTALLATION
dcf081157630w02

(2) Rear seat back (See 09-13-5 REAR SEAT REMOVAUINSTALLATION.)
(3) Rear seat belt upper anchor installation bolt (See 08-11-5 Rear)
(5) Front scuff plate (See 09-17-20 FRONT SCUFF PLATE REMOVAUINSTALLATION.)
(6) Remove the B-pillar lower trim (See 09-17-16 B-PILLAR LOWER TRIM REMOVAUINSTALLATION.)
(7) Front seat belt upper anchor installation bolt (See 08-11-4 Front)
(8) Remove the B-pillar upper trim (See 09-17-16 B-PILLAR UPPER TRIM REMOVAUINSTALLATION.)
12 ., Ri:~,~e in the order indicated in 'he table.

2
i.J
Adjuster anchor
39-78
{3.9-8.0,
29-57}
Nm {kgfm, ftlbf}
DCF811ZWB004
08-11-5
SEAT BELT
SEAT BELT INSPECTION
dcf08115700Ow02
Belt
1. Verify that the belt is installed properly with no twists or kinks.
2. Verify that there is no damage to the seat belt and no deformation of the metal fittings.
If there is any malfunction, replace the seat belt.
ELR
1. Verify that the belt can be pulled out smoothly,
and that it retracts smoothly.
If there is any malfunction, replace the seat
belt.
2. Verify that the retractor locks when the belt is
pulled quickly.
belt.
3. Remove the retractor.
DCF811 ZWB008
4. While pulling the seat belt out, make sure that the
seat belt does not lock when the retractor is tilted
slowly up to 15 from the mounted position and
locks when the retractor is tilted 40 or more.
belt.
B3E0811 W009
Load Limiter Retractor

Warning
When the load limiter operates, the belt and anchor rub against each other strongly leaving wear
tracks. If the seat belt is used in this state, the seat belt will not function at its full capability and
there is the possibility of serious injury to passengers. Be sure to replace the seat belt once the
load limiter operates.
1. If the vehicle has been subjected to a shock in an
accident, pull the belt from the retractor and
confirm that there are no wear tracks (the load
limiter has not operated) by visually inspecting
and feeling the belt.
belt.
ANCHOR
TRACE
OF WEAR
B3E0811W010
08-11-6
SEAT BELT
BUCKLE REMOVAUINSTALLATION
Bench Seat (Driver-side and Passenger-side)
1
2
IBolt
Buckle
dcf08115762Ow01
.-. ?
39-78 {3.9-B.O,
29-57}
k~,I,
,--r-::-:----r------.f
....
Nm {kgfm, ftlbf}
DCF811 ZWBOl 0
Bench Seat (Center)

1. Remove the seat. (See 09-13-2 SEAT REMOVAUINSTALLATION.)
r-----------------------,
IBolt
39-7B {3.9-B.O,
29-57}
CD~ \
>&
Nm {kgfm, ftlbf}
DCF811ZWB011
Separate Seat
1. Remove the seat or front seat. (See 09-13-2 SEAT REMOVAUINSTALLATION.) (See 09-13-4 FRONT SEAT
2. Remove the side cover. (See 09-13-3 SEAT DISASSEMBLY/ASSEMBLY.) (See 09-13-4 FRONT SEAT
1
2
IBolt
Buckle

