Documente Academic
Documente Profesional
Documente Cultură
Repair Manual
(English, German, French, Spanish,
Italian, Portuguese)
Overhaul Manual
(English, German, French, Spanish,
Italian)
Wiring Diagrams
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . .
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . .
SERVICING PROCEDURE . . . . . . . . . . . . . . .
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . .
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . .
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNDAMENTAL PROCEDURES . . . . . . . . . . . .
PREPARATION OF TOOLS AND
MEASURING EQUIPMENT . . . . . . . . . . . . . .
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION DURING REMOVAL,
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
GI11
GI11
GI11
GI13
GI13
GI13
GI14
GI15
GI15
GI15
GI15
ARRANGEMENT OF PARTS . . . . . . . . . . . . . .
CLEANING OF PARTS . . . . . . . . . . . . . . . . . . .
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
RUBBER PARTS AND TUBING . . . . . . . . . . .
HOSE CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . .
TORQUE FORMULAS . . . . . . . . . . . . . . . . . . . .
VISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . .
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . .
NEW STANDARDS . . . . . . . . . . . . . . . . . . . . . . . .
ABBREVIATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .
GI15
GI15
GI15
GI16
GI16
GI16
GI16
GI16
GI17
GI17
GI18
GI10
GI15
SERVICING PROCEDURE
Inspection, Adjustment
The procedures for inspections and adjustments
are divided into steps. Important points in regard to
the location and contents of the procedures are
explained in detail and are shown in the
illustrations.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
GI1
SST
Meaning
shown below.
Example:
Kind
Apply oil
New appropriate
engine oil or
gear oil
New appropriate
brake fluid
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
Appropriate SST
ADVISORY MESSAGES
Youll find several Warnings, Cautions, Notes,
Specifications and Upper and lower limits in this
manual.
Warning
A Warning indicates a situation in which
serious injury or death could result if the
warning is ignored.
Caution
A Caution indicates a situation in which
damage to the vehicle could result if the
caution is ignored.
Note
A Note provides added information that will
help you to complete a particular procedure.
Specification
The values 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.
TEXT SEQUENCE
GI3
UNITS
The actual converted values for 2.7 kgf/cm2 are
UNITS
Electric current
A (ampere)
Electric power
W (watt)
Electric resistance
(ohm)
Electric voltage
V (volt)
Length
mm (millimeter)
in (inch)
kPa (kilo pascal)
Negative pressure
Positive pressure
Number of
revolutions
Torque
Volume
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight
g (gram)
oz (ounce)
GI4
FUNDAMENTAL PROCEDURES
FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
Be sure that all necessary tools and measuring
equipment are available before starting any work.
SXU00008
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.
SXU00004
49 SE01 310
SXU00009
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
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.
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.
SXU00010
SXU00007
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:
GI5
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
FUNDAMENTAL PROCEDURES
FUNDAMENTAL PROCEDURES
PREPARATION OF TOOLS AND MESURING
EQUIPMENT
Be sure that all necessary tools and measuring
equipment are available before starting any work.
SXU00008
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.
SXU00004
49 SE01 310
SXU00009
CLEANING OF PARTS
All parts to be reused should be carefully and
thoroughly cleaned in the appropriate method.
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.
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.
SXU00010
SXU00007
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:
GI5
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
FUNDAMENTAL PROCEDURES
When reinstalling, position the hose clamp in the
SXU00011
SXU00015
TORQUE FORMULAS
When using a torque wrenchSST combination,
the written torque must be recalculated due to the
extra length that the SST adds to the torque
wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit
Formula
Nm
Nm [L/(L+A) ]
kgfm
kgfm [L/(L+A) ]
kgfcm
kgfcm [L/(L+A) ]
ftlbf
ftlbf [L/(L+A) ]
inlbf
inlbf [L/(L+A) ]
SXU00012
ADJUSTMENT
Use suitable gauges and/or testers when making
adjustments.
SST
SXU00016
VISE
When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
SXU00013
SXU00017
SXU00014
HOSE CLAMPS
GI6
FUNDAMENTAL PROCEDURES
When reinstalling, position the hose clamp in the
SXU00011
SXU00015
TORQUE FORMULAS
When using a torque wrenchSST combination,
the written torque must be recalculated due to the
extra length that the SST adds to the torque
wrench. Recalculate the torque using the following
formulas. Choose the formula that applies to you.
Torque Unit
Formula
Nm
Nm [L/(L+A) ]
kgfm
kgfm [L/(L+A) ]
kgfcm
kgfcm [L/(L+A) ]
ftlbf
ftlbf [L/(L+A) ]
inlbf
inlbf [L/(L+A) ]
SXU00012
ADJUSTMENT
Use suitable gauges and/or testers when making
adjustments.
SST
SXU00016
VISE
When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
SXU00013
SXU00017
SXU00014
HOSE CLAMPS
GI6
ELECTRICAL SYSTEM
2. Inspect the terminals of waterproof connectors
from the connector side, as they cannot be
accessed from the wiring harness side.
ELECTRICAL SYSTEM
CONNECTORS
Disconnecting Connectors
When disconnecting two connectors, grasp the
connectors, not the wires.
Caution
To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.
SXU00020
SXU00024
SXU00021
Locking Connector
When locking connectors, listen for a click that will
indicate they are securely locked.
SXU00022
Inspection
1. When a tester is used to inspect for continuity or to
measure voltage, insert the tester probe from the
wiring harness side.
SXU00023
GI7
NEW STANDARDS
NEW STANDARDS
Following is a comparison of the previous standard and the new standard.
New Standard
Abbreviation
AP
Name
Previous Standard
Abbreviation
Accelerator Pedal
Accelerator Pedal
ACL
Air Cleaner
Air Cleaner
A/C
Air Conditioning
Air Conditioning
Barometric Pressure
Atmospheric Pressure
VB
Battery Voltage
Brake Switch
Stoplight Switch
Calibration Resistor
Corrected Resistance
CAC
Intercooler
CLS
Feedback System
CTP
Fully Closed
Idle Switch
Clutch Position
BARO
B
CMP
sensor
CPP
CIS
CS sensor
CKP
sensor
EGI
CSP
sensor
Remark
Name
#6
DLC
Diagnosis Connector
DTM
Test Mode
DTC
#6
#1
Service Code(s)
DI
Distributor Ignition
Spark Ignition
DLI
Distributorless Ignition
Direct Ignition
Electronic Ignition
ECT
Water Thermo
EM
Engine Modification
Engine Modification
EVAP
Evaporative Emission
Evaporative Emission
EGR
FC
Fan Control
Fan Control
FF
Flexible Fuel
Flexible Fuel
4GR
Fourth Gear
Overdrive
#3
#6
EI
FSO
solenoid
FCV
GEN
Generator
Alternator
GND
Ground
Ground/Earth
HO2S
Oxygen Sensor
IAC
#2
With heater
GI8
NEW STANDARDS
New Standard
Abbreviation
Name
Previous Standard
Abbreviation
Injection Pump
FIP
Pulse Generator
IAT
KS
Knock Sensor
Knock Sensor
MIL
MAP
MAF
sensor
Airflow Sensor
MFL
OBD
On-Board Diagnostic
Diagnosis/Self-Diagnosis
OL
Open Loop
Open Loop
OC
Catalytic Converter
O2S
Oxygen Sensor
Oxygen Sensor
PNP
Park/Neutral Position
Park/Neutral Range
Remark
Name
#6
Main Relay
PSP
PCM
ECU
Pulsed
injection
NE Sensor
#6
Inject with
compressor
Reed Valve
PAIR
AIR
SAPV
SFI
Shift Solenoid A
Shift Solenoid B
Shift Solenoid C
3GR
Third Gear
3rd Gear
TWC
Catalytic Converter
Throttle Body
Throttle Body
Throttle Sensor
TB
TP sensor
TCV
TCC
Lock-up Position
TCM
ATF Thermosensor
TR
Inhibitor Position
TC
Turbocharger
Turbocharger
Voltage Regulator
IC Regulator
VSS
VR
TCV
GI9
#6
#4
#6
New Standard
Abbreviation
VAF
sensor
WU-TWC
WOT
Name
Previous Standard
Abbreviation
Catalytic Converter
Fully Open
ABBREVIATIONS
1ST . . . . . . . . . . . . . . . . .
2ND . . . . . . . . . . . . . . . . .
2W . . . . . . . . . . . . . . . . . .
3RD . . . . . . . . . . . . . . . . .
4TH . . . . . . . . . . . . . . . . .
4W . . . . . . . . . . . . . . . . . .
5TH . . . . . . . . . . . . . . . . .
BTDC . . . . . . . . . . . . . . . .
CARB . . . . . . . . . . . . . . .
CIS . . . . . . . . . . . . . . . . . .
EX . . . . . . . . . . . . . . . . . .
FIP . . . . . . . . . . . . . . . . . .
HLA . . . . . . . . . . . . . . . . .
H....................
IN . . . . . . . . . . . . . . . . . . .
L ....................
max. . . . . . . . . . . . . . . . . .
min. . . . . . . . . . . . . . . . . .
SST . . . . . . . . . . . . . . . . .
TDC . . . . . . . . . . . . . . . . .
First
Second
2-wheel
Third
Fourth
4-wheel
Fifth
Before top dead center
Carburetor
Continuous fuel injection
system
Exhaust
Fuel injection pump
Hydraulic lash adjuster
High
Intake
Low
Maximum
Minimum
Special service tool
Top dead center
GI10
Remark
Name
#5
New Standard
Abbreviation
VAF
sensor
WU-TWC
WOT
Name
Previous Standard
Abbreviation
Catalytic Converter
Fully Open
ABBREVIATIONS
1ST . . . . . . . . . . . . . . . . .
2ND . . . . . . . . . . . . . . . . .
2W . . . . . . . . . . . . . . . . . .
3RD . . . . . . . . . . . . . . . . .
4TH . . . . . . . . . . . . . . . . .
4W . . . . . . . . . . . . . . . . . .
5TH . . . . . . . . . . . . . . . . .
BTDC . . . . . . . . . . . . . . . .
CARB . . . . . . . . . . . . . . .
CIS . . . . . . . . . . . . . . . . . .
EX . . . . . . . . . . . . . . . . . .
FIP . . . . . . . . . . . . . . . . . .
HLA . . . . . . . . . . . . . . . . .
H....................
IN . . . . . . . . . . . . . . . . . . .
L ....................
max. . . . . . . . . . . . . . . . . .
min. . . . . . . . . . . . . . . . . .
SST . . . . . . . . . . . . . . . . .
TDC . . . . . . . . . . . . . . . . .
First
Second
2-wheel
Third
Fourth
4-wheel
Fifth
Before top dead center
Carburetor
Continuous fuel injection
system
Exhaust
Fuel injection pump
Hydraulic lash adjuster
High
Intake
Low
Maximum
Minimum
Special service tool
Top dead center
GI10
Remark
Name
#5
ENGINE
(WL, WL Turbo, WL3, WLT3)
ENGINE OVERHAUL SERVICE
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . B2 1
ENGINE MOUNTING/DISMOUNTING . . . . B2 1
MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . B2 1
DISMOUNTING . . . . . . . . . . . . . . . . . . . . . . . B2 2
ENGINE DISASSEMBLY/ASSEMBLY . . . . B2 3
TIMING BELT DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . B2 3
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY (I) . . . . . . . . . . . . . . . . . . . . . . . B2 5
CYLINDER HEAD DISASSEMBLY/
ASSEMBLY (II) . . . . . . . . . . . . . . . . . . . . . . B2 8
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (I) . . . . . . . . . . . . . . . . . . . . . . . . B211
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (II) . . . . . . . . . . . . . . . . . . . . . . B213
CYLINDER BLOCK DISASSEMBLY/
ASSEMBLY (III) . . . . . . . . . . . . . . . . . . . . . . B219
ENGINE INSPECTION/REPAIR . . . . . . . . . . B222
CYLINDER HEAD INSPECTION/
REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B222
VALVE INSPECTION . . . . . . . . . . . . . . . . . . B222
VALVE GUIDE INSPECTION . . . . . . . . . . B223
VALVE GUIDE REPLACEMENT . . . . . . . B223
VALVE SEAT INSPECTION/REPAIR . . . B224
VALVE SPRING INSPECTION . . . . . . . . . B224
CAMSHAFT INSPECTION . . . . . . . . . . . . . B224
CAMSHAFT OIL CLEARANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B225
CAMSHAFT END PLAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . B225
ENGINE MOUNTING/DISMOUNTING
Warning
D Continuous exposure with USED engine oil
has caused skin cancer in laboratory mice.
Protect your skin by washing with soap and
water immediately after this work.
MOUNTING
1. Install the engine hanger (JE48 10 561C) to the
cylinder head by using bolt (99794 0820) or
(M8X1.25, 6T, Length 20mm {0.79 in}) as shown.
B21
Tightening torque
1925 Nm {1.92.6 kgfm,1418 ftlbf}
ENGINE MOUNTING/DISMOUNTING
2. Install the SSTs (arms and attachments) to the
holes as shown, and hand tighten the SST (bolts).
49 0107 680A
49 L010 102
49 L010 107
49 L010 106
Tightening torque
3041 Nm {3.04.2 kgfm, 2230 ftlbf}
49 L010 101
DISMOUNTING
D Dismount in the reverse order of mounting.
49 L010 105
49 L010 104
PLATE
ARM
HOOK
ENGINE
NUT
WASHER
BOLT
Warning
D Self-locking brake system of the engine
stand may not be effective when the engine
is held in an unbalanced position.
This could lead to sudden, rapid movement
of the engine and mounting stand handle
and cause serious injury.
Never keep the engine in an unbalanced
position, and always hold the rotating
handle firmly when turning the engine.
7. Mount the engine on the SST (engine stand).
B22
ENGINE DISASSEMBLY/ASSEMBLY
ENGINE DISASSEMBLY/ASSEMBLY
TIMING BELT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
5.08.8 Nm
{5090 kgfcm, 4478 inlbf}
R
R
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
Water pump
Vacuum pump
Nm {kgfm, ftlbf}
Pulley plate
Timing belt
+ Disassembly Note
+ Assembly Note
TIMING MARK
CAMSHAFT
PULLEY
TIMING MARK
TENSIONER
SPRING
TENSIONER
FIP PULLEY
B23
ENGINE DISASSEMBLY/ASSEMBLY
Timing belt deflection
9.010.0 mm {0.360.39 in} at
98 N {10 kgf, 22 lbf}
Caution
D The following will damage the belt and
shorten its life; Forcefully twisting it,
turning it inside out, or allowing oil or
grease on it.
D Mark the timing belt rotation on the belt for proper
reinstallation.
FAULTY
FAULTY
ROTATION
ARROW
FAULTY
FAULTY
DEFLECTION
CHECKING
POINT
TIMING
MARK
TIMING MARK
Thickness
1.52.5 mm {0.0600.098 in}
CAMSHAFT
PULLEY
TENSIONER
SPRING
TENSIONER
FIP PULLEY
Caution
D Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.
2. Verify that the FIP attaching bolts and nuts are
tightened to the specified torque.
This must be done to prevent overtensioning of the
timing belt after it has been installed.
3. Install the timing belt.
4. Install the tensioner, tensioner spring, and the lock
bolt.
5. Turn the crankshaft clockwise twice, and align the
timing marks. If they are not aligned, remove the
timing belt and repeat from Timing Belt Assembly
Note step 1.
6. Loosen the tensioner lock bolt to apply tension to
the belt. Do not apply tension other than that of the
tensioner spring.
7. Tighten the tensioner lock bolt. Be sure the
tensioner does not move together with the bolt
rotation.
8. Turn the crankshaft clockwise twice, and check the
timing belt deflection as shown. If it is incorrect,
repeat from Tensioner, Tensioner Spring
Disassembly Note.
B24
A
ENGINE
FRONT
B
ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER HEAD DISASSEMBLY/ASSEMBLY (I)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
29 {3.0, 22} + (90 105 ) + (90 105 )
6.49.3 Nm
{6595 kgfcm, 5782 inlbf}
R
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
Blind cover
+ Assembly Note
Seal plate
+ Assembly Note
Cylinder head
+ Disassembly Note
+ Assembly Note
Camshaft pully
+ Disassembly Note
+ Assembly Note
B25
ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Pulley Disassembly Note
D Hold the camshaft by using a wrench on the cast
hexagon.
PAINT MARK
A
90 105
90 105
PAINT MARK
A
6. Tighten bolts A.
Cylinder Head Gasket Assembly Note
D Apply silicone sealant to the cylinder head as
shown.
Tightening torque
1819 Nm {1.82.0 kgfm, 13.114.4 ftlbf}
Seal Plate Assembly Note
D Tighten the seal plate bolts in the order shown.
Thickness
2.03.0 mm {0.080.11 in}
16.0 mm
{0.63 in}
40.5 mm
{1.59 in}
48.5 mm
{1.91 in}
ENGINE
FRONT
9.0 mm
{0.35 in}
Tightening torque
29 Nm {3.0 kgfm, 22 ftlbf}
B26
ENGINE DISASSEMBLY/ASSEMBLY
Water Temperature Sender Unit Assembly Note
D Apply silicone sealant to the thread of the water
temperature sender unit as shown.