39-78Nm
{3.9-B.O kgfm,
29-57 ftlbf}
Double Cab
Rear
IBolt
Nm {kgfm, ftlbf}
DCF811ZWB012
08-11-7
SERVICE TOOLS
08-60
SERVICE TOOLS
RESTRAINTS SST ................. 08-60-1
RESTRAINTS SST
dcf08600000OwO 1
49 H066 002
Deployment tool
~~~
490066002
49 L066 002
Adapter
harness
Adapter
harness
49 N088 OAO
Fuel and
Thermometer
checker
08-60-1
BODY & ACCESSORIES

ON-BOARD DIAGNOSTIC
[IMMOBILIZER SYSTEM] ... 09-02A
ON-BOARD DIAGNOSTIC
[AUDIO] ................. 09-02B
SYMPTOM
TROUBLESHOOTING
[POWER WINDOW SYSTEMS
(WITH AUTO-OPEN/CLOSE
FUNCTION FOR
DRIVER-SIDE)] ........... 09-03A
SYMPTOM
TROUBLESHOOTING
[KEYLESS ENTRY
SYSTEM] . . . . . . . . . . . . . . . . 09-03B
SYMPTOM
TROUBLESHOOTING
[IMMOBILIZER SYSTEM] ... 09-03C
SYMPTOM
TROUBLESHOOTING
[AUDIO] ................. 09-03D
BODY PANELS ............ 09-10
DOORS AND LlFTGATE ..... 09-11
GLASSIWINDOWS/
MIRRORS ............... 09-12
SEATS .................... 09-13
SECURITY AND LOCKS ..... 09-14
EXTERIOR TRIM ........... 09-16
INTERIOR TRIM ............ 09-17
LIGHTING SYSTEMS ........ 09-18
WIPERIWASHER SYSTEM ... 09-19
ENTERTAINMENT .......... 09-20
POWER SYSTEMS .......... 09-21
INSTRUMENTATION/DRIVER
INFO.................... 09-22
SERVICE TOOLS ........... 09-60
09-02A ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM]

FOREWORD
[IMMOBILIZER SYSTEM] ...........
DTCTABLE
[IMMOBILIZER SYSTEM] ...........
DTC 01 . . . . . . . . . . . . . . . . . . . . . . . . . . .
DTC 02 ...........................
09-02A-1
09-02A-2
09-02A-2
09-02A-3
DTC 03
DTC 11
DTC 21
DTC 24
DTC 30
.......................... 09-02A-3
........................... 09-02A-4
........................... 09-02A-4
........................... 09-02A-5
........................... 09-02A-5
FOREWORD [IMMOBILIZER SYSTEM]
dcf09026700Ow01
Caution
When the engine does not start or stalls and the following DTCs are not indicated, go to engine
symptom troubleshooting.
Note
When the immobilizer system is defective, the engine cannot be started .
. If engine condition is normal but light stays on, inspect for short circuit between security light and
immobilizer unit connector terminal M. Repair or replace the wiring harness if necessary.
The DDS1 is installed to the FIP with set bolts and cannot be removed. if there is a possibility that the
DDS1 is faulty, be sure to ask your distributor to repair it.
1. Turn the ignition switch to ON position.
2. Verify the security light condition and read the DTC if indicated.
3. If the DTC is indicated, go to troubleshooting referring to the DTC table.
09-02A-1
ON-BOARD DIAGNOSTIC [IMMOBILIZER SYSTEM]

DTC TABLE [IMMOBILIZER SYSTEM]
DTC
01
02
JUl
Output pattern
r
r
03
11
21
24
Page
Description
ID number unregistered in immobilizer unit is (See 09-02A-3 DTC
01 [IMMOBILIZER
input after engine switch is turned to ON
position or cranking engine.
SYSTEM])
(See 09-02A-3 DTC
ID number format error (voltage range,
02[IMMOBILIZER
frequency)
SYSTEM])
ID number is not input into immobilizer unit
(See 09-02A-4 DTC
03[IMMOBILIZER
after engine switch is turned to ON position
SYSTEM])
or cranking engine.
(See 09-02A-5 DTC
Coil or wiring harness between immobilizer
11 [IMMOBILIZER
unit and coil is open circuit.
SYSTEM])
(See 09-02A-5 DTC
Code word/lD number stored in immobilizer
21 [IMMOBILIZER
unit EEPROM cannot be read.
SYSTEM])
(See 09-02A-6 DTC
Open or short circuit in wiring harness
24[IMMOBILIZER
between immobilizer unit and DDS1.
SYSTEM])
25
IG circuit of immobilizer unit is open circuit or

IG circuit of DDS1 is for short to B+ circuit.
30
DDS1 is defective. (Malfunction of

communication line inside DDS1)
41
Immobilizer unit or DDS1 is defective. (Code

words of immobilizer unit and DDS1 do not
match)
42
DDS1 is defective. (Communication error

between immobilizer unit and DDS1)
44
DDS1 is defective. (Malfunction of DDS1,

except for malfunctions related to DTC 30,
41, or 42
(See 09-02A-8 DTC

30[IMMOBILIZER
SYSTEM])
Note
If DTC 25 and the other DTC are indicated, go to DTC 25 first and then go to the other DTC.
Note
Perform the following if the security light stays on:

If engine stalls, go to symptom troubleshooting "NO.4 ENGINE STALLS-AFTER START/AT IDLE".
If engine will not start, go to symptom troubleshooting "NO.5 CRANKS NORMALLY BUT WILL NOT
START:' (See 01-03A-13 NO.5 CRANKS NORMALLY BUT WILL NOT START [WL-3])
If engine condition is normal but light stays on, inspect for continuity between the following wiring
harness and body ground: security light and immobilizer unit connector terminal M. Repair or replace
the wiring harness.
DTC01
DTC 01
POSSIBLE
CAUSE
dcf09026700Ow03
ID number unregistered in immobilizer unit is input after engine switch is turned to ON position or
engine cranking.
ID number is unregistered in immobilizer unit.
STEP
09-02A-2
INSPECTION
I --
ACTION
Go to ID number input procedure.
(See 09-14-24 Key Replacement or Addition)

DTC02
dcf090267000w04
OTC02
POSSIBLE
CAUSE
10 number format error (voltage range, frequency)
Defective transponder in the key
INSPECTION
STEP
ACTION
Dispose of defective key.

Duplicate key if necessary.
(See 09-14-24 Key Replacement or Addition)
DTC03
dcf09026700OwOS
OTC03
POSSIBLE
CAUSE
10 number is not input into immobilizer unit after engine switch is turned to ON position or cranking
engine.
No transponder in the key

Defective transponder in the key (lD number is not output.)
Defective coil at steering lock
Defective wiring harness between coil and immobilizer unit
COIL HARNESS SIDE
CONNECTOR
I, c I
I~~
A ]
STEP
INSPECTION
ACTION
Does security light indicate DTC 11?
Yes
Go to DTC 11.
Does security light indicate DTC 30?
No
Yes
Go to next step.
Go to DTC 30.
No
Yes
Go to next step.
Dispose of defective key.
Duplicate key if necessary.
(See 09-14-24 Key Replacement or Addition .)
Go to next step.
INSPECT FOR OTHER PROPER KEYS

Does engine start with other proper keys?
INSPECT COIL CIRCUIT FOR SHORT TO

GNO OR COIL CIRCUIT FOR CONTINUITY
Disconnect the coil connector.
Inspect for short circuits between coil
connector terminals A and C and ground,
and also between coil connector terminals A
and C.
Is there a short?
No
Yes
No
Repair the wiring harness connected to terminals A and/or

C.
Troubleshooting is completed.
09-02A-3

DTC 11
dcf090267000w06
DTC 11
POSSIBLE
CAUSE
Coil or wiring harness between immobilizer unit and coil is open circuit.
Open circuit in coil
Poor connection of coil connector
Poor connection of immobilizer unit
Defective wiring harness between immobilizer unit and coil
COIL HARNESS SIDE
CONNECTOR
[g]
I,
I~~
IMMOBILIZER UNIT
~ ~ ~3tf~ ~ I ~ I : I
A ]
I I
IGt~ I
STEP
1
INSPECTION
INSPECT CONNECTOR CONNECTION
Is connector of coil or immobilizer unit
connected securely?
INSPECT COIL CIRCUIT FOR CONTINUITY
Is there continuity between coil terminals A
and C?
INSPECT COIL CIRCUIT FOR CONTINUITY
Disconnect coil connector and immobilizer
unit connector.
Inspect if either of the following wiring
harnesses has continuity.
- Immobilizer unit 0 to coil C, and
immobilizer unit F to coil A
- Immobilizer unit 0 to coil A, and
immobilizer unit F to coil C
Yes
No
ACTION
Go to next step.
Connect connector securely.
Yes
No
Go to next step.
Replace coil.
Yes
Replace immobilizer unit and reprogram immobilizer

system.
(See 09-14-28 Immobilizer Unit Replacement)
Repair wiring harness between coil and immobilizer unit.
No
Note
Vehicle harness which is connected to
immobilizer unit terminals 0 and F, uses a
twisted pair wire. Because twisted pair
wire does not have polarity, immobilizer
unit connector terminal 0 may be
connected to coil connector terminal A or
C. Likewise, immobilizer unit connector
terminal F may be connected to coil
connector terminal A or C.
DTC21
dcf090267000w07
DTC21
POSSIBLE
CAUSE
Code word/lD number stored in immobilizer unit EEPROM cannot be read.
Defective immobilizer unit
STEP
-
INSPECTION
INSPECT IMMOBILIZER UNIT
Turn engine switch from LOCK position to
START position for 2 seconds.
Does security light indicate DTC 21 again?
09-02A-4
Yes
No
ACTION
Replace immobilizer unit and reprogram immobilizer
system.
(See 09-14-28 Immobilizer Unit Replacement)
Immobilizer system is o!{ay.

DTC24
DTC24
POSSIBLE
CAUSE
Open or short circuit in wiring harness between immobilizer unit and DDS1
Defective immobilizer unit
Defective DDS1
Defective wiring harness
IMMOBILIZER UNIT HARNESS
SIDE CONNECTOR
I~ I: ~1R~ ~ I~ I~ I
I~~I
INSPECTION
STEP
INSPECT CONNECTOR CONNECTION
1
Are both immobilizer unit and FIP connectors
connected properly?
INSPECT COMMUNICATION CIRCUIT FOR
2
CONTINUITY
Disconnect FIP connector.
Measure voltage at FIP connector terminal
H.
Is voltage more than 10 V?
INSPECT COMMUNICATION CIRCUIT FOR
3
CONTINUITY
Disconnect immobilizer unit and FIP
connectors.
Is there continuity between immobilizer unit
connector terminal A and FIP connector
terminal H?
4
INSPECT IMMOBILIZER UNIT FOR SHORT
TOGND
Is there continuity between immobilizer unit
connector terminal A and ground?
INSPECT POWER CIRCUIT FOR OPEN
5
CIRCUIT TO DDS1
Measure voltage at FIP connector terminal
G.
Is voltage more than 10 V?
INSPECT DDS1 FOR SHORT TO GND
6
Disconnect FIP connector.
Is there continuity between FIP connector
terminal F and ground?
INSPECT INNER CIRCUIT OF IMMOBILIZER
7
UNIT
Replace immobilizer unit and reprogram
immobilizer system.
(See 09-14-5 IMMOBILIZER SYSTEM
REPROGRAM PROCEDURE.)
Dose engine start?
Yes
No
Yes
ACTION
Go to next step.
Connect connectors properly.
No
Go to Step 5.
Go to next step.
Yes
Go to next step.
No
Repair wiring harness between DDS1 and immobilizer unit.
Yes
Repair for short circuit in wiring harness between DDS1 and

immobilizer unit.
No
Go to next step.
Yes
No
Go to next step.
Repair wiring harness between ENGINE 15 A fuse and
DDS1.
Yes
Go to next step.
No
Repair wiring harness between DDS1 and ground.
Yes
Immobilizer unit was defective.
No
Replace DDS1 and reprogram immobilizer system.

(See 09-14-5 IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE.)
II
09-02A-5

DTC 30[IMMOBILIZER SYSTEM]
DTC30
POSSIBLE
CAUSE
id0902e4904800
DDS1 is defective (Malfunction of communication line inside DDS1)
Defective DDS 1
STEP
09-02A-6
INSPECTION
-
ACTION
Replace DDS1 and reprogram immobilizer system.

(See 09-14-5 IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE.)
ON-BOARD DIAGNOSTIC [AUDIO]
09-02B ON-BOARD DIAGNOSTIC [AUDIO]

STARTING PROCEDURE FOR
ON-BOARD DIAGNOSTIC TEST
MODE ................... 09-02B-1
SUPPLIER IDENTIFICATION
PROCEDURE .............. 09-02B-1
MEMORY CLEARING PROCEDURE ... 09-02 B-2
DTC TABLE [AUDIO SYSTEM] ....... 09-02B-2
DIAGNOSTIC ASSIST FUNCTION .... 09-02B-4
STARTING PROCEDURE FOR ON-BOARD DIAGNOSTIC TEST MODE
dcf09026690Ow01
Note
All OTCs displayed in the on-board diagnostic test mode should be entered in the Audio Repair Order
Form.
1. Turn the engine switch to the ACC or ON position.
2. Turn the POWER button off.
3. While pressing the POWER button,
simultaneously press the FM 1 button and the
MEOlA button for 2 s or more.
1
2
3
4
FM 1 button
MEDIA button
SEEK switch
POWER button
Note
If several OTCs are in the memory, they can
be displayed using the SEEK switch (up or
down).
4
DCF902ZWBS01
4. To stop the on-board diagnostic test mode, turn the engine switch off.
SUPPLIER IDENTIFICATION PROCEDURE
dcf09026690Ow02
Note
The supplier can vary with the module. When asking the supplier (service center) for repair or
replacement, identify the supplier and fill in the Audio Repair Order Form with the following procedures.
Identification Using the Label or Inscribed Lettering
1. Remove the audio unit.
2. Verify the supplier by referring to the label attached to each unit.
Jdentification Using the On-board Diagnostic Test Mode.
1. Start the on-board diagnostic test mode.
2. Identify the device and supplier codes by referring
to the information display.
Note
If no OTC is stored, no codes will be
displayed.
Supplier code
Supplier name
SANYO Automedia
2
3
4
Panasonic
Clarion
Part
number
03
05
SUPPLIER CODE
,....-...
I.
I
.:.
...., ..... . ....

II
I I .
,.1.I
II I
'.11' II'
II
1111
II
I.
. ... 11
II...
.
PART NUMBER
CHU0902WM02
Pioneer
Part name
CD player
CD changer (external)
09-028-1

Part
number
06
O?
09
10
21
22
Part name
CD changer (upper module)
MD player (lower module)
Base unit
Center panel
MP3 applicable CD changer (upper module)
MEMORY CLEARING PROCEDURE
dcf090266900w03
1. Start the on-board diagnostic test mode.

2. While pressing the POWER button,
simultaneously press the AUDIO CaNT button for
2 s or more.
IAUDIO CO NT button
2
POWER button
Caution
Before clearing the memory, be sure to
enter all of the DTCs displayed in the onboard diagnostic test mode in the Audio
Repair Order Form.
DCF902ZWBS02
3. To stop the on-board diagnostic test mode, turn

the engine switch off.
DTC TABLE [AUDIO SYSTEM]

Screen display
DTC
(When starting on-board
diagnostic test function)
03: Er01
03: Er02
03: ErO?
dcf090266900w04
Detection condition
CD player cannot implement
insert and eject commands.
Cannot change tracks.
CD reading error.
CD player does not operate.
03: Er10
05: Er01
05: ErO?
05: Er10
06: Er01
06: Er02
CD changer (external) cannot

implement insert, eject, and disc
change commands.
CD reading error.
CD changer (external) does not

operate.
CD changer cannot implement
insert, eject, and disc change
commands.
CD reading error.
06: ErO?
CD changer does not operate.
06: Er10
09-028-2
Possible cause/inspection
CD player malfunction
Defective CD (scratches or dirt)
Malfunction of connectors between base unit and CD
player
Defective CD (curved, broken or foreign material stucki
attached, etc.)
CD changer (external) malfunction
attached, etc.)
attached, etc.)
attached, etc.)
CD changer malfunction
attached, etc.)
attached, etc.)
Malfunction of connectors between base unit and CD
changer

Screen display
DTe
(When starting on-board
diagnostic test function)
Detection condition
Possible cause/inspection
07: Er01
MD player cannot implement

insert and eject commands.
MD player malfunction
07: Er02
07: Er07
MD reading error.
Blank unrecorded MD is inserted.
Defective MD
07: Er08
MD player does not operate.

07: Er10
09: Er20
09: Er21
09: Er22
10: Er01
10: Er02
10: Er07
10: Er09
Audio system does not operate.

Broken sound/No sound
No radio reception
MP3 applicable CD player cannot
implement insert and eject
commands.
MP3 CD reading error.
MP3 CD data is unreadable.
10: Er10
MP3 applicable CD player does

not operate.
21: Er17
21: Er18
Incorrect combination (base unit

and center panel)
21: Er19
22: Er01
22: Er02
22: Er07
22: Er09
22: Er10
no Err
Communication error between

base unit and center panel
MP3 applicable CD changer
cannot implement insert, eject,
and disc change commands.
CD reading error.
MP3 CD data is unreadable.

MP3 applicable CD changer does
not operate.
No DTCs stored
Defective MD
Malfunction of connectors between base unit and MD
player
Voltage at base unit is low.
Inspect the audio system operation according to vehicle
condition.
Inspect the radio operation according to vehicle condition.
MP3 applicable CD player malfunction

Incorrect format CD
CD data error
No playback data on the CD
Malfunction of connectors between base unit and MP3
applicable CD player
Install the correct base unit or the center panel.
Malfunction of connectors between base unit and center
panel
attached, etc.)
MP3 applicable CD changer malfunction

attached, etc.)

attached, etc.)
CD data error
No playback data on the CD
Malfunction of connectors between base unit and MP3
applicable CD changer
No DTCs stored
09-028-3

DIAGNOSTIC ASSIST FUNCTION
dcf090266900w05
Structural View
Buttons
@ II
17
DCF902ZWBS03
CLOCK button
10
Preset button 4
11
12
Preset button 5
Preset button 6
13
DISP/AUTO-M button
SEEKlAPCITRACK switch
FM 1 button
3
4
FM 2 button
AM button
CD button
MEDIA button
14
15
Preset button 1
16
Preset button 2
Preset button 3
17
6
7
8
9
Traffic information button

AUDIO CONTITUNEITEXT button
POWERNOLUME button
Information Display Inspection

1. With the audio power on, press the POWER button and simultaneously press the SEEK switch (up or down) for
approx.1s.
2. Inspect according to the following table:
INSPECTION
Start the information display
inspection mode.
DISPLAY
IBB:BBlfgml1ll'iriiii'it
ACTION
The characters displayed
The information display is
on the information display normal.
are not truncated or faint.
Except above
Replace the base unit.

(See 09-20-4 AUDIO UNIT
DISASSEMBLYI
ASSEMBLY [TYPE A].)
3. Turn the audio off or the ignition switch to the LOCK position to stop the diagnostic assist function.
09-028-4

Speaker Inspection
1. With the audio power on, press the POWER button and simultaneously press the AUTO-M button for approx.
1s.
INSPECTION
Start the speaker inspection
mode.
Does each speaker output
sound in the following order?
1. Front speaker and tweeter
(LH)
2. Front speaker and tweeter
(RH)
3. Rear speaker (RH)*1
4. Rear speaker (LH) *1
DISPLAY
Yes
ACTION
Speakers, and wiring harness between
the base unit and speakers are normal.
No
Inspect the following parts .

- Malfunctioning speaker
- Wiring harness between base unit
and malfunctioning speaker
*1 : Mayor may not be equipped, depending on the vehicle.
Radio Reception Condition Inspection
1. With the audio power on and at radio mode, press the POWER button and simultaneously press the Preset 2
button for approx. 1 s.
Caution
Even if the system is normal, radio reception may be difficult depending on where the system is
inspected (indoors/outdoors, or conditions at the location). Before inspecting the system, verify
that radio reception is adequate.
When inspecting, select a frequency band (radio station) with the best reception.
INSPECTION
Start the radio reception
condition inspection mode.
DISPLAY
ACTION
Antenna, antenna feeder and base unit are normal
NORMAL CONDITION
S-METER 5
I
S~METER
S-METER 3
Change the frequency (radio station) and inspect again.
S-METER 4
MALFUNCTION PRESENT
S-METER 0
I
Inspect the antenna and antenna feeder.

If either the antenna or the antenna feeder is not
normal, replace the malfunctioning part.
If the antenna and antenna feeder are normal,
replace the base unit.
S-METER 2
09-028-5

Antenna control condition inspection
1. With the audio power on and at radio mode, press the POWER button and simultaneously press the FM 2
button for approx. 1 s.
2. Inspect the antenna control conditon according to the following table:
Inspection
Start antenna control condition
inspection mode.
Display
I=INT-ON
I=INT-OFF
Sound quality is good.

Sound quality is poor.
Action
System is okay.
Inspect the roof antenna.
Replace base unit.
09-028-6
SYMPTOM TROUBLESHOOTING [POWER WINDOW SYSTEMS (WITH AUTOOPEN/CLOSE FUNCTION FOR DRIVER-SIDE)]
09-03A SYMPTOM TROUBLESHOOTING [POWER

WINDOW SYSTEMS (WITH AUTO-OPEN/CLOSE FUNCTION
FOR DRIVER-SIDE)]
POWER WINDOW SYSTEM
FOREWORD ......................
POWER WINDOW SYSTEM
TROUBLESHOOTING
QUESTIONNAIRE . ................
CHART . .........................
BASIC POWER WINDOW SYSTEM
INSPECTION . ....................
NO.1 THE AUTO OPEN/CLOSE
FUNCTION ON THE DRIVER'S SIDE
,POWER WINDOW IS INOPERATIVE
[WITH AUTOMATIC DOOR GLASS
RETURN FUNCTION] ..............
NO.2 THE DRIVER'S SIDE POWER
WINDOW INOPERATIVE ...........
NO.3 POWER WINDOWS OTHER

THAN DRIVER'S SIDE DO NOT
OPERATE BY SUBSWITCH ......... 09-03A-9
OPERATE BY MAIN SWITCH ....... . 09-03A-9
OPERATE BY MAIN SWITCH AND
SUBSWITCH . .................... . 09-03A-9
WINDOW AUTOMATICALLY OPENS
IN THE CLOSING OPERATION . ..... . 09-03A-11
NO.7 ABNORMAL NOISE DURING
THE POWER WINDOW
OPERATION . .................... . 09-03A-13
09-03A-1
09-03A-2
09-03A-3
09-03A-4
09-03A-4
09-03A-7
09-03A-7
POWER WINDOW SYSTEM WIRING DIAGRAM

MANUAL
CLOSE
dcf09035800Ow13
MANUAL AUTO
OPEN
POWER WINDOW MAIN SWITCH
IG1
B+
POWER-CUT
SWITCH
CLOSE/,
CLOSE/
CLOSE/
OPEN
OPEN
OPEN
OPEN
RELAY
CLOSE
RELAY
DOOR SWITCH
(DRIVER'S SIDE)
L....+---*--+--l
HALL EFFECT SWITCH NO.1
1--.-----!:~--4~
I--.----~,-i
1--._ _ _ _ _
' ---.
I
DOOR SWITCH
(REAR LEFT SIDE)
1--._ _ _ _ _.;..:--I
HALL EFFECT SWITCH NO.2,
FRONT
MOTOR (DRIVER'S SIDE)
I! -
:
:
I
..
:l
I
..
POWEFiwiNOOW -------- WINDOW

FRONT POWER
MOTOR
:
:
~
l
I
POWER
WINDOW
SUBSWITCH
..
REAR POWER
REAR POWER WINDOW
'WINDOW
MOTOR (RIGHT SIDE)
: MOTOR
_____________________________, (LEFT SIDE)
y:
(PASSENGER'S SIDE)
I " "
POWER
WINDOW
SUBSWITCH
WITH REAR POWER WINDOW SYSTEM
POWER
WINDOW
SUBSWITCH
DBR912ZT2003
09-03A-'1
FOREWORD
dcf09035800Ow14
Troubleshooting Procedure
Confirm to the customer using the "Power Window System

Troubleshooting Questionnaire"
NO
Confirm the symptom on-vehicle
Is there same symptom in the

Symptom Troubleshooting
Chart?
NO
Carry-out the basic

inspection
YES
Follow the appropriate
diagnostic procedure
Repair the problem
Complete
DCF903ZWB101
Caution
The power window system initialization is required after performing below operations. Because of
both the automatic operation and tow-step down return function are reset by the operations.
- Disconnect the negative battery cable from the battery terminal.
- Disconnect the power window main switch connector.
- Remove the fuse for the power window system.
Power window system initialization procedures:
2. Fully open the driver side front door glass by operating the driver side front window switch.
3. Fully close the driver side front door glass using the driver side front window switch and hold
the switch for two seconds.
Slightly shake the wiring harness and connectors while performing the inspection to discover
whether poor contact pOints are the cause of any intermittent malfunctions.
09-03A-2
POWER WINDOW SYSTEM TROUBLESHOOTING QUESTIONNAIRE
dcf090358000w15
Date:
When the malfunction is occurred.
Weather condition
Driving condition
Duplicate symptom
Road conditions
o Fair weather DCloudy 0
Rain 0 Snow 0 Other (
o Driving OStop (Engine is :

OYES ONO
o Running 0
Frequency
o City OOuter city 0
Outside
temperature
I Approx.
Stoped)
I o Always 0
Sometimes (
times/month)
Freeway OOther (
) /0 Pavage 0 Dirt track
,
*Follow the appropriate diagnostic procedures shown below or perform the basic flow of Troublesho.
o (No.1) The auto open/close function on the driver's side power window inoperative.
o (No.2) The driver's side power window inoperative.
o (No.3) Power windows other than driver's side do not operate by sub-switch.
o (No.4) Power windows other than driver's side do not operate by main swhch.
o (No.5) Power windows other than driver's side do not operate by main switch and sub-switch.
o (No.6) The driver's side power window automatically opens in the closing operation.
Please clarify the position that the driver side front door glass opens automatically. 0 Completely closed position
Approx. ( )mm lower than completely position
OApprox. ( )mm upper than the completely position.
o
o (No.7) Abnormal noise during the power window operation
o Other (Describe the symptom below if there is no symptom in the above list.)
iI(!
l~
1111
Please describe any condition when the malfunction occurs.

(Example) : Operate outside door mirror operation, etc
Please describe any condition that the system returns to normal operation after malfunctioning.
(Example) : Turn the ignition switch to ON position after inserting the ignition key into the key cylinder, etc
Installed Accessory Part availability

(Example) : Side visor, Immobilizer, Rader, ect(regardless genuine parts or sfter-market parts)
DCF903ZWB102
09-03A-3
SYMPTOM TROUBLESHOOTING CHART
dcf090358000w16
Malfunction symptom
No.
1
09-03A-7 NO.1 THE AUTO OPEN/CLOSE FUNCTION ON THE DRIVER'S SIDE POWER WINDOW IS
INOPERATIVE [WITH AUTOMATIC DOOR GLASS RETURN FUNCTION]
09-03A-7 NO.2 THE DRIVER'S SIDE POWER WINDOW INOPERATIVE
3
4
09-03A-9 NO.3 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY SUBSWITCH
09-03A-9 NO.4 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH
09-03A-9 NO.5 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH AND
SUBSWITCH.
09-03A-11 NO.6 THE DRIVER'S SIDE POWER WINDOW AUTOMATICALLY OPENS IN THE CLOSING
OPERATION
09-03A-13 NO.7 ABNORMAL NOISE DURING THE POWER WINDOW OPERATION.
5
6
7
BASIC POWER WINDOW SYSTEM INSPECTION
dcf090358000w17
Manual Mode Function Inspection

STEP
1
INSPECTION
Operate the power window using the manual
open/close function on the power window main
switch.
Does the power window operate properly?
Set the power cut switch to the UNLOCK
position.
Operate the power window using the power
window subswitch.
Set the power cut switch to the LOCK position.
Operate ali power windows other than the driver
side.
Does the power window operate?
ACTION
Yes
No
Yes
No
Yes
No
Inspect the power window main switch and the

wiring harness.

Inspect for the power window subswitch and the
wiring harness.
Repair or replace malfunctioning parts.
Inspect the power cut switch and the wiring harness.

Replace the power window main switch.
Manual mode function is normal.
Perform the automatic mode function inspection.
Automatic Mode function Inspection

Note
Automatic mode function is equipped with automatic door glass return function adapted model.
STEP
1
ACTION
INSPECTION

Operate the power window using the auto open /
close function on the power window main switch.
Yes
No
If the power window automatically opens in

the closing operation:
Go to 09-03A-11 NO.6 THE DRIVER'S SIDE

POWER WINDOW AUTOMATICALLY OPENS IN
THE CLOSING OPERATION
Others:
Operate the power window main switch to the

close position while the power window is in
opening operation.
Is the power window operation stopped?
Yes
Operate the power window main switch to open

position while the power window is in closing
operation.
Is the power window operation stopped?
Yes
09-03A-4
No
No
Go to 09-03A-7 NO.1 THE AUTO OPEN/CLOSE

FUNCTION ON THE DRIVER'S SIDE POWER
WINDOW IS INOPERATIVE [WITH AUTOMATIC
DOOR GLASS RETURN FUNCTION]

Replace the power window main switch. (power
window control unit is malfunctioning.)
Automatic mode function is normal.

Perform the IG-OFF timer function inspection.
Replace the power window main switch. (power
window control unit is malfunctioning.)
IG-OFF Timer Function Inspection
Note
IG-OFF timer function is equipped with automatic door glass return function adapted model.
INSPECTION
STEP
ACTION
Close all doors.

Turn the ignition switch to the ON position ..
In automatic mode, push down the power
window main switch for the driver-side front door
glass. The door glass should move down within
approx. 43s after ignition switch off.
In manual mode (finger continuously depressing
the power window main switch), the door glass
should move down within approx. 43s after
ignition switch off.
Does the driver-side front door glass move
down?
In automatic mode, pull up the power window
main switch for the driver-side front door glass.
The door glass does not move up within approx.
43s after ignition switch off.
Verify that driver-side front door glass does not
operate
Does the driver-side front door glass move up?
Yes
No
Open any doors.

Push/pull the power window main switch for the
door glass within approx. 43s after ignition
switch off.
Verify that the door glass does not move up or
down.
Does the door glass move up or down?
Close all doors.
Push/pull the power window main switch for door
glass after approx. 60 s after ignition switch off.
Verify that the door glass does not move up or
down.
Does the door glass move up or down?

If it does not move up and down upon reinspection,
- Wiring harness for the door open/close signal
system.
- Latch switch.
Repair or replace the malfunctioning part, and
reinspect.
- If operation is not normal, replace the power
window main switch, and then go to the next
step.
Yes
If operation is not normal, replace the power window

main switch, then go to the next step.
No
Yes
Inspect the door switch and related wiring harness.

If above parts are normal, replace the power
window main switch, then go to the next step.
If the above parts have any malfunction, repair or
replace the malfunction part, then go to the next
step.
No
Yes
No
If operation is not normal, replace the power window

main switch, then go to the automatic door glass
return function inspection.
The IG OFF timer function is normal.
Go to the automatic door glass return function
inspection.
09-03A-5
Auto Reverse Pinch Protection Function Inspection
STEP
1
INSPECTION

Fully open the driver's side power window.
Set the hammer (thickness: 10 mm or more) as
shown below. Then, close the power window
using auto close function.
Inspect that the power window opens by 200 mm
after contacting the hammer and stops the
operation.
Does automatic door glass return function
operate properly?
Does power window open before contacting the
hammer?
Yes
ACTION
Automatic door glass return function is normal.
Perform the two-step down function inspection.
No
Yes
No
Go to 09-03A-11 NO.6 THE DRIVER'S SIDE

POWER WINDOW AUTOMATICALLY OPENS IN
THE CLOSING OPERATION
Initialize the power window main switch.
Note
Before initializing the power window main switch,
cut off the power supply to the power window
main switch for 60 seconds. Then, reconnect or
install it again after 60 seconds:
<Power supply cut-off method>
- Disconnect the negative battery cable from the
battery terminal.
- Disconnect the power window main switch
connector.
- Remove the fuse for the power window
system.
DDA903AW4S04
09-03A-6
NO.1 THE AUTO OPEN/CLOSE FUNCTION ON THE DRIVER'S SIDE POWER WINDOW IS INOPERATIVE
[WITH AUTOMATIC DOOR GLASS RETURN FUNCTION]
dcf090358000w18
1
POSSIBLE
CAUSE
The auto open/close function on the driver's side power window is inoperative
No power supply to power window main switch
Power window main switch malfunction (power window control unit malfunction, auto switch
malfunction)
Power window motor malfunction (Sensor inside motor malfunction)
Wiring harness between power window motor (sensor) and power window main switch malfunction
STEP
1
INSPECTION
Inspect the manual mode function.
Dose the manual mode function operate
properly?
Does the sensor built inside the power
window motor send the pulse signals during
operating the power window motor?
Is voltage between the terminals of power
window mortor connecter (4-pin) and ground
approx.6V?
- Terminal1A (sensor 1 signal).
- Terminal1C (sensor 2 signal).
Does the power window main switch receive
the pulse signals during operating the power
window motor?
Is voltage between the terminals of power
window main switch connecter (4-pin) and
ground approx.6V?
- Terminal2D (sensor 1 signal).
- Terminal2B (sensor 2 signal).
ACTION
Yes
No
Yes
No

Replace the power window motor.
Yes
No

Inspect open or short circuit in the wiring harness between
power window motor (sensor) and power window main
switch. Inspect the connection of the power window motor
and power window main switch connectors. (such as
damaged/pulled-out pins, corrosion).Repair or replace the
suspect part if necessary.
NO.2 THE DRIVER'S SIDE POWER WINDOW INOPERATIVE

2
POSSIBLE
CAUSE
dcf090358000w19
The driver's side power window inoperative

Power supply circuit or ground circuit malfunction
- Burnt fuse (B+)
- Open or short circuit in wiring harness between fuse (B+) and power window main switch
- Open or short circuit in wiring harness between power window main switch and power window motor
- Open circuit in wiring harness between power window main switch and ground
Power window main switch malfunction (Internal circuit malfunction, relay malfunction)
Power window motor malfunction (motor malfunction, window regulator guide malfunction)
STEP
INSPECTION
Does the LED on the power window main
switch illuminate?
Operate all power windows other than
driver's side window using the power window
main switch.
ACTION
Yes
No
Go to Step 6.
Yes
No
Inspect open or short circuit and connection in the following

wiring harnesses/connections
Automatic door glass return function is equipped:
P.WIND 30 A fuse-Power window main switch

connector terminal 1F
Power window main switch connector terminal 1Hbody ground.
Automatic door glass return function is not

equipped:
P.WIND 30A fuse-Power window main switch terminal
Power window main switch terminal H-ground.

Repair or replace the suspect part if necessary.
09-03A-7
INSPECTION
STEP
4
5
*1
*2
ACTION
Yes

Go to Step 5.
Automatic door glass return function is not equipped:
(See 09-12-8 POWER WINDOW MAIN SWITCH
No
Inspect the followings:

Short circuit in B+ power supply wiring harness
Short circuit in power window motor
Repair or replace the suspect part if necessary. Replace with
the appropriate standard fuse. Then, go to the next step.
Initialize the power window system.

Operate the power window systemoperation.
Does power window operate properly?
Yes
Re-confirm the symptom and go to Step 1 in this procedure.
Measure the voltage at power window main

switch (battery power supply terminal 11) .
Is the voltage B+?
Yes
No
Inspect open or short circuit in the power window main

switch wiring harness (battery power supply).
Inspect the connection of the power window main switch
connector. (such as damaged/pulled-out pins, corrosion).
Measure the voltage at the power window

main switch (power window motor output
terminal) during operating the power window
using the power window main switch.
Is the voltage B+?
(Open: terminal 1 K*11/(2
Close: terminal 1M*11 /K*2 )
Yes
No
Measure the voltage at power window motor

(2-pin)(battery power supply terminal) during
operating the power window using the power
window main switch.
Is the voltage B+?
(Open: terminal 1 8/ close: terminal1A)
Yes
No
Operate the driver's side power window

using the power window main switch.
Does power window motor operate (rotate)?
Yes

power window main switch and power window motor.
and power window motor connectors. (such as damaged/
No
Replace the power window motor.
Yes
Replace the regulator guide.
No
Inspect for bent regulator guide or other possible facts. If

there is normal, replace the door glass run-channel.
Is the PWIND 30 A fuse normal?
Note
The power window motor does not
operate during the power window motor
internal temperature is too high. Leave the
motor for 3 minutes and inspect the power
window motor operation again after
cooling down the motor temperature.
Remove the door glass from the carrier plate.
Make sure that the door glass moving
smoothly by hand.
Is the door glass move smoothly?
: With automatic door glass return function

: Without automatic dooe glass return function
09-03A-8
No
SYMPTOM TROUBLESHOOTING [POWER WINDOW SYSTEMS (WITH AUTO

OPEN/CLOSE FUNCTION FOR DRIVER-SIDE)]
NO.3 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY SUBSWITCH
dcf090358000w20
Power windows other than driver's side do not operate by subswitch
POSSIBLE
CAUSE
Open or short circuit in power window subswitch wiring harness (battery power supply circuit)
Power window subswitch malfunction
1
ACTION
INSPECTION
STEP
Turn the ignition switch to ON position.

Set power cut-switch on power window main
switch to UNLOCK position.
Measure the voltage at power window subswitch (terminal C).
Is the voltage B+?
Yes
No
Replace the power window subswitch.

power window main switch and power window
subswitch.lnspect the connection of the power window
subswitch connector. (such as damaged/pulled-out pins,
corrosion).Repair or replace the suspect part if necessary.
NO.4 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH
dcf090358000w21
power windows other than driver's side do not operate by main switch
4
POSSIBLE
CAUSE
Open or short circuit in wiring harness between ignition switch (IG1) and power window main switch
(lG1)
Power window main switch malfunction
Diagnostic procedures
STEP
1
INSPECTION
Set power cut-switch on power window main
switch to UNLOCK position.
driver's side using the power window main
switch.
Does power window operate properly?
ACTION
Yes
No

switch wiring harness (battery power supply ).Inspect the
connection of the power window main switch connector.
(such as damaged/pulled-out pins, corrosion). Repair or
replace the suspect part if necessary.
NO.5 POWER WINDOWS OTHER THAN DRIVER'S SIDE DO NOT OPERATE BY MAIN SWITCH AND
SUBSWITCH.
dcf090358000w22
All power windows are inoperative
POSSIBLE
CAUSE
Power supply circuit or ground circuit malfunction

- Burnt fuse (IG1)
- Open or short circuit in wiring harness between ignition switch (IG1) and power window main switch
- Open or short circuit in wiring harness between power window main switch and power window
subswitch
- Open or short circuit in wiring harness between power window main switch and power window motor
- Open circuit in wiring harness between power window main switch and ground
Power window main switch malfunction (power cut-off switch malfunction, switch malfunction)
Power window subswitch malfunction
Power window motor malfunction(motor malfunction, window regulator guide malfunction)
STEP
ACTION
INSPECTION
Set the power cut-off switch on power
window main switch to UNLOCK position.
Inspect the power window system operation
again.
Does the system operate properly?
driver's side window using power window
main switch.
Does any power window operate?
Yes
System is now normal. (power cut-off switch dose not set

properly.)
No
Yes
No
Go to Step 6.
09-03A-9
STEP
3
INSPECTION
ACTION
Operate driver's side power window using

the power window main switch.
Does power window operate?
Yes
No
Is the P.wIND 30 A fuse normal?
Yes
No
Measure the voltage at power window main

switch (battery power supply terminal 11)
Is the voltage B+?
Yes
No
Identify the inoperative power window.

Measure the voltage at suspect power
window motor (battery power supply) during
operating the power window motor using the
suspect power window sub-switch.
Is the voltage B+?
(Open: terminal 8/ close: terminal A)
Operate power window using the power
window sUb-switch.
Does power window motor operate (rotate)?
Yes
Note
The power window motor does not
operate during the power window motor
internal temperature is too high. Leave the
motor for 3 minutes and inspect the power
window motor operation again after
cooling down the motor temperature.
Remove the door glass from the carrier plate.
Make sure that the door glass moving
smoothly byhand.
Is the door glass move smoothly?
Measure the voltage at power window subswitch (power window motor output) during
operating the power window sub-switch.
Is the voltage B+?
(open:terminal F/close:terminal 8)

Inspect open circuit in the wiring harness between power
window main switch and body ground.
Automatic door glass return function is not equipped:
Replace power window main switch.(See
09-12-8 POWER WINDOW MAIN SWITCH REMOVAL!
INSTALLATION)
Replace with the appropriate standard fuse.

- If the fuse is melted, inspect the wiring harness for
short to ground.Repair or replace the wiring harness,
then replace the fuse.
Replace power window main switch.
switch wiring harness (battery power supply).
connector. (such as damaged/pulled-out pins; corrosion).
No

Go to Step 9.
Yes
No
Replace power window motor.
10
11
Yes
Replace regulator guide.
No
Inspect for bent regulator guide or other possible facts. If

there is normal, replace the door glass run-channel.
Yes

power window sub-switch and power window motor.
Inspect the connection of the power window subswitch and
power window motor connectors. (such as damaged/pulledout pins, corrosion).
No
Disconnect power window sub-switch

connector.
Inspect the continuity between power
window sub-switch terminal 8 and ground.
Is there a continuity?
Yes

Inspect open or short circuit in the power window sub-switch
wiring harness.
Inspect the connection of the power window subswitch
Repair or replace the suspect part if necessary
Then, go to STEP 12.

window sub-switch terminal F and ground.
Yes
09-03A-10
No
No
Replace power window subswitch.

Inspect open or short circuit in the power window sub-switch
wiring harness.
Inspect the connection of the power window sub-switch
Repair or replace the suspect part if necessary
Then, go to STEP 12.
STEP
12
INSPECTION
Note
Do not operate the power window main
switch during the following inspection.
13
*1
*2

window main switch terminals (1 A, 1B, 1J)*1/
(A, B, J) *2 and ground.
Note
Do not operate the power window main
switch during the following inspection.
window main switch terminal (1 C, 10, 1L)*1 /
(C, 0, L)*2 and ground.
Is there a continuity?
ACTION
Yes
No
Replace the power window main switch .
Yes

power window main switch and power window sub-switch.
and sub-switch connectors. (such as damaged/pulled-out
pins, corrosion).
Replace power window main switch.
No
: With automatic door glass return function

: Without automatic door glass return function
NO.6 THE DRIVER'S SIDE POWER WINDOW AUTOMATICALLY OPENS IN THE CLOSING OPERATION
dcf09035800OW23
The driver's side power window automatically opens in the closing operation.
Increase sliding resistance of door glass while raising the glass.
- Improper installation of side visor
- Regulator motor malfunction
- Pinch any foreign material between door glass and door glass run channel
- Inadequate installation of carrier plate and door glass
- Door glass run channel malfunction
- Door glass guide malfunction
POSSIBLE
CAUSE
Note
When the switch detects to pinch something, auto reverse pinch protection function operates to open
the door glass automatically.
If the sliding resistance of door glass is increased and door glass raising speed is slow down, the
auto reverse pinch protection function sometime operates.
If the door glass raising speed is slow down, inspect the following parts:
- If door glass rotates forward slightly: inspect the vehicle front side of door glass guide and/or door
glass run channel.
- If door glass rotates backward slightly: inspect the vehicle rear side of door glass guide and/or
door glass run channel.
STEP
INSPECTION
Confirm the symptom.
Does the symptom occur under the following
condition?
- Bumping road.
- Opening/closing door.
Yes
ACTION
System is normal.
(Explain to customer that this is normal operation on this
system.)
No
Yes
No

Install the side visor properly, then go to the next step.
Yes
Put the mark the speed change position on either door shell
or door glass run channel. Go to STEP 5.
Inspect the side visor installation condition.

Is the side visor normal?
Put any tape on the back side of the door

glass.
Run the engine at idle.
Inspect the door glass operating speed.
Is there any speed change? (e.g., slow
down)
No
Inspect the door glass operating speed again Yes Replace the regulator motor. Then go to STEP 8.
Is the speed change frequently (e.g., 5-6
f---,N""'0-I-G
=-0-'-to-S-=-t-e-p-8-.--=---------=------------1
times)?
09-03A-11
STEP
INSPECTION
Is there any foreign material between door
glass run channel and door glass?
Is there any rough surface on the sliding
surface?
ACTION
Yes
If there is any foreign material:
Remove the foreign material.
If there is any rough surface on the sliding

surface:
Replace the door glass run channel.
Confirm the symptom again. If there is a same symptom,
return to STEP 3.
No
Inspect the installation condition of carrier

plate and door glass.
Are both parts installed securely?
Yes
No
Install them securely. Confirm the symptom again.

If there is a same symptom, return to STEP 3.
Inspect the door glass run channel and door

glass guide.
Are both parts normal?
Yes
No
Inspect the door glass operating speed.

Is there any speed change?
Yes
No

Install door glass run channel and door glass guide properly.
Confirm the symptom again.
If there is a same symptom, return to STEP 3.
perform STEP 3 in this procedure again.
If door glass slips rearward slightly
Affix tape to rear edge
If door glass slips forward slightly
DCF903ZWB1S0
09-03A-12
NO.7 ABNORMAL NOISE DURING THE POWER WINDOW OPERATION.
7
POSSIBLE
CAUSE
dcf090358000w24
Abnormal noise during the power window operation.

Loosen bolt for installing the door glass to the carrier plate .
Deform resin part on the regulator.
- Wear mark on the resin part caused by cable.
- Deform gear inside regulator motor.
Note
Identify the noise generating place using the stethoscope or any equivalent.
Abnormal
noise
Clicking noise
Groaning noise
Occurrence
timing
Beginning of
door glass
operation
While operating
door glass
Possible route cause

Loosen bolt for installing the door
glass to carrier plate.
Noise is created due to the wear
mark on the resin part of the
regulator guide caused by cable.
Noise generating place

Between carrier plate
and lower side of door
glass.
Regulator guide.
Note
There is no groaning noise
on the vehicle equipped with
roller type regulator guide ..
Deform gear inside regulator motor Gear inside regulator
motor
Action
Re-tighten bolt.
Replace regulator guide
Booming noise
Chattering noise
Replace the regulator

motor
POWER WINDOW MOTOR
CARRIER PLATE
POWER WINDOW
REGULATOR
DCF912ZWB525
OS-03A-13
i.
SYMPTOM TROUBLESHOOTING [KEYLESS ENTRY SYSTEM]
09-03B SYMPTOM TROUBLESHOOTING [KEYLESS

.
ENTRY SYSTEM]
WIRING DIAGRAM .............
FOREWORD ..................
CHECK SHEET ............
PRELIMINARY INSPECTION .......
09-03B-1
09-03B-1
09-03B-2
09-03B-3
ON-BOARD DIAGNOSTIC
FUNCTION .............. 09-03B-4
TROUBLESHOOTING INDEX ...... 09-03B-4
NO.1 ON-BOARD DIAGNOSTIC
FUNCTION INOPERATIVE .......... 09-03B-5
NO.2 TRANSMITTER ID CODE
CANNOT BE REPROGRAMMED .... 09-03B-7
KEYLESS ENTRY SYSTEM WIRING DIAGRAM

B+
IG1
KEYLESS
CONTROL
MODULE
dcf090369000w01
B+
DOOR LOCK
CONTROL MODULE
DOOR
SWITCH
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
DBR914ZWB002
FOREWORD
dcf090369000w02
Go to troubleshooting after identifying the specific malfunction by performing a keyless entry system
preliminary inspection.
Flowchart
START
Interview customer using keyless

entry system check sheet
Keyless entry system

preliminary inspection
(
ZLU0903W001
09-038-1

KEYLESS ENTRY SYSTEM CHECK SHEET
dcf090369000w03
Use the sheet below as a customer interview sheet when accepting a vehicle for service.
If the symptom is "Power door lock system does not operate with transmitter at all;' find out how the customer
uses the keyless entry system by following the check sheet below.
Perform the following inspection with customer:
Q1. What's the customer's complaint?
D Power door lock system does not operate with transmitter (door does not lock/unlock).
DOther_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
Q2. Is system factory-installed or after-market?
D Factory-installed system
-7 Go to Q3.
D After-market system
-7 Perform troubleshooting according to after-market keyless entry system manual.
Q3. Operate transmitter with customer from 2.5 m {8.2 ft} away from center of vehicle. (Make sure the ignition
key is either in the LOCK position or removed.)
Does keyless entry system work?
DYes
-7 Explain the following to the customer:
Keyless entry system does not work when ignition switch is in ON position.
Keyless entry system does not work from excessive distances (more than 2.5 m {8.2 ft} away from
center of vehicle}.
D No
-7 Go to Q4.
Q4. Check location where customer uses keyless entry system.
Does a particular area, such as being near TV towers, power plants, power lines, or factories, have an
effect on malfunction?
DYes Place_-:----:--:----:-=--:-:---=-__-:-_-::-:---:-_-::--_ _ _ _ _-:--_ _ _ _ _ _ _ _ __
-7Area of operation is bad. Explain effect of outside interferenc~ on transmitter to customer.
D No
-7 Go to Q5.
Q5. Make sure there are no after-market electrical parts installed on vehicle.
Are there any of the following present?
Cellular phone
Radio-wave equipment
Remote engine starter
TV, etc.
DYesParts _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ___
D No
Perform the keyless entry system preliminary inspection.
ZLU0903W002
09-038-2

KEYLESS ENTRY SYSTEM PRELIMINARY INSPECTION
dcf090369000w04
Perform the following preliminary inspection before troubleshooting.

STEP
INSPECTION
ACTION
Is system an after-market one?
Yes
Perform troubleshooting according to after-market keyless

entry system manual.
No
Go to next step.
Did customer activate keyless entry system

when ignition switch was in LOCK position?
Yes
No
Go to next step.
Did customer use keyless entry system in

particular area, such as being near TV
towers, power plants, power lines, or
factories?
Yes
Explain to customer that system does not work when

ignition is in ON position.
Turn ignition switch to LOCK position, then go to next
step.
Attempt to lock/unlock doors with transmitter in

non-interference area.
If system operates:
Area of operation is bad. Explain effect of outside

interference on transmitter to customer.
If system does not operate:
Are any of the following after-market

electrical parts on the vehicle?
- Cellular phone
- Radio-wave equipment
- Remote engine starter
-TV, etc.
No
Yes
Disconnect after-market electrical part connectors and

attempt to lock/unlock doors with transmitter.
If system operates:
After-market electrical parts are interfering with keyless

entry system.
If system does not operate:

No
Go to next step.
Go to next step.
Go to next step.
Perform on-board diagnostic function.

(See 09-03B-4 ON-BOARD DIAGNOSTIC
FUNCTION.)
Does on-board diagnostic function work?
Yes
No
Go to next step.
Go to next step.
Go to Step 1 of NO.1 ON-BOARD DIAGNOSTIC
FUNCTION INOPERATIVE.
Attempt to reprogram transmitter ID code.

Can transmitter ID code be reprogrammed?
Yes
System is normal now.
No
Go to Step 1 of troubleshooting NO.2 TRANSMITTER ID

CODE CANNOT BE REPROGRAMMED.
09-038-3

dcf090369000w05
1. Remove ignition key from steering lock.

2. Close all doors.
I Open driver-side door.
Note
Perform the following procedures within 24 seconds.
1. Insert ignition key into steering lock.
2. Repeat the following 4 times.
TL!rn ignition switch to ON position, then back to LOCK
position.
3. Remove ignition key from steering lock.
4. Push driver-side door switch 3 times.
Confirm the following operations in order every 1 second:

All doors lock.
Driver-side door unlocks.
Passenger-side and rear doors unlock.
Yes
On-board diagnostic function is operated

properly.
On-board diagnosis is completed.
Are above operations okay?
~ No
Did you conduct on-board diagnosis properly?
Yes IOn-board diagnostic function is inoperative.

Perform symptom troubleshooting.
No
Wait for 40 seconds.
I Return
DBR903MWBOOl
TROUBLESHOOTING INDEX
No.
1
On-board diagnostic function
inoperative
Transmitter 10 code cannot be
reprogrammed
09-038-4
dcf090369000w06
DESCRIPTION
Theft-deterrent control module's onboard diagnostic function does not
operate.
Theft-deterrent control module's
transmitter 10 code reprogram function
does not work.
PAGE
(See 09-038-5 NO.1 ON-80ARD
DIAGNOSTIC FUNCTION
INOPERATIVE.)
(See 09-038-7 NO.2 TRANSMITTER
10 CODE CANNOT 8E
REPROGRAMMED.)

NO.1 ON-BOARD DIAGNOSTIC FUNCTION INOPERATIVE
dcf090369000w07
When performing an asterisked (*) troubleshooting inspection, shake the wiring harness and connectors while
performing 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 harness are
On-board diagnostic function inoperative
1
DESCRIPTION Theft-deterrent control module's on-board diagnostic function does not operate.
POSSIBLE
Malfunction in door lock control module system
CAUSE
Malfunction in door lock linkage
Malfunction in power door lock system
Malfunction in theft-deterrent control module
Malfunction in theft-deterrent control module power supply circuit
Malfunction in theft-deterrent control module ground circuit
Malfunction in IG1, B+ signal circuit of keyless control module
- keyless control module power supply fuse malfunction
- Malfunction in wiring harness between keyless control module power supply fuse(s) and keyless
control module itself
Malfunction in keyless control module's door open/closed signal circuit
- Door switch, keyless control module malfunction
Malfunction in keyless control module GND signal circuit
- Malfunction in wiring harness between keyless control module and ground
- Malfunction in wiring harness between keyless control module and door switch(es)
Malfunction in keyless control module door lock/unlock signal circuit
- keyless control module malfunction
- Malfunction in wiring harness between keyless control module and theft-deterrent control module
STEP
1
INSPECTION
ACTION
INSPECT ON-BOARD DIAGNOSTIC

FUNCTION OPERATION
Did any of the following items work during
on-board diagnostic function operation?
- All doors locked
- Driver's side door unlocked
- All doors unlocked
Yes
Go to next step.
No
Go to Step 7.
INSPECT DOOR LOCK LINKAGE SYSTEM

Operate inner door lock knob and make sure
door locks and unlocks manually.
Do all door's lock systems work?
Yes
No
Go to next step.
Troubleshoot the door lock linkage.
Yes
Go to next step.
Inspect power door lock system, then go to step 15.

IS IN DOOR LOCK CONTROL MODULE,
DOOR LOCK ACTUATOR, A KEY CYLINDER
SWITCH AND RELATED WIRING HARNESS,
OR ELSEWHERE
Do all of the following items work when
inserting ignition key into driver's door key
cylinder and operating ignition key?
- All doors locked
- All doors unlocked
INSPECT POWER DOOR LOCK SYSTEM
Turn ignition switch to LOCK.
Disconnect keyless control module
connector.
Measure voltage at following keyless control
module connector terminals.
- Terminal 0
-Terminal K
Is voltage approximately 5 V?
INSPECT THEFT-DETERRENT CONTROL
MODULE
Turn ignition switch to LOCK position.
Disconnect theft-deterrent control module
connector (24-pin)
Measure voltage at theft-deterrent control
module connector (24-pin) terminal V.
Is resistance approximately 1.3 kilohm?
No
Yes
Replace keyless control module and reprogram transmitter

ID code, then go to Step 15.
No
Inspect theft-deterrent control module and wiring harness

(between keyless control module terminal 0, terminal K and
theft-deterrent control module terminal Q)
Yes
Go to next step.
No
Replace theft-deterrent control module, then go to Step 15.
09-038-5

INSPECTION
STEP
6*
10*
11*
12*
13*
ACTION

KEYLESS CONTROL MODULE AND THEFTDETERRENT CONTROL MODULE FOR
CONTINUITY AND SHORT
connector.
Inspect wiring harness between keyless
control module connector terminal J and
theft-deterrent control module connector (24pin) terminal V.
Is there open circuit and/or short circuit at
above wiring harness?
Yes
INSPECT KEYLESS CONTROL MODULE

AND THEFT-DETERRENT CONTROL
MODULE POWER SUPPLY FUSES
Are keyless control module and theftdeterrent control module power supply fuses
okay?
Yes
INSPECT DOOR SWITCHES

Are door switches installed securely?
Yes
No
Go to next step.
INSPECT THEFT-DETERRENT CONTROL

MODULE INSTALLATION
Is theft-deterrent control module installed to
joint box securely?
Yes
No
Go to next step.

KEYLESS CONTROL MODULE POWER
SUPPLIES AND KEYLESS CONTROL
MODULE FOR CONTINUITY
module terminals:
-IG1 signal (Terminal A)
- B+ signal (Terminal 8)
Yes
Go to next step.
Repair wiring harness between fuse block and keyless
control module, then go to Step 15.

KEYLESS CONTROL MODULE POWER
SUPPLY, KEYLESS CONTROL MODULE AND
GROUND FOR SHORT TO B+
connector.
module connector terminal A.
KEYLESS CONTROL MODULE AND
GROUND FOR CONTINUITY
Is there continuity between keyless control
module connector terminal L and ground?
KEYLESS CONTROL MODULE AND DOOR
SWITCH FOR CONTINUITY AND SHORT
connector.
Inspect wiring harness between keyless
control module connector terminal C and
door switch connector terminal.
Is there open circuit and/or short circuit at
above wiring harness?
09-038-6
No
No
No
Yes
Repair wiring harness between keyless control module and

theft-deterrent control module, then go to Step 15.
ID code, then go to Step 15.
Go to next step.
Check for a short to ground on blown fuse's circuit. Repair or
replace if necessary. Install appropriate amperage fuse.
Install door switch(es) securely, then go back to Step 2 of

keyless entry system preliminary inspection.
Install theft-deterrent control module securely, then go to
Step 15.
No
Repair malfunctioning wiring harness, then go to Step 15.

Go to next step.
Yes
Go to next step.
No

ground, then go.to Step 15.
Yes

door switch or replace malfunction door switch, then go to
Step 15.
No
Go to next step.

STEP
INSPECTION
14* INSPECT THEFT-DETERRENT CONTROL
MODULE POWER SUPPLY SYSTEM FOR
CONTINUITY AND SHORT
Remove theft-deterrent control module from
joint box.
Measure voltage at following theft-deterrent
control module (16-pin) terminals.
-Terminal C
15
Does keyless entry system operate
properly?
Yes
No
Yes
No
ACTION
Go to next step.
10 code, then go to next step.
malfunction recurs.
NO.2 TRANSMITTER 10 CODE CANNOT BE REPROGRAMMED
dcf09036900Ow08
Transmitter ID code cannot be reprogrammed.

2
DESCRIPTION Theft-deterrent control module's transmitter 10 code reprogram function does not work.
POSSIBLE
Malfunction in transmission circuit
CAUSE
- Transmitter battery, transmitter, keyless control module bracket, keyless control module bracket
ground screw or keyless control module malfunction
STEP
INSPECTION
1
INSPECT TRANSMITTER BATTERY
INSTALLATION AND TYPE
Visually inspect transmitter battery.
Are below items okay?
- Transmitter battery installation (correct
polarity)
- Battery type (CR2025)
2
TERMINALS FOR RUST AND POOR
CONNECTION
Visually inspect transmitter.
- Is there rust on transmitter battery
terminals (positive or negative pole)?
- Is there poor connection between
terminals and battery?
3
Inspect transmitter battery.
Is battery voltage normal?
4
INSPECT KEYLESS CONTROL MODULE
BRACKET INSTALLATION
Is keyless control module bracket installed
securely?
5
INSPECT GROUND SCREW INSTALLATION
BETWEEN KEYLESS CONTROL MODULE
AND KEYLESS CONTROL MODULE
BRACKET
Are keyless control module and keyless
control module bracket connected securely
to ground screw?
6
IS IN TRANSMITTER BATTERY OR
ELSEWHERE
Replace with a known good transmitter
battery.
properly?
Yes
No
Yes
ACTION
Go to next step.
Set transmitter battery properly or replace with specified
transmitter battery (CR2025), then go to Step 8.
No
Replace transmitter battery or repair transmitter battery

terminal, then go to Step 8.
Go to next step.
Yes
No
Go to next step.
Replace transmitter battery, then go to Step 8.
Yes
No
Go to next step.
Install bracket securely, then go back to Step 6 of keyless
entry system preliminary inspection.
Yes
No
Go to next step.
Install screw securely, then go back to Step 6 of keyless
entry system preliminary inspection.
Yes
No
Replace transmitter battery, then go to Step 8.

Go to next step.
09-038-7

INSPECTION
STEP

IS IN TRANSMITTER OR KEYLESS
CONTROL MODULE
Reprogram transmitter ID codes by using
another known good transmitter.
Does keyless entry system operate okay?
properly?
09-038-8
ACTION
Yes
No
Yes
No
Replace transmitter and reprogram transmitter ID code,

then go to next step.
ID code, then go to next step.
malfunction recurs.
SYMPTOM TROUBLESHOOTING [IMMOBILIZER SYSTEM]
09-03C SYMPTOM TROUBLESHOOTING [IMMOBILIZER

SYSTEM]
CHART [IMMOBILIZER SySTEM] .... 09-03C-1
No.1 SECURITY LIGHT DISPLAY IS

NOT NORMAL .................... 09-03C-1
SYMPTOM TROUBLESHOOTING CHART [IMMOBILIZER SYSTEM]

No.
The security light display is not normal.
dcf090367000w01
DESCRIPTION
The security light remains illuminated 2 min or more after the ignition
switch is turned to the ON position
The security light does not illuminate when the ignition switch is turned to
the ON position.
The security light remains illuminated while the ignition switch is at the
LOCK position.
The security light does not flash or the flashing interval is abnormal while
the ignition switch is at the LOCK position.
No.1 SECURITY LIGHT DISPLAY IS NOT NORMAL
dcf090367000w02
The security light display is not normal.

The security light remains illuminated 2 min or more after the ignition switch is turned to the ON position
The security light does not illuminate when the ignition switch is turned to the ON position.
DESCRIPTION The security light remains illuminated while the ignition switch is at the LOCK position.
The security light does not flash or the flashing interval is abnormal while the ignition switch is at the
LOCK position.
Keyless unit malfunction
Open or short circuit in the wiring harness between the instrument cluster and immobilizer unit
Note
If the security light remains illuminated for approx. 1 min after the ignition switch is turned to the ON
position and then displays a DTC, perform immobilizer system malfunction diagnosis according to that
DTC. (See 09-02A-2 DTC TABLE [IMMOBILIZER SYSTEM].)
While performing immobilizer system security access using the WDS, the security light does not
illuminate even if the ignition switch is turned to the ON position. Verify the illumination condition of the
security light by disconnecting the DLC-2 to release security access.
POSSIBLE
CAUSE
NOTE: SECURITY LIGHT FLASHING SEQUENCE

WHEN IGNITION SWITCH IS TURNED TO LOCK POSITION
(IMMOBILIZER SYSTEM IS NORMAL)
Jl
::::':::EO tPPROX 19 S, ~ ,APPROX 1.9 ~ ~

.. ::..
II
APPROX. 0.1 S
09-03C-1
SYMPTOM TROUBLESHOOTING [IMMOBILIZER SYSTEM]

INSPECTION
STEP
1
Yes
No
Inspect the instrument cluster.

(See 09-22-2 INSTRUMENT CLUSTER
INSPECTION.)
Turn the ignition switch to the LOCK position.

Disconnect the instrument cluster connector (24pin).
Yes

INSTALLATION.)
No

Disconnect the immobilizer unit connector
Yes

Repair or replace the wiring harness for short to GND
between the immobilizer unit connector terminal M and
the instrument cluster terminal1J.

Ground instrument cluster terminal1J using a
jumper wire.
Disconnect the immobilizer unit connector
Ground immobilizer unit connector terminal M
using a jumper wire.
Yes
ACTION

Do other warning lights in the instrument cluster
illuminate normally?
09-03C-2
No
No
Yes
No

INSTALLATION.)
Replace the immobilizer unit.
(See 09-14-22 IMMOBILIZER UNIT REMOVAU
INSTALLATION. )
Repair or replace the wiring harness for short to GND
between the immobilizer unit connector terminal M and
the instrument cluster terminal1J.
SYMPTOM TROUBLESHOOTING [AUDIO]
09-030 SYMPTOM TROUBLESHOOTING [AUDIO]

FOREWORD
[ENTIRE AUDIO SySTEM] ........ 09-030-1
CONFIRMATION STEP 1:
AUDIO PANEL SWITCH
CONFIRMATION ............ 09-030-3
NO.1 AF NOISE OR POP NOISE ON
ALL SOURCES (RADIO, CD) ...... 09-030-3
NO.2 NO POWER ON THE ENTIRE
AUDIO SYSTEM ........... 09-030-4
NO.3 NO SOUND FROM ALL THE
SPEAKERS ........... 09-030-5
NO.4 NO SOUND FROM SOME
SPEAKERS ............. 09-030-6
NO.5 BROKEN SOUND OR POOR
SOUND QUALITY ....... 09-030-7
NO.6 SOUND BECOMES LOUDLY OR
WEAKLY WHILE DRIVING THE
VEHICLE .................. 09-030-7
NO.7 ALC FUNCTION IS
INOPERATIVE .............. 09-030-8
NO.8 AUDIO SYSTEM ILLUMINATION
DOES NOT ILLUMINATE AT ALL. .... 09-030-8
NO.9 LCD DOES NOT DISPLAY
AT ALL ................... 09-030-9
FOREWORD [RADIO] .......... 09-030-9
CONFIRMATION STEP 1: RECEPTION
CONDITION SYMPTOM
(EXAMPLE) ................ 09-030-10
CONFIRMATION STEP 2: ANTENNA
SYSTEM SYMPTOM (EXAMPLE) ... 09-030-11
SYSTEM SIMPLE INSPECTION ..... 09-030-11
NO.1 NO RADIO RECEPTION
(AM/FM)/NO OR LOW VOLUME ..... 09-030-11
NO.2 NOISE FROM RADIO
(AM ONLY) .............. 09-030-13
NO.3 NOISE FROM RADIO

(FM ONLY) .................. 09-030-14
NO.4 CANNOT TUNE
(SEEK DOES NOT STOP) ......... 09-030-16
NO.5 CANNOT PRESET
(PRESET FUNCTION DOES NOT
OPERATE) ................. 09-030-16
NO.6 RECEPTION FREQUENCY OF
RADIO SLIPS .............. 09-030-17
FOREWORD
[CD PLAYER/CHANGER] ......... 09-030-17
NO.1 CD PLAYER/CHANGER
DOES NOT LOAD THE CD OR
EJECTS THE CD IMMEDIATELy ...... 09-030-19
DOES NOT EJECT THE CO ........ 09-030-19
DOES NOT PLAY THE
CD/NO SOUND ................ 09-030-20
NO.4 SOUND JUMPS ........... 09-030-20
SCRATCHES ON THE CD ........... 09-030-21
NO.6 DISC CHANGER IS
INOPERATIVE ................ 09-030-21
NO.7 CD PLAYER DOES NOT PLAY
THE MP3-FORMATTEO FILE ...... 09-030-22
NO.8 MP3-FORMATTEO FILE FOLDER
SELECTION IS INOPERATIVEITRACK
SEARCH IS INOPERATIVE ..... 09-030-23
NO.9 CD PLAYER DOES NOT
INDICATE THE MP3 TITLE TEXT ..... 09-030-24
THE AUDIO DATA (CODA) .......... 09-030-24
NO.11 TRACK CHANGE IS
INOPERATIVE ............... 09-030-25
RADIO [REFERENCE] ............ 09-030-25
AUDIO CD [REFERENCE] ..... 09-030-27
FOREWORD [ENTIRE AUDIO SYSTEM]
dcf09036690Ow01
Note
Record all radio programs set by customer prior to the repairs. Set all radio programs and adjust the time
after repairs.
Symptom
No.
Possible DTC
09:Er20, 09:Er21
1
2
AF noise or POP noise on all sources (Radio, CD)
No sound from all the speakers
4
5
6
No sound from some speakers
7
8
ALC function is inoperative

Audio system illumination does not illuminate at all
09:Er20, 21 :Er19
LCD does not display at all
09:Er20, 21 :Er19
No power on the entire audio system
Broken sound or poor sound quality

Sound becomes loudly or weakly while driving the vehicle
09:Er20
OO:Er10, 03:Er07, 03:Er10, 09:Er20,
09:Er21
-
09:Er21
09-030-1

Quick Diagnostic Chart (Entire Audio System)
X: Applicable
1
Q)
C3
:.c
5'
()
:5
6
'6
c
.s;:
~
::>
0
C/)
Cti
c
0
Possible factor
Q)
C/)
0
c
0...
0...
0
Q)
C/)
0
C
u..
Low vehicle battery voltage
Jammed radio signals from after market equipment
Speaker malfunction (e. g., any foreign material, broken)
Improper speaker installation
Poor connection of audio unit connector, terminal damage
Antenna malfunction (e.g., poor ground)
Cti
::>
'6
~t1l
t1l
a.
C/)
::>
Q)
E
Q)
Q)
C/)
Q)
:5
'ijj
Ci1
a;
>-
-0
Q)
::>
c
0
C/)
00
a.
-0
::>
>'5
::>
.2
C/)
Q)
E
0
()
Q)
::>
0
::>
a.
C/)
C/)
.::
::>
co
(J)
C/)
Q)
(5
:;2
t1l
.c
"0
C
C/)
Q)
Q)
>
~Q)
a.
0
.!:
.!!2
c
0
t5c
.2
()
....J
0
"0
c
0
~
c
Burnt fuse (ACC)
Open or short circuit in power supply (B+) wiring harness
Open or short circuit in power supply (ACC) wiring harness
1il
~
i5..
(5
*
>-
C/)
C/)
=a
c
C/)
Q)
-0
::>
()
....J
'6
X
X
X
X
Open circuit in wiring harness between audio unit and speaker
CAN signal wiring harness malfunction
Open or short circuit in vehicle speed signal wiring harness (e.g., instrument cluster)
Burnt fuse (TNS signal)
Open or short circuit in TNS signal wiring harness
Center panel malfunction
Information display malfunction
Cti
X
X
Short circuit inside speaker
,g
0-
-0
:.c
"0
Burnt fuse (B+)
Vibration of door trim and/or package trim
.!!1
E
Q)
1ii
>C/)
Audio unit malfunction
Short circuit in wiring harness between audio unit and speaker
Q)
Ci1
fS
C/)
Ci1
Cl
t1l
Q)
Cti
Q)
X
DBG903AWBS01
09-030-2

CONFIRMATION STEP 1: AUDIO PANEL SWITCH CONFIRMATION
dcf090366900w02
Make sure the customer complain and identify either the center panel malfunction or audio unit malfunction.
How to activate audio panel switch confirmation mode

1. Turn the audio system to ON.
2. Press both POWER SW and CLOCK buttons for a second at the same time.
3. The audio panel switch confirmation mode is now activated.
STEP
1
INSPECTION
Press each button on the center panel.
Does buzzer sound when pressing each
button?
Disassemble and reassemble the center

. panel and audio unit.
Activate the audio panel switch confirmation
mode.
Does buzzer sound when pressing each
button?
Does the audio system operate properly?
Yes
No
Yes
No
Yes
No
ACTION
Make sure the customer complain and then go to the
appropriate symptom troubleshooting procedure.
Replace the center panel.
The system is normal.

Make sure the customer complain and then go to the
appropriate symptom troubleshooting procedure.
NO.1 AF NOISE OR POP NOISE ON ALL SOURCES (RADIO, CD)
dcf090366900w03
IAF noise or POP noise on all sources (Radio, CD)/Possible DTC: 09:Er20, 09:Er21
Troubleshooting hints
Low vehicle battery voltage

Jammed radio signals from after market equipment
Speaker malfunction (e.g., any foreign material, broken)
Antenna malfunction (e.g., poor ground)
Note
AF noise is "Petit Petit" noise that generally occurs with switch ON/OFF operations of electrical equipment other than
the audio unit, or "Gee" continual noise that occurs when electrical equipment is operated.This is caused by noise
entrance to the power supply wiring, signal wiring, speaker cable or head of cassette deck etc. Therefore noise can be
heard regardless of radio wave condition or audio volume position. The noise will start after one click from the minimum
position of volume button but normally does not change even when volume is turned to higher position.
POP noise is "Putsun", "Poco" or "Putsun" noise that occurs with switch ON/OFF operation of the audio unit, or with
switching Radio to CD. Even normal audio unit sometimes emit small noise depending on conditions.
STEP
INSPECTION
Inspect the vehicle battery voltage.

Is the vehicle battery voltage normal?
Specification:
ACTION
Yes
No

Charge the battery, then go to the next step.

The system is normal. Explain to the customer that the
vehicle battery voltage was low.
Go to the Step 5.
Ignition switch ON: 11.5 V or more

Idle: 12.5 V or more
Turn the audio system to ON.

Is there any noise?
Yes
No
Yes
No
Remove the after-market equipment.

Turn the audio system to ON.
Is there any noise?
Is any of the following after-market

equipment installed? (Inspect especially near
the antenna.)
-Radar
- Remote engine starter
- Anti-theft device
-Other
Yes
No

The system is normal. The after-market electrical devices
might make a noise.
09-030-3

INSPECTION
STEP
5
6
Is there the noise from all speakers?
ACTION
Go to the Step 7.
Yes
No
Inspect the suspect speaker.

Is the speaker normal?
Yes
No
If there is any foreign material on the speaker:

Remove the foreign material from the speaker.
If the speaker is malfunctioning:
Replace the speaker.
If the speaker is not installed properly:
Install the speaker properly.
Attempt to duplicate the symptom on the

other vehicle.
Is the noise better than the customer's
vehicle?
Yes
No
The system is normal. Explain the noise generation

mechanism to the customer.
Note
The noise may be heard depends on the operating
speed of audio power and/or mode switch.
Yes
No

Remove the audio unit.
Inspect the connection of the audio unit
connector (24-pin) (for sound signal line).
Is the connector connected securely?
Is there any noise?
Yes
10
Inspect the ground condition of the antenna.

Is the ground condition normal?
11
Is there any noise?
No
Yes
No
Yes
No

If poor connection of audio unit connector:
Securely connect the audio unit connector.
If the audio unit side connector is wrong:
Replace the audio unit.
If the wiring harness-side connector is wrong:
Repair or replace the pins and/or the connector.
After treating either the above-mentioned, then go to the
next step.
Repair or replace the ground. Go to the next step.
NO.2 NO POWER ON THE ENTIRE AUDIO SYSTEM
dcf090366900w04
INo power on the entire audio system/Possible OTC: 09:Er20
Burnt fuse (B+)
Burnt fuse (ACC)
Open or short circuit in power supply (B+) wiring harness
Open or short circuit in power supply (ACC) wiring harness
INSPECTION
STEP
1
Inspect the following fuses:
-RADIO
-ROOM
Are the fuse normal?
2

connector (24-pin).
Disconnect the audio unit connector and
inspect both the audio unit and wiring
harness-side connectors for poor
connection. (such as damaged/pulled-out
pins, corrosion).
- Terminal B (B+)
- Terminal R (ACC)
- Terminal W GND)
Are all the pins normal?
09-030-4
ACTION
Yes
No

Replace with the appropriate standard fuse.
If the fuse is melted, inspect the wiring harness for short
to ground. Repair or replace the wiring harness, then
replace the fuse.
Yes
No


STEP
INSPECTION
Connect
the
audio
unit connector.
Inspect the voltage for the power supply line

(8+, ACC).
Specification:
Ignition switch ON: 11.5 V or more
Idle: 12.5 V or more
Is the voltage normal?
Remove the audio unit connector (24-pin).
Inspect the continuity between the audio unit
wiring harness-side connector terminal W
and the ground.
Is there the continuity?
Yes
No
ACTION
Repair or replace the suspect wiring harness.
Yes
No

Repair or replace the wiring harness.
NO.3 NO SOUND FROM ALL THE SPEAKERS

3
dcf09036690Ow05
INo sound from all the speakers/Possible DTC: OO:Er10, 03:Er07, 03:Er10, 09:Er20, 09:Er21
Short circuit in wiring harness between audio unit and speaker
STEP
INSPECTION
Press AUDIO CaNT button more than 1
second.
Play the CD or Radio.
Adjust the volume between "10" to "15".
Is there the sound?
2
Disconnect the audio connector (24-pin).
wiring harness-side connector terminal and
ground:
For front speaker
- Terminal A (L+) - GND
- Terminal C (L-) - GND
- Terminal D (R+) - GND
- Terminal F (R-) - GND
For rear speaker
- Terminal S (L+) - GND
- Terminal U (L-) - GND
- Terminal V (R+) - GND
- Terminal X (R-) - GND
- Is there a continuity?
Remove the speaker.

Disconnect the speaker connector (2-pin).
Inspect the continuity between the speaker
wiring harness-side connector (2-pin)
terminal and ground:
For each speaker
- Terminal A - GND
- Terminal 8 - GND
ACTION
Yes
No

Yes
Repair or replace the suspect wiring harness or speaker

unit.
No
Note
If there is a short circuit between the speaker harness
or speaker lead wire and ground, the protector circuit
inside the audio unit operates to cut the sound.
Yes
No

09-030-5

NO.4 NO SOUND FROM SOME SPEAKERS
dcf090366900w06
INo sound from some speakers/Possible OTC: -
Open or short circuit in wiring harness between audio unit and speaker
INSPECTION
STEP
Turn
the
audio
unit
to ON.
1
Press AUDIO CO NT button more than one

second (BAUFAD cancel mode).
Press both POWER and AUTO-M buttons
more than 1 second at the same time.
No
Note
ACTION
Yes
If no sound from some speaker:

If no sound at all:
Go to the troubleshooting of "No.3 No sound from all
speakers".
The troubleshooting is completed.
The sounded speaker now changes in

the order of left - front speaker, right
- front speaker, right - rear speaker
and left - rear speaker.
Is there any speaker with no sound?

Disconnect the audio unit connector (24-pin).
wiring harness-side connector (24-pin)
terminal and ground.
Yes
No
Repair or replace the suspect wiring harness or speaker

unit.
Note
If there is a short circuit between the speaker harness
or speaker lead wire and ground, the protector circuit
inside the audio unit operates to cut the sound.
Remove the suspect speaker.

Disconnect the speaker connector (2-pin)
and inspect the resistance of speaker.
Is the resistance normal?
Specification
Speaker resistance + wiring harness
resistance
Yes
Yes
No
Inspect the wiring harness between the

audio unit and the suspect speaker.
Inspect the suspect speaker.
Is the speaker normal?
Yes

Go to the next step.,
Note
If the speaker lead wire contacts to either
ground or vehicle frame, replace the
speaker.
09-030-6
No
No

Repair or replace the suspect wiring harness.

NO.5 BROKEN SOUND OR POOR SOUND QUALITY
dcf090366900w07
IBroken sound or poor sound quality/Possible DTC: 09:Er21

Vibration of door trim and/or package trim
INSPECTION
STEP
ACTION
Are there a broken sound or poor sound

quality from all speakers?
Yes
No
Inspect the sound while adjusting the sound

volume.
Is there a broken sound or poor sound
quality between "15" and "20"?
Yes
No
Inspect the BASSITREB.

Is there a poor sound quality at "-3 "BASSITREB"?
Yes
No

If there is a broken sound at "+6- -6" of BASSITREB with
the maximum volume, the system is normal.
+3" of
Note
When press the AUDIO CONT button for
a few seconds, BASSITREB is set at "0".
Attempt to duplicate the symptom on the
other vehicle.
Is the sound better than the customer's
vehicle?
Identify the speaker with a broken sound by
adjusting BAUFADE.
Is the suspect speaker installed upward?

Go to the Step 5.
6
7
Inspect the speaker installation condition.

Is the speaker installed properly?
Remove the speaker.
Is there any foreign material or damage on
the speaker?
Inspect the sound again.
Is there broken sound?
Replace with the speaker known to be good.

(e.g., swap right and left speakers)
Does the broken sound appear at the same
location?
Yes
No
Yes
No
Go to the Step 7.
Yes
No
Yes

Install the speaker properly.
No
Repair or replace the suspect speaker.

Yes
No
Yes
No

Inspect the vibration from the door trim and/or package trim.
Repair or replace the suspect trim as necessary.
NO.6 SOUND BECOMES LOUDLY OR WEAKLY WHILE DRIVING THE VEHICLE

6
dcf090366900w08
Sound becomes loudly or weakly while driving the vehicle/Possible DTC: -
Note
Inspect the ALC function while driving the vehicle with playing the CD, etc.
STEP
INSPECTION
Does the ALC function turn to ON?
Turn the ALC fur,ction to OFF.

Does the sound change while driving the
vehicle?
ACTION
Yes
No
Yes

No
The system is normal. Explains the ALC function to the

customer.
09-030-7

NO.7 ALC FUNCTION IS INOPERATIVE
dcf090366900w09
7
I ALC function is inoperative/Possible OTC: Troubleshooting hints
CAN signal wiring harness malfunction
Open or short circuit in vehicle speed signal wiring harness (e. g., instrument cluster)
Note
Inspect the ALC function while driving the vehicle with playing the CD, etc.
STEP
INSPECTION
1
Turn the ALC function to ON.
Inspect the ALC function operation when

driving the vehicle.
Does the ALC system operate properly?
Retrieve the DTCs from all vehicle modules
using the WDS or equivalent.
Is there the following DTC displayed?
- Vehicle speed signal wiring harness
- CAN signal wiring harness
ACTION
Yes
No
The system is normal. Explains the ALC function to the

customer.
Yes
No
Go to the appropriate DTC inspection.

NO.8 AUDIO SYSTEM ILLUMINATION DOES NOT ILLUMINATE AT ALL
dcf090366900w10
8
Audio system illumination does not illuminate at alVPossible OTC: 09:Er20, 21 :Er19

Burnt fuse (TNS signal)
Open or short circuit in TNS signal wiring harness
STEP
INSPECTION
ACTION
Are all illumination on the audio unit turned

OFF?
Yes
No
Yes
No

Inspect the fuse (ILLUMI).
Is the fuse normal?
Disconnect the audio unit connector (24-pin)
and inspect the continuity between the audio
unit wiring harness-side connector terminal E
(TNS) and the ground.
Yes

connector (24-pin).
Inspect both the audio unit and wiring
harness-side conne9tor terminal E for poor
connection (such as damaged/pulled-out
pins, corrosion).
Are all the pins normal?
Yes
No
Connect the audio unit connector (24-pin).

Turn the ignition switch to the ACC position.
Inspect the voltage at the audio unit
connector terminal E (TNS).
Is the voltage B+ when the light switch is
turned to the TNS position?
Yes
No
Repair or replace the suspect wiring harness (TNS signal).
,.
09-030-8
No

Replace the center panel.
Go to the Step 4.
Repair or replace the short circuit in the suspect wiring
harness. After repair the harness, replace with the
appropriate standard fuse.


NO.9 LCD DOES NOT DISPLAY AT ALL
dcf090366900w11
ILCD does not display at all/Possible DTC: 09:Er20, 21 :Er19
Information display malfunction
INSPECTION
STEP
1
ACTION
Turn the audio unit to ON.

Press both POWER ON/OFF and SEEK UP
buttons for 0.2 seconds at the same time.
Does the LCD display properly?
Yes
No
Replace the information display.
Press either CLC or SET/INFO button on the

information display.
Does the beep sound?
Yes
No

Replace both audio unit and information display.
(CAN communication malfunction)
FOREWORD [RADIO]
dcf090366900w12
Note
In case location, time, and broadcasting station etc. can be specified through interview to customer,
possibility that signal environment causes problem is high.
Perform confirmation of symptom and evaluation under conditions that customer reported (location, time,
broadcasting station etc.). If not possible, perform it under equivalent conditions.
Before inspection or repair, record the broadcasting stations that customer preset and reset them
accordingly after the inspection or repair. Adjust the clock too.
No.
1
2
Symptom
No radio reception (AM/FM)/No or low volume
Noise from radio (AM only)
Noise from radio (FM only)
Cannot tune (SEEK does not stop)

Cannot preset (preset function does not operate)
Reception frequency of radio slips
Possible DTC
09:Er20, 09:Er22
09:Er22
09:Er22
09:Er20, 09:Er22
21 :Er19
09:Er22
09-030-9

Quick Diagnostic Chart (Radio)
X: Applicable
1
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Antenna plug poor connection
Antenna feeder
Electronic jamming from outside, or inferior condition of broadcasting station radio wave
Antenna rod not installed
Antenna installation loosened
X
X
Center panel
tll
()
c
c
Battery
li
Ol
Charging system
0..
0-
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'0
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Audio unit
Noise from electrical system on vehicle (e.g. fuel pump)
t5c
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Jamming from aftermarket electronic equipment (two-way radio, navigation system, mobile phone, etc)
S,
0
Z
Ol
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X
DPE903EW1003
CONFIRMATION STEP 1: RECEPTION CONDITION SYMPTOM (EXAMPLE)

Symptom
Only a buzzing sound from
the speakers
A buzzing or crunching sound

and normal sound produced
at the same time from the
speakers
A thumping sound and normal

sound produced at the same
time from the speakers (FM
only)
09-030-10
Antenna signal condition

There is no broadcasting wave.
Signals from antenna to audio unit are not
transmitted.
Though signals are transmitted from
antenna to audio unit, electric noise from
other sources is larger.
Noise occurs due to radio wave

environment at specific places (e.g. in
valleys between buildings). Noise varies
when own vehicle or surrounding vehicles
moves. (FM only)
dcf09036690Ow13
Source
Electric noise caused by the operation of
internal circuit from audio unit itself
Atmosphere noise
Electrical noise caused by operation of
electrical component on vehicle
Electrical noise from high tension wire,
transformer substation (factory), electrical
feeder line (street car), or motorcycle.
Interference between direct and reflected
waves of FM signals causes noise
(Multipass noise).

CONFIRMATION STEP 2: ANTENNA SYSTEM SYMPTOM (EXAMPLE)
Possible cause
Antenna feeder axis, open circuit
Antenna feeder plug not attached
AM reception condition
NG: No reception
Antenna feeder axis (+) to ground (-), open circuit

Antenna feeder and antenna, poor ground
NG: No reception
YES: Reception possible
(Noise may occur)
Antenna feeder, jack and plug poor connection
NG: No reception
(Depending on connection
conditions)
CONFIRMATION STEP 3: ANTENNA SYSTEM SIMPLE INSPECTION
dcf09036690OW14
FM reception condition
YES: Reception possible.
(Sensitivity decreases, but reception is
possible under strong electric field.)
NG: No reception
(Sensitivity decreases, but reception is
possible under strong electric field.)
(Depending on connection conditions)
dcf090366900w15
Note
Because the antenna system is equipped with a capacitor, the continuity cannot be checked. Therefore
proceed the following simple inspection.
1. Turn the AM radio on.
2. Tune to the frequency that there is no broadcast and you will hear a buzzing sound.
3. Turn a work light on and shake it around the antenna rod (around 10-20 mm)
4. If a whirring sound from the speaker synchronized to the work light movement is confirmed, the
antenna system is normal.
Note
Use a fluorescent light type for the
inspection. Accurate diagnostic cannot be
done with an incandescent light.
CPJ902EWB011
NO.1 NO RADIO RECEPTION (AM/FM)/NO OR LOW VOLUME

1
POSSIBLE
CAUSE
dcf090366900w16
No radio reception (AM/FM)/no or low volume/Possible DTC: 09:Er20, 09:Er22

Jamming from aftermarket electronic equipment (two-way radio, navigation system, mobile phone, etc.)
Antenna feeder malfunction
Antenna rod is not installed
STEP
INSPECTION
Turn the audio unit ON.
Is the LCD indicated correctly?
Measure voltage at B+ and ACe terminals.
Is voltage okay?
Specification
Yes
No
Yes
No
With ignition switch ON: 11.5 V or more

At idling: 12.5 V or more
Set volume to 10 to 15.

Is buzzing sound or voice confirmed?
Yes
No
ACTION
Go to the Step 3.
Follow diagnostic procedure for symptom No.2 (Entire
audio system).
Follow diagnostic procedure for symptom NO.3 (Entire
audio system) or NO.4 (Entire audio system).
09-030-11

INSPECTION
STEP
4
ACTION
Tune to local broadcasting station and check

reception condition.
Is reception okay?
Push PRESET buttons and check preset
conditions.
Has preset been stored?
Yes
No
Go to the Step 6.
Yes

Preset broadcasting stations.
Is aftermarket electronic equipment (two-way

radio, navigation system, mobile phone, etc.)
installed?
Yes
No
Note
TV antenna located closely to audio
antenna can be cause of noise. Relocate
TV antenna.
Remove aftermarket electronic equipment.
Turn audio unit ON and check reception
condition.
Is reception improved?
No

Go to the Step 8.
10
11
Refer to confirmation step 3, and inspect

antenna system.
Is a whirring sound present?
Inspect antenna plug connection condition.
Is connection okay?
Measure continuity between antenna feeder
axis and ground.
Compare reception with other audio unit on
same model (model/unit) under same
problem conditions.
Is reception equivalent between customer's
unit and compared unit?
Note
Due to following differences, you may feel
difference in reception efficiency.
(Vehicle side factor)
Antenna installation location, height,

feeder wiring routing, optional electrical
equipment
(Audio unit factor)

-
Volume concern type: It decreases

change of volume when signals
become weak. (Noise is easy to be
conspicuous)
Noise decrease type: It decreases
volume when signals become weak, so
that noise is not conspicuous.
09-030-12
Yes

(Explain to customers that aftermarket electronic equipment
is cause of noise)
No
Yes
No
Yes
Replace audio unit.

Insert antenna plug securely.
No
Yes
Replace antenna feeder.
No
Yes

(It is caused by electronic jamming from outside, or inferior
broadcasting station signal condition.)
No
Replace audio unit.

NO.2 NOISE FROM RADIO (AM ONLY)
2
dcf090366900w17
Noise from radio (am only)/Possible OTC: 09:Er22
POSSIBLE
CAUSE

Battery malfunction
STEP
1
INSPECTION
Tune to local broadcasting station and check

Is reception okay?
Inspect antenna rod condition.
Is antenna rod installed?
installed?
Yes
ACTION
Tune to correct frequency of broadcasting station.
If not preset, preset it.
No
Yes
No

Advise customer to install antenna rod when radio is used.
Yes
No
Go to the Step 5.
Yes
The system is normal. (Explain to customers that

aftermarket electronic equipment is cause of noise)
Note
TV antenna located closely to audio
antenna can be cause of noise. Relocate
TV antenna.

condition.
Measure battery voltage.
Is battery voltage okay?
Standard
No
Yes
No

Charge battery. Inspect charging system, and repair or
replace if necessary.
Yes
No

Go to the Step 8.
Yes
No


Note
Inspect that battery cables are connected
to terminals securely.
Is noise occurring only when vehicle

electrical system (e.g. fuel pump) operates?
Note
Identify subject electrical component by
disconnecting fuse, turning switch ON &
OFF, or disconnecting & connecting
connector.
It will be easy when simulation function on
WDS is used.
Inspect power supply, ground condition, and

noise prevention capacitor for electrical
component.
Is noise present after inspection?
Note
Inspect following:
- Power supply to electrical component
for voltage drop (compare with battery
voltage)
- Resistance between ground of
electrical component and body.
(Should be close to 0 ohm)
- Installation condition of noise
prevention capacitor for fuel pump etc.
Note
The audio unit supplies 12 V battery power to the
antenna amplifier for the AM radio reception in the
radio mode. The audio unit cannot receive the AM
signals without the 12 V battery power to the antenna
amplifier. If the AM signals become strong, the audio
unit may receive the signal with noises.
09-030-13

STEP
INSPECTION
Is connection okay?

axis and ground.
same model (model/unit) under same problem
conditions.
10
Note
Due to following differences, you may feel
difference in reception efficiency.
(Vehicle side factor)
- Antenna installation location, height,
feeder wiring routing, optional electrical
equipment
(Audio unit factor)
- Volume concern type: It decreases
change of volume when signals
become weak. (Noise is easy to be
conspicuous)
- Noise decrease type: It decreases
volume when signals become weak, so
that noise is not conspicuous.
Retighten ground fixation for antenna
installation part and antenna amplifier.
Retighten antenna rod.
Is noise present, after retightening?
Yes
No
Yes
No
ACTION
No
The system is normal (It is caused by electronic jamming

from outside, or inferior broadcasting station signal
condition).
Yes
No
Replace audio unit.

Yes
11
NO.3 NOISE FROM RADIO (FM ONLY)
dcf090366900w18
Noise from radio (FM only)/Possible OTC: 09:Er22
POSSIBLE
CAUSE

Battery malfllnction
Note
FM broadcast has feature "sound quality is good" and "resistant to noise", but FM broadcast has
particular noises. Though audio unit is designed to reduce noise, there are times noise occurs due to
conditions.
INSPECTION
STEP
Tune
to
local
broadcasting
station and check
1
Is reception okay?
Inspect antenna rod condition.

Is antenna rod installed?
installed?
09-030-14
Yes
No
Yes
No
Yes
No
ACTION
Tune to correct frequency of broadcasting station.
If not preset, preset it.
Advise customer to install antenna rod when radio is used.
Go to the Step 5.

STEP
4
INSPECTION

condition.
Yes
ACTION
The system is normal. (Explain to customers that
aftermarket electronic equipment is cause of noise)
No
Measure battery voltage.

Is battery voltage okay?
Yes
No
Charge battery. Inspect charging system, and repair or

replace if necessary.
Yes
No
Yes
No

Yes
No
Yes

No
Yes
The system is normal (It is caused by electronic jamming

from outside, or inferior broadcasting station signal
condition).
Standard

Note
Inspect that battery cables are connected
to terminals securely.
Is noise occurring only when vehicle
electrical system (e.g. fuel pump) operates?
Note
Identify subject electrical component by
disconnecting fuse, turning switch ON &
OFF, or disconnecting & connecting
connector.
It will be easy when simulation function on
WDS is used.
Inspect power supply, ground condition, and
noise prevention capacitor for electrical
component.
Is noise present after inspection?
Go to the Step B.
Note
Inspect following:
- Power supply to electrical component
for voltage drop (compare with battery
voltage)
- Resistance between ground of
electrical component and body.
(Should be close to 0 ohm)
- Installation condition of noise
prevention capacitor for fuel pump etc.
B
9
10
11

Is connection okay?
axis and ground.
problem conditions.
Retighten ground fixation for antenna
installation part and antenna amplifier.
Retighten antenna rod.
Is noise present, after retightening?
Note
When antenna is not grounded perfectly,
FM particular noise is likely to be
conspicuous.
No
Yes
Replace audio unit.
No
II
09-030-15

NO.4 CANNOT TUNE (SEEK DOES NOT STOP)
4
POSSIBLE
CAUSE
dcf090366900w19
Cannot tune (seek does not stop)/Possible DTC: 09:Er20, 09:Er22

STEP
1
Perform confirmation step 1: audio panel switch

confirmation. Replace center panel if necessary.
Yes
No

Is connection okay?
Yes

axis and ground.
Check if number of broadcasting stations
changes depending on time and place.
Does it change?
No
Yes
No

Yes
The system is normal. (Explain to customer that SEEK

sometimes does not stop depending on signal reception
condition.)
No
Manually tune to local broadcasting station

and check reception condition.
Is reception okay?
Yes
ACTION
Yes
Inspect indication of LCD.

Is frequency indication increased or
decreased when SEEK button is pushed?
INSPECTION
Inspect if feel of SEEK button is normal when
button is pushed and released.
Is it okay?
No
Perform confirmation step 1: audio panel switch

confirmation. Replace center panel if necessary.
Go to the Step 6.
Note
Signals tend to reach longer distances in the night. It
is conspicuous in AM signals, several audio functions
may stop due to foreign broadcasting station or noise.
Though the audio system restrains sensitivity of
SEEK and SCAN functions in the night, the audio
system may select other than desired broadcasting
station when signals are considerably strong.This
function is linked to the parking light. When the
parking light or headlight is turned on, SEEK and
SCAN may not function for weak signals.
No
Replace audio unit.
NO.5 CANNOT PRESET (PRESET FUNCTION DOES NOT OPERATE)
dcf090366900w20
Cannot preset (preset function does not operate)/Possible DTC: 21 :Er19
5
POSSIBLE
CAUSE

STEP
1
INSPECTION
ACTION
Tune to desired station and push channel

preset button 1 for about 2 seconds to store
it.
Repeat above for other stations using
channel preset buttons 2 to 5.
Push channel preset butto., 1 to 6 one by
one.
/l.re stored stations present?
Yes
No
Go to the Step 3.
Turn ignition switch to LOCK and then to

ACC.
Check if preset stations are stored by
pushing preset buttons.
Are stations stored?
Yes
The system is normal. (Explain preset procedure to

customer using Owner's Manual)
No
Replace audio unit.
09-030-16

STEP
INSPECTION
Remove center panel from audio unit, and
reinstall center panel to audio unit.
Turn audio power switch ON.
Push POWER SW button and MEDIA button
at same time for approximately 1 second to
enter system to switch check mode.
Push all buttons and check if buzzer sounds.
Is all buttons okay?
ACTION
Yes
No
Replace audio unit.

Replace center panel.
NO.6 RECEPTION FREQUENCY OF RADIO SLIPS

6
dcf09036690OW21
Reception frequency of radio slip/Possible DTC: 09:Er22
POSSIBLE
CAUSE

STEP
INSPECTION
Push SEEK button and check if desired
broadcasting station is tuned.
Is it okay?
Check if other broadcasting station is

received at certain place when indication of
reception frequency stays.
Is other station received?
ACTION
Yes
No
Go to the Step 3.
Yes
No

Replace audio unit.
Yes
No
Troubleshooting completed (Audio unit is normal).

Replace audio unit.
Note
When you receive weak signal from one
broadcasting station and come close to
broadcasting antenna which emits strong
signal, broadcasting with strong signal is
sometimes received.

problem conditions.
FOREWORD [CD PLAYER/CHANGER]
dcf090366900w22
No.
Items
CD player/changer
Symptom
CD player/changer does not load the CD or ejects the
CD immediately
03:Er01, 03:Er1 0
CD player/changer does not eject the CD
03:Er01
CD player/changer does not play the CD/No sound

Sound jumps
03:Er07, 03:Er10
03:Er02
CD player/changer scratches on the CD

Disc changer is inoperative
03:Er02
CD player does not play the MP3-formatted file
10:Er09, 22:Er09
MP3-formatted file folder selection is inoperativelTrack

search is inoperative
10:Er09,22:Er09
4
5
6
7
8
CD changer
MP3 applicable
CD player
CD player does not indicate the MP3 title text
10
CD player does not play the audio data (CODA)
11
CD player/changer
Track change is inoperative
Possible DTC
03:Er02
09-030-17

X: Applicable
0;
Cl
0;
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CD player/changer
c:
co
.s::
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>:::
MP3 applicable
CD player
C.
0
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co
C.
Troubleshooting Item
tl0>
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0
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Defective CD (egg., cracked, badly bent, rough edges, scratch, dirty CD, condensation)
Non-conventional discs (e.g., 8 cm (3 in) CD, 8 cm (3 in) disc adapter,

heart-shaped disc, octagonal disc)
Poor connection of audio unit connector or terminal (e.g., damaged, bent, pUll-out pin, corrosion)
Improper center panel installation
Improper CD cover installation
co
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.S
C.
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X
X
X
X
X
X
X
MP3 and other format data are in the CD-R/RW
File extension for MP3-formatted file is incorrect (Correct: ".mp3", Incorrect: e.g., RIFF)
Defective CD-R/RW (e.g., dirty, scratch)
X
X
CD-R/RW (MP3 files are all written to RIFF format)
Conflict of 10 tag version for CD-R/RW
Improper folder and/or music title in CD-R/RW
The number of characters of folder/music file name in CD-R/RW exceeds

the maximum number of characters
Improper encode in CD-R/RW
Data other than the audio data is in CD-R/RW
:0
0>
CD-R/RW written format is out of specification
Input title text by 2-bytes characters
co
'0
Inadequate tire pressure
No title input in CD-R/RW
.l!l
Improper audio unit installation (e.g., rattle, loose)
MP3 applicable CD player is malfunctioning
~
~
Il..
11
0>
:2.
10
~0>
E iii
0>
.E VJ
co
C.
Center panel is malfunctioning
0>
0>
0
VJ
0;
CD is inserted upside down
Multiple CDs are inserted into the CD player at the same time
0..
:2
~ ~ c.iU'
0>
c- o
0; 0
c:
VJ
Audio unit is malfunctioning
Deformed disc is used (e.g., out of specification (thickness), bent disc)
'"
0>
0>
>:::
c:
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ffiE
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0>
co
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B
X
X
X
EPU903EW3002
09-03D-18

NO.1 CD PLAYER/CHANGER DOES NOT LOAD THE CD OR EJECTS THE CD IMMEDIATELY
1
dcf09036690Ow23
ICD player/changer does not load the CD or ejects the CD immediately

Possible DTC: 03:Er01, 03:Er10
Audio units is malfunctioning
Defective CD (e.g., cracked, badly bent, rough edges, scratch, dirty CD, condensation)
Non-conventional discs (e.g., 8 cm (3 in) CD, 8 cm (3 in) disc adapter, heart-shaped disc, octagonal disc)
Poor connection of audio unit connector or terminal (e.g., damaged, bent, pulled-out pin, corrosion)
STEP
INSPECTION
1
Is CD inserted properly, label-side up?
Replace with a CD known to be good.

Does the CD player/changer load the CD?
Visually inspect the CD.

- Is there any dirt, scratch or deformation on
the CD?
- Is the CD a non-conventional disc?
connector (24-pin).
Inspect both audio unit connector and wiring
harness-side connector for poor connection.
(such as damaged/bentlpulled-out pins,
corrosion)
All the pins and connector normal?
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
Explain to the customer that CD should be inserted into the
slot, label-side up.
Explain to the customer that the defective CD or nonconventional disc cannot be use.
If the audio unit connector/pin is wrong:
If the wiring harness-side connector/pin is wrong:
NO.2 CD PLAYER/CHANGER DOES NOT EJECT THE CD

2
dcf090366900w24
ICD player/changer does not eject the CD

Possible DTC: 03:Er01
Poor connection of audio unit connector or terminal (e.g., damaged, bent, pulled-out pin, corrosion)
Improper CD cover installation
Note
The CD may be malfunctioning if the CD player/changer does not eject the certain CD only. Inspect the CD player/
changer operation using the CD known to be good.
STEP
INSPECTION
ACTION
Inspect the operation of the audio system
Yes Go to Step 3.
other than CD player/changer (e.g. Radio).
Does other audio system operate?
2
Turn the ignition switch to the LOCK position. Yes Go to the next step.
I-::N
"7"o-l-:I:-:-f--:th=-e-a-u-d:-:-io-u-n-:i'-t-c-o-n-n-e-c-to-r-:/p-in-is-w-ro-n-g-:- - - - - I
connector (24-pin).
Inspect both audio unit connector and wiring
If the wiring harness-side connector/pin is wrong:
hamess-side connector for poor connection.
(such as damaged/bentlpulled-out pins,
corrosion)
All the pins and connector normal?
09-030-19

STEP
3
INSPECTION
ACTION
Eject the CD.

Is the CD ejected from the CD player/
changer?
Yes
No
Inspect the center panel and CD cover installation. Securely

install the center panel and/or CD cover as necessary.
Insert the CD into the CD player/changer.

Does the CD insert into the CD player/
changer smoothly?
Yes
No
Is the CD ejected from the CD player/

changer?
Yes
Install the center panel and/or CD cover properly, then go to

the next step.
Explain repairs to the customers.
No
NO.3 CD PLAYER/CHANGER DOES NOT PLAY THE CDINO SOUND
dcf09036690Ow25
CO player/changer does not play the CD/No sound

jPossible OTC: 03:Er07, 03:Er10

STEP
1
3
4
INSPECTION
Turn the radio ON and inspect that there is a
sound.
Is there a sound?
Note
Check for the volume dial position .
Was CD inserted properly, label-side up?
ACTION
Yes
Go to the next step ..
No
Go to the symptom troubleshooting No.3 (Audio system).
Yes
No
Explain to the customer that CD should be inserted into the

slot, label-side up.
Replace the CD known to be good.

Does the CD player/changer load the CD?
Yes


- Is there any dirt, scratch or deformation on
the CD?
- Is the CD a non-conventional disc?
- Is there a CD in MP3 recording?
Yes
Explain to the customer that the defective CD or nonconventional disc cannot be use.
No
No
NO.4 SOUND JUMPS
dcf090366900w26
Sound jumps
IPossible OTC: 03:Er02

Improper audio unit installation (e.g., rattle, loose)
Inadequate tire pressure
Note
The CD may be malfunctioning if the sound jumps on the certain CD only. Inspect the CD player/changer operation
using the CD known to be good.
STEP
1
INSPECTION
Does the sound jump when the vehicle is
stopped?
Drive the vehicle.
Does the sound jump when driving over
uneven surfacl3s?
09-030-20
ACTION
Go to the Step 6.
Yes
No
Yes
No

Go to the Step 6.

INSPECTION
STEP
3
Is the audio unit installed securely?
Yes
Inspect the tire pressure.

Is the tire pressure normal?
Yes
No
Adjust the tire pressure within specification.

Does the sound jump when driving the
vehicle?
Does the sound jump when driving the
vehicle?
Yes

No
Audio system is normal. Explain repairs to the customers.
5
6
ACTION
No
Yes
No

Install the audio unit securely.

Audio system is normal. Explain to the customer that the CD
is malfunctioning.
NO.5 CD PLAYER/CHANGER SCRATCHES ON THE CD

5
dcf090366900w27
ICD player/changer scratches on the CD

STEP
1
Were the multiple CDs inserted into the CD

player at the same time?
INSPECTION
Yes
No

Is the CD a deformed disc (e.g., out of
specification (thickness), bent disc)?
Yes

Audio system is normal. Explain to the customer that the CD
is malfunctioning.
No
ACTION
Explain to the customer to insert a CD one by one.
NO.6 DISC CHANGER IS INOPERATIVE
dcf09036690Ow28
IDisc changer is inoperative
Possible DTC: -
STEP
INSPECTION
ACTION
Inspect the CD changer operation.

Does the CD changer operate properly?
Yes
No
Inspect the followings:

- Is the display shown properly when
operating the disc change button?
- Does the radio band selection operate
properly?
Yes

Go to the symptom troubleshooting "No.3 CD playerl
changer does not play the CDINo sound".
No
Inspect the center panel installation.

Does the CD changer change the disc
properly after re-installing the center panel?
Yes
Install the center panel securely and properly.
No
Go to the "No.1 Audio panel switch inspection" in this

section. Replace the center panel as necessary.
09-030-21

NO.7 CD PLAYER DOES NOT PLAY THE MP3-FORMATTED FILE
dcf090366900w29
CD player does not play the MP3-formaUed file

jPossible DTC: 10:Er09, 22:Er09

MP3 and other format data are in the CD-R/RW
File extension for MP3-formatted file is incorrect (Correct. ".mp3", incorrect: e.g., MP3 pro)
Defective CD-R/RW (e.g. dirty CD, scratch)
Note
The free-software for the MP3-formatted file in the field may cause the deterioration of sound quality, noise, or defective
play, so that the CD player won't play the customer made MP-3-formatted file.
The CD player may not play the CD-R/RW properly due to the disc condition.
If there are MP-3-formatted file and other file in the same disc, the CD player may not play the disc.
If there are MP-3-formatted file and audio data in the same disc, the CD player loads and plays the first session of the
data only.
STEP
1
INSPECTION
Inspect the written format of the recorded
data on the CD-R/RW.
Is the written format correct?
Inspect the recorded data in the CD-R/RW.
Is there MP3 and other format data in the
CD-R/RW.
ACTION
Yes
No
Write the CD-R/RW with the correct specification.
Yes
Replace with the CD-R/RW known to be good (MP3formatted file data only), then inspect the CD player
operation.
If the CD player plays the MP3-formatted file:

Audio system is normal. Explain to the customer that the
CD player does not operate properly if the MP3 and
other format data are in the CD-R/RW.
If the CD player does not play the MP3-formatted

file:
Inspect the CD-R/RW written format.

Is the written format within the specification
(".mp3" is the correct file extension)?
No
Yes

Replace with the CD-R/RW using the ".mp3" file extension,

then inspect the CD player operation.
If the CD player plays the MP3-formatted file:

CD player does not operate properly if the correct file
extension is not used.
If the CD player does not play the MP3-formatted

file:
Visually inspect the CD-R/RW.

Is there any dirt or scratch on the CD-R/RW?
No
Yes
No
09-030-22

Clean the disc or replace with the CD-R/RW known to be

good.

NO.8 MP3-FORMATTED FILE FOLDER SELECTION IS INOPERATIVEITRACK SEARCH IS INOPERATIVE
dcf09036690Ow30
IMP3-formatted file folder selection is inoperativefTrack search is inoperative
Possible DTC: 10:Er09, 22:Er09

Conflict of ID tag version for CD-R/RW
Improper folder and/or music title in CD-R/RW
The number of characters of folder/audio file name in CD-R/RW exceeds the maximum number of characters
Note
103 is a tagging format for MP3-formatted file. 103 allows metadata (e.g., title, artist, track number, etc.) to
be added to the MP3-formatted file .
There are two versions in the 10 tag.
- 103v1: This is the most widespread standard tag formats and most software is compatible with this
version. There is a limitation on the maximum number of characters for the text data.
- 103v2: There are a variety of version in V2, but there is no interchangeability among the versions.
Limitation on the maximum number of characters for the text data (ID3v1)
Maximum number of characters
Item
Title
Artist
Album
Year
Genre
Comment
Track
Description
30
30
30
Music title
Artist name
Album title
Album produced year/CD wholesale year
Music category selection
Free comment
Track number
30
3
STEP
1
2
3
INSPECTION
Is there any dirt or scratch on the CD/R/RW?
Inspect the ID tag version.

Is ID tag correct?
Inspect the encode for the folder and audio

file name in the CD-R/RW.
Is the encode correct?
Inspect folder and audio file name.

Are all file name input correctly?
Note
Unreadable characters may be displayed
if incorrect encode is used.
Inspect the number of characters for the
folder and audio file name.
Is the number of characters within the
maximum number of characters?
Yes
No
Yes
No
Yes
No
Yes
No
ACTION
good.
Write the CD-R/RW with the correct ID tag version.
Use the CD-R/RW that a folder and audio file name is input
correctly.
Use the correct encode.
Yes
No

Input the folder and audio file name within the maximum
number of characters.
09-030-23

NO.9 CD PLAYER DOES NOT INDICATE THE MP3 TITLE TEXT
dcf090366900w31
ICD player does not indicate the MP3 title text
Possible DTC: -

Conflict of ID tag version for CD-R/RW
The number of characters of folder/audio file name in CD-R/RW exceeds the maximum number of characters
No title input in CD-R/RW
Input title text by 2-bytes characters
STEP
1
3
4
INSPECTION

Is there any dirt or scratch on the CD/R/RW?
Inspect the display the LCD.

Is the CD (other than MP3 compatible)
displayed on the LCD?
Inspect the ID tag version.

Is the ID tag correct?
Is the title text input into the CD-R/RW?
Inspect the encode for the folder and audio

file name in the CD-R/RW.
Is the encode correct?
Inspect the number of characters for the
folder and audio file name.
Is the number of characters within the
maximum number of characters?
Yes
No
Yes
No
ACTION
good.
Go to the symptom troubleshooting No.9 (Entire audio
system).
Yes
No
Yes
Write the CD-R/RW with the correct ID tag version.
No

Input the title text.
Yes
No
Note
Do not input the title text by two-bytes character.
Use the correct encode.
Yes
No

Input the folder and audio file name within the maximum
number of characters.
NO.10 CD PLAYER DOES NOT PLAY THE AUDIO DATA (CDDA)
dcf090366900w32
ICD player does not play the audio data (CODA)
10
Possible DTC: -

Defective CD-R/RW (e.g., dirty CD, scratch)
Data other than the audio data is in CD-R/RW
Note
The CD player may not play the CD-R/RW properly due to the disc condition.
If there are MP-3-formatted file and audio data in the same disc, the CD player loads and plays the first session of the
data only.
STEP
1
INSPECTION
Replace with the audio-CD known to be
good.
Does the CD player play the audio-CD
properly?
Inspect the written format of the recorded
data on the CD-R/RW.
Is the written format correct?
09-030-24
ACTION
Yes
No
Yes

Write the CD-R/RW with the correct specification.
No

INSPECTION
STEP
Inspect the recorded data in the CD-R/RW.

Is any data other than the audio data
recorded in the CD-R/RW?
ACTION
Yes
Replace with the CD-RlRW known to be good (record audio

data only), then inspect the CD player operation.
If the CD-R/RW plays:

CD player does not operate properly if the audio data
and other data are recorded in the CD-R/RW.
If the CD-R/RW does not play:

No

Is there any dirt or scratch on the CD-RlRW?
Yes
No


good.
NO.11 TRACK CHANGE IS INOPERATIVE

11
dcf09036690Dw33
ITrack
change is inoperative

STEP
1
INSPECTION
Does the CD player change the track?
Inspect the center panel installation.
Does the CD player change the track
number on the display when pressing the
track up or down button?
RADIO [REFERENCE]
1. Multipath Noise
Signals from an FM transmitter are a high
frequency and similar to beams of light because
they do not bend around corners, but they do
reflect. Since FM signals can be reflected by
obstructions, it is possible to receive both the
direct signal and the reflected signal at the same
time. This causes a slight delay in reception and
may be heard as a broken sound or a distortion.
Yes
ACTION
Explain to the customer that the defective CD or nonconventional disc cannot be used.
No
Yes

No
Go to the "No.1 Audio panel switch inspection" in this

section. Replace the center panel as necessary.
dcf090366900w34
E6U902HWB007
2. Flutter/Skip Noise
Signals become weak in valleys between
mountains, tall building, and other obstacles.
When the vehicle passes through such an area,
the reception conditions may change suddenly,
resulting in annoying noise.
E6U902HWB008
09-030-25

3. Stereo and Monaural Receptions
As signals become weak, noise may appear more in stereo reception. Comparing to stereo reception, noise in
monaural receptions is relatively less striking.
Measures in Audio System
Separation control
Utilizing the characteristic of monaural reception that noise is relatively less striking than stereo reception, the
audio system automatically changes the reception from stereo to monaural and lessens annoying noise when
signals become weak or a multipath phenomenon occurs.
High tone control
When signals become weak or a multipath phenomenon occurs, the audio system restrains volume level in
high frequency band and lessens annoying noise.
Effect Setting of Separation Control and High Tone Control
The separation and high tone controls influence sound quality, Therefore they are specifically tuned for
individual model. (Comparison of characteristic must be done on the same models)
High tone setting
Less effective range
Noise is conspicuous
Noise restraint setting
Wider effective range
Noise is less conspicuous

DPE903EW1VOA
Remarks
Signals tend to reach longer distances in the night. It is conspicuous in AM signals, several audio functions may
stop due to foreign broadcasting station or noise. though the audio system restrains sensitivity of SEEK and
SCAN functions in the night, the audio system may select other than desired broadcasting station when signals
are considerably strong. This function is liked to the parking light. When the parking light or headlight is turned
on, SEEK and SCAN may not function for weak signals.
Daytime
530
A: The level that AUTO-M, SEEK, SCAN function.

AUTO-M, SEEK, .,d SCAN ,"00 to 4 ',oad",,'o, ,tabo",
Ast.
Bst.
Cst.
Dst.
Est. Fst. Gst.

Frequency (kHz)
Hst.
1st.
Hst.
1st.
Jst.
1710
Night
When the TNS is turned on: 4 broadcasting
,ations are tuned, just like
Ast.
Bst.
Cst.
Dst.
Est.
Fst.
Gst.
Frequency (kHz)
the TNS is turned off: As signal strength is higher in the night, AUTO-M, SEEK, and
SCAN tune to 10 broadcasting stations (A to J st.).
EPU903EW3003
09-030-26

AUDIO CD [REFERENCE]
dcf090366900w35
The CD player/changer has been designed to

play CDs bearing the identification logo,
COMPACT DISC DIGITAL AUDIO, as shown. No
other discs can be played on the CD player/
changer other than MP3 applicable one.
The CD player/changer may not play the following
CD:
DIGITAL AUDIO
DIGITAL AUDIO
Defective CD (e.g., cracked, badly bent, rough
edges, scratch, dirty CD condensation,
trc:lnsparent)
8 cm (3 in) CDs accessories (e.g., 8 cm (3 in)
disc adapter, sticker, label)
E6U903HWB010
Nonstandard CD (e.g., Diameter/thickness is
out of specification)
Specification: 119.7-120.3 mm (4.668-4.692 in) of diameter, 12+0.3 or -0.1 mm (0.047+0.012 or 0.004
in) of thickness
Do not use non-conventional discs. The CD player/changer could be damaged.
Examples:
Although the same physical size as the compact
disc, SACD uses a different kind of digital audio
signal, Direct Stream Digital.
The CD player/changer may not play the CD-R/
RW properly due to the disc condition (excluding
the MP3).
TEXT
E6U903HWB011
MP3-Formatted File
Outline of CD-R and CD-RW
Definition
CD-R: The CD-R is a non-rewritable version. Once a section of a CD-R is written, it cannot be erased or
rewritten,
CD-RW: The CD-RW is a re-writable version of CD-ROM and can be written the data an unlimited number
of times.
Since a reflected laser beam amount of the CD-R/RW is less than the reflected laser beam amount of the
conventional CD media, the CD player/changer may not play the CD-R/RW or have the sound jumped.
Since the recording quality of the CD-R/RW vary widely, some CD-R/RW may not be played.
Recording method
There are two methods for recording.
Classification by recorder
Record the audio data in the audio-CD by audio recorder
The price of the audio recorder and original audio-CD includes the copyright fee.
Recorded the audio data in the conventional data-CD by the personal computer
The data-CD is cheaper than the audio-CD. But, there is a CD with the low quality.
Classification by audio data uncompression/compression
Uncompressed audio data
The CD-R/RW player can play the uncompressed audio data.
Compressed audio data
It is possible to record the large quantity of music in a disc. The sound quality varies depends on the
audio data compression format. The compressed audio data can be played on the applicable player
only.
Type of compression format:
MP3: MPEG Audio Layer 3 - Mazda genie MP3 applicable CD player is available.
WMA: Windows Media Audio
ATRAG: Adaptive TRansform Acoustic Coding
09-030-27

MP3
The following condition should be met in order to record the MP3-formatted data on the MP3 applicable CD
player:
Media
Logical format
Number of directly
Number of files
103 TAG
File extension
Packet writing
Bit rate
Sampling rate
09-030-28
Applicable to the CD-RlRW
ISO 9660 level 1&2/ Joliet / Romeo

8 directly
Maximum 255 as a total number of file and folder
Maximum 155 for folder
Applicable to Ver1.1, 2.3 and 2.4
MP3
Not applicable
8kbps-320kbpsNBR
11.025kHz-48kHz
SYMPTOM TROUBLESHOOTING [INSTRUMENT CLUSTER]
09-03E SYMPTOM TROUBLESHOOTING [INSTRUMENT

CLUSTER]
NO.4 MIL ILLUMINATES
[INSTRUMENT CLUSTER] . ......... 09-03E-1
NO.8 TACHOMETER INDICATION IS

DEFECTIVE
[INSTRUMENT CLUSTER] .......... 09-03E-2
NO.4 MIL ILLUMINATES[INSTRUMENT CLUSTER]

4
POSSIBLE
CAUSE
id0903d7807700
MIL illuminates
PCM malfunction
DTC is stored in PCM.
Connector or pin malfunction
Short to GND circuit between instrument cluster and PCM.
STEP
1
2
INSPECTION
ACTION
Start the engine.

Does the MIL turn off?
Connect the current diagnostic tool to DLC-2.
Perform KOEO and KOER self-test and
retrieve continuous memory DTC for PCM.
Is there any DTC displayed?
Inspect the instrument cluster connector
terminals for poor connection (such as
damaged/pulled-out pins, and corrosion).
Are the terminals normal?
Short to GND at PCM terminal 256 (WLT-1,
WLT-2, WL-C, WE-C), 1E (G6, F2) using the
jumper wire.
Does the auto leveling warning light
illuminate?
Disconnect the instrument cluster connector
(with PCM connector disconnected).
Verify continuity between instrument cluster
terminal 11 and GND.
F5
In!
==-==
I I~L
Yes
No
Yes
No

Perform the appropriate DTC troubleshooting procedure.
Yes
No
Repair or replace the terminal.
Yes
No
Replace the PCM.

Yes
Repair or replace for short to GND.
No
::rn
i10i1Mi1Ki 11 i1Gi1Ei1Ci1Ai
i1Pi1Ni1Li1Ji1Hi1Fi1Di1Bi
.~
Gt~
II
09-03E-1
SYMPTOM TROUBLESHOOTING [INSTRUMENT CLUSTER]

NO.8 TACHOMETER INDICATION IS DEFECTIVE[INSTRUMENT CLUSTER]
8
POSSIBLE
CAUSE
id0903d7808100
Tachometer indication is defective

PCM malfunction
Connector or pin malfunction
Open or short circuit in wiring between instrument cluster and PCM
STEP
1
INSPECTION
Start the engine.
- Does the tachometer needle move
smoothly?
- Does the tachometer needle indicate
correct engine speed?
Start the instrument cluster input/output
check mode.
Inspect the tachometer using the check code
13.
Is the tachometer normal?
Inspect the instrument cluster connector
terminals for poor connection (such as
damaged/pulled-out pins, and corrosion).
Remove the instrument cluster.
cluster terminal2S and GND.
II
I"::5<'J
II
I~~
ACTION
Yes
No
Yes
No
Yes
No
Yes
Repair or replace the wiring harness between the

instrument cluster and GND.
No
Yes

112Wl2UI2S 12al2012MI2K 121 12G 12E 12C 12AII

112Xl2Vl2TI2RI2Pl2NI2L 12J 12HI2FI2DI2BII

Inspect the PCM terminal for poor
connection (such as damaged/pulled-out
pins, and corrosion).
Disconnect the PCM sensor connector (with
the instrument cluster connector
disconnected).
cluster terminal 2S and following:
- PCM terminal 218 (WLT-1, WLT-2, WL-C,
WE-C)
- Igniter (F2)
- PCM terminal 2Z (G6)
09-03E-2
No
Yes
No
Inspect the CKP sensor and related wiring harness.

Repair or replace the wiring harness between the
instrument cluster and PCM.
BODY PANELS
09-10
BODY PANELS
BODY PANEL LOCATION INDEX ......

FUEL-FILLER LID
FUEL-FILLER LID ADJUSTMENT . ....
BONNET REMOVAUINSTALLATION ...
BONNET ADJUSTMENT ............
FRONT BUMPER
FRONT BUMPER
DISASSEMBLY/ASSEMBLY ... ......
09-10-1
09-10-2
09-10-2
09-10-2
09-10-3
09-10-6
09-10-7
REAR BUMPER
REAR BUMPER
FRONT BUMPER REINFORCEMENT
FRONT FENDER PANEL
REAR ACCESS PANEL
REAR ACCESS PANEL
BODY PANEL LOCATION INDEX
dcf091056100w01
r--------------------------------------------------------------------------------------------------------------------------,
,,
,,
,
"
L ___________________________________________________________________________________________________________
_______________
DCF910ZWB001
:--1---:S-onnet--------------------------------------------:
: --4- --: Front -fe-nder panei ------------------- --------------:
:
: (See 09-10-2 BONNET REMOVAUINSTALLATION.):
______________________________________________
_____ 1:
:L ______ : (See
09-10-3 BONNET ADJUSTMENT.)
:
: (See 09-10-9 FRONT FENDER PANEL REMOVAU :
:L ______ : INSTALLATION.)
:
1
: 2 : Front bumper reinforcement

:
:
: (See 09-10-9 FRONT BUMPER REINFORCEMENT:
:L ______ :L REMOVAUINSTALLATION.)
___________________________________________________ :
1
: 3 : Front bumper
:
:
: (See 09-10-6 FRONT BUMPER REMOVAU
:
:
: INSTALLATION.)
:
:
: (See 09-10-7 FRONT BUMPER DISASSEMBLY/
:
______________________________________________
____ .1:
:L ______ :~ ASSEMBLY.)
.
:
:
L ___________________________________________________
:L __
__
: Rear bumper
:
: (See 09-10-8 REAR BUMPER REMOVAU
:
: INSTALLATION.)
:
: (See 09-10-8 REAR BUMPER DISASSEMBLY/
__________________________________________ _____ 1:
: ASSEMBLY.)
~~_~_~
09-10-1
BODY PANELS
6
Fuel-filler lid
(See 09-10-2 FUEL-FILLER LID REMOVAU
INSTALLATION.)
(See 09-10-2 FUEL-FILLER LID ADJUSTMENT.)
Rear access panel

(See 09-10-10 REAR ACCESS PANEL REMOVAU
INSTALLATION.)
FUEL-FILLER LID REMOVAL/INSTALLATION

1.
2.
3.
4.
dcf091042400w01
Remove the bolt.

Remove the fuel-filler lid.
Adjust the fuel-filler lid. (See 09-10-2 FUELFILLER LID ADJUSTMENT.)
3.9-5.9 Nm
{39.S-60.1 kgfcm, 34.5-52.2 inlbf}
BOLT
FUEL-FILLER LID
DCF910ZWB002
FUEL-FILLER LID ADJUSTMENT
dcf091042400w02
1. Measure the gap and height difference between the fuel-filler lid and the body.
2. Loosen the fuel-filler lid installation bolts and
adjust the fuel-filler lid.
Standard clearance
a: 3.5-5.5 mm {0.14-0.21 in}
b: -0.5--2.0 mm {0.01--0.07 in}
3. Tighten the bolts.
~A
...
~
SEC. A-A
DCF910ZWB003
BONNET REMOVAL/INSTALLATION
dcf091 056601 w01
Warning
Removing the bonnet without supporting it could cause the bonnet to fall and cause serious
injury. Always perform the procedure with at least another person to prevent the bonnet from
falling.
2. To remove the bonnet hinges, remove the following parts:
(1) Radiator grille (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
(2) Front bumper (See 09-10-6 FRONT BUMPER REMOVAUINSTALLATION.)
(3) Front combination lights (See 09-18-3 FRONT COMBINATION LIGHT REMOVAUINSTALLATION.)
(4) Front side turn light (See 09-18-6 FRONT SIDE TURN LIGHT REMOVAUINSTALLATION.)
(5) Front over fender (vehicles with front over fender) (See 09-16-4 OVER FENDER REMOVAU
INSTALLATION.)
(6) Front fender panel (See 09-10-9 FRONT FENDER PANEL REMOVAUINSTALLATION.)
3. Disconnect the windshield washer hose.
09-10-2
BODY PANELS
1
2
3
4
5
6
Bonnet insulator
Shroud seal weatherstrip
Parting seal weatherstrip
Bonnet
Bonnet hinge
Bonnet stay

6. Adjustthe bonnet. (See 09-10-3 BONNET
ADJUSTMENT.)
DCF910ZWB004
BONNET ADJUSTMENT
dcf091056601w02
1. Measure the gap and height between the bonnet and the body.
clearance
a: 4.7-7.4 mm {0.16-0.29 in}
b: -1.2-4.2 mm {-0.OS-0.16 in}
c: 2.3---6.7 mm {0.09-0.26 in}
d: -1.6--1.6 mm {-0.06-0.06 in}
e: 2.7-5.3 mm {0.11-0.20 in}
f: -0.5-2.1 mm {-0.02-0.08 in}
g: -0.9-2.1 mm {0.04-0.08 in}
h: 0.0--1.S mm {0.00-0.06 in}
09-10-3
BODY PANELS
BONNET
FRONT BUMPER
FRONT COMBINATION LIGHTS
SEC. A-A
SEC. C-C
SEC. B-B
BONNET
FRONT DOOR
D
DCF910ZWB005
2. If not as specified, adjust the gap and height.
09-10-4
BODY PANELS
Gap Adjustment
1. Loosen the bonnet installation bolts and
reposition the bonnet.
2. Tighten the bonnet installation bolts.
BOLT
DCF910ZWB006
Height Difference Adjustment

1. Remove the Radiator grille. (See 09-16-3
RADIATOR GRILLE REMOVAUINSTALLATION.)
2. Rotate the stop rubber until the projection is
caught in the notch as shown in the figure.
PROJECTION
STOP RUBBER
~...
-~~
NOTCH
DCF910ZWBOOB
3. Rotate the stop rubber further to the position

3/4 TURNS (270)
STOP RUBBER
3 mm
POSITION AT
{0.12 in}
STEP 2
- -~
PROJECTION ON
STOP RUBBER
PROJECTION ON
STOP RUBBER
SHROUD
UPPER
MEMBER
DCF910ZWB019
4. Loosen the bonnet lock installation bolts and nut

and press the bonnet lock up to the highest
position.
5. Tighten the bonnet lock installation bolts.
6. Close the bonnet and loosen the bonnet lock
installation bolts.
7. Slightly pull the bonnet lock down by hand to
lower and tighten the bonnet lock installation bolts
and nut with no excessive play between the
bonnet lock and striker.
(1) Tighten the bolts and nut in order to nut A,
bolt B and bolt C.
8. Verify that there is no gap between the bonnet
and stop rubber.
9. Open the bonnet.
BOLTe
09-10-5
BODY PANELS
FRONT BUMPER REMOVAUINSTALLATION
dcf091 050000wO 1

@4.21-6.17 Nm {42.93-62.91 kgfcm, 37.26-54.60 inlbf}

DCF910ZWB009
4
5
3
Bolt
Fastener B
Front bumper
(See 09-10-6 Front Bumper Removal Note.)
(See 09-10-6 Front Bumper Installation Note.)
4. Disconnect the front fog light connector.

6. Adjust the front fog light aiming for vehicles with front fog lights. (See 09-18-5 FRONT FOG LIGHT AIMING.)
Front Bumper Removal Note
1. Pull the front bumper ends (wheel arch) outward
(1) to detach from the bumper slider.
Caution
When disengaging the front bumper from
the bumper slider, the front bumper could
fall and be damaged. Secure the front
bumper so that it does not fall.
2. Remove the front bumper from the body.
FRONT BUMPER
DCF91 OZWB01 0
Front Bumper Installation Note

1. Spread the front bumper ends apart.
2. Assemble the front bumper to the body.
3, Press the front bumper connecting area into the body to engage with the bumper slider.
09-10-6
BODY PANELS
FRONT BUMPER DISASSEMBLY/ASSEMBLY
dcf09105000Ow02
1. Remove the front fog light. (Vehicles with front fog lights) (See 09-18-5 FRONT FOG LIGHT REMOVAU
INSTALLATION.)
'--,
1~
~A
,
-
'~I~(--'
--~~I
II
,--,
(~I
........"
@,
(j),
(U-' A
\Jr I
'--'
@1.0-1.5 Nm {10.1-15.2 kgfcm, 8.8-13.2 inlbf}
2.0-2.9 Nm {20.3-29.5 kgfcm, 17.7-25.6 inlbf}

DCF910ZWB011
2
3
4
5
6
7
Screw A
Front hole cover (Vehicles without front fog lights)
Front fog light cover (Vehicles with front fog lights)
Nut A
Bolt
Over fender lower
8
9
10
11
12
13
Set plate A
NutC
Set plate B
Screw B
Front bumper fascia upper
Front bumper fascia lower
Nut B
09-10-7
BODY PANELS
REAR BUMPER REMOVAUINSTALLATION
dcf091050000w03

2. Remove the license plate light. (See 09-18-8 LICENSE PLATE LIGHT REMOVAUINSTALLATION.)
IBolt
CD 79-116 Nm
{8.0-11.8 kgf.m, 58.2-85.5 ft.lbf}
DCF910ZWB012
REAR BUMPER DISASSEMBLY/ASSEMBLY
dcf091050000w04

1
Rear bumper step
2
3
4
5
6
7
Bolt
Fastener
Rear bumper fascia
Nut
Rear bumper stay
Rear bumper reinforcement
4
{42.93-62.91 kgfcm, 37.26-54.60 inlbf}
DCF910ZWB013
09-10-8
BODY PANELS
FRONT BUMPER REINFORCEMENT REMOVAL/INSTALLATION
1.
2.
3.
4.

Remove the radiator grille. (See 09-16-3 RADIATOR GRILLE REMOVAUINSTALLATION.)
Remove the front bumper. (See 09-10-6 FRONT BUMPER REMOVAUINSTALLATION.)
dcf09105000Ow05
DCF910ZWB014
IBolt
Bolt A
B
Nut
Front bumper stay
Rear bumper reinforcement

FRONT FENDER PANEL REMOVAL/INSTALLATION
dcf091 05201 Ow01

2. To remove the bonnet hinges, remove the following parts:
(1) Radiator grille (See 09-16-3 RADIATOR GRILLE REMOVAL/INSTALLATION.)
(2) Front bumper (See 09-10-6 FRONT BUMPER REMOVAUINSTALLATION.)
(3) Front combination lights (See 09-18-3 FRONT COMBINATION LIGHT REMOVAUINSTALLATION.)
(4) Front side turn lights (See 09-18-6 FRONT SIDE TURN LIGHT REMOVAUINSTALLATION.)
(5) Front over fender (vehicles with front over fender) (See 09-16-4 OVER FENDER REMOVAU
INSTALLATION.)
09-10-9
BODY PANELS
1
2
3
4
5
Mad guard
Bolt
Nut
Seal plate
Front fender panel
6.87-9.80 Nm
, {70-100 kgfcm, 60.8-86.7 in.lbf}

REAR ACCESS PANEL REMOVAUINSTALLATION
TAB A
DCF910ZWB015
dcf091 0561 00w03

1
2
3
4
Checker
Connector
Rear access panel
Nm {kgfm, ftlbf}
ABR7714W004
09-10-10
BODY PANELS
REAR ACCESS PANEL DISASSEMBLY/ASSEMBLY
dcf091056100w06
1. Remove the rear access panel. (See 09-10-10 REAR ACCESS PANEL REMOVAUINSTALLATION.)
7.S-10.S
{SO-110,7
4.2-6.5
{43-66,3S-57}
-4)
r:
~~--------~~~~~=--~
~: i!
-1
'~~
"'&-'''N'~
{1.S-2.7 kgf.m, ~
13.0-19.5 ftlbf}
Nm {kgfcm, inlbf}
ABR7714W005
1
2
3
Upper latch
Lower latch
Rear access panel remote controller
IOuter handle
09-10-11
DOORS AND LlFTGATE
09-11
DOORS AND LIFTGATE
DOOR LOCATION INDEX ............ 09-11-1

FRONT DOOR
REMOVAUINSTALLATION . ......... 09-11-2
REAR DOOR
REMOVAUINSTALLATION . ......... 09-11-2
DOOR ADJUSTMENT ............... 09-11-2

FRONT DOOR UNIT
REAR DOOR UNIT
DOOR LOCATION INDEX
dcf091100000w01
DCF911ZWB001
Front door
(See 09-11-2 FRONT DOOR REMOVAU
INSTALLATION.)
(See 09-11-2 DOOR ADJUSTMENT.)
Rear door
(See 09-11-2 REAR DOOR REMOVAU
INSTALLATION.)
(See 09-11-2 DOOR ADJUSTMENT.)
Front door unit

(See 09-11-4 FRONT DOOR UNIT REMOVAU
INSTALLATION.)
Rear door unit

(See 09-11-4 REAR DOOR UNIT REMOVAU
INSTALLATION. )
09-11-1
DOORS AND LlFTGATE

FRONT DOOR REMOVAUINSTALLATION
dcf09ll580l awOl

2. Remove the door screen. (See09-11-4 FRONT DOOR UNIT REMOVAUINSTALLATION.)
3. To remove the front door hinge, remove the front fender panel. (See09-10-9 FRONT FENDER PANEL
4. To remove the checker, remove the door speaker. (See09-20-5 FRONT SPEAKER REMOVAU
INSTALLATION.)
1
2
3
Front door harness

Checker pin
Front door hinge
Front door
Checker
~T.~'~<3 ~

7. Adjust the front door. (See 09-11-2 DOOR
ADJUSTMENT.)
: :~
\Sl~~~=====
8.8-12.7 Nm
~~:8~~;:45i~.~~~m,
Nm {kgfm, inlbf}
DCF9l1 ZWB002
REAR DOOR REMOVAUINSTALLATION
dcf09115801 aw02

2. Remove the door screen. (See09-11-4 REAR DOOR UNIT REMOVAUINSTALLATION.)
3. To remove the checker, remove the ashtray bracket. (See 09-11-4 REAR DOOR UNIT REMOVAU
INSTALLATION.)
1
Connector
2
3
4
5
Checker pin
Rear door hinge
Rear door
Checker
6. Adjust the rear door. (See 09-11-2 DOOR

ADJUSTMENT.)
8.8-12.7Nm
{89.7-129.5 kgfcm,
77.8-112.4 inlbf}
Nm {kgfm, ftlbf}
DCF911 ZWB003
DOOR ADJUSTMENT
dcf09115801 aw03
1. Measure the gap and height between the front or rear door and the body.
2. If there is any malfunction, loosen the front or rear door hinge installation bolts or the door lock striker
installation screws, and reposition the door.
Clearance
a: 3.5-6.5 mm {0.14-0.25 in}
b: -1.0-1.5 mm {-0.04-0.06 in}
c: 5.0 mm {0.19 in}
d: 0.0-2.5 mm {0.00-0.09 in}
09-11-2
DOORS AND LlFTGATE
REAR PILLER
8
b
REAR PILLER
FRONT DOOR
REAR PILLER
REAR DOOR
SEC.A-A
SEC. 8-8
SEC. C--C
REAR
ACCESS
PANEL
d
b
a
FRONT DOOR
REAR DOOR
FRONT DOOR
SEC. E-E
SEC. D-D
QUARTER
WINDOW
FRONT DOOR
SEC. F-F
REAR
ACCESS
PANEL
@
FRONT DOOR
SEC.G-G
3. Tighten the bolts or screws.
09-11-3
DOORS AND LlFTGATE

FRONT DOOR UNIT REMOVAL/INSTALLATION
1.
2.
3.
4.
5.
6.
dcf09115997OW01
Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position.
Remove the front door trim. (See 09-17-17 FRONT DOOR TRIM REMOVAUINSTALLATION.)
Remove the front door grass. (See 09-12-3 FRONT DOOR GLASS REMOVAUINSTALLATION.)
Remove the inner handle. (See 09-14-6 FRONT DOOR INNER HANDLE REMOVAUINSTALLATION.)
Disassemble in the order indicated in the table.
3
2
2
3
4
Door screen
Glass run channel
Front glass guide
Rear glass guide
Nm {kgfcm, inlbf}
6.9-9.8
{70.3-99.9,
61.0-86.7}
DCF911 ZWB005
REAR DOOR UNIT REMOVAL/INSTALLATION
dcf09115997OW02
1.
2.
3.
4.
Close the rear door glass completely.

Remove the rear door trim. (See 09-17-18 REAR DOOR TRIM REMOVAUINSTALLATION.)
Remove the rear door grass. (See 09-12-4 REAR DOOR GLASS AND REAR WINDOW REGULATOR
5. Remove the inner handle. (See 09-14-7 REAR DOOR INNER HANDLE REMOVAUINSTALLATION.)
1
2
3
4
Door screen
Glass hole lid
Glass run channel
Glass guide
Nm {kgfcm, inlbf}
{70.3-99.9,
61.0-86.7}
DCF911 ZWB006
09-11-4
09-12
LOCATION INDEX ........... 09-12-2
FRONT DOOR GLASS
REAR DOOR GLASS AND REAR
WINDOW REGULATOR
REAR QUARTER WINDOW GLASS
FRONT POWER WINDOW REGULATOR
REMOVAL/INSTALLATION .... 09-12-5
FRONT MANUAL WINDOW
REGULATOR
REMOVAL/INSTALLATION ...... 09-12-6
REGULATOR HANDLE REMOVAL .... 09-12-6
REGULATOR HANDLE
INSTALLATION .............. 09-12-6
FRONT POWER WINDOW MOTOR
REAR POWER WINDOW MOTOR
REMOVAL/INSTALLATION ..... 09-12-7
POWER WINDOW MOTOR
INSPECTION .................. 09-12-7
INSPECTION ................ 09-12-8
POWER WINDOW SUBSWITCH

INSPECTION ............. 09-12-11
POWER WINDOW SYSTEM INITIAL
SETTING ................ 09-12-11
WINDSHIELD REMOVAL. ........ 09-12-12
WINDSHIELD INSTALLATION ..... 09-12-14
REAR WINDOW GLASS REMOVAL .. 09-12-16
REAR WINDOW GLASS
INSTALLATION ............ 09-12-17
FILAMENT SWITCH
REMOVAL/INSTALLATION ......... 09-12-18
FILAMENT INSPECTION ......... 09-12-18
FILAMENT REPAIR ............. 09-12-18
OUTER MIRROR
OUTER MIRROR GLASS
POWER OUTER MIRROR
INSPECTION ................... 09-12-20
REMOVAL/INSTALLATION ......... 09-12-20
INSPECTION ............... 09-12-21
REARVIEW MIRROR
REMOVAL/INSTALLATION ........ 09-12-21
09-12-1
GLASSIWINDOWS/MIRRORS LOCATION INDEX
dcf091200001w01
Front view
DCF912ZWB800
Power window main switch

INSPECTION.)
Power window subswitch
(See 09-12-11 POWER WINDOW SUBSWITCH
(See 09-12-11 POWER WINDOW SUBSWITCH
INSPECTION.)
Power outer mirror switch
(See 09-12-20 POWER OUTER MIRROR SWITCH
(See 09-12-21 POWER OUTER MIRROR SWITCH
INSPECTION.)
Regulator handle
(See 09-12-6 REGULATOR HANDLE REMOVAL.)
(See 09-12-6 REGULATOR HANDLE
INSTALLATION.)
Front power window regulator
(See 09-12-5 FRONT POWER WINDOW
REGULATOR REMOVAUINSTALLATION.)
(See 09-12-6 FRONT MANUAL WINDOW
REGULATOR REMOVAUINSTALLATION.)
09-12-2
Rear door glass and rear window regulator

(See 09-12-4 REAR DOOR GLASS AND REAR
WINDOW REGULATOR REMOVAUINSTALLATION.)
Rear power window motor
(See 09-12-7 REAR POWER WINDOW MOTOR
(See 09-12-7 POWER WINDOW MOTOR
INSPECTION.)
Front power window motor
(See 09-12-7 FRONT POWER WINDOW MOTOR
(See 09-12-7 POWER WINDOW MOTOR
INSPECTION.)
Rearview mirror
(See 09-12-21 REARVIEW MIRROR REMOVAU
INSTALLATION.)
10 Windshield
(See 09-12-12 WINDSHIELD REMOVAL.)
(See 09-12-14 WINDSHIELD INSTALLATION.)
11
Front door glass

(See 09-12-3 FRONT DOOR GLASS REMOVAU
INSTALLATION.)
Rear view
DCF912ZWBB01
Outer mirror
(See 09-12-19 OUTER MIRROR REMOVAU
INSTALLATION.)
(See 09-12-19 OUTER MIRROR GLASS REMOVAU
INSTALLATION.)
(See 09-12-20 POWER OUTER MIRROR
INSPECTION.)
FRONT DOOR GLASS REMOVAUINSTALLATION
Rear window glass

(See 09-12-16 REAR WINDOW GLASS REMOVAL.)
(See 09-12-17 REAR WINDOW GLASS
INSTALLATION.)
(See 09-12-18 FILAMENT SWITCH REMOVAU
INSTALLATION.)
(See 09-12-18 FILAMENT INSPECTION.)
(See 09-12-18 FILAMENT REPAIR.)
Rear quarter window glass

(See 09-12-5 REAR QUARTER WINDOW GLASS
dcf091259500w01
1. Adjust the door glass position as shown in the

figure.
2. Disconnect the negative battery cable.(Vehicles
with the power window system)
3. Remove the inner garnish. (See 09-17-11 INNER
GARNISH REMOVAUINSTALLATION.)
4. Remove the regulator handle.(Vehicles with
manual window system)(See 09-12-6
REGULATOR HANDLE REMOVAL.)
5. Remove the front door trim. (See 09-17-17
FRONT DOOR TRIM REMOVAU
INSTALLATION.)
6. Remove the screen.
09-12-3
7. Remove the bolts and the front door glass guide
out of the way.
8. Remove the bolts.
9. Lift the front door glass up and remove it in the
direction of the arrow.
BOLTB
~~~~,)"""\
1.96-2.94Nm
{20-29 kgfcm,
18-26 inlbf}
DCF912ZWB002
REAR DOOR GLASS AND REAR WINDOW REGULATOR REMOVAUINSTALLATION
dcf091259500w02
1. Disconnect the negative battery cable.(Vehicies with the power window system)
2. Remove the regulator handle.(Vehicies with manual window system)(See 09-12-6 REGULATOR HANDLE
REMOVAL.)
3. Remove the rear door trim. (See 09-17-18 REAR DOOR TRIM REMOVAUINSTALLATION.)
4. Remove the screws.
5. Remove the glass hole lid.
6. Lift the rear door glass and remove the bolts.
DCF912ZWB003
POWER WINDOW REGULATOR
MANUAL WINDOW REGULATOR
6.7-9.8Nm
{69-99 kgf.cm,
60-86 in.lbf}
DCF912ZWB004
7. Slide the window regulator link to the rear of the rear door glass.
8. Remove the rear window reg ulator through the
,--=---------:-.,---------:-;--r---------,
service hole.
DCF912ZWB200
09-12-4
9. Draw out the rear door glass through the glass
hole.
DCF912ZWB005
REAR QUARTER WINDOW GLASS REMOVAL/INSTAllATION