3 PITCHES
B27
ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER HEAD DISASSEMBLY/ASSEMBLY (II)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
11.314.2 Nm {115145 kgfcm, 100125 inlbf}
R
SST
SST
SST
R
2030 {2.03.1, 1522}
R
3041 {3.04.2, 2230}
Nm {kgfm, ftlbf}
Camshaft cap
+ Disassembly Note
+ Assembly Note
Valve spring
+ Assembly Note
Camshaft
+ Disassembly Note
Rocker arm
+ Assembly Note
Valve
10
Pivot
Valve seal
+ Disassembly Note
+ Assembly Note
Valve keeper
+ Disassembly Note
+ Assembly Note
11
ENGINE
FRONT
B28
ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Disassembly Note
D Measure the camshaft oil clearance.
(Refer to ENGINE INSPECTION/REPAIR,
CAMSHAFT OIL CLEARANCE INSPECTION.)
49 L012 001
49 L012 002
VALVE SEAL
49 L012 005
49 0636 100B
49 B012 0A2
VALVE GUIDE
CYLINDER HEAD
A GREATER
THAN B
B
49 S120 170
CYLINDER HEAD
VALVE SEAL
49 0636 100B
VALVE GUIDE
49 B012 0A2
Dimension A
04 mm {00.1 in}
49 L012 002
49 L012 005
B29
ENGINE DISASSEMBLY/ASSEMBLY
Camshaft Cap Assembly Note
1. Apply silicone sealant to the front camshaft cap
mounting surfaces as shown. Avoid sealant from
projected onto the camshaft journal, oil seal
surface, and camshaft thrust surface.
Caution
D 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 burr on the
thrust receiving area of the cylinder head
journal. To avoid this, the following
procedure must be observed.
2. Tighten the camshaft cap bolts gradually in three or
four steps in the order shown.
ENGINE
FRONT
49 S010 001
CYLIN
DER
HEAD
HAMMER
OIL SEAL
B210
ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (I)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
R
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
R
1925 {1.92.6, 1418}
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
Nm {kgfm, ftlbf}
Oil pan
+ Disassembly Note
+ Assembly Note
Oil strainer
B211
Oil pipe
ENGINE DISASSEMBLY/ASSEMBLY
Oil Pan Disassembly Note
D Remove the oil pan by using a separator tool.
SEPARATOR TOOL
OIL PAN
B212
ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (II)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
2533 {2.53.4,
1924}
5968
{6.07.0,
4450}
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
Nm {kgfm, ftlbf}
Crankshaft pulley
+ Disassembly Note
+ Assembly Note
Flywheel
+ Disassembly Note
+ Assembly Note
FIP pulley
+ Disassembly Note
+ Assembly Note
10
End plate
11
Rear cover
+ Disassembly Note
+ Assembly Note
12
Oil pump
13
Driven gear
FIP gear
+ Disassembly Note
14
Plug
Timing gear
+ Assembly Note
15
Plunger spring
16
Control plunger
FIP
17
B213
ENGINE DISASSEMBLY/ASSEMBLY
Crankshaft Pulley Disassembly Note
D Remove the crankshaft pulley by using the SST.
SEPARATOR TOOL
49 E011 1A0
Caution
D The TDC 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.
RAG
ABOUT
13 TEETH
B214
Note
D If the chip cut gear is hard to find, move the
FIP gear on notch back and forth, then check
the chip cut gear.
ENGINE DISASSEMBLY/ASSEMBLY
VIEW A
FIP GEAR
GEAR NUT
VIEW A
No.2 IDLER
FIP GEAR
(HELICAL GEAR)
49 E011 1A0
ABOUT 0.5 mm
{0.02 in}
ABOUT 0.3 mm
{0.12 in}
SCISSORS GEAR
SEPARATOR TOOL
Warning
D When removing the imjection pump gear,
be sure to fix the scissors gear to the
injection pump gear using a lock bolt
(M8 1.25; length under the bolt head is
approximately 14 mm). Otherwise, the
scissors gear will rotate with the spring
force, causing personal injury.
Caution
D When removing the injection pump gear, be
sure to fix the scissors gear to the injection
pump gear using a lock bolt (M8 1.25;
length under the bolt head is approximately
14 mm) to prevent the scissors gear from
rotating with the spring force. Otherwise,
the scissors gear will not align with the
injection pump gear, and the injection pump
gear with the scissors gear will not engage
with the idler gear.
Note
D A injection pump gear with a scissors gear has
a lock bolt hole.
49 E011 1A0
B215
ENGINE DISASSEMBLY/ASSEMBLY
Thickness
1.52.5 mm {0.0600.098 in}
R
49 S011 103
FIP GEAR
(HELICAL GEAR)
CHIP CUT
GEAR
SCISSORS GEAR
KNOCK PIN
FIP GEAR
VIEW A
VIEW A
49 E011 1A0
PAINT MARK
3. Verify that the 11th and 12th teeth of the FIP gear
(helical gear) and the teeth of the scissors gear are
aligned, then mark a paint mark on the scissors
gear.
B216
ENGINE DISASSEMBLY/ASSEMBLY
SCISSORS GEAR
HELICAL GEAR
11 TEETH
12 TEETH
PAINT MARK
BTDC30
TDC
ABOUT
13 TEETH
49 E011 1A0
LOCK BOLT
49 0259 749
49 S010 301
49 E011 1A0
B217
ENGINE DISASSEMBLY/ASSEMBLY
Caution
D The TDC 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.
B218
ENGINE DISASSEMBLY/ASSEMBLY
CYLINDER BLOCK DISASSEMBLY/ASSEMBLY (III)
1. Disassemble in the order shown in the figure.
2. Assemble in the reverse order of disassembly.
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
42.6645.60 {4.354.65, 31.533.6} +
(90 105 )
Nm {kgfm, ftlbf}
10
Connecting rod
11
12
13
Crankshaft
+ Disassembly Note
14
15
Piston ring
16
Cylinder block
Piston pin
Piston
B219
ENGINE DISASSEMBLY/ASSEMBLY
2. Tighten the bolts in two or three steps in the order
shown.
Tightening torque
7582 Nm {7.68.4 kgfm, 5560 ftlbf}
49 G011 001
90 105
PAINT MARK
PROJECTION FOR
ALIGNING CONNECTING
ROD BEARING
B220
ENGINE DISASSEMBLY/ASSEMBLY
SECTION OF
FIRST RING
SECTION OF
SECOND RING
F MARK
82.5 97.5
PAINT MARK
B221
ENGINE INSPECTION/REPAIR
7. Inspect the combustion chamber insert crack.
ENGINE INSPECTION/REPAIR
CYLINDER HEAD INSPECTION/REPAIR
1. Carry out cooling flaw detection on the cylinder
head surface. Replace the cylinder head if
necessary.
2. Inspect for the following and repair or replace.
(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.
Crack
Limit: 10.0 mm {0.39 in}
8. If it exceeds the specification, replace the cylinder
head.
CRACK
Distortion
X direction: 0.020 mm {0.0008 in} max.
Y direction: 0.050 mm {0.0020 in} max.
Y
Grinding
0.15 mm {0.006 in} max.
VALVE INSPECTION
1. Measure the valve head margin thickness of each
valve. Replace the valve if necessary.
Margin thickness
IN: 1.50 mm {0.059 in}
EX: 0.75 mm {0.030 in}
COMBUSTION CHAMBER
INSERT
THICKNESS
LENGTH
B222
ENGINE INSPECTION/REPAIR
2. Measure the length of each valve. Replace the
valve if necessary.
Standard length
IN: 111.60112.10 mm {4.3944.413 in}
EX: 111.50112.00 mm {4.3904.409 in}
Minimum length
IN: 111.35 mm {4.384 in}
EX: 111.25 mm {4.380 in}
3. Measure the stem diameter of each valve in X and
Y directions at the three points (A, B, and C)
shown. Replace the valve if necessary.
Standard diameter
IN: 6.9706.985 mm {0.27450.2749 in}
EX: 6.9656.980 mm {0.27430.2748 in}
Minimum diameter
IN: 6.920 mm {0.2724 in}
EX: 6.915 mm {0.2722 in}
X
Y
VALVE GUIDE
A
Depth L
14.014.5 mm {0.560.57 in}
49 L012 004
Y
X
A
49 L012 002
49 L012 003
49 L012 004
49 L012 002
Standard height
14.014.5 mm {0.560.57 in}
VALVE GUIDE
B223
ENGINE INSPECTION/REPAIR
VALVE SEAT INSPECTION/REPAIR
1. Measure the seat contact width. If necessary,
resurface the valve seat by using a 45 valve seat
cutter and/or resurface the valve face.
Standard width
IN: 1.62.2 mm {0.070.08 in}
EX: 1.72.3 mm {0.070.09 in}
Pressing force
239268 N {24.327.4 kgf, 53.560.2 lbf}
Standard height
35.5 mm {1.40 in}
60
45
37
EX
60
45
30
CAMSHAFT INSPECTION
1. Set the No.1 and No.5 journals on V-blocks.
Measure the camshaft runout. Replace the
camshaft if necessary.
Recession
IN: 0.611.09 mm {0.0250.042 in}
EX: 0.711.19 mm {0.0280.046 in}
Runout
0.03 mm {0.001 in} max.
Maximum
IN: 1.50 mm {0.059 in}
EX: 1.60 mm {0.063 in}
B224
ENGINE INSPECTION/REPAIR
2. Measure the cam lobe height at the two points as
shown. Replace the camshaft if necessary.
Standard height
IN: 42.4042.50 mm {1.6701.673 in} (WL)
41.22141.321 mm {1.6231.626 in}
(WL Turbo)
EX: 42.39542.495 mm {1.6701.673 in}
Minimum height
IN: 42.050 mm {1.6555 in} (WL)
40.871 mm {1.6091 in} (WL Turbo)
EX:42.045 mm {1.6553 in}
B
A
X
Y
Y
X
B225
ENGINE INSPECTION/REPAIR
CYLINDER BLOCK INSPECTION/REPAIR
1. Measure the distortion of the cylinder block top
surface in the seven directions as shown. Replace
if necessary.
PISTON INSPECTION
D Measure the outer diameter of each piston at right
angle (90 ) to the piston pin, 19 mm {0.75 in}
above the buttom of piston.
Piston diameter
X
mm {in}
Size
Bore
Standard
92.95192.977 {3.65953.6605}
93.18693.212 {3.66883.6697}
93.43693.462 {3.67863.6795}
83.0 mm
{3.27 in}
A
MEASURING
POINT
Note
D Base the boring diameter on the diameter of an
oversize piston. All cylinder must be the same
diameter.
Cylinder bore
Standard clearance
0.0380.056 mm {0.00150.0022 in}
Maximum clearance
0.150 mm {0.0059 in}
mm {in}
Size
Bore
Standard
93.00093.022 {3.66153.6622}
93.25093.272 {3.67133.6721}
93.50093.522 {3.68113.6819}
Wear limit
0.150 mm {0.0059 in}
B226
Standard clearance
Top: 0.060.10 mm {0.00240.0039 in}
Second: 0.040.08 mm {0.00160.0031 in}
Oil: 0.030.07 mm {0.00120.0027 in}
ENGINE INSPECTION/REPAIR
Maximum clearance
0.150 mm {0.0059 in}
A
B
C
D
PISTON
RING
Standard clearance
0.0120.039 mm {0.00050.0015 in}
CRANKSHAFT INSPECTION
1. Measure the crankshaft runout. Replace the
crankshaft if necessary.
Runout
0.05 mm {0.002 in} max.
A
B
C
D
B227
ENGINE INSPECTION/REPAIR
Main journal
Standard clearance
No.1, 2, 4, 5:
0.0330.052 mm {0.00130.0020 in}
No.3:
0.050 mm 0.069 mm {0.00200.0026 in}
mm {in}
Bearing
Diameter
Journal No.
1, 2, 4, 5
Standard
66.93766.955
{2.63542.6360}
66.92066.938
{2.63472.6353}
0.25 {0.01}
undersize
66.68766.705
{2.62552.6261}
66.67066.688
{2.62482.6255}
0.50 {0.02}
undersize
66.43766.455
{2.61572.6163}
66.42066.438
{2.61502.6156}
0.75 {0.03}
undersize
66.18766.205
{2.60582.6064}
66.17066.188
{2.60522.6058}
Wear limit
0.05 mm {0.002 in}
Outofround
0.03 mm {0.001 in}
Crank pin
Maximum clearance
0.08 mm {0.003 in}
mm {in}
Bearing size
Standard
2.0032.018
{0.07890.0794}
2.1212.131
{0.08360.0838}
2.2462.256
{0.08850.0888}
2.3712.381
{0.09340.0937}
mm {in}
Bearing size
Diameter
Standard
54.94054.955
{2.16302.1635}
54.69054.705
{2.15322.1537}
54.44054.455
{2.14342.1438}
54.19054.205
{2.13352.1340}
Wear limit
0.05 mm {0.002 in}
Outofround
0.03 mm {0.001 in}
A
Diameter
mm {in}
Bearing size
Bearing thickness
Standard
2.4552.505
{0.09670.0986}
2.6302.680
{0.10360.1055}
B228
ENGINE INSPECTION/REPAIR
CONNECTING ROD INSPECTION
1. Measure each connecting rod for bending and
distortion. Replace the connecting rod if necessary.
Bending
0.075 mm {0.0030 in} max. /50 mm {2.0 in}
Center-to-center distance
151.95152.05 mm {5.9835.986 in}
mm {in}
Bearing size
Bearing thickness
Standard
1.5041.513
{0.05920.0595}
1.6211.631
{0.06380.0642}
1.7461.756
{0.06870.0691}
1.8711.881
{0.07370.0740}
LENGTH
Maximum clearance
0.080 mm {0.003 in}
B229
ENGINE INSPECTION/REPAIR
4. Measure the balance shaft bore in the cylinder
block. Calculate the clearance between the
balance shaft and balance shaft bore. Replace the
balance shaft and/or cylinder block if necessary.
Standard clearance
Front, rear:
0.0500.115 mm {0.00200.0045 in}
Center:
0.0800.145 mm {0.00320.0057 in}
BOLT INSPECTION
D Measure the length of each bolt. Replace the bolt if
necessary.
Cylinder head bolt
Bolt head mark
mm {in}
Standard
length
Maximum
length
101.2101.8
{3.9854.007}
102.5 {4.035}
113.2113.8
{4.4574.480}
114.5 {4.508}
mm {in}
Standard length
84.785.3 {3.343.35}
Maximum length
86.0 {3.39}
Standard diameter
Front:
41.94541.960 mm {1.65141.6519 in}
Center:
39.94539.960 mm {1.57271.5732 in}
Rear;
37.97537.990 mm {1.49511.4956 in}
LENGTH
B230
ENGINE INSPECTION/REPAIR
FREE LENGTH
ENGINE
FRONT
FEELER GAUGE
ADJUST
SCREW
LOCKNUT
B231
Free length
43.8 mm {1.72 in}
MANUAL TRANSMISSION
(R15MD, R15MXD)
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH HOUSING, EXTENSION
HOUSING, AND TRANSFER
CASE DISASSEMBLY/ASSEMBLY . . . . . . .
5TH/REVERSE GEAR AND
HOUSING PARTS DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
J2 1
J2 1
J2 2
TRANSMISSION CASE
COMPONENTS DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . J210
MAINSHAFT AND COUNTER
SHAFT COMPONENTS
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . J213
MANUAL TRANSMISSION INSPECTION . . . J215
J2 5
MANUAL TRANSMISSION
PRECAUTION
1. Clean the transmission exterior thoroughly by 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 by using cleaning fluids or a steam cleaner can wash the grease out of
the bearing.
2. Clean the removed parts by using cleaning solvent, and dry them by using compressed air.
Clean out all holes and passages by using compressed air, and check that there are no obstructions.
3. Use a plastic hammer when disassembling the transmission case and other light alloy metal parts.
4. Make sure each part is cleaned before assembling.
5. Coat all movable parts with the specified oil.
6. Replace parts whenever required.
7. Remove old sealant from contact surfaces before applying new sealant.
8. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transmission with transmission oil.
J21
MANUAL TRANSMISSION
CLUTCH HOUSING, EXTENSION HOUSING, AND TRANSFER CASE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
42 (R15MD)
SELECTIVE USE
R
SST
R
R
R
4255
{4.25.6, 3040}
7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}
4255
{4.25.6,
3040}
1925
{1.92.6,
1418}
1925
{1.92.6,
1418}
3146
{3.14.5,
2332}
2534
{2.53.5,
1825}
R
1925
{1.92.6,
1418}
R
R
2534
{2.53.5, 1825}
7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}
7.910.7 Nm
{80110 kgfcm,
69.495.4 inlbf}
Nm {kgfm, ftlbf}
14
Snap ring
15
Clutch housing
Boot
16
17
Adjustment shim
+ Assembly Note
18
Under cover
19
Roll pin
20
21
Control rod
Control case
22
Stopper pin
10
23
Oil pass
24
25
Extension housing
11
Snap ring
12
13
Steel ball
J22
MANUAL TRANSMISSION
44 (R15MXD)
SELECTIVE
USE
R
1925
{1.92.6,
1418}
1925
{1.92.6,
1418}
4255
{4.25.6, 3040}
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
1925
{1.92.6, 1418}
3146
{3.14.5,
2332}
R
SST
R
R
2534
{2.53.5,
1825}
R
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3247
{3.24.8,
2734}
2534
{2.53.5, 1825}
4254
{4.25.6,
3140}
Nm {kgfm, ftlbf}
15
Extension housing
+ Disassembly Note
Boot
16
Control rod
17
Under cover
18
Oil seal
+ Assembly Note
19
Oil pass
Roll pin
20
Plug
Transfer case
21
Spring
10
22
Steel ball
11
Input sleeve
23
12
Clutch housing
24
Washer
13
25
Spring
14
Adjustment shim
+ Assembly Note
J23
MANUAL TRANSMISSION
Extension Housing Disassembly Note
Turn the control rod in the direction of the arrow,
and remove the extension housing.