1.
2.
3.
4.
5.
6.
Remove the
Remove the
Remove the
Remove the
Remove the
Install in the
dcf091259500w03
rear access panel trim. (See 09-17-18 REAR ACCESS PANEL TRIM REMOVAUINSTALLATION.)
upper latch. (See 09-10-11 REAR ACCESS PANEL DISASSEMBLY/ASSEMBLY.)
quarter window hinge.
quarter window lock.
window glass.
QUARTER WINDOW LOCK
reverse order of the removal.
BOLT
7.8-10.8
{80-110,
70-95}
QUARTER WINDOW
HINGE
WEATHERSTRIP
QUARTER
WINDOW
GLASS
Nm {kgf.em, in.lbf}
DCF912ZWB006
FRONT POWER WINDOW REGULATOR REMOVAL/iNSTAllATION
dcf091258560wOl

(1) Inner garnish (See 09-17-11 INNER GARNISH REMOVAUINSTALLATION.)
(2) Front door trim (See 09-17-17 FRONT DOOR TRIM REMOVAUINSTALLATION.)
(3) Door screen.
(4) Front door glass (See 09-12-3 FRONT DOOR GLASS REMOVAUINSTALLATION.)
3. Remove the nuts and bolts.
4. Remove the front power window regulator through
the service hole.
NUT
Nm {kgfem, Inlbf}
DCF912ZWB007
09-12-5
FRONT MANUAL WINDOW REGULATOR REMOVAUINSTALLATION
dcf091258560w05

(1) Inner garnish (See 09-17-11 INNER GARNISH REMOVAUINSTALLATION.)
(2) Regulator handle (See 09-12-6 REGULATOR HANDLE REMOVAL.)
(3) Front door trim (See 09-17-17 FRONT DOOR TRIM REMOVAUINSTALLATION.)
(4) Front door glass (See 09-12-3 FRONT DOOR GLASS REMOVAUINSTALLATION.)
2. Remove the nuts and the bolts.
DCF912ZWB153
3. Remove the front manual window regulator

through the speaker installation hole.
POWER
WINDOW
REGULATOR
DCF912ZWB154
REGULATOR HANDLE REMOVAL
dcf091258560w03
1. Using a cloth, remove the regulator handle

installation clip and remove the regulator handle.
REGULATOR HANDLE INSTALLATION
dcf091258560w04
1. Fully raise the door glass.

2. Install the clip to the regulator handle.
3. Install the regulator handle while tilting it as
shown in the figure and press it onto the shaft.
CLIP
B3E0912W330
09-12-6
FRONT POWER WINDOW MOTOR REMOVAUINSTALLATION
dcf09125956Ow01

(1) Inner garnish (See 09-17-11 INNER GARNISH REMOVAL/INSTALLATION.)
(2) Front door trim (See 09-17-17 FRONT DOOR TRIM REMOVAL/INSTALLATION.)
(3) Door screen.
(4) Front door glass (See 09-12-3 FRONT DOOR GLASS REMOVALIINSTALLATION.)
(5) Front power window regulator (See 09-12-5 FRONT POWER WINDOW REGULATOR REMOVAL/
INSTALLATION.)
3. Disconnect the power window motor connector.
5. Remove the power window motor from the power
window regulator.
o
DCF912ZWB008
REAR POWER WINDOW MOTOR REMOVAUINSTALLATION
dcf091259560w02

(1) Rear door trim (See 09-17-18 REAR DOOR TRIM REMOVAL/INSTALLATION.)
(2) Door screen.
(3) REAR DOOR GLASS AND REAR WINDOW REGULATOR REMOVALlINSTALLATION(See 09-12-4 REAR
DOOR GLASS AND REAR WINDOW REGULATOR REMOVAL/INSTALLATION.)
(4) Rear window regulator (See 09-12-4 REAR DOOR GLASS AND REAR WINDOW REGULATOR
REMOVAL/INSTALLATION.)
3. Disconnect the power window motor connector.
5. Remove the power window motor from the power
window regulator.
BOLT
DCF912ZWB009
POWER WINDOW MOTOR INSPECTION
dcf091259560w03
1. Apply battery positive voltage and connect the

ground to the power window motor terminals, and
then inspect the power window motor operation.
If the power window motor does not operate
as indicated in the table, replace it.
Caution
If the power window motor temperature is
high, the motor may not rotate due to the
motor internal bimetal function. Leave it
untouched for abOl-lt 3 min to cool it
down, then reinspect.
Operation
Close
Open
DCF912ZWB071
Terminal
2A
B+
Ground
28
Ground
B+
09-12-7
POWER WINDOW MAIN SWITCH REMOVAUINSTALLATION
2. Detach clip C using a tape-wrapped flathead
screwdriver.
3. Detach clip B and clip C by pulling it in the
direction of the arrow, and remove the switch
panel from the front door trim.
4. Disconnect the power window main switch
connector and the power outer mirror switch
connector.
dcf091266330w01
HOOK A
p=
'* FRONT SIDE
Til
CLIP B
~
CLIP C
5. Remove the screws, then remove the power

window main switch.
POWER WINDOW MAIN SWITCH INSPECTION
dcf091266330w06
Driver's Side
1. Measure the voltage at each terminal (other than terminal 1H).
If the voltage is not as specified in the Terminal Voltage Table, inspect the parts under "Inspection item (s)"
and related wiring harnesses.
3. Inspect the power window main switch connector for continuity at terminal 1H.
4. If the system does not work properly even though
r--------------------------,
the inspection items or related wiring harnesses
do not have any malfunction, replace the power
HARNESS
SIDE CONNECTOR
window main switch.
[~I~lmlgl~l
I~~
DCF912ZWB651
Terminal
Signal
Connected to
Test condition
Ignition switch is at ON position
IG1
P. WIND 30 A fuse
Ground
GND
Open
output
Power window
motor
Open
output
Power window
motor
09-12-8
Ignition switch is at LOCK position

Under any condition: inspect for
continuity to ground
While door glass is opening
Voltage (V)/
Continuity
Action
B+
Below 1.0
Yes
B+
While door glass is closing
Below 1.0
B+
Below 1.0
Inspect P. WIND 30 A
fuse
Inspect related
harness
Inspect GND
Power window motor
Inspect related
harness
Power window motor
Inspect related
harness
Terminal
L
0
M
A
J
B
Signal
Connected to
Open
output
Power window
motor
Open
output
Power window
motor
Close
output
Power window
motor
Close
output
Power window
motor
Close
output
Power window
motor
Close
output
Power window
motor
Test condition
Voltage (V)/
Continuity
B+
Below 1.0
B+
Below 1.0
Below 1.0
B+
Below 1.0
B+
Below 1.0
B+
Below 1.0
B+
Action
Power window motor

Inspect related
harness
Power window motor
Inspect related
harness
Power window motor
Inspect related
harness
Power window motor

Inspect related
harness
Power window motor

Inspect related
harness
Power window motor

Inspect related
harness
09-12-9
Except Driver's Side
1. When inspecting the passenger-side and rear power windows, turn the power-cut switch to UNLOCK.
2. Inspect for continuity between the power window main switch terminals.
If not as specified, replace the power window main switch.
3. Connect battery positive voltage to terminal 1B and ground to terminal 1M. Verify that there is continuity.
If not as specified, replace the power window main switch.
Passenger's side
Switch position
Rear right
0---0 . Continuity
Terminal
CLOSED
CLOSED
()
r--o- -0
OPEN
0- ~
Terminal
CLOSED
0- ~ ~
OPEN
0- ~
0---0 : Continuity
Terminal
H
UNLOCK
()
LOCK
r--o- ~
OFF
0-
OPEN
0- ~
MANUAL
CLOSE
()
OFF
Switch
position
Power-cut switch
0---0 : Continuity
0-
Switch position
Terminal
Switch position
OFF
Rear left
0---0 : Continuity
MANUAL AUTO
OPEN
POWER-CUT
SWITCH
CLOSE/
CLOSE/
CLOSE/
OPEN
OPEN
OPEN
PIWf-----II----+-h
eM
Passenger's side
Rear right
Rear left
DBG912ZWB900
09-12-10
POWER WINDOW SUBSWITCH REMOVAUINSTALLATION
dcf09126633Ow03
Passenger's Side and Rear

screwdriver.
panel from the door trim.
4. Disconnect the power window subswitch
connector.
HOOK A
Til
CLIP B
~
CLIP C
DCF912ZWB012
5. Remove the screws, then remove the power

window subswitch.
~:
<"(/

~
POWER WINDOW
SUBSWITCH
SCREW
DCF912ZWB013
POWER WINDOW SUBSWITCH INSPECTION
dcf091266330w04
1. Verify continuity as indicated in the table.

power window sUbswitch.
0---0 : Continuity
Switch position
CLOSED
Terminal
B
A
E
0- f-()
0--0
OFF
0- f-O
OPEN
0-
ro
0-
ro
DCF912ZWB074
D
DCF912ZWB075
POWER WINDOW SYSTEM INITIAL SETTING
dcf091266330w05
Note
Initial setting must be performed for the switch of each seat.
If the following operations have been performed, initial setting is reset, and auto up/down are disabled.
Therefore, performing initial setting is necessary.
Negative battery cable disconnected or power window system power supply fuse removed (perform
initial setting for the switches of all seats.)
Power window switch connector disconnected (Perform initial setting for the switch connected with the
connector.)
Prolonged open/close operation of the power window main or sub switches causes the circuit breaker
to activate and automatic operation is disabled.
2. Press the switch of each seat and fully open the door glass.
3. Pull the switch of each seat to the manual-up position to fully close the door glass, and keep holding the switch
up at the position for approx. 2 s.
09-12-11
WINDSHIELD REMOVAL
dcf091263900w01

(1) Windshield wiper arm and blade (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAU
INSTALLATION.)
(2) Cowl grille (See 09-16-2 COWL GRILLE REMOVAUINSTALLATION.)
(3) Rearview mirror (See 09-12-21 REARVIEW MIRROR REMOVAUINSTALLATION.)
(4) Sunvisor (See 09-17-21 HEADLINER REMOVAL/INSTALLATION.)
(5) Interior Iight(See 09-18-13 INTERIOR LIGHT REMOVAUINSTALLATION.)
(6) A-pillar trim (See 09-17-14 A-PILLAR TRIM REMOVAUINSTALLATION.)
3. Set the headliner out of the way.
4. Apply protective tape along the edge of the body.
Note
Overlap and adhere the protective tape to
the corners to prevent damage.
PROTECTIVE TAPE
WINDSHIELD
UPPER MOLDING
5. Remove the windshield molding by pulling it

outward.
Note
If the windshield molding is difficult to
remove, warm the windshield molding using
a hot air blower.
The windshield molding is a replacement
part.
LIP
DCF912ZWB030
Not Reusing Windshield

Note
For the areas of the sealant that are difficult to cut, use the SST (piano wire) and follow the procedure
under "Reusing Windshield".
1. Cut out the sealant all around the glass using a

sealant remover.
2. Remove the windshield.
SEALANT
REMOVER
ADA7738W002
09-12-12
Reusing Windshield
Warning
Using the SST (piano wire) with bare hands can cause injury. Always wear gloves when using the
SST (piano wire).
Note
Before removing the windshield from the body, mark the position of the windshield by affixing tape to the
windshield and body panel.
1. On the inside of the vehicle, insert the SST (piano
wire) which has been cut to sufficient length.
2. Wind each end of the SST (piano wire) around a
bar.
PROTECTIVE TAPE
~.
I '
Note
Use a long sawing action to spread the work
over the whole length of the SST (piano
wire) to prevent it from breaking due to
localized heating.
DCF912ZWB031
3. Secure one end of the SST (piano wire), and

while pulling the other end, cut the sealant around
the windshield.
4. Pinch the pin from the inside of the vehicle and
detach it.
A6E7738W021
6. Remove the dam from the glass.

CENTER
DAM
DCF912ZWB032
7. Remove the windshield upper molding and the

windshield side molding from the windshield.
WINDSHIELD SIDE MOLDING
iii
DCF912ZWB033
09-12-13
WINDSHIELD INSTALLATION
dcf091263900w02
Warning
Using a razor with bare hands can cause injury. Always wear gloves when using a razor.
Caution
If a door is opened or closed when all the window glass is closed, the resulting change in air
pressure could cause the sealant to crack preventing the proper installation of the glass. Keep the
door glass opened until the windshield installation is completed.
1.
2.
3.
4.
Remove the sealant along the perimeter of the glass using a cutting a razor. (When reusing the glass)
Clean and degrease an approximately 50 mm {1.97 in} wide strip along the perimeter of the windshield.
Inspect the glass for cracks. If it is cracked, chamfer it using sandpaper.
Install the windshield upper molding from the
,------------------------,
center toward both sides.
5. Align the upper edge of the windshield side
molding with the glass mark.
Caution
To prevent weakening of the primer
adhesion, keep the bonding surface free
of dirt, moisture, and grease. Do not
touch the surface with your hand.
Note
Make sure to apply primer to the hollowed
marks in the ceramic coating.
6. Install the windshield side molding from the upper
part towards the lower part.
GLASS MARK
WINDSHIELD
DCF912ZWB034
GLASS MARK
WINDSHIELD
SIDE MOLDING
WINDSHIELD
DCF912ZWB035
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 {O.57 in} from the lower and side
edge.
8. Temporarily install the glass onto the body and
adjust the glass to body clearance.
9. Make a mark on the glass directly above the Vnotch of spacers.
CENTER 8.5 {O.33}
14.5 {O.57}
CERAMIC
PARTING
LINE
mm {in}
DCF912ZWB036
09-12-14
10. Verify that the gap along the upper edge is 7.5
mm {0.30 in}.
MARKING
Caution
To prevent weakening of the primer
adhesion, keep the bonding surface free
of dirt, moisture, and grease. Do not
touch the surface with your hand.
12. 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.
GLASS
8.5 {0.33}
Bo:'~~ER
14.5 {0.57}
PRIMER
13.0 {0.51}
19.0 {0.75}
UPPER
SIDE
BODY
PRIMER
BODY
PRIMER
LOWER
16.0 {0.63}
WINDSHIELD
UPPER MOLDING
WINDSHIELD
SIDE MOLDING
BODY PRIMER
mm {in}
DCF912ZWB038
13. 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.
14. Align the glass marks with the V-notches in
spacers and install the glass onto the body.
15. Press firmly inward on the glass to compress the
sealant.
16. Verify that the gap along the upper and side edge
is 7.5 mm {0.30 in}.
5.0
{0.20}
11.0
(O.43)
~- i
~.
-t~)
DAM
'\
mm {in}
DCF912ZWB039
09-12-15
17. Adjust the sealant as indicated in the figure.
Hardening time of sealant

Temperature
Surface
hardening time
5C {41F}
20C {68 OF}
35C {95 OF}
Approx. 1.5 h
Approx.1 h
Approx. 10 min
Time required
until car can be
put into service
UPPER
WIN
Approx. 12 h
Approx. 4 h
Approx.2 h
SEALANT
IN THIS AREA
SIDE
1S. Use white gasoline to remove any sealant that

oozes out.
WINDSHIELD
19. Install the following parts:
(1) A-pillar trim (See 09-17-14 A-PILLAR TRIM
DAM
(2) Interior light (See 09-1S-13 INTERIOR LIGHT
ADJUST SEALANT
IN THIS AREA
(3) Sunvisor (See 09-17-21 HEADLINER
DCF912ZWB040
(4) Rearview mirror (See 09-12-21 REARVIEW
MIRROR REMOVAL/INSTALLATION.)
(5) Cowl grille (See 09-16-2 COWL GRILLE REMOVAL/INSTALLATION.)
(6) Windshield wiper arm and blade (See 09-19-3 WINDSHIELD WIPER ARM AND BLADE REMOVAL/
INSTALLATION.)
20. Allow the sealant to harden completely.
2'
}tJl<.BODY
Sealant hardening time: 24 h

REAR WINDOW GLASS REMOVAL
dcf09126390Ow03

2. Remove the front seat belt upper anchor installation bolt. (Regular cab) (See OS-11-1 SEAT BELT REMOVAL/ <'
INSTALLATION.)
3. Remove the back upper trim. (Stretch cab(with Rear Access System),Regular cab) (See 09-17-19 BACK
UPPER TRIM REMOVAL/INSTALLATION.)
4. Remove the B-pillar trim. (See 09-17-15 B-PILLAR TRIM REMOVAL/INSTALLATION.)
5. Disconnect the filament connector.
6. Remove the headliner. (See 09-17-21 HEADLINER REMOVAL/INSTALLATION.)
7. While another person presses the rear window
,---------------------,
glass, use flat head screwdriver to push the lip of
REAR WINDOW WEATHERSTRIP
the rear window weatherstrip from the inside.
S. 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.
9. Remove the rear window weatherstrip from the
rear window glass.
10. Remove the rear window glass.
DCF912ZWB050
09-12-16
REAR WINDOW GLASS INSTALLATION
dcf09126390Ow04
1. Clean and degrease the body and rear window glass.

2. Install the rear window weatherstrip to the rear
window glass.
DCF912ZWB051
3. Fit string ~4.5mm {0.17 in} into the rear window

weatherstrip and cross the ends as shown, leave
200 mm {7.S7 in}.
200 {7.87}
mm {in}
arnffw00001637
4. Apply soapy water as shown.

5. Align the rear window glass with the rear window
weatherstrip and body.

BODY
SOAPY WATER
DCF912ZWB053
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 string and install the rear window glass.
7. Install the rear window filament connector if
equipped.
8. Install B-pillar trim. (See 09-17-15 B-PILLAR
TRIM REMOVAUINSTALLATION.)
9. Install the back upper trim. (Stretch cab(with Rear
Access System),Regular cab) (See 09-17-19
BACK UPPER TRIM REMOVAUINSTALLATION.)
10. Install the front seat belt upper anchor installation
bolt. (Regular cab) (See 08-11-1 SEAT BELT
11. Install the rear window glass.
"
12. Install the headliner. (See 09-17-21 HEADLINER REMOVAUINSTALLATION.)
13. Connect the filament connector.
14. Install the B-pillar trim. (See 09-17-15 B-PILLAR TRIM REMOVAUINSTALLATION.)
15. Install the back upper trim. (Stretch cab (with Rear Access System),Regular cab)(See 09-17-19 BACK UPPER
TRIM REMOVAUINSTALLATION.)
16. Install the front seat belt upper anchor installation bolt .(Regular cab) (See 08-11-1 SEAT BELT REMOVAU
INSTALLATION.)
09-12-17
FILAMENT SWITCH REMOVAUINSTALLATION
dcf091263000w05

2. Remove the center pane unit. (vehicles with audio unit) (See 09-20-3 CENTER PANEL UNIT REMOVAU
INSTALLATION [TYPE A].)
3. Disconnect the defroster switch connector.
4. Disconnect the hazard warning switch connector.
6. Remove the defroster switch.
DCF912ZWB100
FILAMENT INSPECTION
dcf091263000w01

2. Turn the rear window defroster switch on.
Caution
Directly touching the rear window
defroster filament with the lead of the
tester could damage it. Wrap aluminum
foil around the end of the lead and
inspect the filament by touching it with
the foil.
3. Connect the positive lead of the tester to the
positive side of each filament and the negative
lead to ground.
LEAD OF VOLTMETER
ALUMINUM FOIL
A6E7736W001
4. Gradually slide the positive lead from the positive

side to the negative side and verify that the
voltage decreases accordingly.
If the voltage changes rapidly, the filament
has a malfunction. Repair the filament.
Measured part
Voltage (Reference)
(1) to (2)
Approx. 11 V to 0 V
A6E7736W002
FILAMENT REPAIR
1. Clean the filament using isopropyl alcohol.
2. Attach tape to both sides of the filament.
3. Using a small brush or marking pen, apply silver
BROKEN FILAMENT
paint.
4. After 2-3 min, carefully remove the tape without
damaging the applied area.
Caution
Do not operate 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. Dry the repaired part according to the following
procedure.
When the room temperature is 25C {77 OF},
leave it as it is for 24 h.
When a hot air blower is used, dry with the 150C {302 OF} air for 30 min.
09-12-18
dcf091263000w02
TAPE
-----
A6E7736W003
OUTER MIRROR REMOVAL/INSTALLATION
dcf091269100w01
1.
2.
3.
4.
Disconnect the negative battery cable. (Power outer mirror)

Remove the inner garnish. (See 09-17-11 INNER GARNISH REMOVAUINSTALLATION.)
Remove the front door trim. (See 09-17-17 FRONT DOOR TRIM REMOVAUINSTALLATION.)
Disconnect the power outer mirror
connector.(Power outer mirror)
5. Remove the screws.
6. Remove the outer mirror.
DCF912ZWB150
OUTER MIRROR GLASS REMOVAL/INSTALLATION
dcf091269100w07
Outer mirror glass removal

1. Press area A of the mirror glass so that area B
moves outward.
2. Pull the mirror glass holder.
OUTER MIRROR
GLASS
DCF912ZWB155
3. Detach clip A while lifting up the inside of the

mirror glass.
,,r----------------------------------------------------------,
,
,,,
,,
,,
~
CLIP A
L _____________________________________________________ _____
DCF912ZWB151
Outer mirror glass installation

1. Press part A on the outer mirror glass.
09-12-19
POWER OUTER MIRROR INSPECTION
dcf091269100w06
1. Apply battery positive voltage to the power outer

mirror terminals and inspect the operation of the
power outer mirror.
If not as specified, replace the power outer
mirror.
Mirror operation
Up
Down
Left
Return
Retract
~
t:ttt:j
M -
terminal
B+
F
C
D
A
E
GND
C
F
M)-----....I
UP/DOWN ADJUSTMENT
MOTOR
C
E
RETRACT/RETURN
MOTOR
I~~I
DCF912ZWB076
POWER OUTER MIRROR SWITCH REMOVAL/INSTALLATION

screwdriver.
panel from the front door trim.
4. Disconnect the power outer mirror switch
connector.
dcf091266600w01
HOOKA
*~
FRONT SIDE
~I
CLIPS
5. Remove the screws, then remove the power outer

mirror switch.
SWITCH PANEL
SCREW
POWER OUTER
MIRROR SWITCH
DCF912ZWB060
09-12-20
POWER OUTER MIRROR SWITCH INSPECTION
dcf091266600w02
1. Inspect for continuity between the power outer mirror switch terminals using an ohmmeter.
power outer mirror switch.
0----0 . Continuity
Operation
Up
Down
LH
Right
RH
,...
'-'
'-'
Down
Left
0-
ro
Right
RETURN/ RETURACT
RETRACT
SWITCH RETURN
Left
Up
0- ~
0- ~
~
,...
0- k>
'-'
,...
*1 : RETURN *2: RETRACT
0- ~
~
,...
~
,...
~
DCF912ZWB078
DCF912ZWB077
REARVIEW MIRROR REMOVAL/INSTALLATION
1.
2.
3.
4.
dcf09126922Ow01

Remove the covers and screw.
Remove the rearview mirror.
DCF912ZWB079
09-12-21
ALPHABETICAL INDEX
0-9
4-WHEEL DRIVE LOCATION INDEX ........... 03-18-1
4x41NDICATOR SWITCH INSPECTION ........ 03-18-2
II
AlC AMPLIFIER INSPECTION ................ 07-40-9

AlC COMPRESSOR
REMOVAUINSTALLATION ................. 07-11-6
AlC SWITCH INSPECTION ....... , .......... 07-40-10
AlC SWITCH REMOVAUINSTALLATION ....... 07-40-10
ABBREVIATIONS ......................... 00-00-32
ABS CONTROL MODULE (CM)
INSPECTION [REAR ABS) ................. 04-13A-3
ABS CONTROL MODULE (CM)
REMOVAUINSTALLATION [REAR ABS) ...... 04-13A-3
ABS HU/CM INSPECTION [4W-ABS) .......... 04-13B-5
ABS HU/CM REMOVAUINSTALLATION
[4W-ABS) ............................... 04-13B-3
ABS HU/CM SYSTEM INSPECTION
[4W-ABS) ............................... 04-13B-2
ABS HYDRAULIC UNIT (HU)
INSPECTION [REAR ABS) ................. 04-13A-2
ABS HYDRAULIC UNIT (HU)
ABS LOCATION INDEX [4W-ABS) ............ 04-13B-1
ABS LOCATION INDEX [REAR ABS) .......... 04-13A,1
ABS RELAY INSPECTION [REAR ABS) ........ 04-13A-7
ABS RELAY REMOVAUINSTALLATION
[REAR ABS) ............................ 04-13A-6
ABS SPEED SENSOR INSPECTION
[REAR ABS) ............................ 04-13A-5
ABS SPEED SENSOR
ABS SYSTEM WIRING DIAGRAM [4W-ABS) .... 04-02B-1
ACCELERATOR
PEDAL ADJUSTMENT [WL-3) .............. 01-13A-9
ACCELERATOR PEDAL
ADJUSTMENT [WL-C, WE-C] .............. 01-13B-12
REMOVAUINSTALLATION [WL-3) .......... 01-13A-9
ACCELERATOR PEDAL
COMPONENT REMOVAU
INSTALLATION [WL-C, WE-C] ............. 01-13B-11
(APP) SENSOR INSPECTION [WL-3) ....... 01-40A-20
(APP) SENSOR INSPECTION
[WL-C, WE-C] .......................... 01-40B-28
ACCESSORY SOCKET INSPECTION ......... 09-20-10
ACCESSORY SOCKET
ADJUSTER ANCHOR
AFTER REPAIR PROCEDURE [WL-3) ......... 01-02A-9
AFTER REPAIR PROCEDURE [WL-3) ......... 01-14A-5
[WL-C, WE-C] .......................... 01-02B-10
AFTER REPAIR
PROCEDURE [WL-C, WE-C] ............... 01-14B-4
AIR BAG MODULE AND
DEPLOYMENT PROCEDURES .............. 08-10-9
AIR BAG MODULE AND
DISPOSAL PROCEDURES ................. 08-10-18
(ON-BOARD DIAGNOSTIC) ................. 08-02-1
(SYMPTOM TROUBLESHOOTING) ........... 08-03-1
AIR BAG SYSTEM .......................... 08-03-1
AIR BLEEDING ............................ 04-11-3
AIR BLEEDING ............................ 06-14-3
AIR CLEANER ELEMENT
INSPECTION [WL-3) ...................... 01-13A-4
AIR CLEANER ELEMENT
INSPECTION [WL-C, WE-C) ............... 01-13B-5
AIR OUTLET DUCT
DISASSEMBLY/ASSEMBLY ................. 07-11-6
AIR OUTLET DUCT
REMOVAUINSTALLATION .................. 07-11-5
ANTI LOCK BRAKE SYSTEM WIRING
DIAGRAM [REAR ABS) .................... 04-02A-2
A-PILLAR TRIM
AUDIO CD [REFERENCE) ..................09-03D-27
AUDIO UNIT DISASSEMBLY/ASSEMBLY
[TYPE A) ................................ 09-20-4
AUDIO UNIT REMOVAUINSTALLATION
[TYPE B) ................................ 09-20-5
AXLE SHAFT REMOVAUINSTALLATION ....... 03-12-2
B
BACK LOWER TRIM
BACK UPPER TRIM
BACK-UP LIGHT SWITCH INSPECTION
[R 15M-D) ................................ 09-18-9
BACK-UP LIGHT SWITCH INSPECTION
[S15M-D, S15MX-DJ ....................... 09-18-9
BACK-UP LIGHT SWITCH
REMOVAUINSTALLATION [R15M-D) .......... 09-18-8
REMOVAUINSTALLATION
[S15M-D, S15MX-D) ....................... 09-18-8
BASIC POWER WINDOW SYSTEM
INSPECTION ............................ 09-03A-4
BATTERY INSPECTION ..................... 01-17-2
BATTERY RECHARGING .................... 01-17-4
BATTERY REMOVAUINSTALLATION .......... 01-17-2
BEFORE REPAIR PROCEDURE [WL-3) ........ 01-14A-4
BEFORE REPAIR
PROCEDURE [WL-C, WE-C] ............... 01-14B-3
BLOWER MOTOR INSPECTION ............... 07-40-2
BLOWER MOTOR
AI-1
II
.&
ALPHABETICAL INDEX
BLOWER UNIT DISASSEMBLY/ASSEMBLY ..... 07-11-2
BLOWER UNIT REMOVAUINSTALLATION ...... 07-11-2
BODY & ACCESSORIES SST ................. 09-60-1
TECHNICAL DATE. ........................ 09-50-1
BODY PANEL LOCATION INDEX .............. 09-10-1
BONNET ADJUSTMENT ..................... 09-10-3
BONNET LATCH AND RELEASE
LEVER REMOVAUINSTALLATION ............ 09-14-5
BONNET REMOVAUINSTALLATION ........... 09-10-2
BONNET SWITCH INSPECTION .............. 09-14-19
BONNET SWITCH
BOOST SENSOR INSPECTION [WL-3] ....... 01-40A-19
BOOST SENSOR INSPECTION
[WL-C, WE-C] ..........................01-40B-27
B-PILLAR LOWER TRIM
REMOVAUINSTALLATION ................ 09-17-16
B-PILLAR TRIM REMOVAUINSTALLATION ..... 09-17-15
B-PILLAR UPPER TRIM
BRAKE FLUID LEVEL SENSOR INSPECTION .... 04-11-7
BRAKE PEDAL INSPECTION ................. 04-11-4
BRAKE PEDAL REMOVAUINSTALLATION ...... 04-11-5
BRAKE SWITCH INSPECTION ................ 04-11-6
BRAKE SWITCH REMOVAUINSTALLATION ..... 04-11-5
BRAKE TECHNICAL DATA ................... 04-50-1
BRAKES SST .............................. 04-60-1
BUCKLE REMOVAUINSTALLATION ........... 08-11-7
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY

[4x2 (EXCEPT Hi-Rider)] ................... 04-11-20
CALIPER (FRONT) DISASSEMBLY/ASSEMBLY
[Hi-Rider, 4x4] ........................... 04-11-21
INSPECTION [WL-C, WE-C] ...............01-40B-37
CAMSHAFT POSITION (CMP)
SENSOR REMOVAU
CENTER PANEL REMOVAUINSTALLATION .... 09-17-13
CENTER PANEL UNIT
DISASSEMBLY/ASSEMBLY [TYPE A] ......... 09-20-4
CENTER PANEL UNIT
REMOVAUINSTALLATION [TYPE A] .......... 09-20-3
CHARGING SYSTEM LOCATION INDEX ........ 01-17-1
INSPECTION [WL-3] ...................... 01-16A...,.7
CIGARETTE LIGHTER INSPECTION ........... 09-20-9
CIGARETTE LIGHTER
CLEARING DTC ............................ 08-02-2
ADJUSTMENT ............................ 07-40-8
DISASSEMBLY/ASSEMBLY ................. 07-40-8
CLIMATE CONTROL UNIT INSTALLATION ...... 07-40-7
CLIMATE CONTROL UNIT REMOVAL .......... 07-40-7
CLOCK SPRING ADJUSTMENT ............... 08-10-7
CLOCK SPRING INSPECTION ................ 08-10-8
CLOCK SPRING REMOVAUINSTALLATION ..... 08-10-7
CLUTCH COVER INSPECTION .............. 05-10-16
CLUTCH DISC INSPECTION ................. 05-10-17
AI-2
CLUTCH FLUID AIR

BLEEDING/REPLACEMENT ................ 05-10-3
CLUTCH FLUID INSPECTION ................ 05-10-3
CLUTCH LOCATION INDEX ................. 05-10-2
CLUTCH MASTER CYLINDER'
DISASSEMBLY/ASSEMBLY ................ 05-10-8
CLUTCH PEDAL ADJUSTMENT .............. 05-10-4
SWITCH INSPECTION [WL-3] ............. 01-40A-33
SWITCH INSPECTION [WL-C, WE-C] ...... 01-40B-42
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY ... 05-10-6
CLUTCH PEDAL REMOVAUINSTALLATION .... 05-10-5
CLUTCH RELEASE COLLAR INSPECTION .... 05-10-17
DiSASSEMBLy/ASSEMBLy ............... 05-10-11
CLUTCH UNIT REMOVAUINSTALLATION ..... 05-10-12
CODE WORD INPUT PROCEDURE .......... 09-14-31
COIL REMOVAUINSTALLATION ............. 09-14-23
COLUMN COVER REMOVAUINSTALLATION ... 09-17-8
COMBINATION SWITCH
COMBINATION SWITCH
COMMON RAIL
INSPECTION [WL-C, WE-C] .............. 01-14B-14
COMPRESSION INSPECTION [WL-3] ......... 01-10A-6
COMPRESSION INSPECTION
[WL-C, WE-C] .......................... 01-10B-6
CONDENSER INSPECTION ................. 07-11-8
CONDENSER REMOVAUINSTALLATION ...... 07-11-8
CONFIRMATION STEP 1: RECEPTION
CONDITION SYMPTOM (EXAMPLE) ....... 09-03D-10
CONFIRMATION STEP 1:
AUDIO PANEL SWITCH
CONFIRMATION ........................ 09-03D-3
SYSTEM SYMPTOM (EXAMPLE) .......... 09-03D-11
SYSTEM SIMPLE INSPECTION ........... 09-03D-11
CONSOLE DiSASSEMBLy/ASSEMBLy ....... 09-17-13
CONSOLE ILLUMINATION BULB
CONSOLE REMOVAUINSTALLATION ........ 09-17-12
CONTROL BOX
CONTROL BOX
INSPECTION [WL-3] .................... 01-40A-27
CONTROL SYSTEM DIAGRAM [WL-3] ........ 01-40A-6
CONTROL SYSTEM
DIAGRAM [WL-C, WE-C] .................. 01-40B-8
CONTROL SYSTEM
LOCATIOI-J INDEX [WL-3] ................. 01-40A-2
CONTROL SYSTEM
LOCATION INDEX [WL-C, WE-C] ........... 01-40B-2
CONTROL SYSTEM
CONTROL SYSTEM
ALPHABETICAL INDEX
LOCATION INDEX ........................ 04-11-2
REMOVAUINSTALLATION [WL-3] .......... 01-12A-6
REMOVAUINSTALLATION [WL-C, WE-C] ..... 01-12B-6
COOLING FAN INSPECTION [WL-3] .......... 01-12A-9
COOLING FAN INSPECTION [WL-C, WE-C] .... 01-12B-8
COOLING FAN
REMOVAUINSTALLATION [WL-3] ........... 01-12A-8
COOLING FAN REMOVAU
INSTALLATION [WL-C, WE-C] .............. 01-12B-8
COOLING SYSTEM
CAP INSPECTION [WL-3] .................. 01-12A-5
COOLING SYSTEM CAP
INSPECTION [WL-C, WE-C] ................ 01-12B-5
COOLING SYSTEM
LOCATION INDEX [WL-3] .................. 01-12A-1
COOLING SYSTEM
LOCATION INDEX [WL-C, WE-C] ............ 01-12B-1
COOLING SYSTEM
SERVICE WARNINGS [WL-3] ............... 01-12A-2
COOLING SYSTEM SERVICE WARNINGS
[WL-C, WE-C] ........................... 01-12B-2
COOLING UNIT DiSASSEMBLy/ASSEMBLy .... 07-11-4
COOLING UNIT REMOVAUINSTALLATION ..... 07-11-3
COWL GRILLE REMOVAUINSTALLATION ...... 09-16-2
C-PILLAR TRIM REMOVAUINSTALLATION .... 09-17-17
SENSOR INSPECTION [WL-3] ............. 01-40A-31
SENSOR INSPECTION [WL-C, WE-C] ....... 01-40B-39
SENSOR REMOVAU
INSTALLATION [WL-3] ................... 01-40A-31
[WL-C, WE-C] .......................... 01-40B-38
REPLACEMENT [WL-3] ................... 01-10A-8
REPLACEMENT [WL-C, WE-C] ............. 01-10B-9
D
DASHBOARD DiSASSEMBLy/ASSEMBLy ...... 09-17-6
DASHBOARD MEMBER
DASHBOARD REMOVAUINSTALLATION ....... 09-17-4
DIAGNOSTIC ASSIST FUNCTION ............ 09-02B-4
[4x2 (EXCEPT Hi-Rider)] ................... 04-11-19
[Hi-Rider,4x4] ........................... 04-11-20
DOOR ADJUSTMENT ....................... 09-11-2
DOOR LOCATION INDEX .................... 09-11-1
DOOR LOCK CONTROL MODULE
INSPECTION ............................ 09-14-11
DOOR LOCK STRIKER
DOOR SASH FILM INSTALLATION ............ 09-16-6
DOOR SASH FILM REMOVAL ................ 09-16-6
DOOR SWITCH INSPECTION ................ 09-18-15

DOOR SWITCH REMOVAUINSTALLATION .... 09-18-15
DRIVE BELT ADJUSTMENT [WL-3] ........... 01-10A-4
DRIVE BELT ADJUSTMENT [WL-C, WE-C] ..... 01-10B-4
DRIVE BELT INSPECTION [WL-3] ............ 01-10A-3
DRIVE BELT INSPECTION [WL-C, WE-C] ...... 01-10B-3
DRIVE SHAFT LOCATION INDEX ............. 03-13-1
DRIVELINE/AXLE SST ...................... 03-60-1
DRIVELINE/AXLE TECHNICAL DATA .......... 03-50-1
DTC 01 .................................. 09-02A-2
DTC 02 .................................. 09-02A-3
DTC 03 .................................. 09-02A-3
DTC 10 [REAR ABS] .... " ................. 04-02A-9
DTC 11 [REAR ABS] ...................... 04-02A-1 0
DTC 11 .................................. 09-02A-4
DTC 12 [REAR ABS] ...................... 04-02A-1 0
DTC 13 [REAR ABS] ...................... 04-02A-11
DTC 2 [REAR ABS] ........................ 04-02A-4
DTC 21 .................................. 09-02A-4
DTC 24 .................................. 09-02A-5
DTC 3 [REAR ABS] ........................ 04-02A-4
DTC 30 .................................. 09-02A-5
DTC 4 [REAR ABS] ........................ 04-02A-5
DTC 5 [REAR ABS] ........................ 04-02A-6
DTC 6 [REAR ABS] ........................ 04-02A-7
DTC 7 [REAR ABS] ........................ 04-02A-8
DTC 8 [REAR ABS] ........................ 04-02A-8
DTC 9 [REAR ABS] ........................ 04-02A-9
DTC B 1231 ................................ 08-02-8
DTC B1317, B1318 [4W-ABS] ................ 04-02B-7
DTC B1317, B1318 ......................... 08-02-8
DTC B1342 [4W-ABS] ...................... 04-02B-8
DTC B 1342 ................................ 08-02-9
DTC B1484 [4W-ABS] ...................... 04-02B-8
DTCB1869, B1870 ........................ 08-02-10
DTC B1877, B1878, B1879, B1885 ............ 08-02-12
DTC B1881, B1882, B1883, B1886 ............ 08-02-14
DTC B1913, B1916, B1932, B1934 ............ 08-02-16
DTC B1913, B1925, B1933, B1935 ............ 08-02-18
DTC B1992, B1993, B1994, B1995 ............ 08-02-20
DTC B1996, B1997, B1998, B1999 ............ 08-02-22
DTCB2444, U2017 ........................ 08-02-24
DTCB2445, U2018 ........................ 08-02-25
DTC B2867 ............................... 08-02-27
DTC C1095, C1096 [4W-ABS] ................ 04-02B-9
DTC C1145, C1155, C1165, C1175
[4W-ABS] .............................. 04-02B-11
DTC C1186 [4W-ABS] ..................... 04-02B-12
DTC C1194, C1198, C1202, C1206,
C1210, C1214 [4W-ABS] .................. 04-02B-13
DTC C1222 [4W-ABS] ..................... 04-02B-14
DTCC1233, C1234,C1235,C1236
[4W-ABS] ............ '" ............... 04-02B-16
DTC C1414 [4W-ABS] ..................... 04-02B-17
DTC C1730, C1949, C1950 [4W-ABS] ......... 04-02B-18
DTC DISPLAY ............................. 08-02-2
DTC P0016 [WL-C, WE-C] .................. 01-02B-15
DTC P0045 [WL-C, WE-C] .................. 01-02B-16
DTC P0046 [WL-C, WE-C] .................. 01-028-18
DTC P0047 [WL-C, WE-C] .................. 01-02B-19
DTC P0048 [WL-C, WE-C] .................. 01-028-21
DTC P0088 [WL-C, WE-C] .................. 01-02B-23
DTC P0093 [WL-C, WE-C] .................. 01-02B-24
AI-3
11
..
ALPHABETICAL INDEX
DTC P0097 [WL-C, WE-C] .................. 01-02B-25
DTC P0098 [WL-C, WE-C] .................. 01-02B-27
DTC P0100 [WL-3] ........................01-02A-13
DTC P0102 [WL-C, WE-C] .................. 01-02B-29
DTC P01 03 [WL-C, WE-C] ..................01-02B-31
DTC P0105 [WL-3] ........................ 01-02A-15
DTC P0106 [WL-C, WE-C] .................. 01-02B-33
DTC P0107 [WL-C, WE-C] .................. 01-02B-35
DTC P0108 [WL-C, WE-C] .................. 01-02B-38
DTC P0110 [WL-3] ........................01-02A-18
DTC P0112 [WL-C, WE-C] .................. 01-02B-41
DTC P0113 [WL-C, WE~C] .................. 01-02B-42
DTC P0115 [WL-3] ........................ 01-02A-20
DTC P0117 [WL-C, WE-C] .................. 01-02B-44
DTC P0118 [WL-C, WE-C] ..................01-02B-46
DTC P0120 [WL-3] ........................01-02A-22
DTC P0122 [WL-C, WE-C] .................. 01-02B-48
DTC P0123 [WL-C, WE-C] .................. 01-02B-50
DTC P0180 [WL-3] ........................01-02A-26
DTC P0182 [WL-C, WE-C] .................. 01-02B-52
DTC P0183 [WL-C, WE-C] .................. 01-02B-54
DTC P0191 [WL-C, WE-C] .................. 01-02B-56
DTC P0192 [WL-C, WE-C] .................. 01-02B-57
. DTC P0193 [WL-C, WE-C] .................. 01-02B-59
DTC P0201 [WL-C, WE-C] .................. 01-02B-61
DTC P0202 [WL-C, WE-C] .................. 01-02B-62
DTC P0203 [WL-C, WE-C] .................. 01-02B-64
DTC P0204 [WL-C, WE-C] .................. 01-02B-66
DTC P0222 [WL-C, WE-C] ..................01-02B-68
DTC P0223 [WL-C, WE-C] ..................01-02B-71
DTC P0227 [WL-C, WE-C] .................. 01-02B-74
DTC P0228 [WL-C, WE-C] .................. 01-02B-76
DTC P0251 [WL-3] ........................01-02A-28
DTC P0300 [WL-C, WE-C] .................. 01-02B-78
DTC P0301, P0302, P0303,
P0304 [WL-C, WE-C] ..................... 01-02B-80
DTC P0335 [WL-3] ........................ 01-02A-31
DTC P0335 [WL-C, WE-C] .................. 01-02B-81
DTC P0340 [WL-C, WE-C] ..................01-02B-84
DTC P0380 [WL-C, WE-C] ..................01-02B-86
DTC P0400 [WL-3] ........................01-02A-33
DTC P0403 [WL-C, WE-C] .................. 01-02B-89
DTC P0405 [WL-C, WE-C] .................. 01-02B-91
DTC P0406 [WL-C, WE-C] .................. 01-02B-93
DTC P0489 [WL-C, WE-C] .................. 01-02B-95
DTC P0490 [WL-C, WE-C] .................. 01-02B-96
DTC P0500 [WL-3] ........................ 01-02A-34
DTC P0500 [WL-C, WE-C] .................. 01-02B-98
DTC P0510 [WL-3] ........................01-02A-36
DTC P0563 [WL-C, WE-C] .................01-02B-100
DTC P0602 [WL-C, WE-C] .................01-02B-102
DTC, P0606 [WL-3] ........................01-02A-37
DTC P0606, P2530 [WL-C, WE-C] ........... 01-02B-102
DTC P0607 [WL-C, WE-C] .................01-02B-102
DTC P0610 [WL-C, WE-C] .................01-02B-103
DTC P0627 [WL-C, WE-C] ................. 01-02B-104
DTC P0628 [WL-C, WE-C] .................01-02B-106
DTC P0629 [WL-C, WE-C] ................. 01-02B-107
DTC P0642 [WL-C, WE-C] ................. 01-02B-109
DTC P0643 [WL-C, WE-C] ................. 01-02B-112
DTC P0652 [WL-C, WE-C] ................. 01-02B-116
DTC P0653 [WL-C, WE-C] ................. 01-02B-119
DTC P0660 [WL-C, WE-C] ................. 01-02B-123
DTC P0661 [WL-C, WE-C] ........, ......... 01-02B-125
DTC P0662 [WL-C, WE-C] .................01-02B-127
AI-4
DTC P0663 [WL-C, WE-C] ................ 01-02B-128

DTC P0664 [WL-C, WE-C] ................ 01-02B-130
DTC P0665 [WL-C, WE-C] ................ 01-02B-132
DTC P0685 [WL-C, WE-C] ................ 01-02B-134
DTC P0698 [WL-C, WE-C] ................ 01-02B-136
DTC P0699 [WL-C, WE-C] ................ 01-02B-138
DTC P1110 [WL-3] ....................... 01-02A-38
DTC P1182 [WL-3] ....................... 01-02A-40
DTC P1189 [WL-3] ....................... 01-02A-42
DTC P1195 [WL-3] ....................... 01-02A-44
DTC P1196 [WL-C, WE-C] ................ 01-02B-141
DTC P1226 [WL-3] ....................... 01-02A-44
DTC P1259 [WL-C, WE-C] ................ 01-02B-142
DTC P1260 [WL-C, WE-C] ................ 01-02B-144
DTC P1312 [WL-3] ....................... 01-02A-46
DTC P1318 [WL-3] ....................... 01-02A-49
DTC P1391 [WL-C, WE-C] ................ 01-02B-144
DTC P1392 [WL-C, WE-C] ................ 01-02B-147
DTC P1402 [WL-3] ....................... 01-02A-51
DTC P1602 [WL-C, WE-C] ................ 01-02B-149
DTC P1603 [WL-C, WE-C] ................ 01-02B-149
DTC P1604 [WL-C, WE-C] ................ 01-02B-150
DTC P1621, P1622, P1623,
P1624 [WL-C, WE-C] ................... 01-02B-150
DTC P1649 [WL-3] ....................... 01-02A-54
DTC P1675 [WL-C, WE-C] ................ 01-02B-151
DTC P1676 [WL-C, WE-C] ................ 01-02B-152
DTC P1812 ............................... 03-02-2
DTC P1813 ............................... 03-02-4
DTC P1814 ............................... 03-02-6
DTC P1815 ............................... 03-02-8
DTC P1878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-02-10
DTC P1879 .............................. 03-02-11
DTC P1880 .............................. 03-02-12
DTC P1885 .............................. 03-02-14
DTC P2135 [WL-C, WE-C] ................ 01-02B-152
DTC P2136 [WL-C, WE-C] ................ 01-02B-153
DTC P2143 [WL-C, WE-C] ................ 01-02B-154
DTC P2144 [WL-C, WE-C] ................ 01-02B-156
DTC P2145 [WL-C, WE-C] ................ 01-02B-158
DTC P2146 [WL-C, WE-C] ................ 01-02B-160
DTC P2147 [WL-C, WE-C] ................ 01-02B-160
DTC P2148 [WL-C, WE-C] ................ 01-02B-162
DTC P2149 [WL-C, WE-C] ................ 01-02B-164
DTC P2150 [WL-C, WE-C] ................ 01-02B-165
DTC P2151 [WL-C, WE-C] ................ 01-02B-167
DTC P2227 [WL-C, WE-C] ................ 01-02B-170
DTC P2228 [WL-C, WE-C] ................ 01-02B-170
DTC P2229 [WL-C, WE-C] ................ 01-02B-171
DTC TABLE [AUDIO SYSTEM] .............. 09-02B-2
DTC TABLE [WL-3] ....................... 01-02A-11
DTC TABLE [WL-C, WE-C] ..... '.~ .......... 01-02B-11
DTC TABLE ............................... 08-02-3
DTC TABLE [IMMOBILIZER SYSTEM] ........ 09-02A-2
DUAL-MASS FLYWHEEL
INSPECTION [S15M-D, S15MX-D] .......... 05-10-19

VALVE INSPECTION [WL-3] ............... 01-16A-6
INSPECTION [WL-C, WE-C] ............... 01-16B-6
ALPHABETICAL INDEX
EGR SOLENOID VALVE (VACUUM)
INSPECTION [WL-3] ..................... 01-16A-5
EGR SOLENOID VALVE (VENT)
INSPECTION [WL-3] ...................... 01-16A-5
EGR SOLENOID VALVE
INSPECTION [WL-C, WE-C] ............... 01-168-5
EGR SYSTEM
EGR SYSTEM REMOVAU
INSTALLATION [WL-C, WE-C] .............. 01-168-4
EGR VALVE INSPECTION [WL-3] ............ 01-16A-5
EGR VALVE INSPECTION [WL-C, WE-C] ...... 01-168-5
INSPECTION [WL-3] .................... 01-40A-32
INSPECTION [WL-C, WE-C] .............. 01-408-40
ELECTRICAL SYSTEM ..................... 00-00-19
ELECTRONIC GOVERNOR
INSPECTION [WL-3] .................... 01-14A-15
EMISSION SYSTEM DIAGRAM [WL-3] ........ 01-16A-3
EMISSION SYSTEM
DIAGRAM [WL-C, WE-C] .................. 01-168-3
EMISSION SYSTEM
EMISSION SYSTEM
LOCATION INDEX [WL-C, WE-C] ............ 01-168-1
OPERATION INSPECTION [WL-3] .......... 01-03A-35
ENGINE CONTROL SYSTEM OPERATION
INSPECTION [WL-C, WE-C] ............... 01-038-62
ENGINE COOLANT
LEAKAGE INSPECTION [WL-3] ............ 01-12A-5
INSPECTION [WL-C, WE-C] ................ 01-128-5
ENGINE COOLANT
LEVEL INSPECTION [WL-3] ................ 01-12A-2
ENGINE COOLANT
LEVEL INSPECTION [WL-C, WE-C] .......... 01-128-2
ENGINE COOLANT
PROTECTION INSPECTION [WL-3] .......... 01-12A-2
ENGINE COOLANT
PROTECTION INSPECTION [WL-C, WE-C] ... 01-128-2
ENGINE COOLANT REPLACEMENT [WL-3] .... 01-12A-3
ENGINE COOLANT
REPLACEMENT [WL-C, WE-C] ............. 01-128-3
(ECT) SENSOR INSPECTION [WL-3] ....... 01-40A-26
(ECT) SENSOR INSPECTION
[WL-C, WE-C] .......................... 01-408-35
(ECT) SENSOR REMOVAU
INSTALLATION [WL-3] ................... 01-40A-26
(ECT) SENSOR REMOVAU
INSTALLATION [WL-C, WE-C] ............. 01-408-34
ENGINE DISASSEM8LY/ASSEM8LY
[WL-3] ................................ 01-10A-20
ENGINE DISASSEM8LY/
ASSEM8LY [WL-C, WE-C] ................ 01-103-21
ENGINE OIL LEVEL INSPECTION [WL-3] ...... 01-11A-2
ENGINE OIL LEVEL INSPECTION
[WL-C, WE-C] ........................... 01-118-2
ENGINE OIL REPLACEMENT [WL-3] .......... 01-11A-3
ENGINE OIL REPLACEMENT

[WL-C, WE-C] ........................... 01-118-3
ENGINE REMOVAU
INSTALLATION [WL-C, WE-C] ............. 01-108-19
ENGINE REMOVAUINSTALLATION [WL-3] .... 01-10A-18
ENGINE SST [WL-3] ....................... 01-60A-1
ENGINE SST [WL-C, WE-C] ................. 01-608-1
ENGINE SWITCH INSPECTION ............... 09-21-3
ENGINE SWITCH REMOVAUINSTALLATION .... 09-21-2
ENGINE TECHNICAL DATA [WL-3] ............ 01-00-1
ENGINE TECHNICAL DATA [WL-3] ........... 01-50A-1
ENGINE TECHNICAL DATA [WL-C, WE-C] ..... 01-508-1
ENGINE TUNE-UP [WL-3] .................. 01-10A-20
ENGINE TUNE-UP [WL-C, WE-C] ............ 01-108-21
ENTERTAINMENT LOCATION INDEX .......... 09-20-2
EVAPORATIVE CHAM8ER
INSPECTION [WL-3] ...................... 01-16A-7
EVAPORATOR INSPECTION ................. 07-11-5
EXHAUST SYSTEM INSPECTION [WL-3] ...... 01-15A-1
EXHAUST SYSTEM
INSPECTION [WL-C, WE-C] ................ 01-158-1
EXHAUST SYSTEM
EXHAUST SYSTEM
REMOVAUINSTALLATION [WL-C, WE-C] ..... 01-158-2
EXTERIOR TRIM LOCATION INDEX ........... 09-16-1
F
FAN SWITCH INSPECTION ................. 07-40-10
FILAMENT INSPECTION .................... 09-12-18
FILAMENT REPAIR ........................ 09-12-18
FILAMENT SWITCH
FLASHER UNIT INSPECTION ................ 09-18-12
FLASHER UNIT REMOVAUINSTALLATION .... 09-18-12
FLOOR COVERING
FLYWHEEL INSPECTION [R15M-D] ........... 05-10-18
FOREWORD [4W-A8S] ..................... 04-038-2
FOREWORD [RADIO] ...................... 09-03D-9
FOREWORD [REAR A8S] ................... 04-03A-1
FOREWORD [WL-3]. ....................... 01-02A-4
FOREWORD [WL-C, WE-C] ................. 01-028-6
FOREWORD .............................. 03-03-1
FOREWORD ...................... '" ..... 07-03-1
FOREWORD .............................. 08-02-1
FOREWORD ............................. 09-03A-2
FOREWORD ...................... '" .... 09-038-1
FOREWORD [CD PLAYER/CHANGER] ....... 09-03D-17
FOREWORD [ENTIRE AUDIO SYSTEM] ....... 09-03D-1
FOREWORD [IMM081L1ZER SYSTEM] ........ 09-02A-1
FREEZE FRAME DATA [WL-C, WE-C] ......... 01-028-6
FRONT A8S WHEEL-SPEED SENSOR
INSPECTION ............................ 04-138-9
REMOVAUINSTALLATION
[4W-A8S (4x2 (EXCEPT Hi-Rider))] .......... 04-138-7
REMOVAUINSTALLATION
[4W-A8S (Hi-Rider, 4x4)] ................... 04-138-8
[4x2 (EXCEPT Hi-Rider)] ................... 03-11-1
FRONT AXLE LOCATION INDEX [4x4] .......... 03-11-2
AI-5
II
i.
ALPHABETICAL INDEX
FRONT AXLE LOCATION INDEX [Hi-Rider] ...... 03-11-2
FRONT BELTLiNE MOLDING
FRONT BRAKE (DISC) INSPECTION .......... 04-11-15
FRONT BRAKE (DISC)
REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] ................... 04-11-16
FRONT BRAKE (DISC)
REMOVAUINSTALLATION [Hi-Rider, 4x4] ..... 04-11-17
FRONT BUMPER REINFORCEMENT
FRONT BUMPER DISASSEMBLY/ASSEMBLY ... 09-10-7
FRONT BUMPER REMOVAUINSTALLATION .... 09-10-6
FRONT DIFFERENTIAL ASSEMBLY .......... 03-14A-8
FRONT DIFFERENTIAL DISASSEMBLY ....... 03-14A-4
FRONT DIFFERENTIAL LOCATION INDEX ..... 03-14A-1
FRONT DIFFERENTIAL OIL INSPECTION ...... 03-14A-1
FRONT DIFFERENTIAL OIL REPLACEMENT ... 03-14A-2
FRONT DIFFERENTIAL
REMOVAUINSTALLATION ................. 03-14A-2
FRONT DOOR GLASS
FRONT DOOR INNER HANDLE
FRONT DOOR LATCH AND LOCK
ACTUATOR INSPECTION ................... 09-14-7
FRONT DOOR LATCH AND
LOCK ACTUATOR
FRONT DOOR TRIM
FRONT DOOR UNIT
FRONT DOOR REMOVAUINSTALLATION ... : .. 09-11-2
FRONT DRIVE SHAFT
DiSASSEMBLy/ASSEMBLy ................. 03-13-4
FRONT DRIVE SHAFT INSPECTION ........... 03-13-1
FRONT DRIVE SHAFT
FRONT FENDER PANEL
FRONT FLAP REMOVAUINSTALLATION ....... 09-16-4
FRONT FOG LIGHT AIMING .................. 09-18-5
FRONT FOG LIGHT BULB
FRONT FOG LIGHT
FRONT FOG LIGHT SWITCH INSPECTION ..... 09-18-10
FRONT LOWER ARM INSPECTION ........... 02-13-13
FRONT MANUAL WINDOW REGULATOR
FRONT OIL SEAL REPLACEMENT [WL-3] ..... 01-10A-15
FRONT OIL SEAL
REPLACEMENT [WL-C, WE-C] ............. 01-10B-16
FRONT OUTER HANDLE
FRONT POWER WINDOW MOTOR
FRONT POWER WINDOW REGULATOR
FRONT SCUFF PLATE
FRONT SEAT DiSASSEMBLy/ASSEMBLy ...... 09-13-4
AI-6
FRONT SEAT REMOVAUINSTALLATION ...... 09-13-4