49 U027 003
PIPE
J24
MANUAL TRANSMISSION
5TH/REVERSE GEAR AND HOUSING PARTS DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
5TH/REVERSE
CLUTCH HUB
FRONT
FRONT
R
R
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
SST
157235
{1624,
116173}
4058
{4.06.0,
2943}
SST
SST
R
R
1826
{1.82.7, 1419}
SELECTIVE
USE
SST
1925
{1.92.6,
1418}
SELECTIVE
USE
SST
FRONT
SST
RETAINING
RING
R
128196
{1320,
95144}
8.913.7 Nm
{90140 kgfcm,
79121 inlbf}
Nm {kgfm, ftlbf}
J25
MANUAL TRANSMISSION
38
Locknut (Mainshaft)
+ Disassembly Note
+ Assembly Note
Retaining ring
39
Spring retainer
Spring
40
41
Reverse gear
Bearing housing
42
Bearing
Snap ring
43
Inner race
10
Thrust washer
44
Thrust washer
11
C-washer
+ Assembly Note
45
Thrust washer
46
12
Retaining ring
47
13
48
Thrust washer
49
Bearing cover
50
51
Oil pass
14
15
16
17
18
Spacer
19
20
Center housing
21
Oil pass
22
Blind cover
23
24
Steel ball
25
5th gear
26
Bearing
27
Retaining ring
28
29
30
Retaining ring
+ Disassembly Note
+ Assembly Note
31
32
Spring
33
34
Interlock pin
+ Assembly Note
35
36
Interlock pin
+ Assembly Note
37
49 H017 101
49 0839 425C
J26
MANUAL TRANSMISSION
49 1243 465A
49 S120 440
49 0839 425C
RETAINING
RING
Tightening torque
157235 Nm {1624 kgfm, 116173 ftlbf}
49 1243 465A
Note
The total combined thickness of the front and
rear thrust washers must equal 6.0 mm {0.236
in}.
3. Inspect the clearance between the synchronizer
key and the exposed edge of the synchronizer ring.
If it is not as specified, adjust with the thrust
washers on the front and rear of the mainshaft
bearing.
J27
MANUAL TRANSMISSION
Clearance
2.0 mm {0.079 in} max.
Available thrust washer thickness
2.5 mm {0.098 in}, 3.0 mm {0.118 in}
3.5 mm {0.138 in}
49 0862 350
5TH/REVERSE SHIFT ROD
49 S017 401
J28
MANUAL TRANSMISSION
PIPE
49 F401 331
49 S120 440
J29
MANUAL TRANSMISSION
TRANSMISSION CASE COMPONENTS DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
SST
SELECTIVE
USE
SST
SST
SELECTIVE USE
SELECTIVE USE
SST
MOLYBDENUM
GREASE
Snap ring
Thrust washer
+ 5TH/REVERSE GEAR AND HOUSING PARTS
DISASSEMBLY/ASSEMBLY, Locknut (Mainshaft) Assembly Note
10
11
12
Bearing
13
14
15
16
Transmission case
J210
MANUAL TRANSMISSION
1. Install the SST between the 4th gear synchronizer
ring and main drive synchromesh gear.
49 F017 101
49 0839 425C
49 H017 101
49 0839 425C
49 0839 425C
49 F401 331
49 0839 425C
J211
TRANSMISSION
CASE
MANUAL TRANSMISSION
(2) Measure the mainshaft center bearing height.
The difference between the two measurements
indicates the required thickness of the
adjustment shim.
0.91.0 mm
{0.035
0.039 in }
49 F401 335A
49 F401 331
PIPE
J212
49 F017 101
MANUAL TRANSMISSION
2. Install the main drive gear bearing by using the
SSTs.
49 F017 101
49 0500 330
FRONT
3RD/4TH
1ST/2ND
FRONT
FRONT
J213
SST
MANUAL TRANSMISSION
2. Install the main drive gear bearing by using the
SSTs.
49 F017 101
49 0500 330
FRONT
3RD/4TH
1ST/2ND
FRONT
FRONT
J213
SST
MANUAL TRANSMISSION
1st/2nd Clutch Hub Component Disassembly Note
Hold the mainshaft, and press the 1st/2nd clutch
hub component, 2nd synchronizer ring component,
and 2nd gear from the mainshaft.
1st gear
Bearing
Bearing race
Synchronizer key
10
11
Bearing
12
3rd gear
13
14
15
Synchronizer key
16
17
18
19
Inner cone
20
Double cone
21
Synchronizer ring
22
2nd gear
23
Bearing
24
Mainshaft
25
26
Diaphragm spring
27
Friction gear
28
Counter shaft
INNER CONE
2ND GEAR
49 0636 145
J214
MANUAL TRANSMISSION
3rd/4th Clutch Hub Component Assembly Note
Set the needle bearing, 3rd gear, 3rd synchronizer
ring, and the 3rd/4th clutch hub component on the
mainshaft. Press the parts onto the mainshaft by
using the SST, while keeping the parts from
becoming crooked or misaligned.
49 F401 331
J215
MANUAL TRANSMISSION
3rd/4th Clutch Hub Component Assembly Note
Set the needle bearing, 3rd gear, 3rd synchronizer
ring, and the 3rd/4th clutch hub component on the
mainshaft. Press the parts onto the mainshaft by
using the SST, while keeping the parts from
becoming crooked or misaligned.
49 F401 331
J215
MANUAL TRANSMISSION
J216
TRANSFER
TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DRIVE SPROCKET COMPONENT
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . .
J3 1
J3 1
J3 2
J3 4
TRANSFER
PRECAUTION
1. Clean the transfer exterior thoroughly by 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 by using cleaning fluids or a steam cleaner can wash the grease out of
the bearing.
2. Clean the removed parts by using cleaning solvent, and dry them by using compressed air.
Clean out all holes and passages by using compressed air, and check that there are no obstructions.
3. Use a plastic hammer when disassembling the transfer case and other light alloy metal parts.
4. Make sure each part is cleaned before assembling.
5. Coat all movable parts with the specified oil.
6. Replace parts whenever required.
7. Remove old sealant from contact surfaces before applying new sealant.
8. Assemble the parts within 10 minutes after applying sealant. Allow all sealant to cure at least 30 minutes after
assembly before filling the transmission with transmission oil.
J31
TRANSFER
TRANSFER COMPONENT DISASSEMBLY
Disassemble in the order indicated in the table.
SST
SST
SST
Stopper pin
14
Oil passage
15
Roll pin
Locknut
+ Disassembly Note
16
Spacer
17
HL shift fork
Companion flange
18
HL shift rod
19
Roll pin
20
Roll pin
21
Retainer
22
Spacer
Snap ring
23
10
24
Roll pin
11
Adjustment shim
25
12
Chain cover
26
Spring
13
Interlock pin
27
Spacer
28
J32
TRANSFER
29
Retainer
30
31
32
Bearing
33
Adjustment shim
34
Adjustment shim
35
Lock plate
36
37
O-ring
38
Thrust washer
39
Counter gear
40
Bearing
41
Spacer
42
Thrust washer
43
Oil seal
44
Snap ring
45
46
Oil seal
49 0839 425C
49 S120 710
49 F401 331
J33
TRANSFER
FRONT DRIVE SPROCKET COMPONENT
DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
SST
SST
Bearing
+ Disassembly Note
+ Assembly Note
49 0727 415
J34
TRANSFER
OUTPUT SHAFT COMPONENT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
SST
SST
10
11
Steel ball
12
Low gear
Drive sprocket
13
Needle bearing
Needle bearing
14
Roll pin
Spacer
15
HL hub sleeve
Thrust washer
16
Output shaft
J35
TRANSFER
Bearing (2W4W Clutch Hub Side) Disassembly
Note
Remove the bearing from output shaft by using the
SST.
49 0839 425C
49 0727 415
49 F401 331
49 F401 336B
J36
TRANSFER
TRANSFER COMPONENT ASSEMBLY
Assemble in the order indicated in the table.
R
R
R
R
1925
{1.92.6,
1418}
SST
128177
{1318,
94130}
SELECTIVE USE
SST
SST
R
2534
{2.53.5,
1825}
1925
{1.92.6,
1418}
1925
{1.92.6,
1418}
R
SST
SST
SELECTIVE USE
SST
1925
{1.92.6,
1418}
3747
{3.74.8,
2734}
SST
R
R
SELECTIVE USE
SST
Nm {kgfm, ftlbf}
13
Adjustment shim
+ Assembly Note
Snap ring
14
Oil seal
+ Assembly Note
15
Input shaft
Thrust washer
16
Snap ring
Spacer
17
Bearing
Bearing
18
Counter gear
19
Thrust washer
20
Chain
+ Assembly Note
10
O-ring
21
HL shift fork
11
22
Spacer
12
Lock plate
23
HL shift rod
24
Roll pin
J37
TRANSFER
Adjustment Shim Assembly Note
1. Measure the bearing bore depth (A) of the transfer
case by using vernier calipers.
25
26
Spacer
27
28
Retainer
29
Spacer
30
Spring
31
32
Retainer
33
Roll pin
34
Oil passage
35
Adjustment shim
+ Assembly Note
36
Adjustment shim
+ Assembly Note
37
Interlock pin
38
Chain cover
39
40
41
42
43
Oil seal
+ Assembly Note
44
Companion flange
45
Locknut
+ Assembly Note
46
47
Stopper pin
TRANSFER CASE
BEARING
CLEARANCE
49 G030 797
ADJUSTMENT SHIM
TRANSFER CASE
HOUSING
INPUT SHAFT
49 G026 102
Standard clearance
00.1 mm {00.0039 in}
Adjustment shim thickness
0.6 mm {0.024 in}, 0.7 mm {0.028 in},
0.8 mm {0.032 in}, 0.9 mm {0.035 in},
1.0 mm {0.039 in}, 1.1 mm {0.043 in},
1.2 mm {0.047 in}, 1.3 mm {0.051 in},
1.4 mm {0.055 in}
49 0259 749
J38
TRANSFER
Bearing (Input Shaft Gear) Assembly Note
Press the bearing on the input shaft gear by using
the SSTs.
49 0727 415
49 U027 003
J39
TRANSFER
49 U017 3A0A
49 0727 415
TRANSFER INSPECTION
Hub Sleeve and Shift Fork Inspection
1. Measure the clearance between the hub sleeve
and shift fork.
Clearance
0.380.52 mm {0.0150.020 in}
Maximum
0.8 mm {0.031 in}
J310
TRANSFER
49 U017 3A0A
49 0727 415
TRANSFER INSPECTION
Hub Sleeve and Shift Fork Inspection
1. Measure the clearance between the hub sleeve
and shift fork.
Clearance
0.380.52 mm {0.0150.020 in}
Maximum
0.8 mm {0.031 in}
J310
TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . TD1
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TD1
TECHNICAL DATA
ENGINE
F2
Item
Specification
Cylinder head
Height
(mm {in})
(mm {in})
(mm {in})
Standard
91.9592.05 {3.6213.624}
Maximum
grinding
0.20 {0.008}
Maximum
0.15 {0.006}
Maximum
0.15 {0.006}
Maximum
grinding
0.20 {0.008}
Margin thickness
IN
EX
(mm {in})
Standard
Minimum
Standard
Minimum
Standard
Maximum
Standard
Maximum
Standard
IN
Valve length
(mm {in})
EX
IN
Valve stem diameter
(mm {in})
EX
(mm {in})
(mm {in})
(mm {in})
1.21.6 {0.0480.062}
Valve seat
Valve seat contact width
Valve seat angle
(mm {in})
IN
45
EX
45
Standard
Maximum
TD1
TECHNICAL DATA
Item
Specification
Valve spring
H: 41.0 mm
{1.614 in} (CARB)
H Inner: 36.5 mm
{1.437 in}
Outer: 41.0 mm
{1.614 in} (CIS)
H: 41.0 mm
{1.614 in} (CARB)
240.37272.03 {24.5127.74,53.9361.02}
EX
H Inner: 36.5 mm
{1.437 in}
Outer: 41.0 mm
{1.614 in} (CIS)
IN
Maximum
EX
Maximum
IN
Pressing
g force at valve spring
g
height H
(N {kgf, lbf})
Outofsquare
(mm {in})
Valve seal
Depth L
(mm {in})
Camshaft
Camshaft runout
(mm {in})
Maximum
0.03 {0.0012}
IN
Standard
EX
Standard
Standard
Minimum
(mm {in})
Journal diameter
(mm {in})
Standard
No.1, 5
No.2, 3, 4
Maximum
End play
lay
(mm {in})
0.15 {0.006}
Standard
0.080.16 {0.003150.00629}
Maximum
0.20 {0.008}
(mm {in})
0 {0}
Standard
Standard
Standard
(mm {in})
Cylinder block
Standard
301.43301.57 {11.86811.872}
Height
(mm {in})
Maximum
grinding
0.20 {0.008}
Distortion
(mm {in})
Maximum
0.15 {0.006}
TD2
TECHNICAL DATA
Item
Cylinder bore diameter
[M
[Measure
the
h cylinder
li d bore
b
at
70 mm {2.76 in} below the to
top
surface]
(mm {in})
Specification
Standard
86.00086.019 {3.38593.3865}
86.25086.269 {3.39573.3964}
86.50086.519 {3.40563.4062}
Wear limit
(mm {in})
0.15 {0.006}
Piston
Piston diameter
[M
[Measured
d at 90 to pin
i bore
b
axis and 18.0 mm {0.709 in}
below oil ring groove] (mm {in})
Clearance between piston and
cylinder oil
Standard
85.94385.965 {3.383583.38444}
86.19386.215 {3.393423.39428}
86.44386.465 {3.403273.40412}
Standard
0.0350.076 {0.00140.0029}
Maximum
0.15 {0.006}
Top
Standard
Second
Standard
0.0300.070 {0.00120.0027}
Oil
Standard
0.0700.160 {0.00280.0062}
Top,
Second
Maximum
0.15 {0.0059}
Oil
Maximum
(mm {in})
Piston ring
0.17 {0.0067}
Top
End g
gap
[Measured in cylinder]
(mm {in})
0.200.35 {0.0080.013}
Second
0.150.30 {0.0060.011}
Oil
0.200.70 {0.0080.027}
Maximum
1.0 {0.039}
Piston pin
Piston pin diameter
(mm {in})
Standard
21.97421.980 {0.86520.8653}
(mm {in})
Standard
21.98821.998 {0.86570.8660}
Standard
0.0370.013 {0.00140.0006}
Standard
0.0080.024 {0.000320.0094}
(mm {in})
Standard
158.45158.55 {6.2396.242}
Bending
(mm {in})
Maximum
Distortion
(mm {in})
Maximum
Standard
21.94321.961 {0.86390.8646}
Standard
0.1100.262 {0.0050.010}
Maximum
0.30 {0.012}
Connecting
g rod bearing
g size
(mm {in})
(mm {in})
Standard
1.5051.510 {0.05930.0594}
1.6301.635 {0.06420.0643}
1.7551.760 {0.06910.0692}
1.8801.885 {0.07410.0742}
Connecting
g rod bearing
g oil clearance
(mm {in})
Standard
0.0270.067 {0.00110.0026}
Maximum
0.10 {0.004}
Maximum
0.03 {0.0012}
Crankshaft
Crankshaft runout
(mm {in})
TD3
TECHNICAL DATA
Item
Specification
Standard
59.93759.955 {2.35982.3604}
59.68759.705 {2.34992.3505}
59.43759.455 {2.34012.3407}
59.18759.205 {2.33022.3309}
((mm {{in})
})
Standard
Maximum
0.10 {0.004}
No.1, 2, 4, 5: 2.0042.022 {0.078900.07960}
No.3: 2.0042.019 {0.078900.07948}
Standard
Main bearing
g size
((mm {{in})
})
No.3 bearing
g width
(mm {in})
2.1292.139 {0.083820.08421}
2.2542.264 {0.088740.08913}
2.3792.389 {0.093670.09405}
Standard
50.94050.955 {2.00562.0060}
50.69050.705 {1.99571.9962}
50.44050.455 {1.98591.9864}
50.19050.205 {1.97601.9765}
Standard
27.9427.99 {1.10001.1019}
28.0428.09 {1.10401.1060}
28.1228.17 {1.10711.1090}
28.2028.25 {1.11031.1122}
(mm {in})
Standard
0.080.18 {0.003150.00708}
Maximum
0.30 {0.012}
Timing belt
Timing belt deflection
[Applied pressure 98 N {10 kgf, 22 lbf}]
(mm {in})
(mm {in})
63.0 {2.48}
Oil pump
Clearance between inner rotor
tooth tip and outer rotor
(mm {in})
(mm {in})
Side clearance
(mm {in})
Maximum
0.18 {0.007}
Standard
0.0900.176 {0.00360.0069}
Maximum
0.20 {0.008}
Standard
0.030.09 {0.00120.0035}
Maximum
0.10 {0.004}
(mm {in})
(mm {in})
46.4 {1.827}
0 {0}
(mm {in})
TD4
00.5 {00.019}
TECHNICAL DATA
G6
Item
Specification
Cylinder head
Cylinder
y
head g
gasket contact surfaces
distortion
(mm {in})
Maximum
0.15 {0.006}
Maximum grinding
0.20 {0.008}
Maximum
0.15 {0.006}
Maximum grinding
0.20 {0.008}
(mm {in})
Valve and valve guide
Margin thickness
(mm {in})
IN
Valve length
(mm {in})
EX
IN
EX
IN
Maximum
1.0 {0.0394}
EX
Maximum
1.5 {0 .0591}
Standard
Maximum
112.215 {4.418}
Standard
113.42114.22 {4.4664.496}
Maximum
112.945 {4.447}
Standard
6.9706.985 {0.27440.2749}
Maximum
6.920 {0.2724}
Standard
6.9656.980 {0.27430.2748}
Maximum
6.915 {0.2722}
(mm {in})
(mm {in})
23.524.1 {0.9260.948}
EX
23.524.1 {0.9260.948}
(mm {in})
IN
(mm {in})
EX
1.21.6 {0.0480.062}
45
EX
IN
7.017.03 {0.27600.2767}
IN
Valve dimension
112.29113.09 {4.4214.452}
45
Standard
49.0 {1.929}
Maximum
49.6 {1.953}
Standard
49.0 {1.929}
Maximum
49.6 {1.953}
Valve spring
Pressing
g force at valve spring
g height
g H
(N {kgf, lbf})
Out-of-square
(mm {in})
IN
H: 43.0 mm
{1.69 in}
EX
H: 43.0 mm
{1.69 in}
Maximum
TD5
1.73 {0.068}
TECHNICAL DATA
Item
Specification
Camshaft
Runout
(mm {in})
IN
(mm {in})
EX
Standard
Journal diameter
(mm {in})
Minimum
(mm {in})
Standard
Maximum
0.03 {0.0012}
Standard
41.714 {1.6423}
Minimum
41.514 {1.6344}
Standard
41.988 {1.6531}
Minimum
41.788 {1.6452}
No.1, 5
29.94029.965 {1.17881.1797}
No.2, 3, 4
29.91029.935 {1.17761.1785}
No.1, 5
No.2, 3, 4
No.1, 5
(mm {in})
29.860 {1.1756}
0.0350.085 {0.00140.0033}
No.2, 3, 4
0.0650.115 {0.0260.0045}
Standard
0.020.15 {0.00080.0059}
Maximum
0.20 {0.0079}
Minimum
End play
lay
29.890 {1.1768}
0.15 {0.006}
(mm {in})
21.00021.033 {0.82680.8280}
(mm {in})
20.95920.980 {0.82520.8259}
(mm {in})
0.0200.074 {0.00080.0029}
Cylinder block
Cylinder head gasket contact surfaces distortion
(mm {in})
(mm {in})
Maximum
0.15 {0.006}
Maximum
grinding
0.20 {0.008}
Standard
92.00092.022 {3.62213.6229}
92.25092.272 {3.63193.6327}
92.50092.522 {3.64183.6425}
Wear limit
(mm {in})
0.15 {0.006}
Piston
Piston diameter
[M
[Measured
d at 90 to pin
i b
bore axis
i and
d
18 mm {0.71 in} above the bottom of
piston]
(mm {in})
Standard
91.93392.957 {3.61943.6203}
92.18392.207 {3.62933.6301}
92.43392.457 {3.63913.6400}
(mm {in})
Standard
0.0580.074 {0.00230.0029}
Maximum
0.15 {0.006}
(mm {in})
22.98823.000 {0.90510.9055}
Piston ring
Clearance between piston ring and ring groove
(mm {in})
Top
0.030.07 {0.00120.0027}
Second
0.030.07 {0.00120.0027}
Maximum
End g
gap
[Measured in cylinder]
(mm {in})
0.15 {0.0059}
Top
0.200.35 {0.0080.013}
Second
0.200.40 {0.0080.015}
Oil (rail)
0.200.70 {0.0080.027}
Maximum
1.0 {0.039}
Piston pin
Diameter
(mm {in})
22.97422.980 {0.90450.9047}
(mm {in})
(mm {in})
0.0080.026 {0.00040.0010}
TD6
TECHNICAL DATA
Item
Specification
Crankshaft
Runout
(mm {in})
Standard
59.93759.955 {2.35982.3604}
59.68759.705 {2.34992.3505}
59.43759.455 {2.34012.3407}
59.18759.205 {2.33022.3309}
Out-of-round
Crank pin
in diameter
(mm {in})
(mm {in})
50.94050.955 {2.00562.0060}
50.69050.705 {1.99571.9962}
50.44050.455 {1.98591.9864}
50.19050.205 {1.97601.9765}
(mm {in})
(mm {in})
0.03 {0.001}
Standard
0.0250.044 {0.00100.0017}
Maximum
0.08 {0.003}
Standard
2.0072.022 {0.07900.0796}
2.1322.137 {0.08400.0841}
2.2572.262 {0.08890.0890}
2.3822.387 {0.09380.0939}
0.03 {0.001}
Standard
Out-of-round
0.03 {0.0012}
(mm {in})
Standard
Maximum
0.080.18 {0.003150.00708}
0.30 {0.012}
Standard
25.9425.99 {1.0221.023}
26.0426.09 {1.0261.027}
26.1226.17 {1.0291.030}
26.2026.25 {1.0321.033}
Connecting rod
Small end inner diameter
(mm {in})
22.94322.961 {0.90330.9039}
(mm {in})
166.45166.55 {6.5546.557}
Bending
(mm {in})
Distortion
(mm {in})
Connecting
g rod bearing
g oil clearance
(mm {in})
Connecting
g rod bearing
g
thickness
(mm {in})
Standard
0.0270.067 {0.00110.0026}
Maximum
0.10 {0.0039}
Standard
1.5051.510 {0.05930.0594}
1.6301.635 {0.06420.0643}
1.7551.760 {0.06910.0692}
1.8801.885 {0.07410.0742}
(mm {in})
Standard
0.1100.262 {0.00440.0103}
Maximum
0.30 {0.012}
Balance shaft
Clearance between balance shaft and
balance shaft bore
(mm {in})
Front
0.0500.115 {0.00200.0045}
Center
0.0800.145 {0.00320.0057}
Rear
0.0800.145 {0.00320.0057}
TD7
TECHNICAL DATA
Item
Specification
Oil pump
Relief spring free length
(mm {in})
46.4 {1.827}
Standard
0.020.18 {0.0080.0070}
(mm {in})
Maximum
0.22 {0.0087}
Standard
0.1130.186 {0.00450.0073}
Maximum
0.20 {0.079}
Standard
0.0350.105 {0.00140.0041}
Maximum
0.14 {0.0055}
Side clearance
(mm {in})
Oil seal
Rear oil seal tapping amount
(mm {in})
00.5 {00.019}
(mm {in})
00.7 {00.027}
WL, WL Turbo
Item
Cylinder head
Specification
Distortion
(mm {in})
Margin thickness
(mm {in})
IN
Valve length
(mm {in})
EX
Valve and
valve guide
IN
Valve stem diameter
(mm {in})
EX
IN
1.50 {0.059}
EX
0.75 {0.030}
Standard
111.60112.10 {4.3944.413}
Minimum
111.35 {4.384}
Standard
111.50112.00 {4.3904.409}
Minimum
111.25 {4.380}
Standard
6.9706.985 {0.27450.2749}
Minimum
6.920 {0.2724}
Standard
6.9656.980 {0.27430.2748}
Minimum
(mm {in})
(mm {in})
(mm {in})
Seat angle
Valve seat
IN
Valve recession (mm {in})
EX
Valve spring
6.915 {0.2722}
7.0257.045 {0.27660.2773}
IN
14.014.5 {0.560.57}
EX
14.014.5 {0.560.57}
IN
1.62.2 {0.070.08}
EX
1.72.3 {0.070.09}
IN
45
EX
45
Standard
0.611.09 {0.0250.042}
Maximum
1.50 {0.059}
Standard
0.711.19 {0.0280.046}
Maximum
1.60 {0.063}
IN
H: 35.5 mm
{1.40 in}
EX
H: 35.5 mm
{1.40 in}
(mm {in})
IN
1.70 {0.0670}
EX
1.70 {0.0670}
TD8
TECHNICAL DATA
Item
Specification
Camshaft runout
(mm {in})
Standard
IN
WL
EX
Lobe height
(mm {in})
WL
Tur
bo
-bo
Camshaft
IN
EX
No 1 5
No.1,
Journal diameter
(mm {in})
No 2 3,
3 4
No.2,
(mm {in})
Distortion
Cylinder block
Piston
42.39542.495 {1.6701.673}
Minimum
42.045 {1.6553}
Standard
41.22141.321 {1.6231.626}
Minimum
40.871 {1.6091}
Standard
42.39542.495 {1.6701.673}
Minimum
42.045 {1.6553}
Standard
25.94025.965 {1.02131.0222}
Minimum
25.890 {1.0193}
Standard
25.91025.935 {1.02011.0210}
0.0650.111 {0.00260.0043}
Standard
0.0300.160 {0.00120.0062}
Maximum
0.200 {0.0078}
X: 0.020 {0.0008} max.
Y: 0.050 {0.0020} max.
Standard
93.00093.022 {3.66153.6622}
93.25093.272 {3.67133.6721}
93.50093.522 {3.68113.6819}
(mm {in})
0.150 {0.0059}
Standard
92.95192.977 {3.65953.6605}
93.18693.212 {3.66883.6697}
93.43693.462 {3.67863.6795}
Standard
0.0380.056 {0.00150.0022}
Maximum
0.150 {0.0059}
Top
0.060.10 {0.00240.0039}
Second
0.040.08 {0.00160.0031}
Oil
0.030.07 {0.00120.0027}
Maximum
Piston ring
End gap
g [Measured
[
in cylinder]
y
]
(mm {in})
0.150 {0.0059}
Top
0.220.32 {0.0090.012}
Second
0.320.47 {0.0130.018}
Oil (rail)
0.220.32 {0.0090.012}
Maximum
Piston pin
25.860 {1.0181}
0.0350.081 {0.00140.0031}
No.2, 3, 4
(mm {in})
Wear limit
Piston diameter measured
at 90
90 to pin
in bore axis and
19.0 mm {0.75} above the
bottom of piston
(mm {in})
42.050 {1.6555}
Standard
No.1, 5
(mm {in})
42.4042.50 {1.6701.673}
Minimum
Minimum
Diameter
(mm {in})
(mm {in})
(mm {in})
TD9
1.00 {0.039}
31.99432.007 {1.25981.2601}
0.0030.013 {0.00010.0005}
0.0120.039 {0.00050.0015}
TECHNICAL DATA
Item
Specification
Crankshaft runout
(mm {in})
Standard
66.93766.955 {2.63542.6360},
66.92066.938 {2.63472.6353} (No.3)
66.68766.705 {2.62552.6261},
66.67066.688 {2.62482.6255} (No.3)
66.43766.455 {2.61572.6163},
66.42066.438 {2.61502.6156} (No.3)
66.18766.205 {2.60582.6040},
66.17066.188 {2.60522.6058} (No.3)
Out-of-round
(mm {in})
Crankshaft
Crankpin diameter
(mm {in})
Out-of-round
Main jjournal oil clearance
Connecting
rod and
connecting
d bearing
b i
rod
Tensioner
spring
((mm {{in})
})
(mm {in})
Standard
54.94054.955 {2.16302.1635}
0.25 {0.01}
undersize
54.69054.705 {2.15322.1537}
0.50 {0.02}
undersize
54.44054.455 {2.14342.1438}
0.75 {0.03}
undersize
54.19054.205 {2.13352.1340}
(mm {in})
Standard
Maximum
0.080 {0.003}
Standard
0.0400.282 {0.00160.0111}
Maximum
0.300 {0.012}
(mm {in})
151.95152.05 {5.9835.986}
Bending
(mm {in})
Standard
0.1100.262 {0.00440.0103}
(mm {in})
Maximum
0.350 {0.037}
Connecting
g rod bearing
g oil clearance
(mm {in})
Standard
0.0310.058 {0.00130.0022}
Maximum
0.080 {0.003}
Connecting
g rod side clearance
Free length
63.0 {2.48}
Gear clearance
(mm {in})
Side clearance
(mm {in})
Oil pump
um
Plunger
spring
Free length
Standard
0.100.19 {0.0040.007}
Maximum
0.20 {0.008}
Standard
0.040.09 {0.0020.003}
Maximum
0.15 {0.006}
(mm {in})
TD10
43.8 {1.72}
TECHNICAL DATA
MANUAL TRANSMISSION
M15MD, M15MXD
Manual transmission
Item
M15MD
M15MXD
Manual transmission
Type
Transmission oil
Viscosity
SAE 75W90
Above 10 C {50 F}
SAE 80W90
Capacity
Mainshaft
Runout
(mm {in})
Clearance between
mainshaft and gear
(or bush)
(mm {in})
Maximum
0.03 {0.0012}
Wear limit
0.15 {0.006}
Reverse
idler gear and
shaft
Clearance between
reverse idler gear bush and
shaft
(mm {in})
Standard
0.020.05 {0.00080.0019}
Wear limit
0.15 {0.006}
Shift fork
and clutch hub
sleeve
Standard
0.20.3 {0.0080.011}
Wear limit
0.5 {0.020}
Synchronizer
y
ring
Clearance between
synchronizer ring and side of
gear when fitted
(mm {in})
Standard
1.5 {0.059}
Wear limit
0.8 {0.031}
Spring
Free length
(mm {in})
66.5 {2.62}
22 5 {0
22.5
{0.89}
89}
Type
Transfer oil
Viscosity
Capacity
All-season
SAE 75W90
Above 10 C {50 F}
(L {US qt, lmp qt})
SAE 80W90
2.0 {2.1, 1.8}
Standard
0.380.52
{0.0150.020}
Wear limit
0.8 {0.031}
TD11
TECHNICAL DATA
R15MD, R15MXD
Manual transmission
Item
R15MD
R15MXD
Manual transmission
Type
Transmission oil
Viscosity
Capacity
Mainshaft
SAE 75W90
(L {US qt, lmp qt})
Runout
(mm {in})
Clearance between
mainshaft and gear
(or bush)
(mm {in})
SAE 80W90
2.8 {3.0, 2.5}
Maximum
0.03 {0.0012}
Wear limit
0.15 {0.006}
Reverse
idler gear and
shaft
Clearance between
reverse idler gear bush and
shaft
(mm {in})
Standard
0.020.05 {0.00080.0019}
Wear limit
0.15 {0.006}
Shift fork
and clutch hub
sleeve
Standard
0.20.3 {0.0080.011}
Wear limit
0.5 {0.020}
Synchronizer
y
ring
Clearance between
synchronizer ring and side of
gear when fitted
(mm {in})
Standard
1.5 {0.059}
Wear limit
0.8 {0.031}
Clearance
0.8 {0.031}
Transfer
A.P.I. Service GL4 or
GL5
Type
Transfer oil
Viscosity
Capacity
All-season
SAE 75W90
Above 10 C {50 F}
(L {US qt, lmp qt})
SAE 80W90
2.0 {2.1, 1.8}
Standard
0.380.52
{0.0150.020}
Wear limit
0.8 {0.031}
TD12
SPECIAL TOOLS
SPECIAL TOOLS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . ST6
TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . ST10
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . ST15
REMOTE FREE WHEEL (4x4) . . . . . . . . . . . ST18
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ST20
ST1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ST21
ST30
ST32
ST33
ST34
ST35
SPECIAL TOOLS
Engine
Mazda Tool Number
49 L010 1A0
49 S013 102
Commercially available
Not
applicable
49 S010 1A0
Commercially available
Not
applicable
49 9014 001
Commercially available
Not
applicable
49 0636 100B
49 B012 0A2
ST2
SPECIAL TOOLS
49 S120 170
49 L012 0A0A
49 0249 010A
Commercially available
Not
applicable
49 G011 001
Commercially available
Not
applicable
49 S015 1A1
Commercially available
Not
applicable
49 S120 215A
49 S010 301
ST3
SPECIAL TOOLS
49 0259 749
Commercially available
Not
applicable
49 S010 001
49 S011 103
49 S011 102A
49 E011 1A0
49 0187 280
Commercially available
Not
applicable
ST4
SPECIAL TOOLS
49 G014 001
49 L011 2A0
49 S120 710
49 S011 103
ST5
Graphic
not
available
Graphic
not
available
SPECIAL TOOLS
Transmission
Mazda Tool Number
49 SE01 310A
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
Center Screw
205-034 (15-002)
ST6
Graphic
not
available
SPECIAL TOOLS
49 H017 101
49 1243 465A
49 0710 520
Remover, Bearing/Gear
205-310 (15-091)
49 F027 005
49 F027 007
ST7
Graphic
not
available
SPECIAL TOOLS
49 F401 331
49 0862 350
Commercially available
Not
applicable
49 F017 101
49 G030 795
ST8
Graphic
not
available
SPECIAL TOOLS
49 F401 335A
49 U027 003
49 S120 440
Screwdriver
Not
applicable
49 S017 401
Gears
Not
applicable
ST9
SPECIAL TOOLS
Transfer Box
Mazda Tool Number
49 S120 710
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
ST10
SPECIAL TOOLS
49 F401 331
Remover, Bearing/Gear
205-310 (15-091)
49 0727 415
ST11
SPECIAL TOOLS
49 0727 415
49 0727 415
49 G030 370
49 G030 797
49 G026 102
ST12
SPECIAL TOOLS
49 0258 749
49 S231 395A
49 0500 330
Graphic
not
available
Remover, Bearing/Gear
205-310 (15-091)
Depth Gauge
Commercially available
Not
applicable
49 U017 3A0A
Graphic
not
available
Commercially available
Not
applicable
49 F401 336B
ST13
SPECIAL TOOLS
49 0636 145
Remover, Bearing/Gear
205-310 (15-091)
ST14
SPECIAL TOOLS
Front Differential
Mazda Tool Number
49 M005 581
49 S120 710
49 H027 002
Remover, Bearing/Gear
205-310 (15-091)
49 0727 570
49 8531 565
49 0305 555
Preload Sleeve
205-060 (15-023)
49 0259 720
ST15
SPECIAL TOOLS
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
49 G030 338
Graphic
not
available
49 F027 004
Commercially available
Not
applicable
49 F027 005
ST16
Graphic
not
available
SPECIAL TOOLS
49 U027 003
49 G030 795
49 0350 555
49 0350 565
49 0350 567
49 0350 568
ST17
Graphic
not
available
SPECIAL TOOLS
49 U027 006
49 U027 004
49 U027 004
49 M005 796
Graphic
not
available
Graphic
not
available
Graphic
not
available
49 0813 215 A
Commercially available
Not
applicable
49 W027 001
ST18