FRONT SHOCK ABSORBER DISPOSAL ....... 02-13-5
FRONT SHOCK ABSORBER INSPECTION ..... 02-13-4
FRONT SIDE TRIM
FRONT SIDE TURN LIGHT
FRONT SPEAKER INSPECTION .............. 09-20-5
FRONT SPEAKER
FRONT STABILIZER AND TENSION
ROD REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] .................. 02-13-16
FRONT STABILIZER REMOVAUINSTALLATION
[Hi-Rider,4x4] .......................... 02-13-17
INDEX [4x2 (EXCEPT Hi-Rider)] ............. 02-13-1
INDEX [4x4] ............................. 02-13-3
INDEX [Hi-Rider] .......................... 02-13-2
FRONT TURN LIGHT BULB
FRONT UPPER ARM INSPECTION ........... 02-13-16
FRONT UPPER ARM
FRONT WHEEL ALIGNMENT [4x2] ............ 02-11-3
FRONT WHEEL ALIGNMENT [4x4] ............ 02-11-5
INSPECTION [WL-3] .................... 01-14A-21
REMOVAUINSTALLATION [WL-3] ......... 01-14A-21
FUEL FILTER
FUEL FILTER REMOVAU
FUEL GAUGE SENDER UNIT INSPECTION .... 09-22-12
FUEL INJECTION PUMP
INSPECTION [WL-3] .................... 01-14A-13
FUEL INJECTION PUMP
FUEL INJECTOR CODE PROGRAM
[WL-C, WE-C] ......................... 01-40B-21
FUEL INJECTOR
FUEL INJECTOR REMOVAU
FUEL METERING
VALVE INSPECTION [WL-C, WE-C] ........ 01-14B-13
INSPECTION [WL-3] .................... 01-40A-24
FUEL SYSTEM DIAGRAM [WL-3] ............ 01-14A-4
FUEL SYSTEM DIAGRAM [WL-C, WE-C] ...... 01-14B-3
FUEL SYSTEM LOCATION INDEX [WL-3] ..... 01-14A-2
FUEL SYSTEM
LOCATION INDEX [WL-C, WE-C] ........... 01-14B-1
FUEL TANK INSPECTION [WL-3] ............ 01-14A-9
FUEL TANK INSPECTION [WL-C, WE-C] ...... 01-14B-8
FUEL TANK
ALPHABETICAL INDEX
FUEL TANK REMOVAU
INSPECTION [WL-3] .................... 01-40A-23
FUEL-FILLER LID ADJUSTMENT .............. 09-10-2
FUEL-FILLER LID AND OPENER
FUEL-FILLER LID REMOVAUINSTALLATION .... 09-10-2
FUEL-INLET FILTER
FUEL-INLET FILTER
REMOVAUINSTALLATION [WL-C, WE-C] .... 01-14B-14
FUSE SERVICE CAUTIONS .................. 09-21-2
II
HEADLIGHT BULB
HEADLINER REMOVAUINSTALLATION ....... 09-17-21
AIR CONDITIONING (HVAC) SST ............ 07-60-1
HIGH-MOUNT BRAKE LIGHT
HORN RELAY INSPECTION ................. 09-22-14
HORN RELAY REMOVAUINSTALLATION ...... 09-22-14
HORN REMOVAUINSTALLATION ............ 09-22-14
HOW TO USE THIS MANUAL ................. 00-00-2
HVAC BASIC SYSTEM LOCATION INDEX ....... 07-11-1
HVAC CONTROL SYSTEM LOCATION INDEX ... 07-40-1
HVAC TECHNICAL DATA .................... 07-50-1
II
G SENSOR INSPECTION [4W-ABS] ......... 04-13B-13

G SENSOR REMOVAUINSTALLATION
[4W-ABS] .............................. 04-13B-12
GENERAL PRECAUTION (STEERING) ......... 06-10-1
GENERAL PROCEDURES (BRAKE) ........... 04-10-1
GENERAL PROCEDURES
(FRONT AND REAR AXLES) ................ 03-10-1
GENERAL PROCEDURES (SUSPENSION) ..... 02-10-1
GENERAL PROCEDURES (CLUTCH) .......... 05-10-3
GENERATOR DISASSEMBLY/ASSEMBLY ...... 01-17-8
GENERATOR INSPECTION .................. 01-17-5
GENERATOR REMOVAUINSTALLATION ....... 01-17-4
LOCATION INDEX ........................ 09-12-2
GLOVE COMPARTMENT LIGHT BULB
GLOVE COMPARTMENT
GLOVE COMPARTMENT UPPER
GLOW PLUG CORD INSPECTION [WL-3] ...... 01-13A-8
GLOW PLUG CORD
GLOW PLUG INSPECTION [WL-3] ............ 01-13A-6
GLOW PLUG INSPECTION [WL-C, WE-C] ..... 01-13B-9
GLOW PLUG RELAY INSPECTION [WL-3] ..... 01-13A-7
GLOW PLUG RELAY
GLOW PLUG RELAY
GLOW PLUG RELAY REMOVAU
GLOW PLUG
GLOW PLUG REMOVAU
GUIDE BLADE ACTUATOR
Il
HAZARD WARNING SWITCH INSPECTION .... 09-18-10

HAZARD WARNING SWITCH
HEADLIGHT AIMING ........................ 09-18-4
~OCATIONS
IDENTIFICATION NUMBER
....... 00-00-29
IDLE SWITCH INSPECTION [WL-3] .......... 01-40A-22
IDLE SWITCH INSPECTION [WL-C, WE-C] .... 01-40B-30
IG KEY ILLUMINATION BULB
IMMOBILIZER SYSTEM LOCATION INDEX ...... 09-14-4
IMMOBILIZER SYSTEM REPROGRAM
PROCEDURE ........................... 09-14-24
IMMOBILIZER UNIT INSPECTION ............ 09-14-22
IMMOBILIZER UNIT
INJECTION NOZZLE
DISASSEMBLY/ASSEMBLY [WL-3] ......... 01-14A-18
INJECTION NOZZLE INSPECTION [WL-3] ..... 01-14A-19
INJECTION NOZZLE
INSPECTION [WL-3] ..................... 01-40A-29
INNER GARNISH REMOVAUINSTALLATION ... 09-17-11
INSTALLATION [R15M-D] .................. 05-11A-6
INSTALLATION [S15M-D] ................. 05-11B-12
AND TRANSFER INSTALLATION
[S15MX-D] ............................. 05-11B-12
INSPECTION OF SST (DEPLOYMENT TOOL) ... 08-10-19
INSTALLATION OF RADIO SYSTEM .......... 00-00-18
INSTRUMENT CLUSTER
INSTRUMENT CLUSTER
INPUT/OUTPUT CHECK MODE ............. 09-22-4
INSTRUMENT CLUSTER INSPECTION ......... 09-22-2
INSTRUMENT CLUSTER
LOCATION INDEX ......................... 09-22-1
SENSOR NO.1 INSPECTION [WL-3] ........ 01-40A-18
~~~~~~_~i1. I~~:.E.~~I.~~
III
.............. 01-40B-26
(FULL) INSPECTION [WL-C, WE-C] ......... 01-16B-7
(HALF) INSPECTION [WL-C, WE-C] ......... 01-16B-6
AI-7
ALPHABETICAL INDEX
INSPECTION [WL-C, WE-C] ................ 01-16B-7
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
LOCATION INDEX [WL-C, WE-C] ............ 01-13B-1
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
REMOVAUINSTALLATION [WL-C, WE-C] ..... 01-13B-3
INTAKE-AIR SYSTEM VACUUM
HOSE ROUTING DIAGRAM [WL-3] .......... 01-13A-2
INTAKE-AIR SYSTEM VACUUM HOSE
ROUTING DIAGRAM [WL-C, WE-C] .......... 01-13B-2
INTERIOR LIGHT INSPECTION .............. 09-18-14
INTERIOR LIGHT REMOVAUINSTALLATION ... 09-18-13
INTERIOR TRIM LOCATION INDEX ............ 09-17-2
TROUBLESHOOTING [WL-3] .............. 01-03A-33
TROUBLESHOOTING [WL-C, WE-C] ........ 01-03B-60
J
JACKING POSITIONS ...................... 00-00-25
JOINT SHAFT COMPONENT ASSEMBLY ....... 03-18-9
JOINT SHAFT COMPONENT DISASSEMBLY .... 03-18-7
K
KEY REMINDER SWITCH INSPECTION ........ 09-21-3
KEY REMINDER SWITCH
KEYLESS CONTROL MODULE
KEYLESS CONTROL MODULE INSPECTION ... 09-14-13
KEYLESS ENTRY SYSTEM CHECK SHEET .... 09-03B-2
PRELIMINARY INSPECTION ...............09-03B-3
WIRING DIAGRAM ....................... 09-03B-1
KOEO/KOER SELF TEST [WL-3] ............ 01-02A-10
KOEO/KOER SELF TEST [WL-C, WE-C] ...... 01-02B-10
L
LICENSE PLATE LIGHT
LIGHT SWITCH INSPECTION ................ 09-18-11
LIGHT SWITCH REMOVAUINSTALLATION ..... 09-18-11
LIGHTING SYSTEMS LOCATION INDEX ........ 09-18-2
VALVE (LSPV) ADJUSTMENT .............. 04-11-13
'
VALVE (LSPV) INSPECTION ............... 04-11-12
VALVE (LSPV) REMOVAUINSTALLATION .... 04-11-14
LOCATION INDEX [WL-3] ...................01-11A-1
LOCATION INDEX [WL-C, WE-C] ............. 01-11B-1
AI-8
LOCATION INDEX ......................... 08-10-1

LOCATION INDEX ......................... 08-11-1
VALVES INSPECTION ..................... 03-18-4
LOWER PANEL REMOVAUINSTALLATION .... 09-17-10
M
MAGNETIC CLUTCH ADJUSTMENT ........... 07-40-4
MAGNETIC CLUTCH INSPECTION ............ 07-40-5
MAGNETIC CLUTCH
MAIN FUSE REMOVAUINSTALLATION ....... , 09-21-2
MAIN RELAY INSPECTION [WL-3] .......... 01-40A-14
MAIN RELAY INSPECTION [WL-C, WE-C] .... 01-40B-23
INDEX [R15M-D] ......................... 05-11A-1
INDEX [S15M-D, S15MX-D] ................ 05-118-2
DATA RESET [WL-C, WE-C] .............. 01-40B-22
MASS AIR FLOW (MAF) SENSOR/
SENSOR NO.2 INSPECTION [WL-3] ........ 01-40A-15
MASS AIR FLOW (MAF) SENSOR/
[WL-C, WE-C] .......................... 01-40B-23
MASTER CYLINDER
MASTER CYLINDER
MECHANICAL LOCATION INDEX [WL-3] ...... 01-10A-2
MECHANICAL LOCATION
INDEX [WL-C, WE-C] .................... 01-10B-2
MEMORY CLEARING PROCEDURE .......... 09-02B-2
METER HOOD REMOVAUINSTALLATION ...... 09-17-8
N
NEUTRAL SWITCH INSPECTION [WL-3] ..... 01-40A-34
NEUTRAL SWITCH INSPECTION
[WL-C, WE-C] ......................... 01-40B-43
NEUTRAL SWITCH REMOVAUINSTALLATION
[R 15M-D] ............................... 05-11 A-2
NEUTRAL SWITCH REMOVAUINSTALLATION
[S15M-D, S15MX-D] ...................... 05-11 B-3
NEW STANDARDS ........................ 00-00-30
NO.1 ON-BOARD DIAGNOSTIC
FUNCTION INOPERATIVE ................ 09-03B-5
NO.1 THE AUTO OPEN/CLOSE
FUNCTION ON THE DRIVER'S SIDE
POWER WINDOW IS INOPERATIVE
[WITH AUTOMATIC DOOR GLASS
RETURN FUNCTION] .................... 09-03A-7
WINDOW INOPERATIVE .................. 09-03A-7
NO.2 TRANSMITTER ID CODE
CANNOT BE REPROGRAMMED ........... 09-03B-7
OPERATE BY SUBSWITCH ............... 09-03A-9
ALPHABETICAL INDEX
OPERATE 8Y MAIN SWiTCH ............... 09-03A-9
OPERATE 8Y MAIN SWITCH AND
SU8SWITCH ............................ 09-03A-9
WINDOW AUTOMATICALLY OPENS
IN THE CLOSING OPERATION ............ 09-03A-11
NO.7 A8NORMAL NOISE DURING
THE POWER WINDOW OPERATION ........ 09-03A-13
NO.1 A8S WARNING LIGHT
ENGINE SWITCH IS TURNED ON.
[REAR A8S] ............................ 04-03A-3
ILLUMINATE WHEN THE ENGINE
POSITION [4W-A8S] ...................... 04-038-6
NO.1 AF NOISE OR POP NOISE ON
ALL SOURCES (RADIO, CD) ............... 09-030-3
NO.1 AIR 8AG SYSTEM WARNING
LIGHT DOES NOT ILLUMINATE .... , ........ 08-03-1
DOES NOT LOAD THE CD OR
EJECTS THE CD IMMEDIATELY ........... 09-030-19
NO.1 INSUFFICIENT AIR (OR NO AIR)
8LOWN FROM VENTS ..................... 07-03-1
NO.1 MELTING OF MAIN OR
OTHER FUSES [WL-3] .................... 01-03A-8
NO.1 MELTING OF MAIN OR OTHER
FUSES [WL-C, WE-C] ................... 01-038-14
NO.1 NO RADIO RECEPTION
(AM/FM)/NO OR LOW VOLUME ............ 09-030-11
FREE TO LOCK (RFW INDICATOR
LIGHT DOES NOT ILLUMINATE) ............ 03-03-3
No.1 SECURITY LIGHT DISPLAY IS
NOT NORMAL. .......................... 09-03C-1
THE AUDIO DATA (CODA) ................ 09-030-24
NO.10 LACK/LOSS OF POWER [WL-3] ....... 01-03A-20
NO,10 LOW IDLE/STALLS DURING
DECELERATION [WL-C, WE-C] ............ 01-038-30
8UCK/JERK, HESITATION/STUM8LE,
SURGES [WL-C, WE-C] .................. 01-038-32
NO.11 POOR FUEL ECONOMY [WL-3] ....... 01-03A-22
NO.11 TRACK CHANGE IS INOPERATIVE .... 09-030-25
LEAKAGE [WL-3] ....................... 01-03A-24
NO.12 LACK/LOSS OF
POWER-ACCELERATION/CRUISE
[WL-C, WE-C] .......................... 01-038-35
CONCERNS-OVERHEATING [WL-3] ........ 01-03A-25
NO.13 KNOCKING/PINGING [WL-C, WE-C] ... 01-038-38
CONCERNS-RUNS COLD [WL-3] .......... 01-03A-26
NO.14 POOR FUEL ECONOMY
[WL-C, WE-C] .......................... 01-038-41
NO.15 EMISSION COMPLIANCE
[WL-C, WE-C] .......................... 01-038-44
NO.15 EXCESSIVE 8LACK SMOKE [WL-3] .... 01-03A-26

NO.16 ENGINE NOISE [WL-3] ............... 01-03A-27
LEAKAGE [WL-C, WE-C] .................. 01-038-47
CONCERNS-OVERHEATING
[WL-C, WE-C] .......................... 01-038-48
(ENGINE) [WL-3] ....................... 01-03A-29
SUFFICIENTLY [WL-3] ................... 01-03A-29
CONCERNS-RUNS COLD [WL-C, WE-C] .... 01-038-50
COMPRESSOR RUNS
CONTINUOUSLY [WL-3] .................. 01-03A-30
NO.19 EXCESSIVE 8LACK SMOKE
[WL-C, WE-C] .......................... 01-038-50
NO.2 A8S WARNING LIGHT REMAINS
ILLUMINATED WITH THE ENGINE
SWITCH IS TURNED ON. [REAR A8S] ....... 04-03A-4
THE ENGINE SWITCH IS TURNED
TO THE ON POSITION [4W-A8S] ............ 04-038-7
NO.2 AIR 8AG SYSTEM WARNING
LIGHT ILLUMINATES CONSTANTLY .......... 08-03-3
NO.2 AMOUNT OF AIR 8LOWN FROM
VENTS DOES NOT CHANGE ................ 07-03-2
DOES NOT EJECT THE CD ............... 09-030-19
NO.2 ENGINE CHECK LAMP
ILLUMINATES [WL-C, WE-C] .............. 01-038-15
NO.2 NO POWER ON THE ENTIRE
AUDIO SYSTEM ......................... 09-030-4
LOCK TO FREE (RFW INDICATOR
LIGHT DOES NOT GO OFF) ................. 03-03-5
NO.2 NOISE FROM RADIO (AM ONLy) ....... 09-030-13
NO.2 WILL NOT CRANK [WL-3] .............. 01-03A-9
NO.20 FUEL ODOR (IN ENGINE
COMPARTMENT) [WL-C, WE-C] ........... 01-038-53
NO.20 INTERMITTENT CONCERNS [WL-3] .... 01-03A-31
NO.21 CONSTANT VOLTAGE [WL-3] ......... 01-03A-31
NO.21 ENGINE NOISE [WL-C, WE-C] ........ 01-038-54
(ENGINE) [WL-C, WE-C] ................. 01-038-56
SUFFICIENTLY [WL-C, WE-C] ............. 01-038-57
COMPRESSOR RUNS CONTINUOUSLY
[WL-C, WE-C] .......................... 01-038-59
NO.25 AlC DOES NOT CUT OFF
UNDER WIDE OPEN THROTTLE
CONDITIONS [WL-C, WE-C] ............... 01-038-59
NO.3 A8S WARNING LIGHT STAYS
ON 4 S OR MORE WHEN THE ENGINE
POSITION [4W-A8S] ...................... 04-038-7_
DOES NOT PLAY THE CD/NO SOUND ...... 09-030-20
NO.3 HARD TO START/LONG
CRANK/ERRATIC START/ERRATIC
CRANK [WL-3] ......................... 01-03A-10
IiJII
AI-9
ALPHABETICAL INDEX
NO.3 NO SOUND FROM ALL THE
SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09-03D-5
NO.3 NO TEMPERATURE CONTROL
WITH CLIMATE CONTROL UNIT ............. 07-03-3
NO.3 NOISE FROM RADIO (FM ONLY) ...... 09-03D-14
NO.3 NOISE ............................... 03-03-7
NO.3 WHEN THE ENGINE SWITCH IS
TURNED ON THE ABS WARNING
LIGHT BLINKS ONCE AND THEN
REMAINS ILLUMINATED. [REAR ABS] ....... 04-03A-6
NO.3 WILL NOT CRANK [WL-C, WE-C] ....... 01-03B-15
NO.4 ABS WARNING LIGHT FLASHES
ON AND OFF WHEN ENGINE SWITCH
IS TURNED ON OR VEHICLE IS
DRIVEN. [REAR ABS] ..................... 04-03A-6
NO.4 AIR FROM VENTS COLD ENOUGH ....... 07-03-4
NO.4 CANNOT TUNE
(SEEK DOES NOT STOP) ................ 09-03D-16
NO.4 ENGINE STALLS-AFTER
START/AT IDLE [WL-3] ...................01-03A-11
NO.4 HARD START/LONG CRANKI
CRANK [WL-C, WE-C] .................... 01-03B-17
NO.4 NO SOUND FROM SOME
SPEAKERS ............................ 09-03D-6
NO.4 OIL LEAKAGE ......................... 03-03-8
NO.4 SOUND JUMPS .................... 09-03D-20
NO.4 THERE IS MALFUNCTION IN
THE SYSTEM EVEN THOUGH ABS
WARNING LIGHT, DO NOT
ILLUMINATE [4W-ABS] ....................04-03B-8
INDICATES ABS IS NORMAL,
HOWEVER, ABS DOES NOT
OPERATE CORRECTLY. [REAR ABS] ........ 04-03A-7
NO.5 BROKEN SOUND OR POOR
SOUND QUALITY ....................... 09-03D-7
NO.5 CANNOT PRESET
(PRESET FUNCTION DOES NOT
OPERATE) ............................ 09-03D-16
SCRATCHES ON THE CD ................ 09-03D-21
WILL NOT START [WL-3] .................01-03A-13
NO.5 ENGINE STALLS-AFTER START/
AT IDLE [WL-C, WE-C] ...................01-03B-19
NO.5 NO COOL AIR ......................... 07-03-6
NO.6 BRAKE SYSTEM WARNING
LIGHT REMAINS ILLUMINATED
WHEN ENGINE IS STARTED. [REAR ABS] .... 04-03A-8
WILL NOT START [WL-C, WE-C] ........... 01-03B-22
NO.6 DISC CHANGER IS INOPERATIVE ..... 09-03D-21
NO.6 NOISE WHILE OPERATING AlC
SYSTEM ................................. 07-03-8
NO.6 RECEPTION FREQUENCY OF
RADIO SLIPS ................. '" ....... 09-03D-17
NO.6 SLOW RETURN TO IDLE!
FAST IDLE [WL-3] ....................... 01-03A-15
NO.6 SOUND BECOMES LOUDLY OR
WEAKLY WHILE DRIVING THE VEHICLE .... 09-03D-7
NO.7 ALC FUNCTION IS INOPERATIVE ...... 09-03D-8
THE MP3-FORMATTED FILE ............. 09-03D-22
AI-10

ROLLING IDLE [WL-3] ................... 01-03A-16
NO.7 SLOW RETURN TO IDLE
[WL-C, WE-C] ......................... 01-03B-24
NO.8 AUDIO SYSTEM ILLUMINATION
DOES NOT ILLUMINATE AT ALL ........... 09-03D-8
ROLLING IDLE [WL-C, WE-C] ............. 01-03B-26
NO.8 MP3-FORMATTED FILE FOLDER
SELECTION IS INOPERATIVEITRACK
SEARCH IS INOPERATIVE ............... 09-03D-23
NO.8 RUNS ON [WL-3] .................... 01-03A-17
NO.9 CD PLAYER DOES NOT
INDICATE THE MP3 TITLE TEXT .......... 09-03D-24
BUCKlJERK, HESITATION/
STUMBLE, SURGES [WL-3] .............. 01-03A-18
NO.9 FAST IDLE/RUNS ON [WL-C, WE-C] .... 01-03B-28
NO.9 LCD DOES NOT DISPLAY AT ALL. ...... 09-03D-9
OIL COOLER BODY INSPECTION [WL-3] ...... 01-11A-5

OIL COOLER BODY INSPECTION
[WL-C,WE-C] .......................... 01-11B-5
OIL COOLER REMOVAU
INSTALLATION [WL-3] .................... 01-11A-4
OIL COOLER REMOVAU
OIL FILTER REPLACEMENT [WL-3] .......... 01-11A-3
OIL FILTER REPLACEMENT [WL-C, WE-C] .... 01-11B-3
OIL PAN REMOVAUINSTALLATION [WL-3] .... 01-11A-5
OIL PAN REMOVAUINSTALLATION
[WL-C, WE-C] .......................... 01-11B-5
OIL PRESSURE INSPECTION [WL-3] ......... 01-11A-2
OIL PRESSURE INSPECTION [WL-C, WE-C] ... 01-11B-2
OIL PRESSURE SWITCH INSPECTION ....... 09-22-13
OIL PUMP INSPECTION [WL-3] .............. 01-11A-9
OIL PUMP INSPECTION [WL-C, WE-C] ...... 01-11B-10
OIL PUMP REMOVAUINSTALLATION [WL-3] .. 01-11A-7
OIL PUMP REMOVAU
INSTALLATION [WL-C, WE-C] .............. 01-11 B-7
REPLACEMENT [R15M-D] ................. 05-11A-3
REPLACEMENT [S15M-D] ................. 05-11 B-4
ON-BOARD DIAGNOSTIC
ON-BOARD DIAGNOSTIC
WIRING DIAGRAM [WL-C, WE-C] .......... 01-02B-2
ON-BOARD DIAGNOSTIC FUNCTION ........ 09-03B-4
ONE-WAY CHECK VALVE INSPECTION ....... 03-18-4
ON-BOARD DIAGNOSIS [4W-ABS] ........... 04-02B-2
ON-BOARD DIAGNOSIS [REAR ABS] ......... 04-02A-2
ON-BOARD DIAGNOSTIC TEST [WL-3] ....... 01-02A-4
ON-BOARD DIAGNOSTIC TEST
[WL-C, WE-C] .......................... 01-02B-7
OUTER MIRROR GLASS
OUTER MIRROR
OVER FENDER REMOVAUINSTALLATION ..... 09-16-4
ALPHABETICAL INDEX
p
(PID) ACCESS [WL-3] .................... 01-02A-4
(PID) ACCESS [WL-C, WE-C] ............... 01-02B-6
PARKING BRAKE CABLE
REMOVAUINSTALLATION [WL-3] ............ 04-12-5
PARKING BRAKE CABLE
REMOVAUINSTALLATION
[WL-C (EXCEPT Hi-Rider)] .................. 04-12-6
PARKING BRAKE CABLE
REMOVAUINSTALLATION
[WL-C (Hi-Rider), WE-C] .................... 04-12-7
PARKING BRAKE LEVER
PARKING BRAKE LEVER ADJUSTMENT ....... 04-12-3
PARKING BRAKE LEVER INSPECTION ........ 04-12-3
PARKING BRAKE SWITCH INSPECTION: ...... 04-12-8
PARKING BRAKE SYSTEM LOCATION INDEX .. 04-12-2
PARKING LIGHT BULB
PCM CONFIGURATION [WL-C, WE-C] ....... 01-40B-20
PCM DATA RESET [WL-C, WE-C] ........... 01-40B-22
PCM INSPECTION [WL-3] .................. 01-40A-7
PCM INSPECTION [WL-C, WE-C] ........... 01-40B-10
PCM REMOVAU INSTALLATION [WL-3] ....... 01-40A-6
PCM REMOVAUINSTALLATION
[WL-C, WE-C] ........................... 01-40B-9
PENDING TROUBLE CODES [WL-C, WE-C] .... 01-02B-6
PID/DATA MONITOR DISPLAY ............... 08-02-5
PID/DATA MONITOR TABLE ................. 08-02-6
PILOT BEARING INSPECTION .............. 05-10-18
POWER BRAKE UNIT INSPECTION ........... 04-11-9
POWER BRAKE UNIT
POWER DOOR LOCK SYSTEM
AND KEYLESS ENTRY SYSTEM
LOCATION INDEX ........................ 09-14-2
INSPECTION ............................ 09-12-21
POWER OUTER MIRROR INSPECTION ....... 09-12-20
POWER STEERING FLUID INSPECTION ....... 06-14-3
POWER SYSTEM LOCATION INDEX .......... 09-21-1
INSPECTION ............................. 09-12-8
POWER WINDOW MOTOR INSPECTION ....... 09-12-7
INSPECTION ............................ 09-12-11
POWER WINDOW SYSTEM INITIAL
SETIING ............................... 09-12-11
POWER WINDOW SYSTEM

TROUBLESHOOTING QUESTIONNAIRE ..... 09-03A-3
POWER WINDOW SYSTEM
WIRING DIAGRAM ....................... 09-03A-1
PRECAUTION [4W-ABS] .................... 04-03B-2
PRECAUTION [REAR ABS] .................. 04-03A-2
PRECAUTION ............................. 03-03-2
PRE-DELIVERY INSPECTION ............... 00-00-33
PROPELLER SHAFT INSPECTION ............ 03-15-4
PROPELLER SHAFT LOCATION INDEX ........ 03-15-1
PROPELLER SHAFT
R
RADIATOR GRILLE
RADIATOR REMOVAU
RADIATOR REMOVAU
RADIO [REFERENCE] ..................... 09-03D-25
TEST RESULTS [WL-3] .................... 01-02A-4
TEST RESULTS [WL-C, WE-C] .............. 01-02B-6
INSPECTION [4W-ABS] .................. 04-13B-11
REMOVAUINSTALLATION
[4W-ABS (4x2 (EXCEPT Hi-Rider))] ......... 04-13B-10
REMOVAUINSTALLATION
[4W-ABS (Hi-Rider, 4x4)] .................. 04-13B-11
REAR ACCESS PANEL STRIKER
REAR ACCESS PANEL TRIM
REAR ACCESS PANEL
REAR ACCESS PANEL
REAR AXLE ADJUSTMENT .................. 03-12-2
REAR AXLE INSPECTION ................... 03-12-1
REAR AXLE LOCATION INDEX ............... 03-12-1
REAR BELTLiNE MOLDING
REAR BRAKE (DRUM) INSPECTION .......... 04-11-22
REAR BRAKE (DRUM)
REAR BUMPER DISASSEMBLY/ASSEMBLY .... 09-10-8
REAR BUMPER REMOVAUINSTALLATION ..... 09-10-8
[LSD (LIMITED SLIP DIFFERENTIAL)] ...... 03-14B-18
[STANDARD DIFFERENTIAL] .............. 03-14B-7
[LSD (LIMITED SLIP DIFFERENTIAL)] " .... 03-14B-16
[STANDARD DIFFERENTIAL] ....... " ..... 03-14B-4
REAR DIFFERENTIAL LOCATION INDEX ...... 03-14B-1
REAR DIFFERENTIAL OIL INSPECTION ....... 03-14B-2
AI-11
II
,
ALPHABETICAL INDEX
REAR DIFFERENTIAL OIL REPLACEMENT .... 03-14B-2
REAR DIFFERENTIAL
REMOVAUINSTALLATION ................. 03-14B-3
REAR DOOR GLASS AND REAR
WINDOW REGULATOR
REAR DOOR INNER HANDLE
REAR DOOR LATCH AND
LOCK ACTUATOR INSPECTION ............. 09-14-9
REAR DOOR LATCH AND LOCK ACTUATOR
REAR DOOR TRIM
REAR DOOR UNIT REMOVAUINSTALLATION ... 09-11-4
REAR DOOR REMOVAUINSTALLATION ........ 09-11-2
REAR FLAP REMOVAUINSTALLATION ......... 09-16-4
REAR OIL SEAL REPLACEMENT [WL-3] ...... 01-10A-17
REAR OIL SEAL
REPLACEMENT [WL-C, WE-C] ............ 01-10B-18
REAR OUTER HANDLE
REAR POWER WINDOW MOTOR
REAR QUARTER WINDOW GLASS
REAR SCUFF PLATE
REAR SEAT DiSASSEMBLy/ASSEMBLy ........ 09-13-5
REAR SEAT REMOVAUINSTALLATION ........ 09-13--5
[4x2 (EXCEPT Hi-Rider)] .................... 02-14-2
[Hi-Rider, 4x4] ............................ 02-14-3
REAR SHOCK ABSORBER DISPOSAL ......... 02-14-4
REAR SHOCK ABSORBER INSPECTION ....... 02-14-4
REAR SIDE TRIM REMOVAUINSTALLATION ... 09-17-14
REAR SPEAKER INSPECTION ................ 09-20-6
REAR SPEAKER REMOVAUINSTALLATION ..... 09-20-6
REAR STABILIZER REMOVAU
INSTALLATION [WL-C, WE-C] ............... 02-14-5
REAR SUSPENSION LOCATION INDEX ........ 02-14-1
REAR WINDOW GLASS REMOVAL ........... 09-12-16
REAR WINDOW GLASS INSTALLATION ....... 09-12-17
REARVIEW MIRROR
RECOVERY ............................... 07-10-3
REFRIGERANT CHARGING .................. 07-10--3
REFRIGERANT LINES
INSPECTION ............................. 07-40-6
REFRIGERANT PRESSURE CHECK ........... 07-10-3
REFRIGERANT SYSTEM GENERAL
PROCEDURES ........................... 07-10-2
CAUTIONS ............................... 07-10-1
WARNINGS .............................. 07-10-1
REFRIGERANT SYSTEM
PERFORMANCE TEST ..................... 07-10-2
AI-'j2
REGULATOR HANDLE REMOVAL ............ 09-12-6

REGULATOR HANDLE INSTALLATION ........ 09-12-6
RESISTOR INSPECTION .................... 07-40--3
RESISTOR REMOVAUINSTALLATION ......... 07-40-3
RESTRAINTS SST ......................... 08-60--1
ON-BOARD DIAGNOSIS. . . . . . . . . . . . . . . . . .. 03-02-1
RFW ACTUATOR INSPECTION .............. 03-18-5
RFW MAIN SWITCH INSPECTION ............ 03-18-4
RFW MAIN SWITCH
RFW SWITCH INSPECTION ................. 03-18-3
ROCKER ARM
ROCKER ARM REMOVAU
ROLLOVER VALVE INSPECTION [WL-3] ...... 01-16A-6
ROLLOVER VALVE INSPECTION
[WL-C, WE-C] .......................... 01-16B-8
ROOF ANTENNA INSPECTION ............... 09-20-8
ROOF ANTENNA INSTALLATION ............. 09-20-8
ROOF ANTENNA REMOVAL ................. 09-20-7
ROOF SIDE TRIM
ROPE HOOK REMOVAUINSTALLATION ....... 09-16-3
SAS CONTROL MODULE

SCHEDULED MAINTENANCE ............... 00-00-34
SEAT BELT INSPECTION ................... 08-11-6
SEAT BELT REMOVAUINSTALLATION ........ 08-11-1
SEAT DiSASSEMBLy/ASSEMBLy ............ 09-13-3
SEAT LOCATION INDEX .................... 09-13-1
SEAT REMOVAUINSTALLATION ............. 09-13-2
SEDIMENTOR SWITCH INSPECTION [WL-3] .. 01-14A-11
SEDIMENTOR SWITCH
SEDIMENTOR WATER DRAINING [WL-3] .... 01-14A-10
SEDIMENTOR
WATER DRAINING [WL-C, WE-C] ........... 01-14B-9
SERVICE CAUTIONS ...................... 00-00-12
SERVICE CAUTIONS ....................... 08-10-3
SERVICE WARNINGS ...................... 08-10-2
SHIFT FORK INSPECTION ................. 03-18-14
SIDE AIR BAG MODULE
SIDE AIR BAG SENSOR
STARTER DiSASSEMBLy/ASSEMBLy ......... 01-19-8
STARTER INSPECTION ..................... 01-19-3
STARTER REMOVAUINSTALLATION [WL-3] .... 01-19-2
STARTER REMOVAU
INSTALLATION [WL-C, WE-C] ............... 01-19-2
STARTING PROCEDURE FOR
ON-BOARD DIAGNOSTIC TEST MODE ...... 09-02B-1
STARTING SYSTEM LOCATION INDEX ........ 01-19-1
INSPECTION ........................... 06-14-13
ALPHABETICAL INDEX
STEERING LOCATION INDEX ................ 06-14-2
STEERING SHAFT INSPECTION .............. 06-14-9
STEERING SST ............................ 06-60-1
STEERING TECHNICAL DATA................ 06-50-1
INSPECTION ............................. 06-14-5
SUPPLIER IDENTIFICATION PROCEDURE .... 09-02B-1
SUPPLY PUMP INSPECTION [WL-C, WE-C] ... 01-14B-13
SUPPLY PUMP REMOVAU
SUSPENSION TECHNICAL DATA ............. 02-50-1
SUSPENSION ............................. 02-60-1
SYMPTOM DIAGNOSTIC INDEX [WL-3] ....... 01-03A-4
SYMPTOM DIAGNOSTIC INDEX
[WL-C, WE-C] ........................... 01-03B-6
SYMPTOM QUICK DIAGNOSIS
CHART [WL-3] ........................... 01-03A-5
SYMPTOM QUICK DIAGNOSIS CHART
[WL-C, WE-C] ........................... 01-03B-8
SYMPTOM TROUBLESHOOTING ............. 03-03-2
SYMPTOM TROUBLESHOOTING [4W-ABS] .... 04-03B-5
[REAR ABS] ............................ 04-03A-2
CHART [IMMOBILIZER SYSTEM] ........... 09-03C-1
SYMPTOM TROUBLESHOOTING CHART ..... 09-03A-4
SYSTEM WIRING DIAGRAM [4W-ABS] ........ 04-03B-1
SYSTEM WIRING DIAGRAM [REAR ABS] ...... 04-03A-1
TIMING BELT
TIMING BELT REMOVAU
ARM REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] ................... 02-13-5
ARM REMOVAUINSTALLATION
[Hi-Rider,4x4] ............................ 02-13-9
TOWING ................................. 00-00-27
TRANSFER LOCATION INDEX ................ 03-16-1
TRANSFER NEUTRAL SWITCH INSPECTION ... 03-18-2
TRANSFER OIL INSPECTION ................ 03-16-1
TRANSFER OIL REPLACEMENT .............. 03-16--2
TRANSMISSION AND TRANSFER
REMOVAUINSTALLATION [S15MX-D] ...... 05-11 B-10
TRANSMISSION OIL INSPECTION [R15M-D] ... 05-11A-2
TRANSMISSION OIL INSPECTION
[S15M-D, S15MX-D] ...................... 05-11B-3
[R 15M-D] ............................... 05-11 A-2
[S15M-D, S15MX-D] ...................... 05-11B-4
TRANSMISSION SST ....................... 05-60-1
TRANSMISSIONITRANSAXLE ................ 05-50-1
[R15M-D] ............................... 05-11A-5
[S 15M-D] ............................... 05-11 B-5
TRANSMITTER BATTERY INSPECTION ....... 09-14-17
TRANSMITTER BATTERY REPLACEMENT .... 09-14-16
TRANSMITTER ID CODE REGISTRATION ..... 09-14-15
TROUBLESHOOTING INDEX ................. 07-03-1
TROUBLESHOOTING INDEX ................ 09-03B-4
TROUBLESHOOTING NOTE [REAR ABS] ...... 04-03A-2
TURBOCHARGER INSPECTION [WL-3] ....... 01-13A-5
TURBOCHARGER
TWEETER INSPECTION ..................... 09-20-7
TWEETER REMOVAUINSTALLATION .......... 09-20-7
T
TAIL GATE STRIKER
TAILGATE ADJUSTMENT ................... 09-16-3
TAILGATE DiSASSEMBLy/ASSEMBLy ......... 09-16--2
THEFT-DETERRENT CONTROL
MODULE INSPECTION ................... 09-14-20
THEFT-DETERRENT HORN
LOCATION INDEX ........................ 09-14-3
THEFT-DETERRENT CONTROL MODULE
THERMISTOR INSPECTION ................. 07-40-5
THERMISTOR REMOVAUINSTALLATION ...... 07-40-5
THERMOSTAT INSPECTION [WL-3] .......... 01-12A-8
THERMOSTAT INSPECTION [WL-C, WE-C] .... 01-12B-8
THERMOSTAT REMOVAU
THERMOSTAT REMOVAU
INSPECTION [WL-3] .................... 01-14A-15
INSPECTION [WL-3] .................... 01-40A-28
UNITS ................................... 00-00-11
<
VACUUM CHECK VALVE

VACUUM LINE INSPECTION ................. 04-11-3
VACUUM PUMP INSPECTION ............... 04-11-11
VACUUM PUMP REMOVAUINSTALLATION .... 04-11-11
VALVE CLEARANCE ADJUSTMENT [WL-3] .... 01-10A-5
VALVE CLEARANCE
ADJUSTMENT [WL-C, WE-C] .............. 01-10B-5
VALVE CLEARANCE INSPECTION [WL-3] ..... 01-10A-511
V~0~~c~~:_~~.~~ .I~~.~~~:~~~
............ 01-10B-5
[WL-C, WE-C] ........................... 01-13B-6
VEHICLE HEIGHT ADJUSTMEtJT [4x2] ......... 02-11-1
VEHICLE HEIGHT ADJUSTMENT [4x4] ......... 02-11-2
AI-13
ALPHABETICAL INDEX
(VIN) CODE .............................. 00-00-1
VEHICLE IDENTIFICATION NUMBERS (VIN) .... 00-00-1
VEHICLE LIFT (2 SUPPORTS) AND
SAFETY STAND (RIGID RACK) POSITION .... 00-00-26
INSPECTION [S15MX-D] ................... 03-16-2
REMOVAUINSTALLATION [S15MX-D] ......... 03-16-2
INSPECTION [R15M-D] ....................05-11A-4
INSPECTION [S15M-D] ....................05-11B-5
REMOVAUI NSTALLATION [R 15M-D] ......... 05-11 A-3
REMOVAUINSTALLATION [S15M-D] ......... 05-11 B-5
VENTILATOR GRILLE
WATER PUMP
WATER PUMP REMOVAU
INSTALLATION [WL-C, WE-C] ..............01-12B-9
INSPECTION ............................ 09-22-13
INSTALLATION [WL-3] .................... 09-22-13
REMOVAL [WL-3] ........................ 09-22-12
WHEEL ALIGNMENT PRE-INSPECTION ........ 02-11-2
WHEEL AND TIRE SPECIFICATION ............ 02-12-1
WHEEL CYLINDER
WHEEL HUB BOLT REPLACEMENT
[Hi-Rider, 4x4] ............................ 03-11-3
INSPECTION [4x2 (EXCEPT Hi-Rider)] ........ 03-11-3
AI-14
INSPECTION [Hi-Rider, 4x4] ................ 03-11-4

REMOVAUINSTALLATION
[4x2 (EXCEPT Hi-Rider)] ................... 03-11-4
REMOVAUINSTALLATION [4x4] ........... 03-11-14
REMOVAUINSTALLATION [Hi-Rider] ......... 03-11-8
WINDSHIELD GARNISH
WINDSHIELD INSTALLATION ............... 09-12-14
WINDSHIELD REMOVAL ................... 09-12-12
WINDSHIELD WASHER HOSE
WINDSHIELD WASHER
MOTOR INSPECTION ..................... 09-19-5
WINDSHIELD WASHER MOTOR
WINDSHIELD WASHER NOZZLE
ADJUSTMENT ........................... 09-19-6
WINDSHIELD WASHER
NOZZLE INSTALLATION .................. 09-19-6
WI NDSH IELD WASH ER NOZZLE REMOVAL. . . . 09-19-5
WINDSHIELD WASHER TANK
WINDSHIELD WIPER AND WASHER
SWITCH INSPECTION .................... 09-19-7
WINDSHIELD WIPER AND WASHER SWITCH
WINDSHIELD WIPER ARM AND
BLADE ADJUSTMENT .................... 09-19-4
WINDSHIELD WIPER ARM AND BLADE
REMOVAUI NSTALLATION. . . . . . . . . . . . . . . . . 09-19-3
WINDSHIELD WIPER LINK
WINDSHIELD WIPER MOTOR INSPECTION .... 09-19-4
WINDSHIELD WIPER MOTOR
WIPERIWASHER
SYSTEM LOCATION INDEX ................ 09-19-2
PJ Ranger
Wiring Diagrams Manual
(Part No. WD380)
f\-.
WARNING
may be useful to non-Ford trained technicians, but a technician
procedures.
problems includes but is not limited to insufficient servicerelated training, use of improper tools, use of replacement parts
not being aware of any revision of this manual.
RANGER
CONTENTS
TITLE
_ WIRING DIAGRAMS
GENERAL INFORMATION
FOREWORD
This wiring diagram incorporates the wiring schematics
of the RANGER and available optional equipment.
Actual vehicle wiring may vary slightly depending on
optional equipment or local specifications, or both.
ENGINE
For proper repair and maintenance, a thorough

familiarization with this manual is important, and it
should always be kept in a handy place for quick and
easy reference.
All the contents of this manual, including drawings and
specifications, are the latest available at the time of
printing.
As modifications affecting repair or maintenance occur,
relevant information supplementary to this volume will be
made available at Ford dealers. This manual should be
kept up-to-date.
Ford Motor Company reserves the right to alter the
specjfications and contents of this manual without
obligation or advance notice.
All rights reserved. No part of this book may be
reproduced or used in any form or by any means,
electronic or mechanical-including photocopying and
recording and the use of any kind of information storage
and retrieval system-without permission in writing.
BODY & ACCESSORIES
Ford Motor Company

ALPHABETICAL INDEX
APPLICATION:
This manual is applicable to vehicles beginning with
the Vehicle Identification Numbers (VIN) shown on
the following page.
2005 Ford Sales & Sarvice

PRINTED IN THAILAND, DEC. 2005
F198-30-05L

(CHASSIS NUMBERS)
Australian specs.
MNA BS1 D90*W
MNA BS1 E90*W
MNA BS2D90*W
MNA BS2E90*W
MNA BSAD10*W
MNA BSAD90*W
MNA BSAE10*W
MNA BSAE90*W
MNA BSBD10*W
MNA BSBD90*W
MNA BSBE10*W
MNA BSBE90*W
MNA BSED90*W
MNA BSEE90*W
MNA BSFD90*W
MNA BSFE90*W
MNA DS1 D90*W
MNA DS1E90*W
MNA DS2D90*W
MNA DS2E90*W
MNA DSAD10*W
MNA DSAD90*W
MNA DSAE10*W
MNA DSAE90*W
MNA DSBD10*W
MNA DSBD90*W
MNA DSBE10*W
MNA DSBE90*W
MNA DSED90*W
MNA DSEE90*W
MNA DSFD90*W
MNA DSFE90*W
MNA LS1 D90*W
MNA LS1 E90*W
MNA LS2D90*W
MNA LS2E90*W
MNA LSAD10*W
MNA LSAD90*W
MNA LSAE10*W
MNA LSAE90*W
MNA LSBD10*W
MNA LSBD90*W
MNA LSBE10*W
MNA LSBE90*W
MNA LSED90*W
MNA LSEE90*W
MNA LSFD90*W
MNA LSFE90*W
MNA US1D90*W
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
MNA
US1 E90*W
US2D90*W
US2E90*W
USAD10*W
USAD90*W
USAE10*W
USAE90*W
USBD10*W
USBD90*W
USBE10*W
USBE90*W
USED90*W
USEE90*W
USFD90*W
USFE90*W
SYSTEM INDEX
00 GENERAL INFORMATION
08 RESTRAINTS
R READING WIRING DIAGRAMS

VEHICLE IDENTIFICATION NUMBER (VIN) CODE ........ 2
VEHICLE IDENTIFICATION NUMBERS (VIN) ................ 3
CONTENTS OF WIRING DIAGRAMS ........................... .4
GROUND POINTS .......................................................... 5
SYSTEM CIRCUIT DIAGRAM/CONNECTOR DIAGRAM ... 6
ROUTING DIAGRAM ........................................ ~ ............. 8
HARNESS SyMBOLS ..................................................... 9
WIRING COLOR CODE .................................................. 9
SyMBOLS ..................................................................... 10
ABBREVIATIONS USED IN THIS MANUAL ................. 12
P ELECTRICAL SYSTEM GENERAL PROCEDURES ...... 14
10 AIR BAG SYSTEM

AIR BAG SYSTEM SERVICE CAUTIONS/
SERVICE WARNINGS ................................................ 62
AIR BAG SYSTEM (INCLUDES PRE-TENSIONER
SEAT BELT INFORMATION) ...................................... 64
09 BODY & ACCESSORIES
12 GLASSIWINDOWS/MIRRORS
REAR WINDOW DEFROSTER ................................... 68
POWER WINDOW SYSTEM ........................................ 70
POWER OUTER MIRROR ........................................... 74
14 SECURITY AND LOCKS
POWER DOOR LOCK SYSTEM .................................. 76
KEYLESS CONTROL MODULE ................................... 80
IMMOBILIZER SYSTEM ............................................... 82
THEFT-DETERRENT SYSTEM .................................... 84
18 LIGHTING SYSTEMS
HEADLIGHT ................................................................. 88
LICENSE PLATE LIGHT ............................................... 90
PARKING LIGHT ........................................................... 90
TAILLIGHT .................................................................... 90
FRONT FOG LIGHT ..................................................... 92
TURN AND HAZARD WARNING LIGHT ...................... 94
BACK-UP LIGHT .......................................................... 96
BRAKE LIGHT .............................................................. 98
HIGH-MOUNT BRAKE LIGHT ...................................... 98
ILLUMINATION LIGHT ................................................ 100
INTERIOR LIGHT ....................................................... 102
19 WIPERIWASHER SYSTEM
WINDSHIELD WIPER AND WASHER ....................... 104
20 ENTERTAINMENT
ACCESSORY SOCKET .............................................. 106
CIGARETTE LIGHTER ............................................... 106
AUDIO SYSTEM ......................................................... 108
22 INSTRUMENTATION/DRIVER INFO.
INSTRUMENT CLUSTER ........................................... 112
HORN ......................................................................... 118
POWER, GROUND & COMMON CONNECTOR

E ELECTRICAL WIRING SCHEMATIC ........................... 18
F- FUSE BOX .................................................................... 20
C COMMON CONNECTOR LlST ..................................... 22
G GROUND POINT ........................................................... 26
DATA LINK CONNECTOR
D DATA LINK CONNECTOR ............................................ 30
01 ENGINE
17 CHARGING SYSTEM ................................................... 32

19 STARTING SySTEM ...................................... :.............. 34
40 CONTROL SYSTEM
WL-3 .............................................................................. 36
WL-C, WE-C .................................................................. 42
03 DRIVELINE/AXLE
18 4-WHEEL DRIVE
REMOTE FREEWHEEL CONTROL SYSTEM .............. 52
04 BRAKES
13 ANTI LOCK BRAKE SYSTEM
4WHEEL ANTI LOCK BRAKE SYSTEM (4WABS) ....... 56
REAR ANTI LOCK BRAKE SYSTEM ............................. 58
07 HEATER, VENTILATION & AIR CONDITIONING
(HVAC)
AI ALPHABETICAL INDEX
ALPHABETICAL INDEX ............................................. 120
40 CONTROL SYSTEM
HEATER AND AIR CONDITIONER ............................... 60
Two digits (section ID) indicated in front of each title are commonly used with the Workshop Manual.
Reading Wiring Diagrams
OOR
MNBBS1D106123456
L_______
=,=1= =1=1= =
Serial No.
Algeria:
Others:
Plant
ModelYesr
Production year
Gulf:
Algeria:
Others:
Engine type
6= F2E (2.2 EGI)

1= WL-C (2.5 L-DI)
9= WE-C (3.0 L-DI)
4= WL-Turbo (2.5L Diesel turbo)
7= G6E (2.6 EGI)
1=
2=
8=
3=
2=
Product sorce
Air bag
o to 9, X
W= A. A. Thailand
Gulf only
Body style
7= 2007, 8=2008, 9=2009 .. .

6= 2006, 7=2007, 8=2008 .. .
Check Digit
Plant
No meaning
Gulf only
Gross vehicle weight
mark
W=A. A. Thailand
Other
0= 2268-2721 kg {5001-6000 Ibs}
E= 2722-3175 kg {6001-7000 Ibs}
Others
1= Stretch cab.
2= Stretch cab.
M= Thailand (for Europe (L.H.D.))
S= Japan (for Australia, General (R.H.D.),
General (L.H.D.), Gulf)
B= Seatbelt only
0= with Air bag (Driver side)
u= with Air bag (Driver, Passenger and Side air bag)
WFO=FORD (European (L.H.D.))
MNB=FORD (General (R.H.D.))
MNC=FORD (General (L.H.D.), Gulf)
: This mark is used only for Algerian model, in order to identify the manufacturer.

Australian specs.
MNA BS1D90*W
MNA BS1E90*W
MNA BS2D90*W
MNA BS2E90*W
MNA BSAD10*W
MNA BSAD90*W
MNA BSAE10*W
MNA BSAE90*W
MNA BSBD10*W
MNA BSBD90*W
MNA BSBE10*W
MNA BSBE90*W
MNA BSED90*W
MNA BSEE90*W
MNA BSFD90*W
MNA BSFE90*W
MNA DS1D90*W
MNA DS1 E90*W
MNA DS2D90*W
MNA DS2E90*W
MNA DSAD10*W
MNA DSAD90*W
MNA DSAE10*W
MNA DSAE90*W
MNA DSBD10*W
MNA DSBD90*W
MNA DSBE10*W
MNA DSBE90*W
MNA DSED90*W
MNA DSEE90*W
MNA DSFD90*W
MNA DSFE90*W
MNA LS1 D90*W
MNA LS1 E90*W
MNA LS2D90*W
MNA LS2E90*W
MNA LSAD10*W
MNA LSAD90*W
MNA LSAE10*W
MNA LSAE90*W
MNA LSBD10*W
MNA LSBD90*W
MNA LSBE10*W
MNA LSBE90*W
MNA LSED90*W
MNA LSEE90*W
MNA LSFD90*W
MNA LSFE90*W
MNA US1D90*W
MNA US1E90*W
MNA US2D90*W
MNA US2E90*W
MNA USAD10*W
MNA USAD90*W
MNA USAE10*W
MNA USAE90*W
MNA USBD10*W
MNA USBD90*W
MNA USBE10*W
MNA USBE90*W
MNA USED90*W
MNA USEE90*W
MNA USFD90*W
MNA USFE90*W
OOR
OOR
CONTENTS OF WIRING DIAGRAMS

This manual comprises the sections shown below.
\
;
Shows circuit and connector

diagrams and component and
I-+E-I-e-ct-ri-c-p-o-w-e-rs-t-e-er-:-in-g-("'-E""P"'S,,")--1 connector location diagrams
BODY &
ACCESSORIES
Depending on the vehicle model, the actual sections may be different.
OOR
GROUND POINTS
This shows ground paints of the harness.
--=
_~O)r~:~@
o@
-11(0)
-~O)
-S(D)
U'"
HARNESS
~w
DASH
r==.~~""
~ESS
~ t:::;;;;~~OSYSTEM"'.':
"'0"'
'0
TO
. ___._.",
ii
_B{O)--@@
::"::'':':':':M:i{Ojnn.n@G):
-s(Il---@
'"--WITHOUT AIR BAGSYSTEM---'
.....'"
"")'"''''0"'
B('N}-----@)0 )
lNTERIOR
LIGHT
_ B - - - @ CORD
Ground indication
On vehide
Indication
The ground connection numbers in system circuit diagrams

correspond to those in the ground point diagram.
11111111
OOR
SYSTEM CIRCUIT DIAGRAM/CONNECTOR DIAGRAM

These diagrams show the circuits for each system, from the power supply to the ground. The power supply side
is on the upper part of the page, the ground side on the lower part. The diagrams describe circuits with the
ignition switch off.
f),
Below is an explanation of the various points in the diagram.

CONTROL SYSTEM
System name
F09
8(E)
MAIN
tOOA
IGKEY
60A
F-07
C-Ql
---i~--<:r~"""'--o"~>---r----l)--BlW(F)---<fW8;:-----
L.....-:F-o~5~_B(FI _ _ _<f~_ _ __
INJOA
FIP
30A
GLOW
40A
F-04
0 .--_ _ _ U R ( E I - - - { f - -
Connector code
tt
LG
L(E) _ _---1~r'--IF&~3_ _....J
The prefix letter indicates the system in which the

connector is used.
t
(EI
lOl 40-10Si
F: Fuse box connectors

J: Joint box/Junction box connectors
C: Common connectors
G: Ground point connectors
0: Data link connector
0112: Cooling system connectors
0114: Fuel system connectors
0117: Charging system connectors
0118: Ignition system connectors
0119: Starting system connectors
0120: Cruise control system connectors
0140: Engine control system connectors
0212: Wheel and tires connectors
0318: 4-Wheel drive connectors
0413: Antilock brake system connectors
0414: Traction control system connectors
0415: Dynamic stability control connectors
0513: Automatic transmission connectors
0514: Automatic transmission shift mechanism
connectors
0517: Automatic transaxle connectors
0518: Automatic transaxle shift mechanism
connectors
0613: Electric power steering (EPS) connectors
0614: Power steering connectors
0740: Heater, ventilation & air conditioning (HVAC)
control system connectors
0810: Air bag system connectors
0811: Seat belt connectors
0912: GlassIWindows/Mirrors connectors
0913: Seats connectors
0914: Security and locks connectors
0915: Sunroof connectors
0918: Lighting systems connectors
0919: WiperIWasher system connectors
0920: Entertainment connectors
0921: Power systems
0922: Instrumentation/Driver info. Connectors
0940: Control system
BRIe
(EM)
(EM)
"
DATA LINK CONNECTOA(DLC)

(SECTION 000)
t)
0140105
ENGINE(E).SHORT CORD (El
E!r
(SHOAT COAD)
ttl
Ground numbers
A harness ground is represented differently than a
unit ground.
Types of grounds
Symbol
Harness
.JJ~
--Sensor~~

The number indicates that the circuit
continues to the related system
diagram.
OOR
System code
Indicates communication with connected parts.

Signals are transmitted back and forth between
connected parts.
Indicates shielded wire!

* Shielded wire:
Prevents signal disturbances from
electrical interference.
Wire is covered by a metal meshing for
grounding.
Connector symbols
Male and female connectors are represented as follows
in the circuit and connector diagrams.
Circuit diagram
symbol
Male
Female
Wire color code (harness symbol)
t
~
Male
<Female
Connector
diagram symbol
a
8
Like connectors are linked by dashed lines between the

connector symbols .
Connector diagrams show connectors on the harness
side. The terminal indicates the view from the harness
side.
Two-color wires are indicated by a two-letter

symbol.The first indicates the base color of the
wire, the second the color of the stripe.
For example:
W/R is a white wire with a red strip
BRN is a brown wire with a yellow strip
(Example)
Symbol
(Ex~mple)
iii
,./
"<
View from harness side
B B
F
Colors for connectors except white are given in locations .

Unused terminals are indicated by *.
The harness symbol is in ( ) following the harness

symbols (refer to P-9.).
OOR
ROUTING DIAGRAM
The routing diagram shows where electrical components are on the system circuit diagram by call out line and
connector symbols.
Connector symbol
Shows the system that uses the
connector.
Shows the names of components

in routing diagrams.
(Example)
Connector
Common connectors
System connectors
Symbol
C-02
10922-051
HARNESS
Shows the ground in system

diagrams.
Reading Wiring ,Diagrams
OOR
HARNESS SYMBOLS
DESCRIPTION OF HARNESS
FRONT HARNESS
(F)
FRONT No.2 HARNESS
(F2)
ENGINE HARNESS
(E)
DASH HARNESS
(D)
REAR HARNESS
(R)
REAR No.2 HARNESS
(R2)
REAR NO.3 HARNESS
(R3)
INSTRUMENT PANEL HARNESS
(I)
EMISSION HARNESS
DESCRIPTION OF HARNESS
SYMBOL
::-:-:-:-:-:.:.:
!...!.!..!..!..
000
~
(EM)
EMISSION No.2 HARNESS
(EM2)
EMISSION No.3 HARNESS
(EM3)
SYMBOL
DOOR No.1 HARNESS
(DR1)
DOOR No.2 HARNESS
(DR2)
DOOR No.3 HARNESS
(DR3)
DOOR No.4 HARNESS
(DR4)
FLOOR HARNESS
(FR)
INTERIOR LIGHT HARNESS
(IN)
AlC HARNESS
(AC)
INJECTION HARNESS
(INJ)
HAND BRAKE HARNESS
(HB)
WIRING COLOR CODE

COLOR
CODE
COLOR
CODE
BLACK
ORANGE
BLUE
PINK
BROWN
BR
RED
DARK BLUE
DL
SKY BLUE
DARK GREEN
DG
TAN
GRAY
GY
VIOLET
GREEN
WHITE
LIGHT BLUE
LB
YELLOW
LIGHT GREEN
LG
SB
OOR
SYMBOLS
Symbol
Meaning
Symbol
Meaning
Battery
Generates electricity through chemical

reaction.
Supplies direct current to circuits.
Light
Emits light and generates heat when

current flows through filament.
leG) I
Ground (1)
-b-
Ground (2)
Connecting point to vehicle body or

other ground wire where current flows
from positive to negative terminal of
battery.
Ground (1) indicates a ground point to
body through wire harness.
Ground (2) indicates point where
component is grounded directly to
body.
---------------
~
Resistance
----'VIIv--
Ground (3)
Remarks
Current will not flow through a circuit if
ground is faulty.
Motor
Converts electrical energy into

mechanical energy.
Pump
Pulls in and discharges gases and

liquids.
Cigarette lighter
Electrical coil that generates heat.
Th Melts when current flow exceeds that

specified for circuit, interrupts current
flow.
Fuse
--cA...r'O-
Precautions
Do not replace with fuses exceeding
specified capacity.
<Blade type>
Fuse (For high

current fuse)/
Fusible link
Transistor (1)
Collector (C)
B..e(B)
"PN
Emitter (E)
Transistor (2)
Collector (C)
Sa,. (B) ~ PNP

Emitter (E)
Accessory socket
c$
~r
<Cartridge type>
<Tube type>
f!jJ ~
<Fusible link>
Horn
indication
mark
ECB
EVC
Reading code.
2 S C 828
Generates sound when current flows.
Speaker
:2:
Heater
Generates heat when current flows.
Ignition switch
u-:-:- Revision mark
TTSemiconductor
T
Number of
terminals
Interior power supply.
Electrical switching component.

Turns on when voltage is applied to
the base (B).
~ Collector
A resistor with a constant value.

Mainly used to protect electrical
components in circuits by maintaining
rated voltage.
~ ~Fftt
A:High-frequency PNP
(rLoW-freqUency PNP
C:High-frequency NPN
D:Low-frequency NPN
10
ACC
Turning ignition key switches circuit to

operate various component.
(NOTE)
Ignition switch is called engine switch
on diesel vehicles.

Symbol
Switch (1)
+'+
Meaning
Harness
Allows or breaks current flow by

opening and closing curcuits.
--0
Normally open
Relay (2)
[]
Normally closed
Sensor (1)
~
Sensor (2)
~
Sensor (3)
-@Sensor (4)
~
Sensor (5)
When circuit C-D

is connected to
circuit A-B, the
connection D is
indicated by a
black dot.
(1)
Diversion point D
for the different
circuits according
to the vehicle's
specification is
indicated by a
white dot.
Automatically shuts off circuit when

certain conditions are met.
Selection
Normally closed
Relay (1)
Connection
(--r-)
Switch (2)
Autostop switch
Meaning
Symbol
Normally open
-~.-
For vehicles with ABS, use the A-B

circuit.
c -
-WITHABS- - - - ,
I
A
IL _ _ _ _ _ _ _ _ _
D
c - -
I
I
.
I
I
-,
WITHOUT ABS-
L ___________
I
I
.1
For vehicles without ABS, use the C-B

circuit.
Current flowing through coil produces electromagnetic force causing contact to open or close.
Ot Nofl~
No current to coil
Current to coil
[] I
Flow
Current flowing through coil produces electromagnetic force causing contact to close.
[f]t
No current to coil
[] I
Current to coil
Flow
Solenoid
Detects characteristics such as intake

manifold vacuum and airflow amount
according to resistance variation.
Detects resistance variation according

to operation of other parts.
Diode
A resistor whose resistance variation

according to temperature variation.
When temperature increases,
resistance decreases.
1411
Noflow
Current flowing through coil generates

electromagnetic force to operate
plungers.
Known as a semiconductor rectifier,

the diode allows current flow in one
direction only.
Cathode(K) --M- Anode(A)
-- Flo, of electric current
K-cr::J-A K-E:}-A K-GEJ-A
Light-emitting
diode
(LED)
Detects pulse signals from rotating

object.
A diode that lights when current flows.

Unlike ordinary bulbs, the diode does
not generate heat when lit.
Cathode(K)
Generates potential difference when

tension or pressure is applied.
'1411
-1D~
Capacitor
OOR
'1411
c:[t::
Anode(A)
Cathode(K)
__ Anode(A)
Flow of current
Reference diode
(Zener diode)
Component that temporarily stores

electrical charge.
:...
-II--
11
Allows current to flow in one direction

up to a certain voltage; allows current
to flow in the other direction once that
voltage is exceeded.
OOR
Symbol
Meaning
Extent of the change in the wiring position (1)
The wiring position can be exchanged freely within the

connector.
I I I
E
The wiring position can be exchanged according to the

following combinations only.
Between A and B, Between C and D, Between E and F
I I I
~
B
The wiring position can be exchanged according to the

following combinations only.
Between 1,2,4 and 7.
The wiring positions may be indicated by numbers for some
connectors.
ABBREVIATIONS USED IN THIS MANUAL

3GR
THIRD GEAR
COMBI
COMBINATION
4GR
FOURTH GEAR
CON
CONDITIONER
AMPERE
CONT
CONTROL
AlC
AIR CONDITIONING
CPU
CENTRAL PROCESSING UNIT
AlF
AIR FUEL
DEF
DEFROSTER
MS
AUTO ADJUSTING SUSPENSION
DI
DISTRIBUTOR IGNITION
ABS
ANTI-LOCK BRAKING SYSTEM
DLC
DATA LINK CONNECTOR
ACC
ACCESSORIES
DLI
DISTRIBUTORLESS IGNITION
ACV
AIR CONTROL VALVE
DOHC
DOUBLE-OVERHEAD CAMSHAFT
ADD
ADDITIONAL
DRL
DAYTIME RUNNING LIGHT
AIS
AIR INJECTION SYSTEM
DTC
DIAGNOSTIC TROUBLE CODE(S)
ALL
AUTOMATIC LOAD LEVELING
DTM
DIAGNOSTIC TEST MODE
AM
AMPLITUDE MODULATION
ECPS
ELECTRONICALLY CONTROLLED
POWER STEERING
AMP
AMPLIFIER
ANT
ANTENNA
ECT
ENGINE CONTROL TEMPERATURE
ASV
AIR SUPPLY VALVE
EGR
EXHAUST GAS RECIRCULATION
AT
ATX
AUTOMATIC TRANSAXLE
EHPAS
ELECTRO HYDRAULIC POWER

ASSIST STEERING
B+
BATTERY POSITIVE VOLTAGE
EI
ELECTRONIC IGNITION
BAC
BYPASS AIR CONTROL
ELEC
ELECTRIC
CAN
CONTROLLER AREA NETWORK
ELR
EMERGENCY LOCKING. RETRACTOR
CIGAR
CIGARETTE
ET
ELECTRONIC THROTTLE
CIS
CONTINUOUS FUEL INJECTION

SYSTEM
EPS
ELECTRIC POWER STEERING
EVAP
EVAPORATIVE EMISSION
CKP
CRANKSHAFT POSITION SENSOR
FRONT
CM
CONTROL MODULE
F/I
FUEL INJECTOR
CMP
CAMSHAFT POSITION SENSOR
FICB
FAST-IDLE CAM BREAKER
12
OOR
FM
FREQUENCY MODULATION
PNP
PARK/NEUTRAL POSITION
FP
FUEL PUMP
PRC
PRESSURE REGULATOR CONTROL
FPR
FUEL PUMP RELAY
PRG
PURGE SOLENOID VALVE
GEN
GENERATOR
PSP
POWER STEERING PRESSURE
PTC
POSITIVE TEMPERATURE
COEFFICIENT HEATER
GND
GROUND
HID
HEATER/DEFROSTER
HEAT
HEATER
PWM
PULSE WIDTH MODULATION
HI
HIGH
QSS
QUICK-START SYSTEM
H02S
HEATED OXYGEN SENSOR
REAR
HS
HIGH SPEED
REC
RECIRCULATION
HU
HYDRAULIC UNIT
RF
RIGHT FRONT
lAC
IDLE AIR CONTROL
RH
RIGHT HAND
IAT
INTAKE AIR TEMPERATURE
RPM
REVOLUTIONS PER MINUTE
IG
IGNITION
RR
RIGHT REAR
ILLUMI
ILLUMINATION
SAS
SOPHISTICATED AIR BAG SENSOR
SFI
SEQUENTIAL MULTIPOINT FUEL

INJECTION
SOL
SOLENOID
INT
INTERMITTENT
JB
JOINT BOX
KS
KNOCK SENSOR
LCD
LIQUID CRYSTAL DISPLAY
SPV
SPILL VALVE
LF
LEFT FRONT
ST
START
LH
LEFT HAND
SW
SWITCH
LO
LOW
TC
TURBOCHARGER
TCC
TORQUE CONVERTER CLUTCH
TCM
TRANSMISSION(TRANSAXLE)
CONTROL MODULE
TCS
TRACTION CONTROL SYSTEM
LR
LEFT REAR
MOTOR
MAF
MASS AIR FLOW
MAP
MANIFOLD ABSOLUTE PRESSURE
MFI
MULTI PORT FUEL INJECTION
TEMP
TEMPERATURE
MID
MIDDLE
TFT
TRANSAXLE FLUID TEMPERATURE
TICS
TRIPLE INDUCTION CONTROL

SYSTEM
MIL
MALFUNCTION INDICATOR LAMP
MIN
MINUTE
MIX
MIXTURE
TNS
TAIL NUMBER SIDE LIGHTS
MPX
MULTIPLEX
TP
THROTTLE POSITION SENSOR
MS
MIDDLE SPEED
TR
TRANSMISSION(TRANSAXLE) RANGE
MT
MANUAL TRANSMISSION
TWS
TOTAL WIRING SYSTEM
MTX
MANUAL TRANSAXLE
VOLT
NEUTRAL
VAF
VOLUME AIR FLOW SENSOR
NC
NORMALLY CLOSED
VENT
VENTILATION
VICS
VARIABLE INERTIA CHARGING

SYSTEM
NO
NORMALLY OPEN
02 S
OXYGEN SENSOR
OBD
ON-BOARD DIAGNOSTIC
VOL
VOLUME
OlD
OVER DRIVE
VR
VOLTAGE REGULATOR
OFF
SWITCH OFF
ON
SWITCH ON
VRIS
VARIABLE RESONANCE INDUCTION

SYSTEM
OSC
OSCILLATOR
VSS
VEHICLE SPEED SENSOR
POWER
PIS
POWER STEERING
VTCS
VARIABLE TUMBLE CONTROL

SYSTEM
PCM
POWERTRAIN CONTROL MODULE
PJB
PASSENGER JUNCTION BOX
13
WATT(S)
WOT
WIDE OPEN THROTTLE
OOP
Electrical System General Procedures
ELECTRICAL PARTS
Battery Cable
86U000000006W03
Before disconnecting connectors or removing

electrical parts, disconnect the negative battery cable.
NEGATIVE BATTERY CABLE
/.-------
WGIWXX0007E
Wiring Harness
To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
WGIWXX0039E
Caution
Do not remove the Harness protective tape.
Otherwise, the wires could rub against the body,
which could result in water penetration and
electrical shorting.
CONNECTORS
Data Link Connector
WGIWXX0040E
Insert the probe into the terminal when connecting a

jumper wire to the data link connector.
Caution
Inserting a jumper wire probe into the data link
connector terminal may damage the terminal.
Disconnecting Connectors
When disconnecting connector, grasp the connectors,
not the wires.
WGIWXX0041E
14
OOP

WGIWXX0042E
Locking Connector
When locking connectors, listen for a click indicating
they are securely locked.
Inspection
measuring voltage, insert the tester probe from the
wiring harness side.
WGIWXX0044E
Inspect the terminals of waterproof connectors from

the connector side since they cannot be accessed
from the wiring harness side.
Caution
To prevent damage to the terminal, wrap a thin
wire around the tester probe before inserting
into terminal.
WGIWXX0045E
15
OOP
Terminals
Inspection
Pull lightly on individual wires to verify that they are
secured in the terminal.
X3UOOOWB4
Replacement
Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to insert it
until it locks securely.
Insert a thin piece of metal from the terminal side of
the connector and with the terminal locking tab
pressed down, pull the terminal out from the
connector.
Sensors, Switches, And Relays

Handle sensors, switches, and relays carefully. Do not
drop them or strike them against other objects.
NO GOOD
X3UOOOWB6
Fuse
Replacement
When replacing a fuse, be sure to replace it with one
of the same capacity. If a fuse fails again, the circuit
probably has a short and the wiring should be
inspected.
Be sure the negative battery terminal is disconnected
before replacing a main fuse.
YMUOOOWA1
16
OOP
When replacing a pullout fuse, use the fuse puller.
PULLER
YMUOOOWAK
ELECTRICAL TROUBLESHOOTING TOOLS
'
Jumper Wire
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
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.
X3UOOOWBB
Voltmeter
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 will be measured and the negative
(-) probe (black lead wire) to a body ground.
VOLTMETER
POWER SOURCE LINE
GROUND
X3UOOOWBC
Ohmmeter
The ohmmeter is used to measure the resistance
between two points in a circuit and to inspect for
continuity and short circuits.
Caution
Do not connect the ohmmeter to any circuit
where voltage is applied. This will damage the
ohmmeter.
YMUOOOWAL
17
ex>
EXCEPT WLT
WLT
"'"
LIB
B/Y
HEAD RH 15A
rio
HEAD LH 15A
:
WITH STARTER
,RELAY
lHEADLIGHT RELAY
'
1
/
'
0918 3
LIGHT
0922-2
HORN
1~
110918-6
BRAKE LIGHT
~BAC0p
0918-4
TURN AND HAZARD
WARNING LIGHT
FRONT FOG LIGHT
'
-e
"
G/W-
G/W
B/Y--
B/Y--
L/Y
LIB
~I, t;:.:
I'
,,
HAZARD lOA
FOG 15A
I'
, r
_ _
I,::
I',
"-T:-+,
I ':'
' .
, : '
STOP 15A
ENGINE15A
D. LOCK 30A
F. OPEN 15A
ABS/sOL 20A
ABS 40A
,
i '
1912-2
POWER WINDOW
SYSTEM
Y _I REAR WINDOW DEFROSTER
4-WHEELANTILDCK
BRAKE SYSTEM(4W-ABSl
~0.:,;4.!.,""o--!.,---------_I
0810-1
A I R BAG SYSTEM
I 0318.
10912-3
POWER OUTER MIRROR
REAR ANTI LOCK BRAKE SYSTEM
G/W
=~~:i::;O:;O;D===========:
IMMOBILIZER SYSTEM
-- B/w ~0~9.:.1;:!.4--4"---------_i
--B/W-
-L/RJ~0~9.!.1~4--~3---------~
---B/Y-
J~0!..!9~1..:!4~-..!.I_ _ _ _ _ _ _ _ __I
~L/Rr-"0-"9"-1.;.:.4--"-2--------
WIG
L/Y-I~0;.;9""!1~4~5"..,._:_::_::_,....,.,,.....,==c:_-_I
FUEL-FILLER LID OPENER
G/W
-- W/BJ~~:.....:--------Y
0413-2
W/B
L/R
---B/W
- - B/W-
--L/W
---R/L-~~~--------_i
-L
--L
ACCESSORY SOCKET
CIGARETTE LIGHTER
L;;;;::;:::========~
,.
SYSTEM
AND AIR
~~---------------i
AND AIR CONDITIONER
, - - - - B/w:1
L ____ BIY-I DATA LINK CONNECTOR
: 1
: ..
__ :~
," '
, '
':
1
,
"
-,-0
J ,,'u'
,,'
I,'
'I_'+
'
' ..
I::
-~--------------------4~~
L ___
__~----------------:----..,~J
-S~--(g-A---------------n:
DEFOG 20A
CIGAR 20A
P. PO I NT 15A
SOCKET
OOE
IJ-~S!:.EC~T!...I~O~N!...-_ _ _ _ _ _ _-I
SYSTEM CIRCUIT
~~~-_"L..::"::"":"::""",,"
RY
--I
--Y-
1--- ----~------~--il.!.... ---L
'P.WIND30A
~_c.~ !
ACCESSORY
WITH 'REAR
,
t-
r-
# .. WLT
I: r - - B
r---~L--_---i.i+----L
R. A/c 20A
ROOM 15A
L/R
----CURRENT FROM ACC