SPECIAL TOOLS
49 U027 007
ST19
Graphic
not
available
SPECIAL TOOLS
Front Axle
Mazda Tool Number
49 T028 3A0
49 H033 101
49 B025 001
49 F019 001
ST20
SPECIAL TOOLS
Rear Axle
Mazda Tool Number
49 S120 645A
49 0603 635A
49 S126 204
Remover, Bearing/Gear
205-311 (15-092)
T57L-500-B
308-047 (T77F-1102-A)
ST21
Graphic
not
available
Graphic
not
available
SPECIAL TOOLS
205-D064 (D84L-1123-A)
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
205-456
205-110 (T76P-4020-A10)
ST22
SPECIAL TOOLS
205-457
ST23
SPECIAL TOOLS
205-105 (T76P-4020-A3)
ST24
SPECIAL TOOLS
205-109 (T76P-4020-A9)
ST25
SPECIAL TOOLS
205-111 (T76P-4020-A11)
205-090 (T75L-1165-B)
ST26
SPECIAL TOOLS
205-024 (T76P-4616-A)
205-092 (T57L-1165-DA)
205-007 (T56T-4676-B)
ST27
SPECIAL TOOLS
49 S126 205
49 S126 208
Remover, Bearing/Gear
205-310 (15-091)
49 S120 748
Commercially available
Not
applicable
49 F027 004
Commercially available
Not
applicable
49 U027 003
ST28
SPECIAL TOOLS
49 H025 001
Commercially available
Not
applicable
T83T-4205-A1
Not essential
Not
applicable
T83T-4205-A2
Not essential
Not
applicable
T83T-4205-A3
Not essential
Not
applicable
T83T-4205-A4
Not essential
Not
applicable
ST29
SPECIAL TOOLS
Steering
Mazda Tool Number
49 T028 3A0
49 1232 670 A
49 H002 671
49 G032 3A4
49 T028 3A0
49 B032 304
ST30
SPECIAL TOOLS
49 0180 510B
49 0223 695E
ST31
Graphic
not
available
SPECIAL TOOLS
Brakes
Mazda Tool Number
49 0259 770B
Commercially available
Not
applicable
49 U043 0A0
Commercially available
Not
applicable
49 0221 600C
49 0208 701A
49 B043 001
49 EC43 003A
Commercially available
Not
applicable
49 B043 004
Commercially available
Not
applicable
ST32
SPECIAL TOOLS
Suspension
Mazda Tool Number
49 U034 2AO
49 U039 615
ST33
Graphic
not
available
SPECIAL TOOLS
Air Conditioning
Mazda Tool Number
49 C081 0A0A
Commercially available
Not
applicable
49 C061 012
Commercially available
Not
applicable
49 C061 013
Commercially available
Not
applicable
49 H061 005
ST34
SPECIAL TOOLS
General
Mazda Tool Number
49 0305 870A
Commercially available
Not
applicable
49 9140 074
49 9200 146
49 9200 147
49 0259 888A
Commercially available
Not
applicable
49 01670280
Commercially available
Not
applicable
49 N088 0A0
Commercially available
Not
applicable
ST35
SPECIAL TOOLS
49 L018 901
Commercially available
Not
applicable
ST36
CONTENTS
Title
Section
General Information
RANGER
Repair
Manual
Engine
FOREWORD
This Manual has been prepared to
provide information covering normal
service repairs and maintenance for the
RANGER SERIES.
B1
WL, WL Turbo
B2
F2
B3
D
Cooling System
E
G6
F1
WL, WL Turbo
F2
F2 CIS
F3
F2 CARB
F4
Clutch
G6
Lubrication System
GI
Manual Transmission
M15MD
M15MXD
R15MD
R15MXD
Transfer
ST
J1
J2
J3
Propeller Shaft
Steering System
Braking System
Suspension
Body
Technical Data
TD
Special Tools
ST
100001
100001
100001
WF0 LMDD30WW
WF0 DMFE40WW
WF0 LMFE40WW
100001
100001
100001
WF0 BMF]30WW
WF0 BME]30WW
WF0 DMF]30WW
WF0 DME]30WW
WF0 LMF]30WW
WF0 LME]30WW
WF0 BMD]30WW
WF0 BMC]30WW
WF0 DMD]30WW
WF0 DMC]30WW
WF0 LMD]30WW
WF0 LMC]30WW
WF0 BMB]30WW
WF0 BMA]30WW
WF0 DMB]30WW
WF0 DMA]30WW
WF0 LMB]30WW
WF0 LMA]30WW
WF0 LMBE40:W
WF0 LMBD20:W
WF0 LMDD20:W
WF0 LMDE40:W
WF0 LMFE40:W
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
WF0 BMFE40WW
WF0 BMEE40WW
WF0 DMFE40WW
WF0 DMEE40WW
WF0 LMFE40WW
WF0 LMEE40WW
WF0 BMD]40WW
WF0 BMC]40WW
WF0 DMD]40WW
WF0 DMC]40WW
WF0 LMD]40WW
WF0 LMC]40WW
WF0 BMB]40WW
WF0 BMA]40WW
WF0 DMB]40WW
WF0 DMA]40WW
WF0 LMB]40WW
WF0 LMA]40WW
WF0 BMBD20:W
WF0 LMAD20:W
WF0 BMDE40:W
WF0 BMDD20:W
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
100001
MNC BSB]30WW
MNC BSA]30WW
MNC BSB]3WWW
MNC BSA]3WWW
100001
100001
100001
100001
MNC BSB]30WW
MNC BSA]30WW
100001
100001
RELATED MATERIALS
RANGER Training Manual . . . . . . . . . . . . . . . . . . . . . . . .
RANGER Overhaul Manual . . . . . . . . . . . . . . . . . . . . . . .
RANGER Wiring Diagrams
(European, General specs. (L.H.D.)) . . . . . . . . . . . . . .
RANGER Wiring Diagrams
(European, General specs. (R.H.D.)) . . . . . . . . . . . . . .
RANGER Standard Repair Times
(Australian, European, General specs.) . . . . . . . . . . .
RANGER Body Measurement Manual
(Australian, European, General specs.) . . . . . . . . . . .
F3261099A
F1612099A
F1613099A
F1614099A
F2181098K
F3271098K
GENERAL INFORMATION
HOW TO USE THIS MANUAL . . . . . . . . . . . . . . .
RANGE OF TOPICS . . . . . . . . . . . . . . . . . . . . .
SERVICING PROCEDURE . . . . . . . . . . . . . . .
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADVISORY MESSAGES . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING PROCEDURE . . . . . .
TEXT SEQUENCE . . . . . . . . . . . . . . . . . . . . . . .
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUNDAMENTAL PROCEDURES . . . . . . . . . . . .
PROTECTION OF THE VEHICLE . . . . . . . . . .
PREPARATION OF TOOLS AND
MEASURING EQUIPMENT . . . . . . . . . . . . . .
SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . .
DISCONNECTION OF THE NEGATIVE
BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . .
REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . .
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
INSPECTION DURING REMOVAL,
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
ARRANGEMENT OF PARTS . . . . . . . . . . . . . .
CLEANING OF PARTS . . . . . . . . . . . . . . . . . . .
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
GI11
GI11
GI11
GI13
GI13
GI13
GI16
GI17
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI18
GI19
GI19
GI19
GI19
GI19
GI10
GI10
GI10
GI10
GI11
GI11
GI11
GI13
GI15
GI15
GI15
GI16
GI17
GI17
GI18
GI18
GI18
GI20
GI21
GI23
SERVICING PROCEDURE
Inspection, Adjustment
D The procedures for inspections and adjustments
are divided into steps. Important points in regard
to the location and contents of the procedures are
explained in detail and are shown in the
illustrations.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
GI1
Procedure
Removal/Installation
Portion
Inspection After
Installation Portion
SHOWS SPECIAL
SERVICE TOOL (SST)
FOR SERVICE OPERATION
SHOWS APPLICATION
POINTS OF GREASE, ETC.
SHOWS TIGHTENING
TORQUE
SPECIFICATIONS
SHOWS DETAILS
SHOWS TIGHTENING
TORQUE UNITS
SHOWS THERE
ARE REFERRAL
NOTES FOR SERVICE
SHOWS SPECIAL
SERVICE TOOL (SST)
NO.
SHOWS REFERRAL
NOTES FOR
SERVICE
GI2
SST
TROUBLESHOOTING PROCEDURE
Basic Flow of Troubleshooting
Appropriate new
engine oil or
gear oil
Appropriate new
brake fluid
Apply automatic
transaxle/
transmission
fluid
Appropriate new
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
Appropriate SST
ADVISORY MESSAGES
Youll find several Warnings, Cautions, Notes,
Specifications and Upper and lower limits in this
manual.
Warning
D A Warning indicates a situation in which
serious injury or death could result if the
warning is ignored.
Caution
D A Caution indicates a situation in which
damage to the vehicle could result if the
caution is ignored.
Note
D A Note provides added information that will
help you to complete a particular procedure.
Specification
D The values indicate the allowable range when
performing inspections or adjustments.
Upper and lower limits
D The values indicate the upper and lower limits
that must not be exceeded when performing
inspections or adjustments.
SECTION F ONLY
ACTUAL TROUBLESHOOTING PROCEDURES
SECTION K
ONLY
IF
MENTIONED
SECTION F
ONLY
On-board diagnosis
D The service codes are important hints for repairing
malfunctions that are difficult to simulate. By
following the service code, perform the inspection
to quickly and accurately diagnose the malfunction.
D The self-diagnostic function is used during
inspection. When a service code is shown,
specifying the cause of a malfunction, continue the
inspection according to the items indicated by the
self-diagnostic function.
Engine tune-up (Section F)
D Any necessary adjustments are made after starting
the engine.
Basic inspection (Section K)
D The basic inspection is performed to quickly
narrow down the possible causes after a
malfunction occurs regardless of the symptoms.
ST The basic inspection is performed to also locate
the region of many malfunction symptoms.
Diagnostic index
D The diagnostic index lists the symptoms of the
malfunctions. Select the symptoms pertaining or
most closely pertaining to the actual malfunction.
Quick diagnosis chart (If mentioned)
D The quick diagnosis chart lists the diagnosis and
inspection procedures to be performed specifically
relating to the cause of the malfunction.
Symptom troubleshooting
D Symptom troubleshooting quickly determines the
location of the malfunction according to the type of
symptoms.
GI3
GI4
ST
GI5
TROUBLESHOOTING
HINTS describes
possible point of
malfunction.
TROUBLE SYMPTOM
INSPECTION
describes an
inspection (method) to
quickly determine the
failed part.
TEXT SEQUENCE
D The text sequence is as indicated by the arrows shown below.
Example:
GI6
UNITS
D The actual converted values for 2.7 kgf/cm2 are
UNITS
Electric current
A (ampere)
Electric power
W (watt)
Electric resistance
W (ohm)
Electric voltage
V (volt)
Length
mm (millimeter)
in (inch)
kPa (kilo pascal)
Negative pressure
Positive pressure
Number of
revolutions
Torque
Volume
ml (milliliter)
cc (cubic centimeter)
cu in (cubic inch)
fl oz (fluid ounce)
Weight
g (gram)
oz (ounce)
ST
Rounding off
D Converted values are rounded off to the same
number of places as the SI unit value. For
example, if the SI unit value is 17.2 and the value
after conversion is 37.84, the converted value will
be rounded off to 37.8.
Upper and lower limits
D When the data indicates upper and lower limits, the
converted values are rounded down if the SI unit
value is an upper limit and rounded up if the SI unit
value is a lower limit. Therefore, converted values
for the same SI unit value may differ after
conversion. For example, consider 2.7 kgf/cm2 in
the following specifications:
210260 kPa {2.12.7 kgf/cm2, 3038 psi}
270310 kPa {2.73.2 kgf/cm2, 3945 psi}
GI7
FUNDAMENTAL PROCEDURES
REMOVAL OF PARTS
D While correcting a problem, try also to determine
its cause. Begin work only after first learning which
parts and subassemblies must be removed and
disassembled for replacement or repair. After
removing the part, plug all holes and ports to
prevent foreign material from entering.
FUNDAMENTAL PROCEDURES
PROTECTION OF THE VEHICLE
D Always be sure to cover fenders, seats, and floor
areas before starting work.
DISASSEMBLY
D If the disassembly procedure is complex, requiring
many parts to be disassembled, all parts should be
marked in a place that will not affect their
performance or external appearance and identified
so that reassembly can be performed easily and
efficiently.
ARRANGEMENT OF PARTS
D All disassembled parts should be carefully
arranged for reassembly.
D Be sure to separate or otherwise identify the parts
to be replaced from those that will be reused.
GI8
FUNDAMENTAL PROCEDURES
D Oil should be applied to the moving components of
parts.
D Specified oil or grease should be applied at the
CLEANING OF PARTS
D All parts to be reused should be carefully and
thoroughly cleaned using the appropriate method.
SXU00012
Warning
D Using compressed air can cause dirt and
other particles to fly out, causing injury to
the eyes. Wear protective eye wear
whenever using compressed air.
ADJUSTMENT
D Use suitable gauges and/or testers when making
adjustments.
SXU00013
REASSEMBLY
D Standard values, such as torques and certain
adjustments, must be strictly observed in the
reassembly of all parts.
If removed, these parts should be replaced with new
ones:
1
Oil seals
Gaskets
O-rings
Lockwashers
Cotter pins
Nylon nuts
ST
SXU00014
HOSE CLAMPS
D When reinstalling, position the hose clamp in the
original location on the hose, and squeeze the
clamp lightly with large pliers to ensure a good fit.
SXU00011
SXU00015
GI9
Formula
kgfm
kgfm
[L/(L+A) ]
kgfcm
kgfcm
ftlbf
ftlbf
[L/(L+A) ]
inlbf
inlbf
[L/(L+A) ]
[L/(L+A) ]
SXU00016
VISE
D When using a vise, put protective plates in the jaws
of the vise to prevent damage to parts.
SXU00017
DYNAMOMETER
When test-running a vehicle on dynamometer :
D Place a fan, preferably a vehicle-speed
proportional type, in front of the vehicle.
D Connect an exhaust gas ventilation unit.
D Cool the exhaust pipes with a fan.
D Keep the area around the vehicle uncluttered.
D Watch the water temperature gauge.
GI10
ELECTRICAL SYSTEM
Disconnecting Connectors
D When disconnecting two connectors, grasp the
connectors, not the wires.
ELECTRICAL SYSTEM
ELECTRICAL PARTS
Battery Cable
D Before disconnecting connectors or removing
electrical parts, disconnect the negative battery
cable.
SXU00020
Wiring Harness
D To remove the wiring harness from the clip in the
engine room, pry up the hook of the clip using a
flathead screwdriver.
SXU00021
Locking Connector
D When locking connectors, listen for a click that will
indicate they are securely locked.
CONNECTORS
Data Link Connector
D Insert the probe into the service hole when
connecting a jumper wire to the data link
connector.
Caution
D Inserting a jumper wire probe into the data
link connector terminal may damage the
terminal.
SXU00022
Inspection
1. When a tester is used to check for continuity or to
measure voltage, insert the tester probe from the
wiring harness side.
SXU00019
SXU00023
GI11
ELECTRICAL SYSTEM
Caution
D To prevent damage to the terminal, wrap a
thin wire around the lead before inserting it
into the terminal.
SXU00027
SXU00024
Terminals
Inspection
D Pull lightly on individual wires to check that they
are secured in the terminal.
Wiring Harness
Wiring color codes
D Two-color wires are indicated by a two-color code
symbol.
D The first letter indicates the base color of the wire
and the second the color of the stripe.
CODE
COLOR
CODE
COLOR
Black
Orange
BR
Brown
Pink
Green
Red
GY
Gray
Violet
Blue
White
LB
Light Blue
Yellow
LG
Light Green
B/R
BR/Y
BLACK
SXU00025
Replacement
D Use the appropriate tools to remove a terminal as
shown. When installing a terminal, be sure to insert
it until it locks securely.
D Insert a thin piece of metal from the terminal side
of the connector, and then, with the terminal
locking tab pressed down, pull the terminal out
from the connector.
RED
BROWN
YELLOW
SXU00028
Fuse
Replacement
D 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.
D Be sure that the negative battery cable is
disconnected before replacing a main fuse.
TYPE A
TYPE B
SXU00026
WGIWXX0049E
GI12
ELECTRICAL SYSTEM
D When replacing a pullout fuse, use the fuse puller.
Other
Vehicle harnessside connectors, such as the DLC2,
have to be viewed from the terminal side.
WGIWXX0050E
WGIWXX0102E
WGIWXX0100E
SXU00032
Voltmeter
D The DC voltmeter is used to measure circuit
voltage. A voltmeter with a range of 15 V or more
is used by connecting the positive (+) probe (red
lead wire) to the point where voltage is to be
measured and the negative () probe (black lead
wire) to a body ground.
WGIWXX0101E
GI13
ELECTRICAL SYSTEM
VOLTMETER
BLACK LEAD
Ohmmeter
D The ohmmeter is used to measure the resistance
between two points in a circuit, and to check for
continuity and short circuits.
Caution
D Do not connect the ohmmeter to any circuit
to which voltage is applied. This will
damage the ohmmeter.
RED LEAD
GROUND
GROUND LINE
OHMMETER
GI14
SXU00034
JACKING POSITIONS
REAR
Warning
D Improperly jacking a vehicle is dangerous.
The vehicle can slip off the jack and cause
serious injury. Use only the correct front
and rear jacking positions and block the
wheels.
Use safety stands to support the vehicle after it has
been lifted.
FRONT
REAR
REAR
GI15
TOWING
(With Manual Transmission)
If the transmission, rear axle, and steering system are
not damaged, the vehicle may be towed on all four
wheels. If any of these components are damaged, use
wheel dollies.
TOWING
Proper lifting and towing are necessary to prevent
damage to the vehicle.
Government and local laws must be followed.
Wheel dollies
Wheel dollies
(4 4 Model)
1. Put the transfer case in 2H.
2. Set the transfer case at 2H and the hubs
at FREE.
Caution
D Do not tow with sling-type equipment. This
could damage your vehicle. Use wheel-lift
or flatbed equipment.
(All Models)
1. Set the transmission in neutral.
2. Turn the engine switch to ACC position.
3. Release the parking brake.
D Remember that power assist for the brakes
GI16
TOWING
TOWING HOOKS
Caution
D The towing hooks should be used only in
an emergency (e.g. to get the vehicle out of
a ditch or a snow bank).
D When using the towing hooks, always pull
the cable or chain in a straight direction
with respect to the hook. Apply no
sideways force.
FRONT
4 4
TIEDOWN HOOKS
Caution
D Do not use the hook loops under the front
for towing. They are designed ONLY for
tying down the vehicle when it is being
transported. Using them for towing will
damage the bumper.
FRONT
4 2
4 4
GI17
IDENTIFICATION NUMBER
LOCATIONS
VEHICLE IDENTIFICATION NUMBER
F2 CIS
F2 CARB
WL, WL Turbo
GI18
ZCF4016W200
GI19
VIN CODE
VIN CODE
VIN CODE
VUE0035456
GI20
NEW STANDARDS
NEW STANDARDS
D Following is a comparison of the previous standard and the new standard.
New Standard
Abbreviation
AP
Name
Previous Standard
Abbreviation
Accelerator Pedal
Accelerator Pedal
ACL
Air Cleaner
Air Cleaner
A/C
Air Conditioning
Air Conditioning
Barometric Pressure
Atmospheric Pressure
BARO
B)
VB
Battery Voltage
Brake Switch
Stoplight Switch
Calibration Resistor
Corrected Resistance
CAC
Intercooler
CLS
Feedback System
CTP
Fully Closed
Idle Switch
CPP
Clutch Position
CIS
CMP
sensor
CS sensor
CKP
sensor
EGI
CSP
sensor
#6
DLC
Diagnosis Connector
DTM
Test Mode
DTC
Service Code(s)
DI
Distributor Ignition
Spark Ignition
DLI
Distributorless Ignition
Direct Ignition
EI
Remark
Name
#6
#1
Electronic Ignition
ECT
Water Thermo
EM
Engine Modification
Engine Modification
EVAP
Evaporative Emission
Evaporative Emission
EGR
FC
Fan Control
Fan Control
FF
Flexible Fuel
Flexible Fuel
4GR
Fourth Gear
Overdrive
#3
#6
FSO
solenoid
FCV
GEN
Generator
Alternator
GND
Ground
Ground/Earth
HO2S
Oxygen Sensor
IAC
IDM Relay
Injection Pump
FIP
Pulse Generator
IAT
KS
Knock Sensor
Knock Sensor
MIL
GI21
#2
With heater
#6
#6
NEW STANDARDS
New Standard
Abbreviation
MAP
Name
Previous Standard
Abbreviation
MAF
sensor
Airflow Sensor
MFL
OBD
On-Board Diagnostic
Diagnosis/Self-Diagnosis
OL
Open Loop
Open Loop
OC
Catalytic Converter
O2S
Oxygen Sensor
Oxygen Sensor
PNP
Park/Neutral Position
Park/Neutral Range
Remark
Name
Main Relay
PSP
PCM
ECU
Pulsed
injection
NE Sensor
#6
Injection with
air pump
Reed Valve
PAIR
AIR
SAPV
SFI
Shift Solenoid A
Shift Solenoid B
Shift Solenoid C
3GR
Third Gear
3rd Gear
TWC
Catalytic Converter
Throttle Body
Throttle Body
Throttle Sensor
TB
TP sensor
TCV
TCC
Lock-up Position
TCM
ATF Thermosensor
TR
Inhibitor Position
TC
Turbocharger
Turbocharger
Voltage Regulator
VSS
VR
VAF sensor
WUTWC
WOT
TCV
IC Regulator
Airflow Meter
Catalytic Converter
Fully Open
#6
#4
#6
#5
GI22
ABBREVIATIONS
ABBREVIATIONS TABLE
A/C
Air conditioner
LSPV
ABDC
Motor
ABS
MAX
Maximum
ACC
Accessories
MFW
Manual freewheel
ATDC
MIN
Minimum
ATF
OFF
Switch off
BBDC
ON
Switch on
BTDC
PCV
CARB
Carburetor
P/S
Power steering
CM
Control Module
PID
Parameter identification
ELR
RF
Right front
EX
Exhaust
RFW
Remote freewheel
FIP
RH
Right hand
HI
High
R.H.D.
HLA
RR
Right rear
HU
Hydraulic unit
SAS
IG
Ignition
SST
IN
Intake
SW
Switch
INT
Intermittent
TDC
LF
Left front
TNS
LH
Left hand
2WD
2 wheel drive
L.H.D.
WDS
LO
Low
4WD
4 wheel drive
LR
Left rear
4 2
4 wheel 2 drive
LSD
4 4
4 wheel 4 drive
P23
ENGINE
(WL, WL Turbo, WL3, WLT3)
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B21
DRIVE BELT INSPECTION . . . . . . . . . . . . . . . . B21
DRIVE BELT ADJUSTMENT . . . . . . . . . . . . . . . B22
VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . B22
VALVE CLEARANCE
INSPECTION/ADJUSTMENT . . . . . . . . . . . . . B22
COMPRESSION INSPECTION . . . . . . . . . . . . . . . B24
TIMING BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B25
TIMING BELT REMOVAL/INSTALLATION . . . . B25
CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . B27
CYLINDER HEAD GASKET
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . B27
ROCKER ARM . . . . . . . . . . . . . . . . . . . . . . . . . . B2 10
ROCKER ARM REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . B2 10
FRONT OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . B212
FRONT OIL SEAL REPLACEMENT . . . . . . . B212
REAR OIL SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . B214
REAR OIL SEAL REPLACEMENT . . . . . . . . B214
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B215
ENGINE REMOVAL/INSTALLATION . . . . . . B215
ENGINE DISASSEMBLY/ASSEMBLY . . . . . B216
DRIVE BELT
Deflection
(mm {in})
Drive belt
*New
Used
Limit
Generator
7.09.0
{0.280.35}
8.010.0
{0.320.39}
16.0
{0.63}
5.06.2
{0.200.24}
6.06.5
{0.240.25}
11.3
{0.44}
9.511.8
{0.380.46}
11.012.5
{0.440.49}
18.0
{0.71}
A/C
MEASURING
POINT
GENERATOR
CRANKSHAFT
PULLEY
MEASURING
POINT a
A/C
CRANKSHAFT
PULLEY
A/C
COMPRESSOR
49 9200 020A
MEASURING
POINT b
WHEN MEASURED
WHEN SET
B21
VALVE CLEARANCE
(N {kgf, lbf})
Drive belt
*New
Used
Limit
Generator
442637
{4565,
99143}
383539
{3955,
86121}
177
{18, 40}
A/C
403519
{4153,
91116}
354431
{3644,
8096}
181
{18.5, 41}
GENERATOR
B
ENGINE
FRONT
A 1925
{1.92.6,
1418}
WATER
PUMP
GENERATOR
3246
A {3.24.7,
CRANKSHAFT
PULLEY
2433}
Caution
D 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.
A/C
3851
{3.85.3, A
2838}
A/C
COMPRESSOR
CRANKSHAFT
PULLEY
Nm {kgfm, ftlbf}
ZCF2212W002
B22
VALVE CLEARANCE
FEELER
GAUGE
ADJUST
SCREW
LOCKNUT
B23
COMPRESSION INSPECTION
COMPRESSION INSPECTION
Warning
D When the engine and the oil are hot, they
can badly burn. Turn off the engine and wait
until they are cool.
1. Verify that the battery is fully charged. Recharge it
if necessary. (Refer to Section G, CHARGING
SYSTEM, BATTERY INSPECTION, Battery.)
2. Warm up the engine to the normal operating
temperature.
3. Stop the engine and allow it to cool off for about 10
minutes.
Warning
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent fuel from
spurting out of the injection nozzle hole, do
not ground the FCV (fuel cut valve) terminal.
4. Disconnect the FCV (fuel cut valve) connector.
5. Remove all the glow plugs. (Refer to Section F2,
INTAKE AIR SYSTEM, GLOW PLUG
REMOVAL/INSTALLATION.)
6. Install the SSTs into the glow plug hole.
49 S010 1A0
49 S013 102
Engine
WL, WL Turbo
Standard
Minimum
B24
TIMING BELT
3. Remove the tensioner and tensioner spring.
TIMING BELT
Free length
63.0 mm {2.48 in}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
FREE LENGTH
Timing belt
+ Removal Note
+ Installation Note
CAMSHAFT
PULLEY
Caution
D Forcefully twisting the belt, turning it inside
out, or allowing oil or grease on it will
damage the belt and shorten its life.
TENSIONER
SPRING
TENSIONER
TIMING MARK
FAULTY
FAULTY
Caution
D Overtensioning of the timing belt can cause
breakage of the belt and the camshaft.
FAULTY
ROTATION
ARROW
FAULTY
CAMSHAFT
PULLEY
TENSIONER
SPRING
TENSIONER
TIMING MARK
FIP PULLEY
FIP PULLEY
B25
TIMING BELT
Timing belt deflection
9.010.0 mm {0.360.39 in} at
98 N {10 kgf, 22 lbf}
TENSIONER
LOCK BOLT
DEFLECTION
CHECKING
POINT
CAMSHAFT
PULLEY
TENSIONER
SPRING
TENSIONER
FIP PULLEY
ST
B26
5.08.8 Nm
{5090 kgfcm,
4478 inlbf}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
Nm {kgfm, ftlbf}
B27
Drive belt
Cylinder head
LENGTH
Tightening torque
29 Nm {3.0 kgfm, 22 ftlbf}
A
Thickness
2.03.0 mm {0.080.11 in}
16.0 mm
{0.63 in}
40.5 mm
{1.59 in}
ENGINE
FRONT
PAINT MARK
90105
48.5 mm
{1.91 in}
90105
9.0 mm
{0.35 in}
ST
Cylinder Head Bolt Installation Note
1. Measure the length of each bolt. Replace the bolt if
necessary.
PAINT MARK
7. Tighten bolts A.
Standard
length
Maximum
length
101.2101.8
{3.9854.007}
102.5 {4.035}
113.2113.8
{4.4574.480}
114.5 {4.508}
B28
Tightening torque
1819 Nm {1.82.0 kgfm, 13.114.4 ftlbf}
A
ENGINE
FRONT
B
B29
ROCKER ARM
ROCKER ARM
ROCKER ARM REMOVAL/INSTALLATION
Caution
D 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. (SeeVALVE CLEARANCE
INSPECTION/ADJUSTMENT.)
1. Disconnect the negative battery cable.
2. Remove the EGR pipe (WL3,WLT3). (See EGR SYSTEM REMOVAL/INSTALLATION.)
3. Remove the air intake pipe and breather chamber. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR
SYSTEM REMOVAL/INSTALLATION.)
4. Remove the timing belt. (Refer to TIMING BELT, TIMING BELT REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
5.08.8 Nm
{5090 kgfcm,
4478 inlbf}
11.314.2 Nm
{115145 kgfcm, 100125 inlbf}
1620 {1.62.1, 1215}
R
SST
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
3041 {3.04.2, 2230}
ST
Nm {kgfm, ftlbf}
Seal plate
+ Installation Note
Camshaft
+ Removal Note
+ Installation Note
Rocker arm
+ Installation Note
Pivot
B210
ROCKER ARM
Camshaft Pulley Removal Note
D Hold the camshaft by using a wrench on the cast
hexagon.
ENGINE
FRONT
ENGINE
FRONT
as
0.51.0 mm
{0.020.03 in}
Dimension A
04 mm {00.1 in}
HAMMER
CYLINDER
HEAD
OIL SEAL
B211
Nm {kgfm, ftlbf}
Drive belt
Crankshaft pulley
+ Removal Note
+ Installation Note
49 S011 102A
B212
RAG
CE2220W003
49 S010 301
00.4 mm
{00.01 in}
HAMMER
49 S011 102A
Caution
(WL3, WLT3)
B213
SST
RAG
REAR COVER
HAMMER
B214
ENGINE
ENGINE
ENGINE REMOVAL/INSTALLATION
Warning
D Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep
sparks and flames away from fuel.
D Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and
damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety
Procedures. (Refer to Section F2, FUEL SYSTEM, FUEL PRESSURE AND SERVICING FUEL
SYSTEM.)
1. Remove the air intake pipe. (Refer to Section F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the battery. (Refer to Section G, CHARGING SYSTEM, BATTERY REMOVAL/INSTALLATION.)
3. Remove the radiator. (Refer to Section E, RADIATOR, RADIATOR REMOVAL/INSTALLATION.)
4. Remove the front pipe. (Refer to Section F2, EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the transmission. (Refer to section J1J2, TRANSMISSION, TRANSMISSION
REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Adjust the drive belt deflection. (Refer to DRIVE BELT, DRIVE BELT ADJUSTMENT.)
9. Bleed air in the fuel line. (Refer to Section F2, FUEL SYSTEM, FUEL FILTER AIR BLEEDING.)
10. Start the engine and
(1) Inspect the engine oil, engine coolant, and fuel leakage.
(2) Inspect the idle speed. (Refer to Section F2, ENGINE TUNE-UP, IDLE SPEED PREPARATION, Idle Speed
Adjustment.)
11. Perform a road test.
1925
{1.92.6,
1418}
9.914.7 Nm
{100150 kgfcm,
86.8130 inlbf}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
2030
{2.03.1, 1522}
Nm {kgfm, ftlbf}
Cooling fan
Drive belt
3
4
Accelerator cable
A/C compressor
+ Removal Note
Engine
+ Removal/Installation Note
B215
ENGINE
A/C Compressor Removal Note
D Remove the A/C compressor with the pipe still
connected. Position the A/C compressor so that it
is out of the way.
P/S Oil Pump Removal Note
D Remove the P/S oil pump with the oil hose still
connected. Position the P/S oil pump so that it is
out of the way.