- - OTHER
-------+---------,-------------------------------------------------------- --"1
' :
~~::..:--------i-------..,
~~~--------J- B/Y- - - - - - - - -
'
L.
,1
----~--L~ I+-_____
' "
-P---------:-----i-------<Y"'.....()------G/B
R. WIP lOA
AUTOMAT I C TRANSM I SS I ON
CONTROL SYSTEM
',
'G'? "'IfACC
W L
~10A
----QURRENT FROM IGI

- - - CURRENT FROM I G2
RB
-~.'
I'
B/R
'Gt'1'
.J \
0919-2
REAR WIPER AND WASHER
10513
r
I
~~~+~~~ET./~B/WOF~Fl~k~OFF
BTNI BOA
W/R
-------.. --------l------~---------t!-----
-+--------......"
r~~~--
--------------.-~
..........
..........
.~
KE~ 40A
PTC/AT 30A
-----,
:
- - :
I
IG
lG KEY2 BOA
..... ~
',METERI5A
-L-------......-------r-------<Y"'.....()------.....
"
WIPER 15A
CLUSTER
ro..
INJ/FIP 20A
"'"
- ~
--------
--v
BTN2 60A
GLOW BOA
"'"'
~ ~
MAIN 80A
--CURRENT FROM BATTERY
,0919
WINDSHIELD WIPER AND
WASHER
I~~;iR~MENT
Y/R
R/Y
~R~L
B/W--
L/W
B/Y
, -K'O
,-
PB/W
Nlv
1
CB
r-~~~--
t
1
rL;;~~================~
HEADLI GHT
0918~L
CONTROL SYSTEM
0140-2. 3. 4
1 CHARGING SYSTEM
0117
1 STARTING SYSTEM
0119
SYSTEM CIRCUIT
II SECTION
-m-
IE?
BATTERY
ELECTRICAL WIRING SCHEMATIC
,
'..
'.
THIS PAGE INTENTIONALLY

LEFT BLANK
I\.)
F-02 FUSE BLOCK (F)
I~'
(E)
W/R
W/R
I_tlwl @ I ~t I
II W
I@ IR/LII
I L I @ I L/WI
(FOG)
G)
15A
30A
30A
20A
(D. LOCK)
(P. WI NO)
(ABS/SOLl
lOA
15A
15A
.15A
15A
20A
lOA
@
@
@
@
@
@
@
@
@
@
@
FUSE NO.
Q)
lffu
(F2)
ROOM
( ) IF EQUIPPED
G)
G)
@
@
TAIL
HEAD LH
G)
HEAO RH
(F. OPEN)
(DEFOG)
(A/C)
FUSE NAME
G)
CD
CD
(0
NO.
CD
IW/RTIB/wll#t/BI
@ @
0
@
(F)
(E)
NOTE:SEEN FROM TERMINAL SIDE
F-Ol MAIN FUSE BLOCK
FUSE BOX
(I NJ/FI p)
30A
lOA
(A/C2)
(P. WI NO)
15A
lOA
20A
20A
15A
15A
15A
lOA
15A
FUSE
WIPER
(R. WI p)
CIGAR
(R. A/C)
(P. POINT)
ENGINE
METER
HAZARO
STOP
FUSE NAME
30A
60A
60A
40A
FUSE
.~
FUEL-FILLER LIO OPENER

REAR ACCESSORY SOCKET
REAR A/C
REAR WIPER AND WASHER
(PTC/AT)
IG KEY2
BTNI
(ABS)
II ... WITH
" ... WI TH
& ... WITH
< >. WITH
G)
CD
CD
FUSE NAME
*# ...
VACANT
... NOT USEO
20A
60A
40A
IG KEYI
BTN2
60A
BOA
FUSE NO.
(GLOW)
MAIN
FUSE NAME
( ) IF EQUIPPEO
G)
G)
CD
CD
(0
NO.
*# ...
VACANT
... AT
OOF

LEFT BLANK
.:I~.
,Xl
I\.J
I\.J
FRONT(~-REAR(R)
(F)
(F)
WITH AIR BAG SYSTEM
lIB
#IB/l
(R)
\-;11 .,...,1 11;-
(R)
(R)
WITH REAR
NOT USED
" ... WITH REAR
& WITH REAR
WITH REAR
@ ...
* ...
< > ..
SYSTEM
POWER WINDOW SYSTEM
SPEAKER
ABS
*# .... ,, VACANT
WI TH THEFT-DETERRENT
* ...
SPEAKER
@ ... WITH HIGH-MOUNT BRAKE LIGHT

" 4 X4 AT
4X4
#1. .. WITH FUEL FILLER LID OPENER
*#
... WITH
VACANT
REAR
SYSTEM
WITH BUCKLE SWITCH
WITH REAR POWER DOOR LOCK SYSTEM
~ ... WITH REAR POWER WINDOW SYSTEM
& ... NOT USED
@I ... AT
#1. .. WITH REAR WIPER AND WASHER
~1. .. 4X4 AT
@ ...
< > ...
*# ...
VACANT
... WITH THEFT-DETERRENT
00(-1
<W>
*
.lG/R
(F)
(FR)
* ...
.~
SYSTEM
NOT USED
" ... WITH REAR POWER WINDOW SYSTEM
& WI TH REAR SPEAKER
WITH REAR POWER DOOR LOCK SYSTEM
< >
*# ...
VACANT
c-04FiiONT (ff:FLOilRTFRi - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --
C-04 FRONT(F)-REAR(R)
C-02
C-OI ENGINE SWITCH (F)
COMMON CONNECTOR LIST
I'-J
W
(F)
C-IO FRONT (F) -DOOR No. I (OR I)
ILlR~IY~
(F)
C-07 FRONT(F)-INTERIOR LIGHT(IN)
C-06 FRONT(F)-ENGINE(E)
Fm3
(I N)
I #*G
(F)
1><1
(F)
r---
L....J
.~'j"-
......
./
~B
'*
IIW/B
'L/W
#*
&LG/R
&2*
Ir
ylR
#W
B/l
(DR Il
-* ... VACANT
(F)
IsIwilGl
(F2)
(E)
*
.GY/R
'G/B
(F)
J~\
(F)
"
# ..
Q ...
SYSTEM
WITH POWER WINDOW SYSTEM
" ... NOT USED

I (ORIl
00(-2
& ... WITH REAR POWER WINDOW SYSTEM
* ... WITH
VACANT
THEFT-DETERRENT
(F2)
* ... VACANT
" ... WITH RFW CONTROL SYSTEM

& ... 4X4 AT
& I. .. 4X2
Q ... AT
&2 ... 4X2 AT
*# ...
VACANT
... WL-3
WL-C.WE-C WITH RFW CONTROL SYSTEM

" ... WITH STARTER RELAY
# ...
Q ...
* ... WLT
VACANT
C-09 FRONT (F) -FRONT No.2 (F2)
I--I~:::+~;f~:"t-=-rn--&R/Y
*# ...
VACANT
.. NOT USEO
VJ
.........
~~~M~~~~~~~~~~
&lG/R
&2*
B/R#*
IIW/B
IR
&2*
#W
B/l
1><1
(E)
~~I~
/'
C-I I FRONT (F) -DOOR No. I (DR I)
c-oa FRONT (F) -FRONT No.2 (F2)
L....J
W/R
W B/l
&1* ........
'W/B .LlW .*
liB
l/R
........
IY/R ~ #*
l
l
BR
.BR/B .G/Y
#V
GY/R
#G/B
&R/Y
..j::o.
I\)
(OR2)
~i
C-17 REAR (R) -DOOR No.4 (OR4)
C-14 REAR (R) -FRONT No.2 (F2)
C-13 REAR (R) -REAR No.2 (R2)
C-12 FRONT (F) -DOOR No.2
(R)
(R)
WITH AIR BAG SYSTEM
(OR4)
(OR3)
(R)
(R)
(F)
f~
IC-17
(FR)
FLOOR (FR) -DOOR No.4 (OR4)

(DR4)
SIg]
~F!Gaij
# ... NOT USED
* ... VACANT
ABS
i ... WI TH 4WABS
" .. BARE WIRE
< >.. DOUBLE CAB WITH REAR ABS
l!! NOT USED
*# ...
VACANT
... WITH REAR
SYSTEM
... WITH POWER WINDOW SYSTEM
(DR3)
B
<->
IBR/W
*# ...
VACANT
(R)
*
*
(F2)
(R2)
(OR2)
OOC-3
ij;~;y;,;;"
U1
I'J
C-26 FRONT(F)-SHORT CORD
C!l3
(F)
EiD
(OR4)
(DR4)
# ...
POWER WINDOW SYSTEM
6 ... WITH REAR SPEAKER
C-24 REAR (R) -DOOR No.4 (OR4) -W I TH AI R BAG SYSTEM

FLOOR(FR)-DOOR No. 4 (OR4) -WITHOUT AIR BAG SYSTEM
ffi) -WITH AIR BAG SYSTEM

(FR) -WITHOUT AIR BAG SYSTEM
(R) -WITH AIR BAG SYSTEM

(FR) -WITHOUT AIR BAG SYSTEM
BiB
* ... WITH
VACANT
REAR
C-22 REAR(R)-DOOR No.4(DR4) -WITH AIR BAG SYSTEM

FLOOR(FR)-DOOR No.4(DR4) -WITHOUT AIR BAG SYSTEM
BE
(R)
(DR3)
SIS
~F!?Jij
(OR4)
(R)
C-18 REAR(R)-DDDR No. 4 (DR4)
C-25 JOINT CONNECTOR (F)
~
Q:E1
ILL

(FR) -W I THOUT AI R BAG SYSTEM
@ ...
* ... VACANT
OOC-4
WITH PANEL LIGHT CONTROL SYSTEM
*# ...
VACANT
... NOT USED
(DR4)
EiD
C!l3
C-23 REAR (R) -DOOR No.4 (OR4) -W I TH AI R BAG SYSTEM
FLOOR (FR) -DOOR No.4 (OR4) -W I THOUT AI R BAG SYSTEM
(DR3)
# ...
POWER WINDOW SYSTEM
6 ... WITH REAR SPEAKER
(DR3)
* ... WITH
VACANT
REAR
(R)
(R)
.,.
N
CJ1
t.i
IBR
p/B
./
L..J
L..J
v/w #v*
V/G
1M!
(F)
G
IR
G/B G/W
.:i
(R)
(E)
(F)
(F)
C-3\ FRONT (F) -ENG I NE (E)
C-30 FRONT(A-ENGINE(8
I~B
'BIYI
B/R
1
P
B/R
L..J
V/G
V/W
,..g"
I'~
(F)
L..J
tIJl1~
(R4)
RILl PILI BILl
IR/Y
firlU(XJl =11t=G/=RIB=R/R1J
(R)
#BR
P/B
G/W G/B
l#B"iv
BII
(E)
(R4)
R/L
SYSTEM
* ... VACANT
*# ...
VACANT
@ ... WITH STARTER CUT SYSTEM
*# ...
VACANT
... 4X4 AT
(E)
OOC-3

LEFT BLANK
t
I'\)
TO
EACH
UNIT
WITH
AI R BAG SYSTEM
B===n
~B===n
@ = = : ===n I
B
I
@==:B===n
CD
B/R (F)
@:
,::-"--
- - - - - - - - - - - - - - - - - - - B / R (F)
I ________________________________________________ JI
L
- - - - - - - - - - - - - - B / R (F)
r - - - - - - - - - R. H. D. SPECS . MALAYSIA MODEL--------------------,
L ______________________________________ I
:-------------------------------------B/R(F)
r------------------~------------------I
CD:
L------------------WU---------------------------B/R(F)
! CD
r------------------------------------------------,
-----------------------B(F)-----~
B(F)
'------B(F)
~ (i)
B (F)
B (F)
! \
- - - - - - - - - - I - - - - - - B (F) - - - - - - ' .
- - - - B (F)
~ ____________________________ !~B_(~)______
(i)
@==:B===n
@==:B===n
#B/R:::::D
~B/R::::::n
wu ~B/R::::::n
r------------------A~-----------------,
B===n
~B===n
WITHOUT
A I R BAG SYSTEM
(i)
B===n
~Y/B:::::D
GROUND POINT
~
-- ,!
,
TO
EACH
UNIT
~B/R::::::n
~B/R::::::n
B===n
~B===n
B===n
~B===n
WLT
@==:B===n
B===n
~B::::::::n
_____________ J
GROUNO PO I NT \!JI
& - B (F)
B (F)
~
AT - - - - - - - - - - - - - - - - - - - - - - - - - - ,
_ _ _ _ _ _ _
B (F)
B (F)
\.V
roo.
0
0
-------------------
B (R)
II
I I
CD
I
I
.~
B(F)
DOOR- - - - - - - - - - - - - - - - - - - - "
WITHOUT AIR BAG SYSTEM-
GROUND PD I NT(i2)
(SECTION OOG-bl
B (FR)
II
@
II CONNE~
JL
- - - - - - - - - - - - - - - - - - -EXCEPT
AIR BAG SYSTEM-
GROUND PO I NTS(ii)@
(SECTION OOG-br'
L-WITH
I
0
I CONNE~
r - - - - - 1 - - - - - - , r------~-------,
B (F)
i - - - - - - - - - - - - - - - :: C-04
:: ::.'*.! ~ ~ ~ ~R_ ~ ~G_ : Y! ~ ~N -- -- -- -- -- -- -- -- -- -- -- -~- -- -- ~
l
- -
i--------------~--------
ilB=::D
B===n
~B===n
L_-_-_-_-_-_-B~)-----T--------------~~~------! ~
t
B(F)

r----------
L__ ~S::T~ ~N_ ~~G~~) _________:
----------------1
~: '~"~::,::~~~;:;[,-;::.~: l -------~ ~~ ~
_____________________
r - - - - - - - - - 5 DDOR--------
L _________ -'
-------;~F~----.,
B (F)
~ fT::~;-------11
i--------WL- C WE-C-------
c ____________________
i--------::~~. H------j-------;~~---'
L_____________________________ ~~~ ______ !
~&B=::D
FRONT
HARNESS
# ... EXCEPT OR. H. D. SPECS . MALAYS I A MODEL WITHOUT I MMOB I L I ZER SYSTEM"
& ... 5 DOOR Ii ... AT
WL-C.
WE-C
r------EXCEPT WLT WITHOUT IMMOBILIZER SYSTEM------,
@==:B===n
#B/R:::::D
~B/R::::::n
FRONT
HARNESS
CD
CD
WL-C.
WE-C
OOG-a
-....J
f\.:)
;mmm (F)
[WL-C, WE-C]
HARNESS SYMBOL:
...... (E) ~ (R)
..
C-04
WITH AlA BAG SYSTEM _ (FHA)

WITHOUT AlA BAG SYSTEM - (F)-(FA)
(FHA) - WITH AlA BAG SYSTEM

(F)-(FA) - WITHOUT AIR BAG SYSTEM
OOG-a
..
ex>
I\)
TO
EACH
UNIT
0)
==B~
==B~
(2) ==B~.
@
==B~
==B~
@ ==B~
==B~
==B~
B (R)
(R2)
i/ o
B (R2)
B (R2)
(2)
HARNESS
1...---8 (R)
-8(R4)--@
8 (R4)
C-33
8 (R)
B (R)
8 (R)
8 (R)
@
@
0)
0)
HARNESS
REAR
HARNESS
) No.4
,m
@ "
1
1
TO
EACH
UNIT
~.
1
)"" ,.,
- - - - - -5 DOOR- - - - - - - - - - - - - - - - - - - - - - - - - ,
(R)~8 (R)-.....- + - - - - -
B (R)
REAR
HARNESS
____________________________________
4_~
"oJ
~l
________________________________________________________ I
-8
C- 13
8 (R)
8 (R2)
r------- --------
- 8 (R2)
I
1
------------,
1-
~R)
L ________________
WITH SEAT WARMER
"!OJLAR CAB
r _5 DOOR. REGU
CONNECT TO
GROUND PO I NTS ~
(SECT ~OG-al
IB
@ ==B~
& ...
@ ==B~
OOG-b
<!J)
<!J)
FRONT No.2
HARNESS
--B(FR)
1
B(FR)
r=I
B(FR)
FLOOR
HARNESS
B(R)l
0 [""@--B (F) ~B (R)
C-03
8 (R)
C-15
REAR
WINDOW
DEFROSTER
GROUND
__ J :
DOOR No.3 1
HARNESS
1
GROUND
~----------------------------------------------------- -----
~B (oR3)-@ @
1
1
1
1
r - - - - - - - - - - - - - - - - - - - - - - - - --'5 DOOR-- - - - - - - - - - - - - - - - --)- :U-D~~ - - - :
------------B
,-----
: (SECT I ON OOG-.)
1 CONNECT TO
1 GROUND PO I NTS
1
1
r----------------STRETCH CAB(WITH REAR ACCESS SYSTEMI-----------------,
'---------,
WITH
rTHEFT-DETERRENT,
SYSTEM
CONNECT TO
GROUND POINTS ~
(SECT I ON OOG-.)
r---------------------WITHOUT AIR BAG SYSTEM----------------------,
- - - - - - - - - - - - - B (F2)
5 DOOR. REGULAR CAB WITH SEAT WARMER
@ ==B~
- - - - - - - - - - - - - B (F2)
@ ==B~
<!J)
r - - - - - - - - - - - - - - - - - - - - - W I T H AIR BAG SYSTEM---------------------I

1
r - - EXCEPT 5 DOOR - - - I
==B~
==B~
&B=:::O
GB~
GROUND POINT
.~
I'V
co
HARNESS SYMBOL:
mmmi (F)
(E) ~ (R)
[STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
.,
(R)-(R2)
C-13
[DOUBLE CAB]
[5 DOOR]
[REGULAR CAB]
(R)-(R2)
[5 DOOR]
OOG-b
VJ
~"
3IS-30)
~\
I ()-I----f~
111111
~_:-..J
LL:--:
r-I-..,-,-r-r..,
I 0 I I 10 I I 0 I
-----------
1010101010101
Lr,.., .... '.LT ... r'--I .... ..,J
~~~
0-02
ENGINE 15A
F-02
FUSE BLOCK
L _________ ....1
NK CONNECTOR-2
b~T~ L
ENGINE SWITCH
F-02
FUSE BLOCK
~ ~~~
R~
r-WL-C. WE-C--I
I
BR/R ____~I----------------------~
I
(F)
I
(F)
L.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ,
Y/R
(F)
ylB
SAS CONTROL MODULE