Engine Removal/Installation Note
D Install the engine hanger (JE48 10 561C) to the
cylinder head by using bolt (99794 0820) or (M8
1.25, 6T, length 20 mm {0.79 in}) as shown.
ENGINE DISASSEMBLY/ASSEMBLY
1. Remove the intake-air system. (Refer to Section
F2, INTAKE-AIR SYSTEM, INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
2. Remove the exhaust system. (Refer to Section F2,
EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.)
3. Remove the oil cooler. (Refer to Section D, OIL
COOLER, OIL COOLER
REMOVAL/INSTALLATION.)
4. Disassemble in the ordre indicated in the table.
5. Assemble in the reverse order of disassembly.
Tightening torque
1925 Nm {1.92.6 kgfm, 1418 ftlbf}
3851
{3.85.3,
2838}
ENGINE
FRONT
3246
{3.24.7,
2433}
3851
{3.85.3,
2838}
Nm {kgfm, ftlbf}
Drive belt
Generator
Idler
B216
LUBRICATION SYSTEM
OIL PRESSURE INSPECTION . . . . . . . . . . . . . . . .
ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OIL INSPECTION . . . . . . . . . . . . . . . . . .
ENGINE OIL REPLACEMENT . . . . . . . . . . . . . . .
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL FILTER REPLACEMENT . . . . . . . . . . . . . . . .
D1
D2
D2
D2
D2
D2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL COOLER REMOVAL/INSTALLATION . . . . .
OIL COOLER BODY INSPECTION . . . . . . . . . .
OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OIL PAN REMOVAL/INSTALLATION . . . . . . . . .
D3
D3
D4
D4
D4
G6
: 305402 kPa
{3.14.1 kgf/cm2, 4558 psi}
[3,000 rpm]
WL
: 452529 kPa
{4.65.4 kgf/cm2, 6676 psi}
[3,000 rpm]
WL Turbo : 402480 kPa
{4.14.9 kgf/cm2, 5969 psi}
[3,000 rpm]
1.02.0 mm
{0.0400.078 in}
49 0187 280
4.06.0 mm
{0.160.23 in}
WL,
WL TURBO
D1
ENGINE OIL
OIL FILTER
49 9014 001
F2
G6
WL, WL
Turbo
Oil replacement
3.9
{4.1, 3.4}
4.5
{4.8, 4.0}
5.6
{5.9, 4.9}
4.2
{4.4, 3.7}
4.7
{5.0, 4.4}
6.3
{6.7, 5.5}
Total
(dry engine)
4.6
{4.9, 4.0}
5.5
{5.8, 4.8}
6.7
{7.1, 5.9}
D2
OIL COOLER
OIL COOLER
OIL COOLER REMOVAL/INSTALLATION
G6, WL, WL Turbo
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to section E, ENGINE COOLANT, ENGINE COOLANT REPLACEMENT.)
3. Remove the turbocharger. (Refer to section F2, EXHAUST SYSTEM, EXHAUST SYSTEM
REMOVAL/INSTALLATION.) (WL Turbo model.)
4. Remove the oil filter. (Refer to OIL FILTER, OIL FILTER REPLACEMENT.)
5. Remove in the order shown in the figure.
6. Install in the reverse order of removal.
7. Fill the radiator with the specified amount and type of engine coolant. (Refer to section E, ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)
8. Inspect the engine oil level. (Refer to ENGINE OIL, ENGINE OIL INSPECTION.)
9. Start the engine and inspect for engine coolant leakage.
G6
Water hose
Nut
Oil cooler
WL, WL TURBO
R
3049 {3.05.0, 2236}
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
1925 {1.92.6, 1418}
R
1925 {1.92.6, 1418}
R
Nm {kgfm, ftlbf}
Dipstick pipe
Radiator hose
Thermostat case
Insulator
D3
Oil cooler
OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}
3851
{3.85.3,
2838}
3851
{3.85.3,
2838}
Nm {kgfm, ftlbf}
D4
Gusset plate
Oil pan
+ Removal Note
+ Installation Note
OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}
3851
{3.85.3,
2838}
3851
{3.85.3,
2838}
Nm {kgfm, ftlbf}
D4
Gusset plate
Oil pan
+ Removal Note
+ Installation Note
OIL PAN
OIL PAN REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine oil. (Refer to ENGINE OIL,
ENGINE OIL REPLACEMENT.)
3. Remove in the order shown in the figure.
4. Install in the reverse order of removal.
5. Fill with the specified amount and type of engine
oil. (Refer to ENGINE OIL, ENGINE OIL
REPLACEMENT.)
6. Start the engine and inspect for engine oil leakage.
F2, G6
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
3041
{3.04.2, 2230}
3851
{3.85.3,
2838}
3851
{3.85.3,
2838}
Nm {kgfm, ftlbf}
D4
Gusset plate
Oil pan
+ Removal Note
+ Installation Note
OIL PAN
Oil Pan Installation Note
WL, WL TURBO
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.
94115
{9.511.8, 6985}
CRACKS
OLD SEALANT
5580
{5.68.2,
4159}
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
Crossmember (4WD)
Oil pan
+ Removal Note
+ Installation Note
Thickness
2.03.0 mm {0.080.11 in}
OIL PAN
D5
COOLING SYSTEM
ENGINE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE COOLANT LEVEL INSPECTION . . . .
ENGINE COOLANT REPLACEMENT . . . . . . . .
ENGINE COOLANT LEAKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR CAP INSPECTION . . . . . . . . . . . . . .
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RADIATOR REMOVAL/INSTALLATION . . . . . . .
E1
E1
E1
E2
E3
E3
E3
E3
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTAT REMOVAL/INSTALLATION . . . .
THERMOSTAT INSPECTION . . . . . . . . . . . . . . .
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PUMP REMOVAL/INSTALLATION . . . .
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING FAN REMOVAL/INSTALLATION . . .
COOLING FAN INSPECTION . . . . . . . . . . . . . . .
E4
E4
E5
E6
E6
E7
E7
E7
ENGINE COOLANT
Warning
Removing the radiator cap or loosening the
radiator drain plug while the engine is
running, or when the engine and radiator
are hot is dangerous. Scalding coolant and
steam may shoot out and cause serious
injury. It may also damage the engine and
cooling system.
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 youre sure all the pressure is gone,
press down on the cap still using a cloth
turn it, and remove it.
When the engine and the engine coolant are
hot, they can badly burn. Turn off the
engine and wait until they are cool before
draining the engine coolant.
ENGINE COOLANT LEVEL INSPECTION
1. Remove the radiator cap.
2. Verify that the coolant level is near the radiator filler
neck.
3. Verify that the coolant level in the radiator reservoir
is between the FULL and LOW marks.
4. Add coolant if necessary.
ENGINE COOLANT REPLACEMENT
1. Drain the coolant in the radiator reservoir.
2. Remove the radiator cap and loosen the radiator
drain plug.
TYPE A
DRAIN
PLUG
TYPE B
E1
ENGINE COOLANT
SPECIFIC
GRAVITY
Caution
Applying more than 103 kPa {1.05 kgf/cm2,
14.9 psi} (F2) or 122 kPa {1.25 kgf/cm2, 17.7
psi} (G6, WL, WL Turbo) can damage the
hoses, fittings, and other components, and
cause leakage.
COOLANT PROTECTION
1,100
1,090
1,080
49 9200 147
1,070
1,060
50%
40%
1,050
30%
1,040
1,030
49 9200 146
1,020
1,010
1,000
0
10
0
10
20
30
40
50
60
70
80
90
{ 14 } { 32 } { 50 } { 68 } { 86 } { 104 }{ 122 } { 140 } { 158 } { 176 } { 194 }
COOLANT TEMPERATURE C { F }
Water
Coolant
Gravity
at 20C
{68F}
65
35
1,054
55
45
1,066
45
55
1,078
Volume percentage
Coolant protection
E2
RADIATOR CAP
RADIATOR
RADIATOR REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indiacted in the table.
3. Install in the reverse order of removal.
4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)
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.
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 youre sure all the pressure is gone,
press down on the cap still using a cloth
turn it, and remove it.
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
1826
{1.82.7, 1419}
1826
{1.82.7,
1419}
Nm {kgfm, ftlbf}
49 9200 147
Radiator hose
Radiator cowling
Radiator
ST
E3
THERMOSTAT
THERMOSTAT
THERMOSTAT REMOVAL/INSTALLATION
1. Drain the engine coolant. (Refer to ENGINE
COOLANT, ENGINE COOLANT REPLACEMENT.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Fill the radiator with the specified amount and type
of engine coolant. (Refer to ENGINE COOLANT,
ENGINE COOLANT REPLACEMENT.)
Thermostat cover
Thermostat
+ Installation Note
WL, WL TURBO
F2
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
1925
{1.92.6, 1418}
R
1925
{1.92.6, 1418}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Thermostat cover
Thermostat
+ Installation Note
Dipstick pipe
Thermostat cover
Thermostat
+ Installation Note
G6
JIGGLE PIN
1925
{1.92.6, 1418}
AA
1925
{1.92.6, 1418}
WL, WL Turbo
Install the thermostat into the thermostat cover,
aligning the projection on the gasket to the
thermostat cover as shown.
Nm {kgfm, ftlbf}
E4
THERMOSTAT
GASKET
PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION
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 the valve
Initial-opening temperature
F2: 83.589.5 C {183193 F}
G6: 86.589.5 C {188193 F} (Main valve)
83.586.5 C {183187 F} (Sub valve)
WL, WL Turbo: 8084 C {176183 F}
Full open temperature
F2, G6
: 100 C {212 F}
WL, WL Turbo : 95 C {203 F}
Full open lift
G6
: 8.0 mm {0.31 in} min. (Main valve)
1.5 mm {0.06 in} min. (Sub valve)
F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
ST
E5
THERMOSTAT
GASKET
PROJECTION
THERMOSTAT COVER
THERMOSTAT INSPECTION
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 the valve
Initial-opening temperature
F2: 83.589.5 C {183193 F}
G6: 86.589.5 C {188193 F} (Main valve)
83.586.5 C {183187 F} (Sub valve)
WL, WL Turbo: 8084 C {176183 F}
Full open temperature
F2, G6
: 100 C {212 F}
WL, WL Turbo : 95 C {203 F}
Full open lift
G6
: 8.0 mm {0.31 in} min. (Main valve)
1.5 mm {0.06 in} min. (Sub valve)
F2, WL, WL Turbo: 8.5 mm {0.33 in} min.
E5
WATER PUMP
WATER PUMP
WL, WL TURBO
1925
{1.92.6, 1418}
F2
1922
{1.92.3, 1416}
Nm {kgfm, ftlbf}
1925
{1.92.6, 1418}
3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}
G6
1922
{1.92.2, 1416}
Nm {kgfm, ftlbf}
E6
Water pump
Idler
COOLING FAN
COOLING FAN
COOLING FAN REMOVAL/INSTALLATION
1. Remove the drive belt.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Adjust the drive belt (generator) deflection. (Refer
to Section B1, B2, B3, DRIVE BELT, DRIVE BELT
ADJUSTMENT.)
Nm {kgfm, ftlbf}
Cooling fan
E7
F21
ENGINE TUNE-UP
2. Verify that the idle speed is within the specification.
ENGINE TUNE-UP
ENGINE TUNE-UP PREPARATION
WL/WLTURBO
1. Warm up the engine to normal operating
temperature.
2. Turn the all electrical loads off.
3. Connect a tachometer.
Specification
General (L.H.D.) : 760800 (780$20) rpm
Europe and UK : 700740 (720$20) rpm
Caution
D Turning the idle switch (Europe and UK
only) with its connector connected can
break the harness. Be sure to disconnect
the connector when turning the idle switch
more than one rotation.
Caution
D Connecting to the wrong DLC terminal may
cause a malfunction. Carefully connect only
to the specified terminal.
IDLE SWITCH
XME3908W005
IAS
ADJUSTING
SCREW B
ADJUSTING
SCREW C
LOCKNUT B
WL Turbo
1. Perform Engine tune-up preparation.
ACTUATOR B
F22
ENGINE TUNE-UP
WL, WL Turbo
ADJUSTING
SCREW B
ADJUSTING
SCREW C
LOCKNUT B
ACTUATOR A
ACTUATOR B
Specification
12001500 (1,350$150) rpm
4. If not within the specification, do as follows;
Loosen the locknut B.
Adjust the idle-up speed by turning the
adjusting screw B.
Tighten the locknut B.
Tightening torque
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
5. Release actuator B to atmosphere and apply
vacuum of 53.3 kPa {400 mmHg, 15.8 inHg} or
over to actuator A, and measure the idle-up speed.
Specification
WL vehicle: 805855 (830$25) rpm
WL Turbo, WL (Europe only):
825875 (850$25) rpm
6. If not as specified, adjust the idle-up speed by
turning adjusting screw C.
WL3/WLT3 (EURO 3 REGULATION MODELS)
1. Perform Engine tune-up preparation.
2. Inspect the idle-up speed.
Verify that the idle-up speed is within the
specification under the following load condition.
(Excludes temporary idle speed drop just after
the electrical loads turn on.)
D If not as specified, replace the PCM.
Specification
Idle-up speed (rpm)
Load condition
A/C ON
Neutral (MT)
P range (AT)
725775 (750 25)
F23
ENGINE TUNE-UP
INJECTION TIMING ADJUSTMENT
Warning
D Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
D Fuel line spills and leaks are dangerous.
Fuel can ignite and cause serious injuries
or death and damage. Fuel can also irritate
skin and eyes. To prevent this, always
observe the Fuel Line Safety Procedures,
Fuel Hose Installation.
INDICATOR PIN
BTDC 0
(YELLOW MARK)
Caution
D After tightening the FIP mounting nuts and
bolt after loosening them, be sure to
inspect the timing belt tension. If the belt
tension is not inspected, the timing belt and
the camshaft may become damaged. (Refer
to Section B2, TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt
Installation Note.)
1. Remove the injection pipes (Refer to FUEL
SYSTEM, FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION.)
2. Remove the cooling fan (Refer to Section E,
COOLING FAN, COOLING FAN
REMOVAL/INSTALLATION.)
3. Turn the crankshaft pulley at slow rotation to align
the timing mark (BTDC 0 : yellow mark) with
indicator pin.
Specification
0.951.05 mm {0.0380.041 in}
(1.0$0.05 mm {0.039$0.019 in})
9. If not as specified, adjust by loosening the FIP
mounting nut and bolt and turn the FIP.
10. Tighten the FIP mounting nuts and then the bolt.
Tightening torque
1925 Nm {1.92.6 kgfm, 1418 ftlbf}
MOUNTING NUT
INDICATOR PIN
BTDC 0
(YELLOW MARK)
MOUNTING BOLT
ATDC 10 (WHITE MARK)
F24
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM
VACUUM HOSE ROUTING DIAGRAM
TO POWER
BRAKE UNIT
WL
FICD SOLENOID
VALVE No.1
FICD SOLENOID
VALVE No.2
FICD ACTUATOR
VACUUM PUMP
WL TURBO
TO POWER
BRAKE UNIT
FICD SOLENOID
VALVE No.2
TO RFW
ACTUATOR
4WD ONLY
FICD SOLENOID
VALVE No.1
EGR VALVE
EGR SOLENOID
VALVE
FICD ACTUATOR
VACUUM PUMP
F25
INTAKE-AIR SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
ZCF4010W004
F26
INTAKE-AIR SYSTEM
INTAKE-AIR SYSTEM REMOVAL/INSTALLATION
Warning
D When the engine and intake-air system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the intake-air system.
WL
1. Disconnect the negative battery cable.
2. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
7.910.7 Nm
{80110 kgfcm,
7095 inlbf}
18.725.4
{1.92.6,
13.818.8}
2.02.9 Nm
{2030 kgfcm, 1826 inlbf}
2.02.9 Nm
{2030 kgfcm,
1826 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
18.725.4
{1.92.6,
13.818.8}
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
Nm {kgfm, ftlbf}
Fresh-air duct
Air cleaner
Air hose
Resonance chamber
Intake manifold
F27
INTAKE-AIR SYSTEM
WL Turbo
1. Disconnect the negative battery cable.
2. Drain the engine coolant from radiator. (Refer to Section E, COOLING SYSTEM, ENGINE COOLANT
REPLACEMENT.)
3. Remove the front mud guard. (Refer to Section S, FRONT FENDER PANEL, FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
4. Remove the injection pipe. (Refer to FUEL SYSTEM, INJECTION NOZZLE REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Refill the engine coolant to radiator.
(Refer to Section E, COOLING SYSTEM, ENGINE COOLANT REPLACEMENT.)
STEP 1
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
2.02.9 Nm
{2030 kgfcm, 1826 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
4.9 Nm
{50 kgfcm, 43 inlbf}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
Fresh-air duct
Air cleaner
Air hose
Air hose
Air hose
F28
INTAKE-AIR SYSTEM
STEP 2
1925
{1.92.6, 1418}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
1925
{1.92.6, 1418}
Nm {kgfm, ftlbf}
Intake manifold
F29
INTAKE-AIR SYSTEM
TURBOCHARGER INSPECTION
Wastegate Actuator Inspection
Caution
D Compressed air used in the workshop is
highly pressurized and can damage the
actuator. Adjust the air pressure with a
transformer, and inspect the actual
pressure by using an air blower before
actual use. Stop blowing air if the rod
moved.