(SECTION 0810-10)
r-'WITH AIR BAG SYSTEM--
DATA LINK CONNECTOR (F)
(~OATA LINK CONNECTOR
I
;11----\===--1-----)
10-021
DATA LINK CONNECTOR-2 (F)
r-,-~-f-l_-:--:-,
.....---ll--+-ol
~~~
BRIR (F)
B/Y
(F)
B/W
(F)
BIL
~~~
~~~
C- 09
(T>r
YIR
cpl
WE-c----r~C-M----:.Ai:::-::-:::::;:
P (F)
(F)
YIR
(F)
Y/R
(F)
B/R
V (F)
I
I
B
(F)
CALH
V (F)
Icp
A
:
I CAN_L
I
I
P (F)
I
I
I
:
ABS Hu/cM
(SECTION 0413-1)
WL C
-
000
4X4 AT
SYSTEM
& ...
P (F)
I
fA)
.~
___
V (F)
f8\
I
I
J:
I
II
II
I:
I (SECTION 0140-2d) I (SECTION 0513-a) II
:;C-M-
*0 ...
VACANT
# .. WL-C. WE-C
... WLT WITHOUT IMMOBILIZER
r---II~::=+::::::~~~--------------------------Y/R
r 1-'"
(F) ------------------------------------+
(F)
Y/B
#R/Y
'--------------+~ I
---------------
(F)
WiG
(SECT I ON
eT
4X4 CONTROL MODULE
I G KEY2 BOA
rr
II
IG KEYI 40A
~~
((
F-OI
BT.!: BOA
~~
PCM
(SECTION 0140-2 4b)
MAIN 80A
I ~~
MAIN FUSE BLOCK

r----.EXCEPT 0 - - - - -
~~
F-OI
r-----4X4 AT------
(~)
r-------WL-C. WE-C-------..,
I PCM
~W/L I
:L.. _(SECTION
0140-2.) ~ (F)
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ....
BATTERY
DATA LINK CONNECTOR
c.v
[WL-C, WE-C]
HARNESS SYMBOL: mmiiii (F) (E) ~ (R)
C-09
(Fj-(F2)
..
(F)-(F2)
000
'"
~o>
~\
~
'--"
-' ,
STARTER (EI
PCM
~B/YTB/Y
(SECT I ON
~ (F)
(F)
0140-3 b. 4b)
I
(F)
mi
(F)
B/L (F)
(F)
.,..C-30
I
I
Il
W/~~-06
R (F) _ _ _ _ _ _ _ _ _ _
~C-30
10119-031
R (E)
DIGITAL TRANSMISSION
RANGE SENSOR
(P OR N RANGE ON)
~0119-031
I
I
I
I
~n~TER
I
I
I I
I
1
II
() I
AT
R F MIT CUT
I :
I SYSTEM
I
I
-I
IMMOBILIZER UNIT!
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ~!~O~~)_ _'
I
I
II
I I
--------------, r
I
I W/B (E)
(F)r
#WR/B
I
I
WITHOUT I
STARTER
CUT
II
1 "'["
Jk
(i 9-og 3 ~
10l
R(E)
DIGITAL
TRANSMISSION
RANGE SENSOR
RANGE ON)
9119-031
(E)
W/B
+C-06
W/B
STARTER RELAY-----------,
ENGINE SWITCH
RELAY
r-------------------------,
ENOOm
F-02
FUSE BLOCK
r---,-------------,
021
STARTER RELAY
-~I 0 II 9
~W
(F)
~/
# ... AT
* ...
VACANT
... WITH STARTER
0119
B/L
B/Y
*
B/w
0119-03
(ft.........
::::>I~
DIGITAL TRANSMISSION RANGE SENSOR (E)
(~
L __________~~_~~_~~_~~_~~ _____________________________ ___________ 1
B/w
(F)
B/Y
(F)
;;--------------,
B/L
+'----=====-1'10119-021
B/Y
~B/~;----i6)-----+--1
I
I
0119-021 STARTER RELAY (F)
I]TDFOfl B/Y
C-05
#B/L
(E)
L-------WITHOUT STARTER
B/Y
: ~-------WLT-------
II
I
I
;~~~~~~~~~~~,-------i
'r[QJTg-::O( 1
B (E)
IG KEY2 60A
MAIN FUSE BLOCK
MAIN aOA
F OI
-
= ,,~. I:[
L '10 '
u . no>.
STARTING SYSTEM
,dJ
[WL-C, WE-C]
01 ENGINE
19 STARTING SYSTEM
F-01
MAIN FUSE BLOCK

(REFER TO OOF SECTION)
C-05
[BLACK]
(F)-(E)
HARNESS SYMBOL: ggggg (F) (E) ~ (R)
.,
[WLT]
STARTER RELAY
ENGINE SWITCH
0119
I
\
~.
""--;.0'
I
I
-'
(W
0119-011 STARTER (E)
71r
BA HERY
Ii "" (~)
F-O II
MAIN 80A
~B/YTn
~ (F)
(F)
~-------WLT-------~
(F)
a/Y
~
~
IT
IG29
IGI
========-
(FI
all
(F)
F-02
FUSE alOCK
CY"'...."O
ENGINEI5A
STARTER RELAY
10119-021
~~r
/F=========::j:::10119-021
(F)
a/Y
W
(F)
B/W
C-OI
-qACC
,-" ",,,,--;,;-;.0;:7,,,
I"\~ ~:~
IMMOBiliZER UNIT
(SECTION 0914-3)
- - - - - - - - - - - - WITH STARTER RElAY-------------
B/Y
(F)
.n
*=====,*C-OI
: : ;_ _ _ _ _ _ _ _ _ _ _ _ _ _- .
-----------------------------------1
- - -
0119-021 STARTER.RElAY(~
"'------(1
II
II
: :
I I
I r--
I
I
a (E) L-------WITHOUT STARTER RElAY-------J
mCTION
0140-3b. 4b)
r':::":::":::::':::":::":::::':::":::":::::':::":::":::::':::":::":::::1- - - - - - --,
:I
IG KEY2 60A
F o
I - I
IG~40A:
MAIN FUSE BLOCK
c:o
STARTING SYSTEM
~
ENGINE SWITCH
i~
* ...
VACANT
... WITH STARTER
RELAY
0119
.J
01
mmm! (F) + + + (E)
01 ENGINE
19 STARTING SYSTEM
F-01
MAIN FUSE BLOCK

[WL-C, WE-C]
HARNESS SYMBOL:
~ (R)
.,
F-01
FUSE BLOCK
F-02
MAIN FUSE BLOCK

[WLT]
(F)-(E)
C-05
[BLACK]
0119
w
CJ)
0140-107
~,
IT]
GLOW PLUG RELAYIFI
~~r
..
GLOW PLUG
IF-O 1
I~
0140-1031 EGR SOLENOID VAlVEIVACUUMI
ffi
GLOW BOA
INJ/FIP 20A
r=:;::
(~I F-o1 T MAIN

~BOA
~~~r
BTNI 60A
061
IFI
s/W
(FI
0140-1081 GLOW PlUGIFI
""1'1
B IFI
1 "'"-lOll
1~r
B/l
(FI
B/l
(FI
~~f
EGR SOLENOID
VALVE
(VACUUMI
B/R (FI
oM'
B/R
B/R
IFI
IF yIFI
i
B/R
CONTROL
,~
G/B
IFI
B 10140-1111
CLUTCH PEDAL
PDS I T I ON
SWITCH
GI~\0140_1I11
C-OB
>
EGR CONTROL
SOLENOID
VALVE
--~---
(FI
WIR
B/l
(FI
SW ITCH IFI
B/~:~25
,~
IG~BI
B/R IFI
19
--
NEUTRAL SWITCH
10140-1121
B/R lEI
*C-05
USEO
* ... VACANT
1# ... NOT
0140-1a
~~~~-+- IEl10140-1121
G/B
(FI
EGR SDlENOIO
VALVE
(VENTI
.... ''1
lG/R
IFI
B/l
(FI
0140-111 1 ~~~mO~EDAl
IW~RjVll
10140-1101
IDLE SWITCH
~IFII0140_1101
GIW
FUEL PUMP
rI40-1101 IDLE SWI TCH (FI
SPEED SENSOR IFI
dn
{r-\\
I'tif: ],,"-""
___ GLOW SHIELD

PLUG RELAY
~---WIRE
R IFI
ft.J
..
F-02
FUSE BLOCK
ROOM 15A
I~ I
,- -- ,- --~:m -"l r-f- j-mu
~~f--'--
II
~ -1""-1011 . fT--f:i
~~Il
loT40~1
MAIN RELAY
10140-1061
IG KEY2 BOA
IG KEYI 40A
I~B/l
ft. '" .ft
MAIN FUSE BLOCK
CONTROL SYSTEM (WL-3)
r'
-....J
mimm (F)
(E) ~ (A)
01 ENGINE
40 CONTROL SYSTEM
F-01
MAIN FUSE BLOCK

HAANESS SYMBOL:
..
0140-1a
.,
~
;!~
.,
"m" ..
ex>
(F)
W
(F)
'"
BR/W
0140-1161 EGR VALVE POSITION SENSOR (E)
c: '7
FUEL INJECTION PUMP
R'LlY L/w R/Y

(F): (F) (F) (F)
0140-1 13 1 FUEL INJECTION PUMP
(F)
aiR
C-25
Bt(~f
t -L
SH I ELD WIRE I
I
I
r----
t
()
I
( )
G Y F
BR/W
(F)
BR/B
(F)
B/Y
(F)
IF
I' ()
(E)
BR/B
(E)
G/Y
(E)
0140-1171 BOOST SENSOR(F)IOI40-118
BOOST SENSOR
COOLANT TEMPERATURE SENSOR (E)
EGR VALVE
POSITION SENSOR
ACCELERATOR PEDAL POSITION SENSOR (F)
INTAKE AIR
TEMPERATURE
SENSOR No.1
'rf,"If,"rf,'
I P:
BR/W
(F)
BR/B
(F)
I ~It 'rf,' lit
PCM
(SENSOR GROUND)
(SECT I ON
0140-lc)
VACANT
NOT USED
,~
A I R TEMPERATURE SENSOR No.1 (E)
ACCELERATOR PEDAL
POSITION SENSOR
1-;;'0'14;-;0:--;-1-;-'16 ; ; - ' l r n 10140-1171 '1"='1"=-=:X:=---"I"IVI'tV-,IOI

I pwx ~
L\ I
Br{,B~Br{,Brn_
==
(F)
BR/w
---------------------------
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10140-1141
10140-1141
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(F)
============
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(F)
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(SECT I ON 000)
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(SECTION 0922-10)
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40 CONTROL SYSTEM
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40 CONTROL SYSTEM
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INTAKE AIR
TEMPERATURE
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(F)
R/W
(F)
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INSTRUMENT CLUSTER A/c AMPLIFIER

(SECTION 0922-10)
(SECT I ON 0740)
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(F)
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SYSTEM
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ACCELERATOR PEDAL POSITION SENSDR(F)
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BRAKE SWITCH
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(SECTION 0918-6) (SECTION 0922-lb)
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40 CONTROL SYSTEM
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*
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121
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118
111
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118
116
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L/W
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13.
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B/W RIB
151
15.
15.
15.
15'
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LIB
10318-051
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TRANSFER NEUTRAL SWITCH
RFW LOCK SWITCH
LG/B (El
TRANSFER NEUTRAL SWITCH (El
B (F)
fC-06
B/R (El
t-B/R
(El
1[1 LGlBI B/R II
10318-041
B/R (El
PCM
~-------------------~
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LG/B (Fl
----~--
4X4 INDICATOR
SWITCH
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0318-05
--
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GY/R (El
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GY/R (Fl
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0318-0414X4 INDICATOR SWITCH (E)

n
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REMOTE FREEWHEEL CONTROL SYSTEM
* ... VACANT
0318-b
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01
01
.,
immm (F)
03 DRIVELINE/AXLE
18 4-WHEEL DRIVE
HARNESS SYMBOL:
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CJ1
CJ1
0318-301
71r
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CONTROL MODULE (F)
(E)
.,
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BATTERY
4X4 CONTROL SYSTEM
G/B (F)
ENGINE 15A
LIB (F)
LG/B(F)
r-l
TCM
(SECT I ON 0513-b)
F-02
FUSE BLOCK
R(F)
0-0
B/W(F)
%r
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0318-3041 4X4 RELAY (F)
0318-3021 LOCK SOLENOID(F)
4X4 CONTROL MODULE
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4X4 RELAY
IWyl
(5IB ) f - - - - -
B (F)
'y'
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$= = - - =- -=$1 0318-3041
LG(F)
A~=====~f(0318-304(
R(F)
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0318-3031 FREE SOLENOID (F)
GXv
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B (F)
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103Ta-302 (
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= = = = = = = =*= = = = = = = = = =*= = = = = = *= = = = = = *= = =~L03iJi-3_Ql]
WIG (F)
DATA LINK CONNECTOR

(SECTION 000)
(~)
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*= = = = = = *= = =
G/B (F)
G/B (F)
L...-
ENGINE SWITCH
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0318-3a
OJ
CJ'I
CJ'I
03 DRIVELINE/AXLE
18 4-WHEEL DRIVE
HARNESS SYMBOL: iiiiiiiii! (F) (E) ~ (R)
.,
F-02
0318-3a
FUSE BLOCK
(REFER TO OaF SECTION)
,.
'1,\1
'.
CJ'I
CJ'I
()
(F)
B/W
(F)
B/l
(F)
RIB
(F)
RIB
(F)
W/l
(F)
RIB
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(F)
W/L
(F)
R/w
B/R
(E)
B/W
(E)
W/L
(E)
MOTOR COMPONENT
B/L
(E)
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(R)
0318-3071 4X4 SW ITCH
~
R/W
(E)
TRANSFER CASE
RIB
(E)
R/W
(E)
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B/R
(F)
4X4 CONTROL MOOULE(8
C-30
B/Y
(E)
(F)
B/Y
(F)
W/L
4X4 CONTROL SYSTEM
(E)
(E)
0318-305
C-06
R/Y
(F)
R/Y
SPEEO SENSORI
CLUTCH COIL
R/W
(E)
(F)
(F)
(R)
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4X4 SWITCH
fo 3 I 8-=3071
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x
....
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B (F)
C-03
B (R)
B (O,R3)
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B (R)
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(WITH REAR
ACCESS
SYSTI'M)
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I
B (R)
1.
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C-30
t
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0119-031 DIGITAL TRANSMISSION RANGE SENSOR (E)
0318-3061 SPEEO SENSOR/CLUTCH
I
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0318-3b
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18 4-WHEEL DRIVE
C-29
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HARNESS SYMBOL: fiifiifiii (F) (E) ~ (R)
.,
(F)-(R)
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0318-3b
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10"
ABS WHEEL-SPEED SENSOR LF
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=============
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FUSE BLOCK
ENGINE 15A
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0413-104
0413-102
ABS WHEEL-SPEED SENSOR RF
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ABS WHEEL-SPEED SENSOR LF(F)
ABS WHEEL-SPEED SENSOR LR
BR/W
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C-14
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0413-103
38
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VACANT
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INSTRUMENT CLUSTER
BRAKE SWITCH
(SECTION 0918-6) (SECTION 0922-lb)
ABS WHEEL-SPEED SENSOR RR(R2)
ABS WHEEL-SPEED SENSOR RF(F)
ABS WHEEL-SPEED SENSOR RR
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ABS/sOL 20A
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13 ANTI LOCK BRAKE SYSTEM
HARNESS SYMBOL:
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0413-1
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RELAY (FJ
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ABS SPEED SENSOR
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W13-2021
ABS RELAY
10413-2011
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LG
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lL(R~----Pf(~)-'- (~J 0---,

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STOP 15A
ABS/SOL 20A
0413-2
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VACANT
WIRE
B/R
(F) ~(~)------------------------~---------------,
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F-02
FUSE BLOCK
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BTN2 60A
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REAR ANTILOCK BRAKE SYSTEM
CO
01
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13 ANTILOCK BRAKE SYSTEM
HARNESS SYMBOL: iii!!!!!!! (F) (E) ~ (R)
.,
WITH AlA BAG SYSTEM _ (FHR)

WITHOUT AIR BAG SYSTEM _ (F)-(FA)
(FHA)
C-02
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(F)-(FA) ~ WITHOUT AIR BAG SYSTEM
C-04
0413-2
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OS13-041 OlD OFF SWITCH
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OSI3-0!l AT OIOOE(F)
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4X4
0513-a
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13 AUTOMATIC TRANSMISSION
C-30
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(F)-(E)
F-01
MAIN FUSE BLOCK

HARNESS SYMBOL: mml1ii (F) (E) ~ (R)
[BLACK]
(FHR)
C-02
.,
F-02
FUSE BLOCK
(REFER TO QOF SECTION)
0513-a
.,
CD
()
01
0513-01 I TCM (El
--
W(El
W/R (El
3.3
I
I
85
TCM
V/G
-----
INTERMEDIATE SHAFT SPEED SENSOR
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V(El
-----
V/W (El
(El
V:tG(FC _30
LL (F1 _
C 06
B-A
~~
II
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VACANT
... 4X4
OS13-b
0513-051 TURBINE SHAFT

10513-061 INTERMEDIATE
SPEED SENSOR(EI
SHAFT SPEED
SENSOR (El
t
L (El
y
y
f
:f(: ____
INSTRUMENT CLUSTER
(SECTION 0922-lbl
(F~ ___
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-------------------------------------
TURBINE SHAFT SPEED SENSOR
84
P/B (El
==0::=========
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BR (El
LG/R (El
LIB (El
LG/B (El
LG/tR
L/tB
-----
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~tB(F~
BRt(Fl __ F ________
----------
INSTRUMENT CLUSTER
(SECTION 0922-lcl
,(F~==::/tB~"
(CF~05 (CF~06
4X4 CONTROL UNIT

(SECTION 0318-3.1
r - - - - - - - - - - - -'4 X4- - - - - - - - - - - - -
(J1
CD
immm (F)
C-30
[GRAY]
(F)-(E)
(E) ~ (R)
05 TRANSMISSIONrrRANSAXLE
HARNESS SYMBOL:
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..
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~-;f'f~
,.,.
CJ1
c.o
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---
all ~/l
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G*
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33
c* G/B ~/W * .'p

0* .L* * * ""*
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(E)
R/W
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(E)
SOLENOID BODY
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W/R
(E)
R/Y
TCN
(E)
RIB
(E)
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(E)
85
r-84
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DIGITAL TRANSMISSION RANGE SENSOR
(E)
0513-081 SOLENOID BODY(E)
I(E)~ (SECTION 0513-d)
~ ~
(E)
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VACANT
... 4X4
OS13-c
CJ'1
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c.o
mmmi (F)
(E) ~ (R)
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HARNESS SYMBOL:
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3.3
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0* .'* * R* *
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G/R
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GiS
j
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84
85
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C* * l V/G W/R ' Y Ep/B R/W

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s/W (El
TCM
=====================================
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0513-071 OUTPUT SHAFT

10119-031 DIGITAL TRANSMISSION RANGE
SPEED SENSOR (El
SENSOR (El
"XI-'_l________
C-31
Y/tS(El
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10119-031
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(F)
R/w
1
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BLOWER RELAY
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II
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I BLOWER
RELAY (F)
BIW
1([W]WaJ)
tfffJ
0740-02
THERMISTOR
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REAR AIC
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B/W
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MOTOR
AMPLIFIER(F)
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0740-10
C-OI
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0740-07 1 AIC RELAY (F)
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I
I
I
I
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WL -3 (F)
I
I
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BLOWER UNIT
ENGINE SWITCH
I RES I STOR
0740-207
0740-06
0740-04
(BLOWER UN I Tl
0740
VACANT
# ... WITH REAR Alc
~ ... WITH PANEL LIGHT CONTROL SYSTEM
* ...
10740-0411.
rRESISTOR
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IA~%f
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F-02
FUSE BLOCK
10740-03 1 FRONT (F) -BLOWER UN I T
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I
1
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B/W
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10740-031
F-OI
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MAIN BOA
PCM
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0140-lc.
Alc RELAY
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(E)
CLUTCH 10740-091 REFRIGERANT PRESSURE SWITCH (F)
CLIMATE CONTROL UNIT(F)
MAGNETIC CLUTCH
I MAGNETIC
(E)
091
REFRIGERANT
PRESSURE SWITCH
0740
(F)
RIB
============
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T C-06
(F)
============
10740-091
(F)
LG/B
(F)
F-02
FUSE BLOCK
---IIi---'Q""'.....O
LGIR
BATTERY
HEATER AND AIR CONDITIONER
mmmi (F)
(E) ~ (R)
" T us
07 HEATER, VENTILATION & AIR CONDITIONING (HVAC)

40 CONTROL SYSTEM
77 m" .. r
HARNESS SYMBOL:
.,
S T "
..
TTl
I F
[r
gT
mmm:r:rr
BLOWER
RELAY
i ____ _
0740
rrnrTnr"""lSr:
..
()r---------------------------------------------------,..
00
()
AIR BAG SYSTEM

SERVICE WARNINGS
DBG081000000W02
Air Bag Module Inspection

Inspecting an air bag module using a tester can operate (deploy) the
air bag module, which may cause serious injury. Do not use a tester
to inspect an air bag module. Always use the on-board diagnostic
function to diagnose the air bag module for malfunctions.
NO GOOD
DPE81 OZWl 002
Air Bag Module Handling

Before removing the air bag module or disconnecting the air bag
module connector, always turn the ignition switch to the LOCK
position, disconnect the negative battery cable, and then wait for 1
min or more to allow the backup power supply of the SAS control
module to deplete its stored power.
Handling a live (undeployed) air bag module that is pointed toward
your body could result in serious injury if the air bag module were to
accidentally operate (deploy). When carrying a live (undeployed) air
bag module, point the deployment surface away from your body to
lessen the chance of injury in case it operates (deploys).
en
G
Z
Z
a:
o
:>
a:
w
en
.....
en
z
i=
GOOD
NO GOOD
DPE810ZW1003
A live (undeployed) air bag module placed with its deployment

surface to ground is dangerous. If the air bag module were to
accidentally operate (deploy), it could cause serious Injury. Always
place a live (undeployed) air bag module with its deployment surface
up.
GOOD-
NO GOOD
module and the seat back (pad, frame, trim) with new parts. After
servicing, verify that the seat operates normally and that the wiring
harness is not caught.
SAS control module Handling
Removing the SAS control module or disconnecting the SAS control
module connector with the ignition switch at the ON position can
activate the sensor in the SAS control module and operate (deploy)
the air bags and pre-tensioner seat belts, which may cause serious
injury. Before removing the SAS control module or disconnecting the
SAS control module connector, always turn the ignition switch to the
LOCK position, disconnect the negative battery cable, and then wait
for 1 min or more to allow the backup power supply of the SAS
control module to deplete its stored power.
Connecting the SAS control module connector with the SAS control
module not securely fixed to the vehicle is dangerous. The sensor in
the SAS control module could send an electrical signal to the air bag
modules and pre-tensloner seat belts. This will operate (deploy) the
air bags and pre-tensioner seat belts, which may result in serious
injury. Therefore, before connecting the connector, securely fix the
SAS control module to the vehicle.
Because a sensor is built into the SAS control module, once the air
bags and pre-tensioner seat belts have operated (deployed) due to a
collision or other causes, the SAS control module must be replaced
with a new one even if the used one does not have any visible
external damage or deformation. The used SAS control module may
have been damaged internally which may cause improper operation.
H the SAS control module is reused, the air bags and pre-tensioner
seat belts may not operate (deploy) normally, which could result in a
serious accident. Always replace the SAS control module with a new
one. The SAS control module cannot be bench-checked or selfchecked.
Side Air Bag Sensor Handling
Removing the side air bag sensor or disconnecting the side air bag
sensor connector with the ignition switch at the ON position can
act!vate the side air bag sensor and operate (deploy) the side air bag,
which may cause serious injury. Before removing the side air bag
sensor or disconnecting the side air bag sensor connector, always
turn the ignition switch to the LOCK position, disconnect the
negative battery cable, and then wait for 1 min or more to allow the
backup power supply of the SAS control module to deplete Its stored
power.
H the side air bag sensor is subjected to shock or the sensor is
disassembled, the side air bag may accidentally operate (deploy) and
cause injury, or the system may fail to operate normally and cause a
serious accident. Do not subject the side air bag sensor to shock or
disassemble the sensor.
Because a sensor is built into the side air bag sensor, once the air
bag has operated (deployed) due to a collision or other causes, the
side air bag sensor must be replaced with a new one even if the used
one does not have any visible external damage or deformation. If the
side air bag sensor Is reused, the side air bag may not operate
(deploy) normally, which could result in a serious accident. Always
replace the side air bag sensor with a new one. The side air bag
sensor cannot be bench-checked or self-checked.
Pre-tensioner Seat Belt Inspection
Inspecting a pre-tensloner seat belt using a tester can operate
(deploy) the pre-tensioner seat belt, which may cause serious injury.
Do not use a tester to inspect a pre-tensioner seat belt. Always use
the on-board diagnostic function to diagnose the pre-tensioner seat
belt for malfunctions.
:J
<C
o
w
o
:>
a:
en
:E
w
I-
en
>
en
G
NO GOOD
DPE810ZW1004
Side Air Bag Module Handling

When a side air bag module operates (deploys) due to a collision, the
interior of the seat back (pad, frame, trim) may become damaged. If a
side air bag does not operate (deploy) normally from a seat back that
has been reused, a serious accident may result. After a side air bag
has operated (deployed), always replace both the side air bag
<C
m
a:
<C
62
E5U810ZW5005
o
.....
SERVICE CAUTIONS
DBG081000000W03
Air Bag System Component Disassembly

Disassembling the air bag system components could cause it to not
operate (deploy) normally. Never disassemble any air bag system
components.
DPE810ZW1005
Air Bag Module, Pre-tensioner Seat Belt Handling

Oil, grease, or water on the air bag modules may cause the air bags
and pre-tensioner seat belts to fail to operate (deploy) in an accident.
Never allow oil, grease, or water to get on the air bag modules or pretensioner seat belts.
Inserting a screwdriver or similar object into the connector of an air
bag module or a pre-tensioner seat belt may damage the connector
and cause the air bag module or the pre-tensloner seat belt to
operate (deploy) improperly, which may cause serious injury. Never
insert any foreign objects into the air bag module or seat belt
connectors.
en
.~
z
a:
<
NO GOOD
:>
a:
en
......
en
z
o
i=
::J
<
o
w
o
NO GOOD
DCF810ZWB002
Air Bag Module, Pre-tensioner Seat Belt Reuse

Even if an air bag module or a pre-tensioner seat belt does not
operate (deploy) In a collision and does not have any external signs
of damage, it may have been damaged internally, which may cause
improper operation. Before reusing a live (un deployed) air bag
module and the pre-tensloner seat belts, always use the on-board
diagnostic to diagnose the air bag module and the pre-tensioner seat
belts to verify that they have no malfunction.
Air Bag Wiring Harness Repair
Incorrectly repairing an air bag wiring harness can accidentally
operate (deploy) the air bag module and pre-tensloner seat belts. If a
problem is found in the air bag wiring harness, always replace the
wiring harness with a new one.
:>
a:
w
en
w
==
I-
en
..,en
>
NO GOOD
CHU0810W606
Cl
<
III
a:
63
CO
0>
B
(E)
SAS CONTROL MOOULE(F)
BATTERY
IR
riG
(F)
II
INFLATOR
Ie
IA
Y/R
(F)
IX
Y/B
~
~'
IG KEY2 60A
IG KEYI 40A
MAIN FUSE BLOCK
MAIN 80A
....,.,
"
rr
F-OI
B/W
(F)
B/L
(F)
0810-104
10810-1011
(F)
IG
rY
~[~!t0]ij
IB/WTy IR IG/R1
0810-105
ORIVER-SIDE AIR BAG MODULE

(CLOCK SPR I NG)
I Y/RIII VlBI
FRONT (F)-CLOCK SPRING

(F)
(CLOCK SPR I NG)
~[~!t~ij
0810-103
INSTRUMENT CLUSTER
(SECTION 0922-lb)
PASSENGER-SIDE AIR BAG MODULE (F)
~/RI VlRTS/wl VI~
SHORT CONNECTOR(F)
OATA LINK CONNECTOR-2

(SECTION 000)
0810-102
Y/G
------------------- =+1 081 0-1 021

(F)
Y/G (F)
(F)
t=-------------------
Y/R
Y/R
F-02
FUSE BLOCK
ENGINE SWITCH
* ... VACANT
0810-1a
+10810-1021
B/W (F)
B/w (F)
===============================================
(F)
SAS CONTROL MOOULE

IR
-----------------------------------------------------------------------------
(F)
ORIVER-SIOE AIR BAG MOOULE
===:::::::::::::::::==
(~d
10810-1041
PASSENGER-SlOE AIR BAG MOOULE
"
F-OI
AIR BAG SYSTEM (INCLUDES PRE-TENSIONER SEAT BELT INFORMATION)
Q')
CJl
mmim (F)
08 RESTRAINTS
10 AIR BAG SYSTEM
HARNESS SYMBOL:
(E) ~ (R)
.,
0810-1a
DRIVER-SIDE
AIR
BAG MODULE
_
i
1 __ _
..
0')
0')
'=.
+I
INFLATOR
(R)
t
(R)
aiL
(R)
2A
2C
ilL
vlvl*I*I~
~J!F]ij
0810-1081 DRIVER-SIDE SIDE AIR aAG MODULECR)
:wl*I*1
2B
* I * IB/RIB/YliY'";RIB/LjW/BI * I *
20
10810-1071
0810-109 I PASSENGER-SIDE SIDE AIR BAG MODULE (R)
~ITf[Y7GJij
::
BELT(D~~l
BELT(D~~l
I DRIVER-SIDE PRE-TENS10NER SEAT
0810-1071 PASSENGER-SIDE PRE-TENS lONER SEAT
0810-106
SAS CONTROL
MODU LE
INFLATOR
(R)
================
::
INFLATOR
(R)
(~)
Y/G
I<rn]3]]J
0810- 111 1 ~mEmRB~bDE

SENSOR (R)
ll @
0810-110 I ~~~~E~I~lg~G
SENSOR (R)
(~) ~
(R)
==================
(R)
Y/R
DRIVER-SIDE SIDE AIR BAG SENSOR
(:) +
(R)
Y/B
==========~============F=======
-=-=-=--=-=-=--=-=-=--=-=-=--=-=-=--=-=-=--=-=-=-"~-_-=-=-_-_-=-=-=--=-=-_-_-=-=-=--=-=-_-_-=-=-_-_____
2G
= = = = = = = = = =I::! = = = = = = = = = = = = = = = = = =
W/a I
(R)
(R)
PASSENGER-SIDE PRE-TENSIONER SEAT BELT
===================
-------------------------------------
10810-1061
aiR
(R)
OR I V"ER-S I DE PRE-TENS lONER SEAT BELT
(R)
W/B
~~H;~T=~~R~C_18
aiR
0810-1011 SAS CONTROL MODULECR)

2V 2S 2P 2M 2J
(DR4)
f
(OR4)
10810-1071
Biy
B/L
(OR3) t
BIR I
~S=H;~T=~A=R~ C-16
aiR I
a/Y
a/Y
10810-1061
INFLATOR
INFLATOR
f
(DR3)
PASSENGER-SIDE PRE-TENS lONER SEAT BELT
DRIVER-SIDE PRE-TENS lONER SEAT BELT
r - - - - - - - - - - - - - - - - - - - - - "#- - - - - - - - - - - - - - - - - - - - - -
r--------------------WITH PRE-TENSIONER SEAT BELT--------------------l
0810-1b
*""" VACANT
@ """ WITH SIDE AIR BAG
# """ STRETCH CAB (W I TH REAR ACCESS SYSTEM)
" """ EXCEPT STRETCH CAB (WITH REAR ACCESS SYSTEM)
r----------------~--"WITH SIDE AIR BAG--------------------l
DRIVER-SIDE SIDE AIR BAG MODULE
AIR BAG SYSTEM (INCLUDES PRE-TENSIONER SEAT BELT INFORMATION)
-....J
CJ)
immm (F)
(E) ~ (R)
08 RESTRAINTS
10 AIR BAG SYSTEM
[REGULAR CAB]
HARNESS SYMBOL:
.,
..,
0810-111
[BLACK]
0810-1b
.,
(j)
(X)
0912 -10 I
71T
Ie
(E)
F-OI
40A
LMJ
10912-1031
(R)
B/L
10912 1031
R/B
G .Rs"G
0912-1021 REAR WINDOW DEFROSTER SWITCH (F)
-------------~
I~
:
,""09"'1;-;;2,...--;-10
..3;01
EXCEPT
5 O,OOR
F I LAMENT
~'-'_ _-!-----1
F I LAMENT
,0912-1031
L ___________ _
O:OOR
C-32
B/L (R4)
: +
B/L
t -------- 1
/1
REAR WINDOW DEFROSTER SW ITCH
ENGINE SWITCH
(R)
~xg6~~
0912-1031 FILAMENT
~0
(SHORT CORD)
(R4)
5 DOOR (SHORT CORD)
(5T6)r-------------------------------------------------------
(F)
*========*10912-1021
lOA
F-02
FUSE BLOCK
A/C2
Y~B/R
__
(F)
(F)
!C-02
(F)
lOll
(F)
(F)
-----------------------
============
(F)
B/L
r -- - f'------------------l------r-------
REAR WINDOW DEFROSTER RELAY
(F)
I~
L-~.~C-_-O-I--------
~~
MAIN FUSE BLOCK
F-02
FUSE BLOCK
L-______________B_T_N_I__
60_A__-J
IG KEY2 60A
0912-1
VACANT
# ... WITH PANEL LIGHT CONTROL SYSTEM
* ...
L-~~D-~--<f~~--~~~~r----------------------------------------------------------------------~
IG KEYI
~~~----------~~~o---~~~~f
F-OI
1 REAR WINDOW DEFROSTER RELAY (F)
BATTERY
-,
CO
0)

12 GLASSIWINDOWSIMIRRORS
HARNESS SYMBOL: 1111111111 (F) (E) ~ (R)
..
, ......... "- ...... ,-WLC.WE-C
(F)-(R)
C-02
[5 DOOR]
0912-1
.,
'~~
'1
"' .....'.,
--...J
(~)
IG KEY2 SDA
MAIN FUSE BLOCK
MAIN aOA
'-"I1~OA:1'-"
B/W
(F)
B/L
(F)
+Nt ~~
-OPEN
10;;0"',9"12;;-::--;;2"05"'1
FRONT POWER WINDOW REGULATOR RH
CLOSE~
II
G/B
(OR I)
r---- =+
RIB
(DRI)
0912-20sl FRONT POWER WINOOW REGULATOR LH(OR2)
(415)
(F)
(F)~
CLOSE
(F)
(F)
R/W (OR2)
FRONT POWER WINDOW REGULATOR LH
10912-2021
G/B (OR2)
1"0"9"1"2--"2oftCs"'l
,...~
"'fi?1
W
(F)---
~C-OI
;a0 ~ACC
0912-2051 FRONT POWER WINDOW REGULATOR RH (oRil
REAR POWER WINOOW SYSTEM---..!
POWER WINDOW SUBSWITCH LF
---I...r;;o"'-;;C"::n"Anl
G/W (OR2)
~---WITH
R/L
(R)
P.~
li"o~~:"o
*=====:::!:::C-Dl
/A."~F; - :~/-OFF
IG29
p'
ST
I~'" ~g~g I ~~Ng~12~~:~W ITCH
tg~
0912-2a
VACANT
WITH REAR POWER WINOOW SYSTEM
ENGINE SWITCH
*# ...
...
1__________________________
L_WITH REAR POWER WINDOW SYSTEM-_I
1
1
0912-2021 POWER WINDOW SUBSW ITCH LF (DR2)
RIB (DR2)
R/L (DR2)
====,,*=======~C-12
~~Wl(D~~11
G/w_
===
C-Q2
(F)
R/L_~--~---------------R/L
RL
-======~IQ912-2011
R/~/Wt(DR ~)=
(F)
OPEN
~R/L~ R/L _
(F) R/L (F) (F) R/W (F)
fC-II
(DRO
POWER-CUT SWITCH
10912-2011*====*===========~
0912-2011 POWER WINOOW MAIN SWITCH (DRI)
y}r
LL
,.," .,'" ~ I~ "'" .,'"
P/W CM
m~
~? ~ ?~~?
10912-2011
R/L
(ORI)
r---------------------------------------------------------------------C-l1
IT I
BATTERY
POWER WINDOW SYSTEM
....L
immm (F)
(E) ~ (R)

HARNESS SYMBOL:
[BLUE]
i __ .
FRONT POWER WINDOW REGULATOR RH
..
0912-2a
f\:)
-....J
[ 1
~ (F)
L/w (ORI)
W (ORI)
G/Y (OR"
t___
109 12-20 II~ === === =~ == = == = = = = = == = = = === = = = = = == = = = = ===

W/R (OR"
CLOSE
REAR POWER WINOOW S Y S T E M - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
W (F)
W (OR3)
RIB (OR3)
POWER WINOOW SUBSWITCH RR
REAR POWER WINDOW REGULATOR RH
10912-2071
(R)
(FR)
15
L/W (OR4)
~~
~@
(R)
(FR)
POWER WINOOW SUBSWITCH LR
REAR POWER WINDOW REGULATOR LH
10912-2081
110912-2041
W (DR4)
~"
~@
-1------ -JR-- ----------------------,
POWER WINOOW MAIN SWITCH
VACANT
WITH REAR POWER WINDOW SYSTEM
@ ... WITH AIR BAG SYSTEM
~ ... WITHOUT AIR BAG SYSTEM
*# ...
...
0912-2b
0"
0"
0912-2081 REAR POWER WINDOW REGULATOR LH (OR4)
0912-2071 REAR POWER WI NDOW REGULATOR RH (OR3)
0912-2031 POWER WINOOW SUBSWITCH RR(DR3)
0912-2011 POWER WINDOW MAIN SWITCH(ORI)
0912-204 I POWER WINDOW SUBSW ITCH LR (OR4)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - --WI TH REAR POWER WI NOOW SYSTEM-- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
15--=-1=======110912-2031
~~
~@
~C-22 ~========+C-23
(R)
(FR)
-R/L ---
~/Y (F~- -___

__ ~/R (F)
----C-04
----
R/L (OR4)
___ - - - - - - - - - - - - - - - - - - - -
~=======JC-20
W (R)
-r-~~ ~ ~~~ ~ lC~~2
L/W (R)
C-19
R/L (OR3) L/W (OR3)
~ (R)
-;I-L ---- - -
l~~~~h~~~UJ~~JL ---
L/W (F)
~------------~R/L------i~~~~~~~-~-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~C~I-
POWER WINDOW SYSTEM
"'W"

(FHR)
(F)-(FR)
C-04
iimmii (F) (E) ~ (R)
WITH AIR BAG SYSTEM WITHOUT AIR BAG SYSTEM -
HARNESS SYMBOL:
.,
(FHR)
C-02
(F)-(DR1)
C-11
,..,
(F)-(R) - WITH AIR BAG SYSTEM

(F)-(FR) - WITHOUT AIR BAG SYSTEM
C-04
0912-2b
(R)-(DR4) - WITH AIR BAG SYSTEM

(FR)-(DR4) - WITHOUT AIR BAG SYSTEM
C-22

(FR)-(DR4) _ WITHOUT AIR BAG SYSTEM
C-23
,.
'':t
'('?"
'5,;.,.,
.....
./:::0.
"-1
(E)
"
0912-301
RIGHT
BR BR/Y
(ORIl (oRIl
LH
RH
OOWNUUP
(R)
BR/Y
BR
BR/Y
LIB
(R)
L/B
J......-...J.....---------J...
C- 12 .,...--.....,.----------'1'
BR
(R)
1C-l0t:-::t:-------n.l..
---------1'
LIB
(ORIl
~==~="f=
DOWN
OUTER MIRROR SW I TCH (OR 1)
OOWN--UP
--n MDI-----'
POWER OUTER I I RIGHT-MIRROR LH
'OO'H"{ff@~~~lr
LEFT
I POWER
UP
1 1"I
MAIN FUSE BLOCK
M;IN-SOA
IG KEY2 60A
OUTER
MIRROR
RH
LEFT
B
(OR Il
L/R
(ORIl
LG/B
(OR Il
BR/B
(ORIl
LIB
(DR I)
LEFT
ACE
BR
c;
BR/Y
"-.7
o
;:::;
LlR L/B L/W
t: l5<: J
L/R (OR 1)
(OR Il
RETRACT/
RETURN MOTOR RH
'--_ _ _ _---+_ _ _ L/R
RETURN
""
JJ
11a E
C-IO
'00 ,,-'" ,
L/W
..- - - - ( O R Il
L/W (OR I)
RETRACT
lt
:~10912 3011
J
L/W (OR Il
RETURN
ORI
CIGAR 20A
F-02
FUSE BLOCK
(F)
RETURN
L/R (OR2)
)}
L/R_~ll-----'
II
I
II
II
II
lt
RETRACT
L/W (OR2)
C-12
L/W
~
(F) --~(f------,I
(F)
'-10
(L/W)~LlW~
, ""y..",
"
LH
(F)-----1
L
::I:::C-OI
""" ""'" 'P'"'",,\"
I ~,~,
~ ~ ~ ~ ~'_0(
* ... VACANT
0912-3
0912-303
""-7
LG/BI BR/BI
ACE
POWER OUTER MIRROR RH/

RETRACT/RETURN MOTOR RH (OR Il
~~_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
0912-3021 POWER OUTER MIRROR LH/

RETRACT/RETURN MOTOR LH(OR2)
RIGHT- -
(F)
~C-II
RETRACT
'"
'"
'"
oJ,
+mmnn+--t
RIGHT
AU
":::,:"iftcs:t'
I
"
,-0(
,..'"
~-"
J" ""
= '" -_
""'0> ,_0(
'
4----l
POWER OUTER MIRROR
"
(Jl
'eV
mmmi (F)
(E) ~ (R)

12 GLASSIWINDOWSIMIRAORS
HARNESS SYMBOL:
..,
(F)-(DR1)
C-10
0912-3
..
'\
',ii
'-I
0>
0914-1011
cr.
(~)
F-O 11
BOA
* ~
IG/OI * * IBR/R
K,.....J
tB IGIRl
oM
BTNI BOA
1*
R TWIG
~~r
LOCK 30A
F-02
FUSE BLOCK
O.
CY"..A
1091FfoTI
cv
~~r-
*# ...
VACANT
r!
SYSTEM
0914-1a
(OR 1l
GID
I * I * IGIRl GIO
rlC8J1I
ItB~/RI
""'"
BR/R
(F)
THEFT-DETERRENT
DOOR KEY
CONTROL MODULE
CYLINDER SWITCH
(SECT ION 0914-4.) (SECTION 0914-4.)
... - - -W I TH THEFT-DETERRENT SYSTEM- - --
(F)
GIO

(SECTION 0914-2)
T
BR/R
(F)
BR/R
(415)~--------------------------------------------------------
(F)
"F.
10914-1021
-=I: :;';:;';:"=";:;';:. : :j~fWDl.'lO!.:O:.tR.lLf. l", _U",
(OR 1l
GIR
r~~~~~~'-"
(L)
(K)
0914-1021 DOOR LOCK-LINK SWITCH(DRI)
Gtv
(F)
(F)
(F)
~(N)
eM)
_0
=========J::* ~1rr=====;== === === ==== == ==== :::::: ::::: :::: :::: ::::::::: ==== ===== 11 0914-1 0 II
--------------,
O
I
WITH THEFT-DETERRENT SYSTEM-'
r-----
MAIN FUSE BLOCK
MAIN
r-
DOOR LOCK CONTROL MODULE (F)
BATTERY
-.....J
-.....J

W"
W'
FUSE BLOCK
(REFER TO OaF SECTION)
J __
-WL-C, WE-C
0914-1a
..
"
.......
"K
"@~
""-.I
WiG
*
#B
0914-101J DOOR LOCK CONTROL MODULE (F)
R
(F)
10914-1011
DOOR LOCK CO~TROL MODULE
10914-1011
G
'---(F)
t'_oo
LOCK
IUNLtK
R
(F)
fC-IO
R
(OR1l
R
(F)
f
1
LOCK
UNLOCK
(F)
(OF"
::1::10914 1041
<W
0914-1051 DOOR LOCK ACTUATOR RR(OR3)
G
(F)
(F)
f
1
LOCK
UNLOCK
0914-1b
-@
~C-04
R
~C-OZ
R
-~
-@
I
I
I
(F)
0914-1061 DOOR LOCK ACTUATOR LR(OR4)
(F)
--~------------------------4--------------------1
(R)
(FR)
+C-23
(OR4)
~1]]14-1061
UNLOCK
f
1
LL-I LOCK
<W
DOOR LOCK ACTUATOR LR
*10914 1061
(OR4)
(FR) -~
C Z3
-
(R)
~~~~~M - - -fG .<:::.O~ - - - - -- - - - - - - - - - - ,
(F)
SYSTEM
~ .. WITHOUT AIR BAG SYSTEM
*# ...
VACANT
R
(R)
:J::C-ZO
(OR3)
REAR
LOCK
DOOR LOCK ACTUATOR RR
~14-1051
R
------~~b~
10914-1051
(OR3)
c zo
-
*:.-~:
<W
r - -
1
(F)
0914-1041 DOOR LOCK ACTUATOR LF (DRZ)
DOOR LOCK ACTUATOR LF
~L0914-1 041
10914-1031 DOOR LOCK ACTUATOR RF (OR1)
~14-1031
"""" '"" "'"""" "'
10914 1031
~'
r'-"
(ORZ)
(F)
(F)
G
(F)
(OR1l
"-I
co
'WI"
(E) ~ (R)
C-1
(F)-(DR2)
mimm (F)

WITH AIR BAG SYSTEM _ (FHR)

WITHOUT AIR BAG SYSTEM - (F)-(FR)
HARNESS SYMBOL:
(FHR)
C-02
~~~~.
~~u~r
, ... "'. .... , - WL-C, WE-C
'WI"
(FHR) - WITH AIR BAG SYSTEM

(F)-(DR2)
0914-1b

..,
".
'1&,',
'\
ex>
BTNI BOA
'""" BOA
IG KEY2
..a-..
'""" 40A
IG KEYI
..a-..
W/R
(F)
B/w
(F)
B/L
(F)

(SECTION 0914-4.)
- - WITH THEFT-DETERRENT SYSTEM- --.
DOOR LOCK
CONTROL MODULE
(SECTION 0914-1.)
BR/R
(F)
===============
F-02
FUSE BLOCK
1ifi,1
B/Y
(F)
FLASHER CONTROL
MODU LE
(SECT I ON 0918-4)
G/R
(F)
===============
R/Y
(F)
(F)
I
LlR
F-02
FUSE BLOCK
R~AI
DOOR SWITCH
(SECTION 0918-8)
===========~========
W/R
(F)
I"
III
II
II
II
II
II
II
Irr
I~~
II
Irr
F-OI
I"
- - - - - - - - - - - - - - - - --I
1
MAIN FUSE BLOCK
MAIN 80A
l~~~
r-----
""
F-OI
KEYLESS CONTROL MDDULE(F)
B
(E)
10914-2011
B
(F)
W
(F)
ENGINE SWITCH
*# ...
VACANT
SYSTEM
0914-2
....L
ex>
immm (F)
(E) ~ (R)

HARNESS SYMBOL:
W'
~
FUSE BLOCK
0914-2
."
.',.i,it,.
(X)
I\)
IT
(~I
r*-1
IBR/BI
iR
(H)
l0
BIR
(FI
BOA
IB/RLW
===- - -
~~~
BRIB
-==,*,,===-
eM)
~~r
INSTRUMENT CLUSTER
(SECTION 0922-lcl
I~
II
II
II
II
II
I-GY
IRI
T*-1 y I
0914-3021 COIL(FI
INSTRUMENT CLUSTER
(SECTION 0922-1.1
I:i= = ===== =
(C)
BTNI
MA I N FUSE BLOCK
11><11 *
I
p yl 1* I
II
II
F-O I
B/W (FI
0)
C0
(K)
F-02
FUSE BLOCK
ENGINE 15A
1===110914-3011
LIR (FI
(A)
....J
(~I ______
(A)
W
(FI
WL-C. WE-C----I
~~~wlp
t.
WITH STARTER RELAY
0140-4091 I NJ ECT I ON PUMP (FI
L ___
STARTER RELAY
(SECTION 01191
R
(FI
I..
COIL
iQl
GY
(FI
109
3021
-:110914-3011
l0~----------~-------------------
I ON
----WLT-------
BIR (FI
L:::::;;:;;;;~L~~~:~ ~CT
10140-4091
(FI
T(F)
SWITCH
RELAY
0914-3
*0 ...
VACANT
... WITH STARTER
--= = r === == =i=*-= =====r=== == ,=1== = = w!== = = = = = === =<= == =
PCM
I (SECTION 0140-2 1
:
e
-1--
IMMOBILIZER UNIT
--------------j
i-------------j r----------------,
F-02
FUSE BLOCK
ROOM 15A
~~~o--.--~~~---+~--------~~r--------------------------------------------------------,
B/wNL/RI
N
GY
..
FOB
.
.
0914-3011 IMMOBILIZER UNIT(FI
-,-}r
EDI
BATTERY
F-O I
IMMOBILIZER SYSTEM
(X)

F-01
MAIN FUSE BLOCK

ENGINE SWITCH
F-02
0914-3
FUSE BLOCK
(REFER TO oaF SECTION)
COIL
..,
\~
(51.
+::>.
(X)
B
(E)
"
.N
F-OI
L/R
W
B/w
I\.\.
I"
W
II
I~;O I
BR/R (F)
""
:::>
0
..J
Z
(.)
:i
5
6
ENGINE 15A
F-02
FUSE BLOCK
ROOM 15A
F
0
A
0914-102
0914-402
DOOR KEY CYLINDER SWITCH LF
10914-4021
B (OR2)
H - 12
B (F)
0
..J
(.)
""
+C-12
BR/R <OR2)
BR/R
(F)
B/L
(F)
B/W
(F)
W/R
(F)
B/W
(F)
L/R
(F)
R/Y
(F)
CONTROL MOOULE
-----------------------
OOOR SWITCH
(SECTION 0918-8)
(.)
ODOR KEY CYLINOER SWITCH RF
CYLINOER SWITCH LF(OR2)
~I
mI~BR/~
~R/R~I mI~ G/~
L*
B (F)
C-II
10914-1021
B (OR Il
0
..J
(.)
""
OOOR KEY CYLINOER SWITCH RF(OR1)
:::>
0
..J
""
BR/R (F)
+C-Il
BR/R <ORI)
INSTRUMENT CLUSTER
(SECTION 0922-lc)
FLASHER CONTROL
MOOULE
(SECTION 0918-4)
* ... VACANT
0914-4a
(F)
G/O
B
(F)
IQ914-4031
BONNET SWITCH
109]4-+031
BR/W
(F)
============
-----------------------
W/R
(F)
(F)
G/R
KEYLESS CONTROL MOOULE

(SECTION 0914-2)
B
(F)
BR/B
(F)
r r r
OOOR LOCK
CONTROL MOOULE
(SECTION 0914-10)
========================================================
BR/R (F)
ENGINE SWITCH
IG""""
KEY2 60A
"""
IG KEYI 40A 1;;
,L"oo
BTN I 60A
...."
""'"
THEFT-OETERRENT CONTROL MOOULE(F)
r MAIN~OA
"""
MAIN FUSE BLOCK
OOOR LOCK CONTROL MOOULE

(SECTION 0914-10)
BATTERY
ex>
(Jl

F-01
MAIN FUSE BLOCK

(REFER TO QOF SECTION)
.,
..
ENGINE SWITCH
FUSE BLOCK
0914-4a
".
(X)
0')
B (R)
L ______ J
_ BTN2 60A _
t=
(R)
""?
=>
co
...J
<.>
""
<.>
co
...J
~10914
LG/R (OR4)
+C-24
(FR)
-Ii
-"
C- 04
LG/R
LG/R (f)
LG/R (F)
B (FR)
* *1*
p/L
L ______ J
*1
*1*
(f)
(E)
~~r
C-02
co
...J
""
<.>
I DOOR LOCK-LINK SWITCH RR
B (F)
l-"
+C-21
B (OR3)
~: Y:i~G/~~
0914-40SI DOOR LOCK-LINK SWITCH RR (OR3)
~: T7i~G/~~
0914-4041 DOOR LOCK-LINK SWITCH LR (OR4)
=>
fI09T4=40!il
""?
<.>
co
...J
P(F)
I NSTRUMENT CLUSTER
(SECTION 0922-1.)
110914-40sl
C-21
LG/R(DR3)
LG/R(R)
- - - - - - - 10914-4011
------------------T------~
DOOR LOCK-LINK SWITCH LR
4041
(F)
LG/R
STOP ISA
F-02
FUSE BLOCK
CY'-O
------------------
fl09144041
* * *1*
r::::::><
IBR/WIG/OI
0914-4071 THEFT-DETERRENT HORN (F)
LlRIW/RIR/YI
IF-OI
MAIN FUSE BLOCK
:cb::@:
B/W I G/R I BR/BI BR/RI LGlRI
F-OII
.--G;r::
0914-4011 THEFT-DETERRENT CONTROL MODULE (F)
L
71r
BATTERY
(~) -----~~HH~.......*-----l~r
~..
0/_
(F)
G/W
IO!lfF4011
(F)
GY/B
:~10914-4061
HORN RELAY
*
GY/B
C G/W
p/L
G/wllA
0914-4061 THEFT-DETERRENT HORN RELAY (F)
(F)
p/L
l1t1J"~~E~:~DETERRENT
~9144061
(F)
G/w
VACANT
I . WITHOUT AIR BAG SYSTEM
* ...
0914-4b
k kZ .
~
1.
"'
-....J
(X)
mmmf (F)
C-04
WITH AIR BAG SYSTEM _ (FHR)

WITHOUT AIR BAG SYSTEM _ (F)-(FR)
(E) ~ (R)

F-01
MAIN FUSE BLOCK

(REFER TO oaF SECTION)
HARNESS SYMBOL:
.,
(FHR)
C-03
(FHR)
C-02
F-02
FUSE BLOCK
'W'

C-04
0914-4b

C-24
.,
c"
"
.....
\.,
-....J
(X)
--.~- .. ---"~ ~
"
(~)
F-O I
BTNI
BOA
MAIN FUSE BLOCK
MAIN aOA
I
F-O I
~~r
F-02 FUSE BLOCK
~5A
FUEL-FillER
LI D OPENER
SWITCH
0914-5QII
FUEL-FillER
liD OPENER
10914-5021
B (R)
I[~
10914-5021
B/l (R)
t,-"
B/l (F)
f::10914-5011
rn
~~i-
* ... VACANT
0914-5
RIG
RIB l/Y B/l
* *
0914-5011 FUEL-FillER LID OPENER SWITCH (F)
0914-5021 FUEL-FillER LID OPENER(R)
~--------------------------~(Irur-------------------------------------------------
TIT
IT j -
BATTERY
FUEL-FILLER LID OPENER
""'"---"-"
OJ
-....J
(X)
mmmi (F)
(E) ~ (R)

F-01
MAIN FUSE BLOCK

HARNESS SYMBOL:
'W'
FUSE BLOCK
..,
(F)-(R)
C-03
0914-5
,.
/y
j,
F,
(X)
(X)
R/G
IF)
BTNI
(F)
R/G
60A
II
INSTRUMENT CLUSTER
(SECTION 0922-1d)
10., 0-1 041
(F)
F-02
FUSE BLOCK
HEAD RH ISA
*
L/BII A
- - -
C LIB
R/Y
0918-1021 HEAOLI GHT RELAY (F)
R/Y
(F)
.l
R/Y
IF)
10918-1021
L-----R/B
(F)
10918 1031
TNS RELAY
10918-1031
=::/,::1 0918-1 0 11
--
=C
(F)
Y/R
11
(F)
C-03
!..lV/RII A
(F)
R/B
R/B
IF)
- - -
IR)
iLR/B~J
-,..\!.]I,
'
R/B
(F)
~~?
~~
3
~@
PARKING LIGHT
(SECT I ON 0918-2)
ILLUMINATION LIGHT
(SECTION 0918-7b. 11.)
(SECTION 0918-2)
IR/wl
qll/;'ITIlIGp
0918-1051 HEADLIGHT RH IF)
q R1 !R/(iP
IR/wl
0918-1041 HEAOLIGHT LH (F)
L _________ ,
VACANT
FRONT FOG LIGHT RELAY

(SECT 1ON 0918-3)
* ...
0918-1
R/B~ TAILLIGHT
.... ~
''ii!i'
(R)~~~~~,
(F)
_ _ _ _ R/B
~R/B~R/B
C~
BR
0918-1031 TNS RELAY (F)
*I
R/Y
(F)
BR
(F)
(F)
Y/R
(F)
HEADLIGHT RELAY
10918-1021
F-02
FUSE BLOCK
*== ~=== = === == = = =
R/G
(F)
=====
------
L/Y (F)
R/L
=====
L/~B
1%)
L/B II)
HEAD LH ISA
L/B
(F)
-----...,,~(F)T~
~
~W/R
~Y/Rn
I"
MAIN FUSE BLOCK
BTN2 60A
MAIN 80A
F-Ol
:1::.::.~.';::;:::", '" :1::.::.~';::;:~:", '"
R
(F)
0918-1011 HEADLIGHT SWITCH(F)
BATTERY
HEADLIGHT
Q:)
co
immm (F)

18 LIGHTING SYSTEMS
F-01
TNS RELAY
(E) ~ (R)
MAIN FUSE BLOCK

HARNESS SYMBOL:
(FHR)
C-03
..,
F-02
FUSE BLOCK
I0918-1021~WL-3
HEADLIGHT RELAY
0918-1
,.
co
0918-207
0918-204
W/G
G/W
(@
LI GHT LH (F)
PARKING
LIGHT LH
fa
TAl LLiGHT RH (R)
B
(F)
R/B
(F)
R/B
(F)
B
(F)
R/B
(F)
PARKING
LIGHT RH
TNS RELAY
(SECTION 0918-0
0918-208
0918-205
0918-202
Ffr]
LICENSE PLATE LIGHT(R4)
LICENSE PLATE LIGHT(R2)
(@
PARKING LIGHT RH (F)
B
(R2)
B
(R 2 ) - - 1
B
(R2)
0918-206
0918-203
LICENSE
PLATE LIGHT
------ -
R/B
(R2)
R/B
(R2)i
TAILLIGHT RH
- - - - - - - - - - - - - - - - - EXCEPT 5
B
(R2)
TAI LL I GHT LH
2031
R/B
(R2)
B
(R2)
R/B
(R2)
t-R/B
(R2)
+C-13
R/B
(R2)
R/B
(R)
r--?- -------
R/B
(R)
LICENSE PLATE LIGHT I PARKING LIGHT I TAILLIGHT
TAILLIGHT
LH
I
B
(R)
B
(R)
(R)
I
R/B
B
(R4)
R/B
(R4)
LICENSE
PLATE LIGHT
TAILLIGHT LH(R)
W/G
G/B
TAILLIGHT LH(R2)
20
18
--------------------------------------------
B
(R)
I
(R)
t
R/B
R/B
(R)
R/B
(R)
C-33
-5 OOOR- - - - - - - - - - - - - - - - - - --,
r-------------------
I
I R/B
I (R)
* ... VACANT
0918-2
-lo.
co

18 LIGHTING SYSTEMS
HARNESS SYMBOL: 1mmm (F) (E) ~ (R)
..
[5 DOOR]
0918-2
'*
c.o
I\)
0918-301
IT.
.,
II
rr
LIB
ruw
.......
L/Y.L!..lRIB
FOG LIGHT RELAY (F)
(F)
(IT2)
B (F)
0918-101
I FRONT
FOG LIGHT SWITCH (F)
~
u
f"'~:~::';" ' '"' .
All10-3031
0918-3031 FRONT FOG LI GHT RH (F)
(5Ts)
B (F)
de
FRONT FOG LIGHT SWITCH
~18-1011
(F)
~
r10910-1011
RIB
TNS RELAY
(SECTION 0910-\)
It:~-:-~~:~-:-~:~~~~~tt1,::::: ', , ' '"' "'"
LIB
0910-3021 FRONT FOG LIGHT LH (F)
~,::~::,~"
' ' ' " ' CO
FUSE BLOCK
F-02
[jj]10-=3021
U.'"
CI*'
INSTRUMENT CLUSTER
(SECTION 0922-ld)
_ WITH FRONT FOG __
LI GHT I NO I CATOR
r-------------,
MAIN FUSE BLOCK
(~) ~A 1-01 ~~r~"""'I---'
I FRONT
BATTERY
FRONT FOG LIGHT
* ... VACANT
0918-3
CD

18 LIGHTING SYSTEMS
F-01
MAIN FUSE BLOCK

.,
..,
~0918-3011-~
FRONT FOG LIGHT RELAY
0918-3
'''1,
'0,.
'?'\""""/;~""'__d'M'.M" ..~.'"
";
co
(F)
"
......
.....,
......
.~
IG KEY2 60A
(F)
G/B (F)
INSTRUMENT CLUSTER
(SECTION 0922-ld)
G/W
. ~~
rr
"
F-OI
~~
(F)
B/w
~H'_'
WIG
G/B
&
B (F)
G/W (F)
(F)
B (F)
SIDE TURN
LIGHT LH
10916 4061
B (F)
5W
&
B (R2)
10916-2041
21W
2 041
REAR
TURN
LIGHT RH
O9I6
(R)
(F)
G/W
WIG
(R)
DOOR-------1
B (R2)
10916-2031
21W
REAR
TURN
LIGHT LH
G/w (F)
G/B (F)
G/B (F)
1 r~g~i ~~~~)
403
0918-2061 TAl LLiGHT LH (R)
,(
B (F)
(F)
G/R~
THEFT-DETERRENT
,
CONTROL MODULE
,
(SECTION 0914-4.) ,
HAZARD WARNING SWITCH
L.
,
,
~~ ~_ ~~E:~I~~!': ~4.:::) _.,
KEYLESS CONTROL
MODULE
-W I TH THEFT-DETERRENT SYSTEM-- 1
t
r
G/R~
L/Y (F)
G/R (F):
(F)
G/R
G/R (F)
0918-4
VACANT
0918-4041 FRONT TURN LIGHT LH(F)
5 DOOR---------
B (R)
10916 2061
21W
REAR
TURN
LIGHT LH
0918-1011 TURN SWITCH(F)
0918-
---------
B (R)
10916 2071
21W
REAR
TURN
LIGHT RH
0916-2071 ~0916-2061
G/W (F)
G/B (F)
-t..----------~C
r
- - - - - - - - - y - 03
G/W (R)
G/B (R)
B (F)
W/R (F)
r--I----------I-------,
::
- - - -,
F-02
FUSE BLOCK
W/B (F)
TURN SWITCH
B/Y (F)
~~~-----~
METER 15A
~9:"9"16'-"2"'03"1
G/B
------- ,
lOA
*# ...
...
~~~-------------------.
HAZARD
t== === === ==+

C-03
G/W
G/B
= === === ==*
C-13
G/W (R2)
G/B (R2)
r - -1- G/W (F)
FRONT S I DE TURN LIGHT LH (F)
0918-204 I REAR
0918-406
0916-4021 HAZARD
TURN
LIGHT LH
10916-4041
21W
G~/B(~~9FR60:T041 G~/B(~~9F1R60N4i61
(F)
ENGINE SWITCH
~---(~)
%)L _____-.
1~r
G/B~G/B
I"
IG KE;;" 40Arr
.~
BTN2 60 A
.~
MAIN FUSE BLOCK
MAIN 60A
FRONT S I DE TURN LI GHT RH (F)
0916-203 I REAR
B (F)
G/W
0918-405
"
F-O,J
r-------+------+---------~~r
(E)
TURN AND HAZARD WARNING LIGHT
CD
CJl
mmmi (F)
(E) ~ (R)

18 LIGHTING SYSTEMS
HARNESS SYMBOL:
ENGINE SWITCH
C-01
F-04
FUSE BLOCK
...,
'0918-204'
0918-4
REAR TURN LIGHT RH
[BLACK]
'W
co
(J)
0"
WL-3
ffrK
>~
IG KEY2 60A
MAIN FUSE BLOCK
BOA
C-13
(R)
R/w (R2)
R/W
tC-03
R/W(F)
%i

(R RANGE ON)
r01l9-031
E:9
10119 031
'
:
(F)
B/W
-L-
L - ________ - - - - - ______ - - - - - -_,
%r
%i
r============~;:::--:::::--:--:;
10918 5011
f09185011
C-05
' - ...~
/'_...
r----7~---o-+-%rE:9
,'-,
\~
~I
,,-',
WL-C. WE-C
WL-C. WE-C
r------------~~------------
MAIN
'-"I~40A
B/L
(F)
%i
A -WL-3
E -WL-C. WE-C
~ug~
BLOCK
C-05~
(~)-
~---C-OI
C-OI
ENGINE SWITCH
2031
BACK-UP LIGHT LH
0918
10918-2031
BACK-UP LIGHT RH
10918-2041
(R2)
21W
~0918-2041
R/W
(R2)
19
WE-C
5021
BACK-UP LIGHT LH
10918-5021
WiG
!5!!
0918-2041 BACK-UP LIGHT RH (R2)
0918-5031 BACK-UP LIGHT RH (R2)
!5!!
G/B
* ... VACANT
0918-5
..
~~-----------T-------------------
(.
BACK-UP LIGHT RH
10918-5031
(R2)
21W
~0918-5031
R/w
(R2)
- - - - - - - - - - - - - - - - -'5 DOOR- - - - - - - - - - - - - - - - - -
(R2)
21W
~0918
R/W
(R2)
0918-2031 BACK-UP LIGHT LH (R2)
10918-5021 BACK-UP LIGHT LH (R2)
~-~---------EXCEPT D~------------J
(R2)
21W
R/w
(R2)
'.~1~~2-)-----------------------_-_-_-_-_-_-_-,_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-~r--~~--~j~--------------------------------------,[--------------;
PL.-v,
[9
BACK-UP LI GHT SW I TCH (E)
(E)
0119-031 DIG I TAL TRANSM I SS I ON RANGE SENSOR (E)
0918-50 I
-Jr I
BATTERY
BACK-UP LIGHT
'"
CD
C-05
[BLACK]
(F)-(E)
C-05

18 LIGHTING SYSTEMS
[WL-3]
[WL-C, WE-C]
[BLACK]
(F)-(E)
HARNESS SYMBOL: ~mmm (F) (E) ~ (R)
..
(R)-(R2)
C-13
0918-5
.,
00
(0
I+
(~)
MAIN FUSE BLOCK
BTN2 60A
F-O I F - O I
fa
~ (F)
WIG
10918-6011
BRAKE SWITCH
~0918-6011
1~r-----------,
~W/G
0918 2031
B
(R2)
B
(R2)
I----l----I---l
11<1
BRAKE LIGHT RH
10918-2041
21W
0918-2041
WIG
(R2)
(R2)
WIG
fC-13
WIG
0918-2031 BRAKE LI GHT LH (R2)
10918 2031
BRAKE LIGHT LH
21W
WIG
(R2)
~_(~~C~~O~_0~~WOL--2C~)WE~I~-----(~---:
I PCN
(R)
r-------------------------:
WIG
(SECT I ON 0413-2)
L-------WTH REAR ABS--------I
r: ;,::: -.
~ -1~-!:;Y~;'~: ~,~ ~,- @. --111---: rr llr~'

~.~: ~ ,'~ ~"'::: :~/~:::i
'+'0-0'
F-02
FUSE BLOCK
IsToGA
1~r~
0918-6011 BRAKE SWITCH (F)I 0918-6021 HIGH-MOUNT BRAKE LIGHT (R)
-rJT
E?
E!>I
BATTERY
BRAKE LIGHT I HIGH-MOUNT BRAKE LIGHT
I
WiG
B
(F)
+C-031
B
(OR3)
fC-15
(~)
"'f- - r - + - - '
(~)
I
I
STRETCH CAB
(W I TH REAR ArCESS SYSTEM)
fiG/WI
!8!
0918-2041 BRAKE LI GHT RH (R2)
~~
~ ~I-::-_=_==_-::-_~_~-_-_---_--_---_-::':_-_-_-_-_-_-_-_-_-_-..I-+-1-----
1
(R)
-------1
B 10918-6021
5WX4
! ~(R)10918-6021
r--------WITH HIGH-MOUNT BRAKE LIGHT--------I
* ___ VACANT
0918-6
co
co

18 LIGHTING SYSTEMS
F-01
MAIN FUSE BLOCK

BRAKE SWITCH
1- . _
_. I
.,
FUSE BLOCK
0918-6
~mO~+~~OW
SWITCH
ILLUMINATION
10912-1021
B
(F)
"1'091&-102]
(F)
RIB
(F)
RIB
t
(F)
RIB
(FiB)
Jf C-26
B
(F)
2FR/~0920-2011
AUDIO UNIT
ILLUMINATION
2~10920-2011
C-26
RIB
(F)
RIB
B
(F)
G)
RIB
(F)
B
(F)
fa
[*
RIB]
ILLUMINATION (FJ
[i JWR I~
0740-111 AIC SWITCH
C!I3
A
0918-4021 HAZARD WARNING SWITCH
B
(F)
G)
RIB
(F)
B
(F)
HEATER
CONTROL
ILLUMINATION
(F)
RIB
B
(F)
G)
(F)
RIB
B
(F)
AIC SWITCH
ILLUMINATION
(F)
RIB
B
(F)
G)
(F)
RIB
B
(FJ
ILLUMINATION(FJ
GIO
12:5;1
m
I
B
B
0920-2011 AUDIO UNIT
B
(F)
2W
2K
21
2A
LlR
L
2M
2B
20
2X
on
L
______________ I
I~~-------
B
(F)
RIB
(F)
CLUSTER 1LLUM I NAT I ON (FJ
GLOVE
COMPARTMENT
LIGHT
I
I
WITH RFW
CONTROL SYSTEM 1
* ... VACANT
0918-7
BIR
Llw
B
(FJ
G)
(F)
CONSOLE
ILLUMINATION
RIB
r------,-1
(F) - - - - 1
RIB
0318-031 RFW MAIN SWITCH 10912-1021 REAR WINDOW

10922-101
ILLUMINATION(FJ
DEFROSTER
SWITCH
I LLUM I NAT I ON (FJ
WARNING
SWITCH
.. , "U'."~'nU
(F)
RIB
HEATER CONTROL 10918-7021 CONSOLE

10918-7031 GLOVE
ILLUMINATION(FJ
ILLUMINATION(FJ
COMPARTMENT
LI GHT (FJ
I NSTRUMENT CLUSTER
ILLUMINATION
II r-=S-H II
2E1
"";-;;-;;---;-,""'
10922 1011*
(F)
RIB
(f)
R/B
~I
(F)
RIB
TNS RELAY
(SECTION 0918-1)
ILLUMINATION LIGHT
...r..
...r..
lilimm (F)
(E) ~ (R)

18 LIGHTING SYSTEMS
HARNESS SYMBOL:
(F)-SHOAT CORD
C-26
CONSOLE ILLUMINATION
[BLACK]
0918-702
REAR WINDOW DEFROSTER SWITCH ILLUMINATION
i __
,.
0918-7
..,
o...L
...L
\lJIi'
r.::tIo..
(F)
RIB
""--
1* IL/ylL/WI
Y IR/GIR/BI
II1Z10
0740-111 Alc SWITCH ILLUMINATION(F)
@@
(F)
RIB
(F)
(F)
RIB
I"
RIG
~~p
10918-7021
CONSOLE
ILLUMINATION
[0918-7021
S\
V
RIB
(F)
'
I
I
I
IgfDl~ggl -WL-C.WE-C
18- 41 -WLT
RFW MAIN SWITCH
ILLUMINATION
10318-g31 -WL-C. WE-C
0318- 041 -WLT
RIB
(F)
-!
-WITH RFW CONTROL SYSTEM--,
r-
GXv
rB~~;)*J
-WLT
-WL-C. WE-C
-----------
RFW MAIN SWITCH ILLUMINATloN(8
0318-204
0318-03
1(1
* ... VACANT
0918-7b
PANEL LIGHT
CONTROL SWITCH
RIB (F)
r=;-;-;;--,.",
Gtv-----------------
T"""r'''''-''''
'I""
I
r :--1------' 'I"
GLOVE
COMPARTMENT
LIGHT
[ij91H031
(F)
R/B _ _ _......_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _- ,
10918~7031
RIB
(F)
0918-7041 PANEL LIGHT CONTROL SWITCH (F)
I_ '"
RIG
(F)
10740-111
Alc SWITCH
ILLUMINATION
9740-111
RIB
(F)
0918-7021 CONSOLE
10918-7031 GLOVE
ILLUMINATION(F)
COMPARTMENT
LI GHT (F)
?tr
\mm:'m.~j;I' ~ '"'"
(SECTION 0918-78)
TNS RELAY
ILLUMINATION LIGHT
....r..
0"
o....r..
mmmi (F)
(E) ~ (R)

18 LIGHTING SYSTEMS
HARNESS SYMBOL:
..,
[BLACK]
..
RFW MAIN SWITCH ILLUMINATION
0918-7b
'~
oI\)
.....
BOA
MAIN FUSE BLOCK
BTNI
MAIN 80A
I F - OI
'~f
I
II
I
C-17
R/Y
(FR)
;1
r=
j[01l18-8061:
r-DOUBLE CAB--,
R/Y
(FR)
-EXCEPT
[0918 803[
r--------r(R)
IIII
IIII:I
-#----i
~!trV! I
c .........-.,.
..
0918-8041 DOOR SW ITCH RR (R)
REGULAR CA8
''''-''<I,m" .. ,,,on,,,
I
[0918-8031 11
DOOR
SWITCH
LF
~ LlRjRIY P
C{
III
1:1
DOOR
SWITCH
LR
8051
-EXCEPT #
0918-8051 DOOR SWITCH LR{SHORT CORD)
(R)
DOOR
SWITCH
LF
:1 R/Y (R)
r==%it1
T-l I
L. ----.1
. -----'
:)_04
R/Y (R) r - # - --,

A-LR/Y
r -EXCEPT #- - - (R)
r-DOUBLE CAB-.., R/Y (R)
1""-"" .... ,,"'" ."..".,
-=-::::..
n_ n
I NSTRUMENT CLUSTER
(SECTION 0922-lcl
R/Y
(R)
804[
~~i
# WITH
R/Y
(R)
8031
DOOR
SW ITCH LF
~0918
R/Y %;;/7
::
: :
::
IIII
R/Y (R)
DOOR
SWITCH
RF
~Q918-8021
%i ~Ri
DOOR SWITCH RF
8021
~0918
R/Y IDR3)
{:)-03
R/Y (R)
R/
R/Y (F)
10918-8011
0918-806
CE!

(FR) -W I THOUT A I R BAG SYSTEM
<2J!jP
fI1*]
(SHORT CORD)
CORD -WITH AIR BAG SYSTEM

FLOOR{FR)-SHORT CORD -WITHOUT AIR BAG SYSTEM
I REAR {R)-SHORT
-EXCEPT # WITH AIR BAG SYSTEM
l~~~) -~~CEPT # WITHOUT AIR BAG SYSTEM
1918-803 DOOR SWITCH LF{R)
L - DOUBLE CAB- -I L - - - - - - - - - - - J L - - - - - - - - - - - - - - -I !... - -EXCEPT # __
DOOR
SWITCH
RR
~0918
R/Y (R)
----+
DOOR 0-.....
O~-
' 't'::"
OFF
r-R~Y ~R~-~~~T~QG- r-----~~~;------~
~~i
I NTER I OR LIGHT
11
I
I
$10918-8011
EXCFPT
VACANT
STRETCH CAB (WI TH REAR ACCESS SYSTEM)
(F)~
R/Y
%i
j --- --- -- ~?"~
%i
r----------
rWITH AIR BAG SYSTEM-t----------,

R/
*# ...
...
--I
I
I
I
0918-8
h/N~-------------------------' r=-=,..,.-:-_~
R~y~OB[
I
I I~0918 I ~0918-8031 I
II
I
III
!~
-=-:.. _:.~-.: ~'=......_"':'" __:.-_-__ _:. _-_-~_:. _"':'"__:.-=-:.._:.-=-:..ti
DOOR SWITCH LF
EXCEPT REGULAR CAB
10918-8051
DOOR
SWITCH
LR:
I
II
i
II
#-,I
r------------~::>__ r(k-+- ~~i
~~i
L -- ---
C-07
r-WITH THEFT-DETERRENT SYSTEM-: THEFT-DETERRENT CONTROL MODU LE

(SECTION 0914-40)
1~f
F-02
FUSE BLOCK
o-"'-A
ROOM 15A
KEYLESS CONTROL MODU LE

(SECTION 0914-2)
r - - - - - - - - - - WITHOUT AIR BAG SYSTEM----------C-04
(~)
F-O II
i (~~~X)
ii! ~R/Y
!~r(R)
I
III
I
I
II:
I
I
-m- ~1~.:-: __:.-=-:.._:.~_"~;.._.:-:
_:.-_-_~_-_~__:."": __ _:.
le
BATTERY
INTERIOR LIGHT
......
o
w
."

18 LIGHTING SYSTEMS
(F)-(A) _ WITH AIR BAG SYSTEM

(F)-(FA) _ WITHOUT AIR BAG SYSTEM
C-04
WITH AIR BAG SYSTEM WITHOUT AIR BAG SYSTEM -
(FHR)
(F)-(FR)
C-04
(FHA)
C-03
..

(F)(FA) - WITHOUT AIR BAG SYSTEM
DOOR SWITCH LF
[BLACK]
0918-803

(FR)-(DA4) - WITHOUT AIR BAG SYSTEM
C-17
0918-8
....Jo.
?t~~~i~ATI ON
10922-101 I
R/B
(F)
RIG
RIB
(F)
RIB
(F)
(F)
(F)
0912-1021 REAR WINDOW

DEFROSTER
SWITCH
I LLUM I NAT I ON (F)
0918-4021 HAZARD WARNING SWITCH
qR/GjR/B~
0918-1101 I HEATER CONTROL ILLUMINATION (F)
RIG
'--_ _ _ RIG
2F
~~?
J
f C-26
RIG
(F)
RIG
10920 2011
ILLUMINATION(F)
RIG
HAZARD WARNING
SW I TCH
ILLUMINATION
RIG
RIB
(F)
HEATER
CONTROL
ILLUMINATION
RIG
RIB
(F)
(R)
0920-20 I
10513-041
OFF SWITCH
(F)
ILLUMINATION(R)
RIG
AUD I 0 UN I T I LLUN I NAT I ON (SHORT CORD)
OlD
(f)
RIG
(SECTION 0918-1)
SWITCH
L ____ ,
4X4 SWITCH
:)_02
RIG (F)
(F)
(R)
(SECTION 0918-1 Ib)
RIG
ILLUMINATION
10'"'9""'1""8--71"10"'5=11
ILLUMINATION(F)
2V
2T
20
2N
2M
2L
2K
2J
21
2F
2H
2D
0922-101J I NSTRUMENT CLUSTER I LLUM I NAT I ON (F)
2X
2B
LIR
2A
'--t---~/-G---~-~-~~i~~tl~:iT~:---
R/
(R)
1
T
RIG
10513-041
~0918-11051
OFF
SW ITCH
ILLUMINATION
~0513-041
OlD
RIB (R)
RIB (R)
+--------'1
RIB (R)
~7
0740-11 1 AIC SWITCH
(f)
RIG
ILLUMINATION
AIC
~(F) ~(F) ~(F)
ILLUMINATION
RIB
(F)
"'Q
LIGHT
...
~ ILLUMINATION
(SECTION 0918-1
I b)
&
* ... VACANT
AT
0918-11a
r--------------------------------TNS RELAY
R
/BjR/
(F)
(F)B T R / B
(F) T R / B
(F)
10920 2011
AUDIO UNIT
2E
R/B
C-26
RIB
(F)
0918-110514X4 SWITCH
ILLUMINATION
REAR WINDOW
DEFROSTER SW ITCH
ILLUMINATION
LI-N-S-TR-U-N-E-N-T--:f~~~~~9~2~2"'-~10~1!"1I-:L(F)
;ri
(')
x
LED)(LEO) I~
(F)
RIB
(F)
RIB
TNS RELAY
(SECTION 0918-11
ILLUMINATION LIGHT (WITH PANEL LIGHT CONTROL SYSTEM)
~'I
.".".~
-.lo.
III
..

18 LIGHTING SYSTEMS
(FHR)
C-02
INSTRUMENT CLUSTER ILLUMINATIpN

._. i
i ____
0918-11a
..
~,NN,:
"!
, 4 , " . '"
LIGHT (F)
g~~~~RTMENT
RIG (F)
RIB (F)
0740-2011 REAR AIC SWITCH ILLUMINATION (F)
0918-1103 1
5)
B (F)
.--------------{I41
~R/G
ILLUMINATION LIGHT
(SECTION 0918-110) ~(F)
()
PANEL LIGHT CONTROL SWITCH
TNS RELAY
~R/B
(SECTION 0918-110) ~ (F)
(F)
RIG
(F)
RIB
(F)
RIG
(F)
RIB
~~?
RIB
(F)
(F)
RIG
(F)
RIB
rr:; Jff,iJ] * 1
0914-5011 FUEL-FILLER LID OPENER SWITCH

I LLUM I NAT I ON (F)
[8
0918-11041 PANEL LIGHT CONTROL SWITCH (F)
~~?
(F)
RIB
--r-
ILLUMINATION LIGHT (WITH PANEL LIGHT CONTROL SYSTEM)
(F)
RIB
(SHORT CORO)
~~?
RIB
(F)
EEC:I~~iION
RIY
(R)
(516)
(F)
(F)
I
RIB
:i t
(19)-------
_ _ _ _ _ _ _ _ _ _ _ _ _ _ .J
B (R)
t'o." ".,
10918-11051
REAR Alc
ILLUMINATION
Q~918"--'--11'-:-;-'051
1" 0""'7"4""0--'-20::-:6"1
RIB
(SHORT CORD)
RIB RIG
ILLUMINATION(F)
C 28
I RIB (R)
R/~ (F)
r - - WITH REAR A/c- --
DR
0318-031 RFW MAIN SWITCH
(F)
RIB
0740-2061 REAR (R) -SHORT CORD
1105
CONSOLE
ILLUMINATION
0918-
~~?
RIB
(F)
* ... VACANT
0918-11b
.CiJJlj
-Jo.

18 LIGHTING SYSTEMS
[BLACK]
0918-1102
GLOVE COMPARTMENT LIGHT

[BLACK]
HARNESS SYMBOL: 1111111111 (F) (E)
(R)
FUEL-FILLER LID OPENER SWITCH ILLUMINATION
0918-11b
"
......
""
F-OI
I~
l
(F)
B LIB
(F) (F)
10919-021
I NT RELAY
MIST
IQ9]9-011
LCF)
l
(F)
WINOSHIElD WIPER MOTOR (F)
ff
II
"
F-OI
IG KEY2 60A "
-"'"
I G KEY! 40A
-'='
MAIN FUSE BLOCK
MAIN BOA
WINOSHIElD WIPER AND WASHER SWITCH (F)
B
(E)
WINDSHIELD WIPER AND WASHER
, -.,
(F)
B/w
B/l
(F)
BIR
(F)
IG2
9T .-
p-
0919-03
WINOSHIELD WASHER MOTOR (F)
B (F)
C-OI
1\
WINDSHIElO WIPER MOTOR
WIPER 15A
F-02
FUSE BLOCK
AIR BAG SYSTEM
WINDSHIELD WASHER MOTOR
WINOSHIElD WIPER AND WASHER SWITCH
ENGINE SWITCH
# ...
* ... WITHOUT
VACANT
0919
....
01
(E) ~ (R)
F-01
MAIN FUSE BLOCK

m;mm (F)

19 WIPERIWASHER SYSTEM
HARNESS SYMBOL:
..,
.,
0919
'~
o0)
....lo.
40A
IG KEY2 BOA
II
__ @_____________ :
10920-1031
B
(F)
l/W
(F)
ACCESSORY SOCKET
WITH REAR
ACCESSORY B
SOCKP
(R)
REAR ACCESSORY
SOCKET
(R)10920_,031
l/W
C-28
B/w
(F)
B/l
(F)
I
.If
IGI))
Ace
'"qi'-:.. ~"i'
*= ====:::j:: c-o
8T ~h....~;F;-:..ii:>-OFF
CIGAR 20A
CIGARETTE lIGHTER
F-02
FUSE BLOCK
ENGINE SWITCH
0920-1
l,w!
iI
0920-1031 REAR ACCESSORY SOCKET (R)
~f-----------------------
(F)
B
(F)
l/w
(F)
1029
------------------------------------------------1---------r----: -: ,,,,H'
\h
--r-----------------r---I{,.--- >~~'-~ ---;;~D
MAIN FUSE BLOCK
MAIN 80A
IG KEYI
F-OI
0920-1021 ACCESSORY SOCKET(F)
<BI
B
(E)
0920-1011 CIGARETTE lIGHTER (F)
Jr
11
BA TTERY
ACCESSORY SOCKET I CIGARETTE LIGHTER
-....J
......\.
'IiiiIIY

20 ENTERTAINMENT
(FHR)
[BLACK)
HARNESS SYMBOL: ~g~m~g (F) (E) ~ (R)
[5 DOOR]
C-28
(F)-(R)
0920-1
REAR ACCESSORY SOCKET

[BLACK]
0920-103
(SECTION 0914-4b)
g~~~o~E~~~~~~T
ODOMETERI
TRIPMETER
PCM
(SECTI ON
0140-1 b. 20)
2J
YIB
2X
2I
--
2K
.<:::::::>.
202M
B/R (R)
2E
2C
#2R/G
#38
2.f/2D
IR/YI GIRl /
2H
2X
B/R
Af-----..,
B/R (F)
B/R (F)
MICROCOMPUTER
OFF"
a
~
-.
(SECTION 0922-lb)
- --- -
;-'10"9'"2'"2--'104"1
II
II
--, r
L/w (F)
~ -(SECTION
--,
:?j
Elom-I041
----------,
-WL-3
-WL-C. WE-C
110922 1011
I~
.". 1
Ic.2c)
===G:~IF~""n
~a140
2-B-----
= == = === = =
(F)
(SECTION 0922-lc)
:~::
IME-TER-I-SAI
=== :::E=
I(F)
2B
L/R
2A
L _____ I
ij!
Ll ij
"J'
w,
JI : iL~wl~
0922-1041 VEH I CLE SPEEDOMETER SENSOR (E)

WL-3 4X2
WL-C.WE-C 4X2
cd3
0922-1021 KEY REMINDER SWITCH(F)
L ____
4X4
0922-1 d)
INSTRUMENT CLUSTER
IB!Rt I
0922-1071 FUEL GAUGE SENDER UNIT (R2)
0922-1031 IGNITIDN KEY I LLUM I NAT I ON (F)
0922-1 a
AT
WITH FRONT FOG LIGHT INDICATOR
AT WITHOUT PANEL LIGHT CONTROL
SYSTEM
ENGINE SWITCH
C-OI
PCM
(SECTION
'qACC
~,
C-OI
--------------MT~----2W
-
r --,- - --yL/w (E) L E)
I-
Ir------
....
I \
IG1P
ST ,
B/Y~ W
i2A fC
LlR1
5V REGULATOR
10922-103de~922-1031
KEY REMINDER SWITCH
L/R
(F)
L/R1(F)
&
#1. ..
#2 ...
#3 ...
*# ...
VACANT
... WL-C.WE-C
II
VEHICLE
VEHICLE
I-f---;
I-t---;
SPEEDOMETER
SPEEDOMETER
~
I B/R EVEREST I B/R RANGER.
SENSOR
SENSOR
~~_:"":"".J
L-"':":"~':"-....I
10922-1071
109Z2-1071
: (F) EXCEPT: (F) EVEREST
I
S D?OR I
S D?OR I L - - - - - - - 4 x 2 - - - - - - - - 1 L--------4x4--------.....J I
----------------''-{17
3
L- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - J
Y(~(R2)
1'lt/J R/BIB/Y
2G
20
TRIPMETER SWITCH
r:
2J
L/o
+========~ (F)----t
Y (R)
Y (F)
10922-10~r::::::::;;l~922-1021
(F)
L/R
1I=:~ ~~N~:I~::!:~~L~~~N::I:: =(:~:~~=
(~)
FUrSE BLOCK P
(F)
EXCEPT S DOOR- J+========,,+C-13
B/R
&P/8
20
BUZZER
P
(F)
F-02
~A
--~=============--===~
00
@ @.
2S SPEEDOMETER TACHOMETER 12K
(SECT I ON 0922-1 b)
0922-1011 INSTRUMENT CLUSTER (F)
TiT
2W
WI~SHECITMIMO:B 10~II;E-:) Sy~I~EM- _~~ J
r.v
L
____
W/L (F)
ex>
L/W
i-----~M~~B-I~~Z~;~~I-T-~-P-~
~ (F) I
(F)
L--<~~~__f ___ W/R~
__~~B/W
(F)
BTNI 60A
THEFT-DETERR-E-N-T--S-Y-ST-E-M-.-----,-----......
MAIN aOA
~~~~,-~~~o-
MAIN FUSE BLOCK

F-O I
F-O I
~~__----------<Y~A>--~~-B/L
(F)
!..------------------------...!
:
I
1- - -W I TH
(E)
Ie
BATTERY
INSTRUMENT CLUSTER
CO
.'

22 I"NSTRUMENTATIONJDRIVER INFO.
[WL-3]
[WL-C, WE-C]
HARNESS SYMBOL: m~m~~~ (F) (E) ~ (R)
(F)-(R)
C-03
ENGINE SWITCH
(R)-(R2)
[5 DOOR]
(R)-(R2)
C-13 -
0922-1 a
EXCEPT 5 DOOR
I
I
I
I
:;-
fa
(F)
(F)
V/G
(F)
v/w
** *
V
(F)
p/B
(F)
ILl J
1H
lG
(SHORT CORD)
IN
I K 11
iif
In
IC
1F
10
1Tii'r
IE
q'
B/RI
I
2X 2V 2T
2P
2R
ffi
(F)
21
4ft
[ffi]
(SHORT CORD)
Hi
PARKING
BRAKE SWITCH
#2R/G
#3S
0922-109
2E 2C 2A
I Y YlBltl't. RIB B/ylL/R
~ I LG P IR/Y G/R I I L
2N 2L 2J 2H 2F 20 2B
* *
&V/W,I &V/G
r-------,
I
L/Y
I
(F)--I
I
I
I
I_- WITH _J
4WABS
(SECT I ON
0922-la)
+0922-1081
BR/W
L/Y
(F)
L/Y
(F)
2K
><
202M
IW/L L/OI
2S
* *
2U
Nlsi *
2W
ZU
0922-1081 FRONT (F)-SHORT CORD
1B
lA
TCM
(SECT I ON ()513-b)
--------------------AT--------------------
I NSTRUMENT CLUSTER (F)

101M
WATER TEMPERATURE
SENDER UNIT
Y/B
: r-'--~
+10922-106': II Y/B
(F) WLI 3
L_
1
Y/B (F)
(F)
Y/B
(F)
MICROCOMPUTER
(SECT I ON
0922-lc)
===~===============
0922-1061 FRONT (F) -SHORT CORD
WL-C.
r---WE-C ----I
(SECT I ON
0922-la)
------------------------------------
INSTRUMENT CLUSTER
ISR/wlQ-
BRAKE
(SHORT CORD)
1 ~~~~b~G
FLUID
SENSOR
(F)
WL-3
WATER TEMPERATURE
ffi
0922-1101 BRAKE FLUID LEVEL
0922-105
(SECTION 0922-lc)
L---WITH REAR ABS---
ABS CM
(SECT I ON 0413-2)
* ...
--
WITH AIR BAG SYSTEM

o ... WITH THEFT-DETERRENT SYSTEM
~ ... WITH REAR ABS
WITH RFW CONTROL SYSTEM.4X4
& AT
#(. .. WITH FRONT FOG LIGHT INDICATOR
#2 ... WITH PANEL LIGHT CONTROL SYSTEM
#3 ... AT WITHOUT PANEL LIGHT CONTROL SYSTEM
*# ...
VACANT
... WL -C. WE-C
< >...
0922-1b

22 INSTRUMENTATIONIDRIVER INFO.
HARNESS SYMBOL: iiimiiii (F) (E) ~ (R)
0922-1b
fa
IN
IL
IK
INSTRUMENT CLUSTER (F)
(SECT I ON
0922-1 b)
IJ
II
IH
IG
INSTRUMENT CLUSTER
IF
IE
10
BR
21'1
2A
L/R
2B
21
SYSTEM~
2X
2K
WITH AIR BAG
SAS CONTROL MODULE

(SECTION 0810-10)
Y/G
(F)
B/R
'Pia
L/W
202M
__ I'll TH RFW CONTROL SYSTEM. __

4X4
RFW CONTROL MODULE

(SECTION 0318-0) MT
TCM
(SECTION 0513-b) AT
LG/R
I
I
I
I
I
WITHOUT
AIR BAG
SYSTEM
______ J
'~
5 6
I
I
I
I
I
I
I
I
B
(F)
r------,-------, r--'---I
:.. -i'lL-C. WE-C-
PCM
{SECT I ON
0140-20)
v/G
(F)
r---'----,
* ...
@ ...
--
ABS Hu/cM
(SECTION 0413-1.2)
LG
(F)
WITH AIR BAG SYSTEM

WITH THEFT-DETERRENT SYSTEM
... WITH REAR ABS
WITH RFW CONTROL SYSTEM.4X4
& AT
#1. .. WITH FRONT FOG LIGHT INDICATOR
#2 ... WITH PANEL LIGHT CONTROL SYSTEM
#3 ... AT WITHOUT PANEL LIGHT CONTROL SYSTEM
*# ...
VACANT
... i'lL -C. WE-C
< > ..
0922-1c
...lIo.
...lIo.

HARNESS SYMBOL: ~~~~mm.(F) (E) ~ (R)
0922-1c
,./:::0.
0922-101
,...-.,.
.,
IP
IN
INSTRUMENT CLUSTER (F)
INSTRUMENT CLUSTER
(SECT I ON
0922-1 a)
IL
IK
(F)
IJ
II
L/W
IH
IG
FRONT FOG LIGHT

RELAY
(SECTION 0918-3)
r - - - - - - -- --#1----- - - - - - ,
INSTRUMENT CLUSTER
IF
IE
10
(F)
IB
G/B
'SaR/f
(F)
G/W
(F)
R/W
2Q
,,,
20
FLASHER CONTROL
MODULE
HEADLIGHT
(SECTION 0918-4) (SECTION 0918-1)
2M
21
2K
IJ
2H
2F
20
2A
2B
L/R
L -
ti
t
I
BRI/B
,-------------,
-W I TH THEFT-DETERRENT SYSTEM- - - - - - -
THEFT-DETERRENT
I MMOB I L I ZER UN I T
CONTROL MODULE
(SECTION 0914-3)
(SECT I ON 0914-4.) _ -W I TH I MMOB III ZER SYSTEM--
BR/B
(F)
BR/B
================== I092EIQT]
DOOR SWITCH
(SECTION 0918-8,12)
RIY
r-----I
* ...
#1. .. WITH FRONT FOG LIGHT INDICATOR

#5 ... WITH BUCKLE SWITCH
@ ... WITH THEFT-DETERRENT SYSTEM
& AT
WITH RFW CONTROL SYSTEM. 4X4
< > ... WITH AIR BAG SYSTEM
*# ...
VACANT
... WL-C, WE-C
0922-1d
0'1
....lo.
....lo.
m:mm (F)
(E) ~ (R)

HARNESS SYMBOL:
.,
.,
0922-1d
00
.....
.....
8ATTERY
HORN
~
8TN2 BOA
B/R
GIW
0922-202
8/R
(F)
0919-01
GIW
(F)
8/R
(F)
HORN SW I TCH (F)
HORN LH (F)
0922-203
8/R
(F)
HORN RELAY
2041
WITH
AIR 8AG
SYSTEM
HORN RH (F)
HORN SWITCH
~ G/R I * I * I ~
0810-102
SHORT CONNECTOR (F)
WITHOUT
AIR 8AG
SYSTEM
--------------
GIR
(F)
0922-204 HORN SW I TCH (F)

(CLOCK SPR I NG)
--------------
HORN SWITCH
t""'-' '
GIR (F)
I
I
I
I
I
I
I
I
-----------,
I
I
I
r--
I
I
I
-----------,
GIR (F)
r--
GIR (F)
-------------------
----------
g=========
GIW
(F)
F-02
FUSE 8LOCK
L/8~
(F)
~A
IF-ol
MAIN FUSE 8LOCK
F-oll
C GIw
GIR
HORN RELAY (F)
8
(E)
"
rYlGI B/wTY/RI G/RJ
* ... VACANT
0922-2
<0
--to.
--to.

*'
0922-2
..
ALPHABETICAL INDEX
4
4X41NDICATOR SWITCH ..................................... 54
A
AlC AMPLIFIER ...................................................... 60
AlC RELAy ............................................................. 60
AlC SWiTCH ........................................................... 60
ABBREVIATION ..................................................... 12
ABS CM .................................................................. 58
ABS HU .................................................................. 58
ABS HU/CM ........................................................... 56
ABS RELAy ............................................................ 58
ABS SPEED SENSOR ........................................... 58
ABS WHEEL-SPEED SENSOR ............................. 56
ACCELERATOR PEDAL
POSITION SENSOR ..................................... 38, 50
ACCESSORY SOCKET ....................................... 106
AIR BAG MODULE ................................................. 64
AUDIO UNIT ......................................................... 108
B
BACK-UP LIGHT .................................................... 96
BACK-UP LIGHT SWITCH ..................................... 96
BLOWER MOTOR .................................................. 60
BLOWER RELAY ................................................... 60
BLOWER UNIT ....................................................... 60
BONNET SWiTCH .................................................. 84
BOOST SENSOR ............................................. 38, 48
BRAKE FLUID LEVEL SENSOR .......................... 114
BRAKE LIGHT ........................................................ 98
BRAKE SWITCH .................................................... 98
.
FILAMENT ...............................................................68
FLASHER CONTROL MODULE ............................. 94
FOG LIGHT ............................................................. 92
FOG LIGHT RELAY ................................................ 92
FOG LIGHT SWITCH ..............................................92
FREE SOLENOID VALVE ....................................... 52
FRONT FOG LIGHT ................................................ 92
FRONT FOG LIGHT RELAY ................................... 92
FRONT FOG LIGHT SWITCH ................................. 92
FRONT POWER WINDOW REGULATOR ........... ..70
FRONT SIDE TURN LIGHT .................................... 94
FRONT SPEAKER ................................................ 108
FRONT TURN LlGHT .............................................. 94
FUEL GAUGE SENDER UNIT .............................. 112
FUEL INJECTION PUMP .................................. 38, 40
FUEL INJECTOR ................................................... .44
FUEL METERING VALVE ...................................... .44
FUEL PRESSURE SENSOR ................................. .46
FUEL PUMP SPEED SENSOR ............................... 36
FUEL TEMPERATURE SENSOR .......................... .48
FUSE BOX ..............................................................20
G
G SENSOR ..............................................................56
GENERAL INFORMATION .......................................2
GENERATOR ..........................................................32
GLOVE COMPARTMENT LIGHT ......................... 100
GLOW PLUG .....................................................36, 42
GLOW PLUG RELAY ........................................36, 42
GROUND POINT .....................................................26
H
CAMSHAFT POSITION SENSOR .......................... 46
CIGARETTE LlGHTER. ........................................ 106
CKP SENSOR ........................................................ 40
CLIMATE CONTROL UNIT .................................... 60
CLOCK SPRING ..................................................... 64
CLUTCH PEDAL POSITION SWITCH ............. 36, 42
COIL ....................................................................... 82
COMMON CONNECTOR LIST .............................. 22
CRANKSHAFT POSITION SENSOR ..................... 48
HAZARD WARNING SWITCH ................................ 94

HEADLIGHT ............................................................ 88
HEADLIGHT RELAY ...............................................88
HEADLIGHT SWITCH ............................................. 88
HIGH-MOUNT BRAKE LIGHT ................................ 98
HORN .................................................................... 118
HORN RELAY ....................................................... 118
HORN SWITCH ..................................................... 118
IDLE SWITCH ................................................... 36, 48

ILLUMINATION
AlC SWITCH ...................................................... 100
AUDIO UNIT ....................................................... 100
CONSOLE .......................................................... 100
HAZARD WARNING SWITCH ........................... 100
HEATER CONTROL .......................................... 100
IGNITION KEY ................................................... 112
INSTRUMENT CLUSTER .................................. 100
REAR WINDOW DEFROSTER SWITCH .......... 100
RFW MAIN SWITCH .......................................... 100
IMMOBILIZER UNIT ................................................82
INSTRUMENT CLUSTER ..................................... 112
SENSOR ........................................ ;... 38, 40, 44, 48
INTAKE SHUTTER SOLENOID VALVE ................ .44
INTERIOR LlGHT .................................................. 102
DATA LINK CONNECTOR ..................................... 30

DATA LINK CONNECTOR-2 .................................. 30
DOOR KEY CYLINDER SWITCH .......................... 84
DOOR LOCK ACTUATOR ..................................... 78
DOOR LOCK CONTROL MODULE ....................... 76
DOOR LOCK-LINK SWITCH ............................ 76, 86
DOOR SWITCH .................................................... 102
DRIVER-SIDE AIR BAG MODULE. ........................ 64
DRIVER-SIDE PRE-TENSIONER SEAT BELT ...... 66
DRIVER-SIDE SIDE AIR BAG MODULE ............... 66
DRIVER-SIDE SIDE AIR BAG SENSOR ............... 66
E
EGR CONTROL SOLENOID VALVE ............... 36, 46
EGR SOLENOID VALVE .................................. 36, 46
EGR VALVE POSITION SENSOR ................... 38, 46
ELECTRICAL WIRING SCHEMATIC ..................... 18
ENGINE COOLANT
TEMPERATURE SENSOR ........................... 38, 48
120
&\1
.'
K
KEY REMINDER SWITCH .................................... 112
KEYLESS CONTROL MODULE ............................. 80
A'\
.,
ALPHABETICAL INDEX
I._
I.,
TRANSFER NEUTRAL SWiTCH ............................ 54

TURN LIGHT .......................................................... 94
TURN SWITCH ....................................................... 94
TWEETER ............................................................ 108
LICENSE PLATE LIGHT ......................................... 90

LOCK SOLENOID VALVE ...................................... 52
M
MAGNETIC CLUTCH ............................................. 60
MAIN RELAY .................................................... 36,42
MASS AIR FLOW SENSOR ............................. 40, 44
VARIABLE BOOST CONTROL

SOLENOID VALVE .............................................. 46
VARIABLE SWIRL CONTROL
SOLENOID VALVE .............................................. 46
VEHICLE IDENTIFICATION NUMBERS (VIN) ......... 3
VEHICLE SPEEDOMETER SENSOR .................. 112
N
NEUTRAL SWITCH .......................................... 36, 42
OIL PRESSURE SWITCH .................................... 116
W
WATER TEMPERATURE
SENDER UNIT................................................... 112
WINDOW DEFROSTER RELAy ............................ 68
WINDOW DEFROSTER SWiTCH .......................... 68
WINDSHIELD WASHER MOTOR ........................ 104
WINDSHIELD WIPER AND
WASHER SWITCH ............................................ 104
WINDSHIELD WIPER MOTOR ............................ 104
WIRING COLOR CODE ........................................... 9
P
PARKING BRAKE SWITCH ................................. 114
PARKING LIGHT .................................................... 90
PASSENGER-SIDE AIR BAG MODULE ................ 64
PASSENGER-SIDE PRE-TENSIONER
SEAT BELT .......................................................... 66
PASSENGER-SIDE SIDE AIR BAG MODULE ....... 66
PASSENGER-SIDE SIDE AIR BAG SENSOR ....... 66
PCM ............................................................ 36, 42, 52
POWER OUTER MIRROR ..................................... 74
POWER OUTER MIRROR SWITCH ...................... 74
POWER WINDOW MAIN SWITCH ........................ 70
POWER WINDOW REGULATOR
(FRONT) .............................................................. 70
(REAR) ................................................................. 72
POWER WINDOW SUBSWITCH ........................... 70
PRE-TENSIONER SEAT BELT .............................. 66
A
(,.
REAR POWER WINDOW REGULATOR ............... 72

REAR SPEAKER .................................................. 110
REAR TURN LIGHT ............................................... 94
REAR WINDOW DEFROSTER RELAY ................. 68
REAR WINDOW DEFROSTER SWITCH ............... 68
REFRIGERANT PRESSURE SWITCH .................. 60
RESiSTOR .............................................................. 60
RETRACT/RETURN MOTOR ................................. 74
RFW LOCK SWITCH .............................................. 54
RFW MAIN SWITCH ............................................... 52
S
SAS CONTROL MODULE ...................................... 64
SEDIMENTOR SWITCH ....................................... 116
SIDE AIR BAG MODULE ........................................ 66
SIDE AIR BAG SENSOR ........................................ 66
SIDE TURN LIGHT ................................................. 94
SPEAKER
(FRONT) ............................................................ 108
(REAR) ............................................................... 110
STARTER ............................................................... 34
T
TAILLIGHT .............................................................. 90
TEST CONNECTOR ............................................... 58
THEFT-DETERRENT CONTROL MODULE .......... 84
THEFT-DETERRENT HORN .................................. 86
THEFT-DETERRENT HORN RELAy ..................... 86
THERMISTOR ........................................................ 60
TNS RELAy ............................................................ 88
121

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._------------------------------GENERAL INFORMATION ... 00-00

VEHICLE IDENTIFICATION NUMBER

VEHICLE IDENTIFICATION NUMBER (VIN) CODE

-..:...P..:.:la:..:.;..nt W=A. A. Thailand

World manufacturer identification

HOW TO USE THIS MANUAL

How To Read Frame Dimensions

DIMENSIONS~ Shows box size

IPay Load:2t Engine:SL Mission:5MT

f-- Shows applicable vehicle

Shows imaginary reference line

Shows point name

Front spring hanger rear

Side member outer front end

Crossmember No.1 guide pipe

Front spring hanger front

Radiator guide bracket

Rear s rin han er rear

Side member standard hole

I-- Shows slot

Shows vehicle section

BODY~TRAIGHT-LINE DIMENSIONS (1)

Shows point symbol

Shows point symbol

Shows point name

Shroud panel datum hole

Center of circular hole

Center elliptical hole

Center of rectangular-shaped hole

Edge of rectangular-shaped hole

Panel seam, bead, etc.

BODY & ACCESSORIES

BODY STRUCTURE [DIMENSIONS]

FRAME DIMENSIONS (UNDERBODY

FRONT BODY STRAIGHT-LINE

BODY STRUCTURE [DIMENSIONS]

Box bracket No.2

Box bracket No.3

Box bracket No.3

Box mounting hole

Box bracket No.2

Rear spring hanger

.... 385 {15.16}

.... 250 {9.84}

.... 125 {4.92}

BODY STRUCTURE [DIMENSIONS]

Cabin mounting bracket No.1

Bumper stay bracket

Front suspension bracket

Box bracket No.1

Box bracket No.1

Box bracket No.3

Box bracket No.3

Box mounting hole

Front spring hanger

Rear spring hanger

BODY STRUCTURE [DIMENSIONS]

Box bracket No.1

Box bracket NO.3

Box bracket No.3

'.... 406 {15.98}