MIRROR
TURBOCHARGER
ROD
MIRROR
Note
D To make work accurate, use a penlight to
inspect.
TURBOCHARGER
F210
INTAKE-AIR SYSTEM
5. If the turbine wheel is interfering with the housing,
it is likely that one or more fins are damaged,
cracked or bent. Replace the turbocharger.
Note
D Grinding marks on the shaft are normal. This
mark is for adjusting the shaft balance at the
factory.
Caution
D Carbon on the glow plug can damage the
glow plug and engine. Remove carbon on
the glow plug and fitting holes before
installing the glow plug.
1. Wrap tape on both a 5.5 mm and a 5.7 mm drills,
starting from the tip to a point 50 mm from the tip.
GRINDING MARK
ZCF4010W002
ZCF4010W001
Glow plug
(SeeGlow plug removal note)
(SeeGlow plug installation note)
(SeeGlow plug cleaning before installation note)
F211
INTAKE-AIR SYSTEM
GLOW PLUG INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Remove the glow plug cord. (SeeGLOW PLUG
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the glow plug
terminal and the cylinder head using an ohmmeter.
YYJ4010W105
: Continuity
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
GLOW PLUG
RELAY
Step
B+
GND
Short circuit
D Glow plug relay connector terminal A (1-pin: R/B)
and battery to GND.
D Glow plug relay connector terminal A (2-pin) and
PCM connector terminal O to GND.
D Glow plug relay connector terminal A (1-pin: R)
and PCM connector terminal I to GND.
4. Repair or replace faulty areas.
5. Install the glow plug relay.
F212
INTAKE-AIR SYSTEM
GLOW PLUG CORD INSPECTION
1. Remove the glow plug cord. (Refer to GLOW
PLUG REMOVAL/INSTALLATION.)
2. Verify that the glow plug cord is not broken or bent.
3. Verify there is continuity at both ends of the glow
plug cord.
4. If there is no continuity, replace the glow plug cord.
R
1925
{1.92.6,
1418}
1925
{1.92.6, 1418}
R
5.0 Nm {50 kgfcm, 44
inlbf}
Idling knob
Idling cable
Accelerator cable
+ Installation Note
Spring pin
Clevis pin
E clip
Pin
Bushing
10
Push rod
11
Clevis
12
Nut
13
Nut
14
Pedal component
+ Installation Note
Nm {kgfm, ftlbf}
F213
Accelerator cable
+ Installation Note
Accelerator pedal
INTAKE-AIR SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
R.H.D.
ZCF4010W013
L.H.D.
ZCF4010W005
Spring pin
Clevis pin
E clip
Pin
Bushing
Push rod
10
Clevis
11
Nut
12
Nut
13
14
ZCF4010W006
F214
Accelerator pedal
Idle switch
(SeeNO TAG IDLE SWITCH ADJUSTMENT)
INTAKE-AIR SYSTEM
ACCELERATOR CABLE
INSPECTION/ADJUSTMENT
1. Warm up the engine, then turn the engine switch
off.
2. Measure the free play of the accelerator cable.
LOCKNUT
Free play
13 mm {0.040.11 in}
3. If not as specified, adjust by turning locknut.
IDLING KNOB, IDLING CABLE INSPECTION
General (R.H.D.)
1. Verify that the accelerator pedal is in the idling
position, when the idling knob is not turned.
2. Verify that the accelerator pedal moves in the
direction that engine speed increases, when the
idling knob is turned to the right.
3. Verify that the accelerator pedal returns to the
idling position when the idling knob is turned to the
left.
IDLING KNOB
F215
FUEL SYSTEM
FUEL SYSTEM
BEFORE REPAIR PROCEDURE
Warning
D Fuel vapor is hazardous. It can very easily
ignite, causing serious injury and damage.
Always keep sparks and flames away from
fuel.
D Fuel in the fuel system is under high pressure
F216
FUEL SYSTEM
FUEL TANK REMOVAL/INSTALLATION
Warning
D Repairing a fuel tank that has not been properly steam cleaned can be dangerous. Explosion or fire
may cause death or serious injury. Always properly steam clean a fuel tank before repairing it.
1. Disconnect the negative battery cable.
2. Complete the BEFORE REPAIR PROCEDURE. (Refer to FUEL SYSTEM, BEFORE REPAIR PROCEDURE.)
3. Remove the drain plug and drain the fuel from the fuel tank.
4. Remove the rear flap.
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Complete the AFTER REPAIR PROCEDURE. (Refer to FUEL SYSTEM, AFTER REPAIR PROCEDURE.)
STRETCH CAB 2WD, DOUBLE CAB 2WD
1.12.1 Nm {1122 kgfcm, 1019 inlbf}
WITH BOX
1.12.1 Nm
{1122 kgfcm,
1019 inlbf}
SEAL
RUBBER
R
2.54.6 Nm
{2547 kgfcm,
2240 inlbf}
2.53.5 Nm
{2536 kgfcm,
2226 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
1622
{1.62.3, 1216}
1622
{1.62.3, 1216}
1.12.1 Nm
{1122 kgfcm,
1019 inlbf}
WITHOUT BOX
3246
{3.24.7, 2433}
EUROPE
DRAIN PLUG
2632 {2.63.3, 1923}
3246 {3.24.7, 2433}
EXCEPT EUROPE
Nm {kgfm, ftlbf}
F217
FUEL SYSTEM
SEAL
R
RUBBER
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
R
WITH BOX
1.12.1 Nm
{1122 kgfcm,
1019 inlbf}
R
2.54.6 Nm
{2547 kgfcm,
2240 inlbf}
2.53.5 Nm
{2536 kgfcm,
2226 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
11.816.6 Nm
{120170 kgfcm,
105147 inlbf}
1622
{1.62.3, 1216}
1.12.1 Nm
{1122 kgfcm,
1019 inlbf}
WITHOUT BOX
1622
{1.62.3, 1216}
3246
{3.24.7, 2433}
EUROPE
DRAIN HOSE
2632 {2.63.3, 1923}
EXCEPT EUROPE
Nm {kgfm, ftlbf}
Joint hose
+ Installation Note
Evaporative hose
+ Installation Note
Breather hose
+ Installation Note
Rollover valve
10
Fuel-filler pipe
3
4
Under guard
11
Dust cover
Fuel hose
+ Installation Note
12
Fuel tank
13
14
Evaporative chamber
F218
FUEL SYSTEM
Evaporative Hose Installation Note
D Fit each hose onto the respective fittings within the
specification, and install clamps as shown.
Length
Evaporative hose: 25 mm {0.98 in}
912 mm
{0.360.47 in}
10 mm {0.39 in}
912 mm
{0.360.47 in}
VIEW A
EVAPORATIVE HOSE
VIEW B
10 mm {0.39 in}
FUEL HOSE
Nm {kgfm, ftlbf}
Length
Breather hose: 25 mm {0.98 in}
10 mm {0.39 in}
BREATHER HOSE
F219
FUEL SYSTEM
Connector
Fuel hose
Priming pump
Fuel filter
+ Assembly Note
Sedimentor switch
+ Assembly Note
Drain plug
Fuel warmer
Float
Continuity
Up
Yes
Down
No
UP
DOWN
FLOAT
SEDIMENTOR SWITCH
ENGINE SWITCH
A
F220
FUEL SYSTEM
pump auxiliary parts are possibly
malfunctioning:
Short circuit
D GND circuit (Sedimentor switch connector
terminal B and body GND to power circuit)
D Power circuit (Sedimentor switch connector
terminal A and engine switch connector
terminal C to GND)
1. Electronic governor
2. Timer position sensor
3. Control sleeve (CS) sensor
4. Fuel temperature sensor
5. Timer control valve (TCV)
ZCF4012W003
Specification
Water temperature C {F}
Resistance ()
20 {68}
0.51.5
F221
FUEL SYSTEM
ZCF4012W007
ZCF4012W005
Terminal
Part name
Terminal
TCV ()
TCV (+)
Part name
CS sensor
CS sensor (+)
CS sensor ()
FSO solenoid
Electronic governor ()
ZCF4012W010
Terminal
Part name
TCV body ()
ZCF4012W006
Terminal
Part name
F222
FUEL SYSTEM
8. Complete the AFTER REPAIR PROCEDURE.
(Refer to FUEL SYSTEM, AFTER REPAIR
PROCEDURE.)
9. Inspect injection timing. (Refer to ENGINE
TUNE-UP, INJECTION TIMING ADJUSTMENT.)
10. Check the timing belt tension. (Refer to Section B2,
TIMING BELT, TIMING BELT
REMOVAL/INSTALLATION, Timing Belt Installation
Note.)
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
2.43.4 Nm
{2535 kgfcm,
2230 inlbf}
FIP PULLY
LOCKNUT
5968
{6.07.0,
4450}
A
1925
{1.92.6,
1418}
A
R
2529
{2.53.0, 1921}
49 S120 215A
1925
{1.92.6, 1418}
Nm {kgfm, ftlbf}
Injection pipe
Accelerator cable
Fuel hose
Connector
Vacuum hose
FIP
+ Removal Note
10
Key
R
R
2.43.4 Nm
{2535 kgfcm,
2230 inlbf}
2529
{2.53.0, 1921}
Nm {kgfm, ftlbf}
F223
Injection pipe
Injection nozzle
+ Installation Note
FUEL SYSTEM
Nozzle washer
Corrugated gasket
+ Installation Note
Caution
D Fuel and fuel tank used for the nozzle tester
must be kept clean. Otherwise, foreign
material may get stuck between the nozzle
and the nozzle tester, causing damage.
INJECTION NOZZLE
FIP
COLOR RING
Caution
D The injection port is very small so it must
be kept clean. Otherwise, foreign material
may get stuck in the injection nozzle,
causing damage.
Note
D Adding/subtracting 0.02 mm {0.0008 in}
thickness shim increases/decreases the
starting pressure approx. 470 kPa {4.8
kgf/cm2, 68 psi}.
ADJUSTING SHIM
2949
{3.05.0,
2236}
Nm {kgfm, ftlbf}
Ring
Shim
Nozzle spring
Spring seat
Spacer
Needle valve
+ Assembly Note
Nozzle body
Retaining nut
Atomization
1. Connect the injection nozzle to the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Lower the handle several times as quickly as
possible so that a pulsating whistling sound is
heard, and note the atomization pattern.
(1) Uniform, proper atomization
(2) Incorrect injection angle and direction
(1)
(2)
F224
FAULTY
ANGLE
FAULTY
DIRECTION
FUEL SYSTEM
4. If necessary, disassemble and clean or replace the
injection nozzle.
Nozzle Leakage
1. Connect the injection nozzle to the nozzle tester.
2. Bleed the air by pumping the nozzle tester handle
several times.
3. Apply 8.8 MPa {90 kgf/cm2, 1,280 psi} pressure to
the injection nozzle, and inspect for fuel leakage
from the nozzle spray port.
CORRECT
WRONG
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect for continuity between the terminals under
the following conditions.
NEEDLE VALVE
ZCF4012W008
NOZZLE
BODY
ZCF4012W009
F225
FUEL SYSTEM
D If as specified, carry out the Circuit
Open/Short Inspection.
Specification
FSO temperature (C {F})
Resistance (ohm)
1333 {55.491.4}
7.59.7
Offvehicle inspection
Operation inspection
1. Remove the FSO solenoid.
2. Connect the battery positive voltage to the FSO
solenoid terminal and ground the FSO solenoid
body.
3. Verify that the valve stem is drawn into the valve.
D If not as specified, replace the FSO solenoid.
D If as specified, carry out the Circuit
Open/Short Inspection.
ZCF4012W004
Specification
ZCF4012W002
Terminal
Atmospheric
temperature (C {F})
Resistance (ohm)
IL
1828 {64.482.4}
0.580.84
ZCF4012W001
Short circuit
D Injection pump connector A terminal J and PCM
connector terminal 4W to GND.
FCV
1525
{1.52.6, 1118}
Nm {kgfm, ftlbf}
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect for resistance between the terminals under
the following conditions.
D Consult authorized BOSCH parts distributor for
repair if the electronic governor is possibly
malfunctioning.
F226
FUEL SYSTEM
2. If the engine does not stop, carry out the following
inspection.
Off-vehicle Inspection
1. Disconnect the negative battery cable.
2. Remove the FCV.
3. Connect the battery positive voltage to the FCV
terminal and GND the FCV body,
4. Verify that the FCV stem is drawn into the FCV.
Step
Port
B+
GND
1
2
B
GND
A
B
B+
C
123456567
AIR FILTER
ENGINE SWITCH
A
ENGINE SWITCH
Short circuit
D GND circuit (FCV body and engine switch
connector terminal IG1 to GND)
D Power circuit (FCV connector terminal and
engine switch connector terminal IG1 to GND)
6. Repair or replace faulty areas.
7. Install the FCV.
8. Reconnect the negative battery cable.
Short circuit
D GND circuit (FICD solenoid valve No.1 connector
terminal B and PCM connector terminal IG1)
D GND circuit (FICD solenoid valve No.2 connector
terminal B and PCM connector terminal P)
D Power circuit (FICD solenoid valve No.1 connector
terminal A and engine switch connector terminal
IG1 to GND)
D Power circuit (FICD solenoid valve No.2 connector
terminal A and engine switch connector terminal
IG1 to GND)
5. Repair or replace faulty areas.
F227
FUEL SYSTEM
D If no continuity is detected, perform resistance
inspection.
ZCF4012W004
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the FIP connector (8pin terminal).
3. Verify that there is continuity between the FIP
connector terminal D and TCV body.
FIP
Resistance inspection
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector D.
D Consult authorized BOSCH parts distributor for
repair if the timer control valve (TCV) is
possibly malfunctioning.
D If as specified, carry out the Circuit
Open/Short Inspection.
Specification
Terminal
Atmospheric
temperature (C {F})
Resistance (ohm)
AB
1030 {5086}
10.311.7
ZCF4012W010
F228
EXHAUST SYSTEM
EXHAUST SYSTEM
EXHAUST SYSTEM INSPECTION
1. Start the engine and inspect each exhaust system component for exhaust gas leakage.
2. If leakage is found, repair or replace as necessary.
EXHAUST SYSTEM REMOVAL/INSTALLATION
Warning
D When the engine and exhaust system are hot, they can badly burn. Turn off the engine and wait
until they are cool before removing the exhaust system.
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
WL
EUROPE and UK
Nm {kgfm, ftlbf}
Tail pipe
Front pipe
Main silencer
Exhaust manifold
L.H.D.)
D OC (Europe and UK)
F229
EXHAUST SYSTEM
WL TURBO
EUROPE and UK
Nm {kgfm, ftlbf}
Tail pipe
Joint pipe
Main silencer
Turbocharger
+ Removal Note
Oil pipe
+ Installation Note
Exhaust manifold
Front pipe
F230
EMISSION SYSTEM
ROLLOVER VALVE INSPECTION
1. Remove the rollover valve. (Refer to FUEL
SYSTEM, FUEL TANK
REMOVAL/INSTALLATION.)
2. Blow from port A and verify that there is airflow.
Tightening torque
2435 Nm {2.43.6 kgfm, 1826 ftlbf}
OIL PIPE
WATER PIPE
F231
EMISSION SYSTEM
EGR VALVE INSPECTION
WL Turbo for Europe and UK
Airflow Inspection
B
GND
Note
D Perform the following test only when directed.
1. Remove the EGR valve.
2. Inspect for airflow between 1 and 2 when vacuum
is applied using a vacuum pump as shown in the
figure.
A
B
B+
AIR FILTER
Airflow
Below 21.325.3
{160 190, 6.3 7.4}
Yes
Except above
No
Airflow
Yes
Except above
No
Short circuit
D EGR solenoid valve connector terminal A and PCM
connector terminal 1R.
5. Repair or replace faulty areas.
6. Install the EGR solenoid valve connector.
Terminal
A
B+
GND
: Airflow
Port
ZCF4016W004
1
2
F232
EMISSION SYSTEM
ZCF4016W003
ZCF4016W005
ZCF4016W006
ZCF4016W004
ZCF4016W005
YTA4114W105
ZCF4016W001
F233
EMISSION SYSTEM
D If as specified, carry out the Circuit
Open/Short Inspection.
Rod movement
Starts to move
Fully pulled
YTA4114W105
ZCF4016W002
ZCF4016W007
F234
EMISSION SYSTEM
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
1925
{1.92.6, 1418}
1925
{1.92.6, 1418}
3540
{3.54.0,
2529}
Nm {kgfm, ftlbf}
EGR pipe
EGR valve
ZCF4016W009
EGR pipe
EGR valve
F235
EMISSION SYSTEM
EGR system installation note
1. Temporarily tighten bolts and nuts in order of A to
E.
2. Tighten the bolts and nuts in order of A to E.
ZCF4016W010
F236
CONTROL SYSTEM
CONTROL SYSTEM
COMPONENT PARTS
WL TURBO
WL TURBO
*1:
*2:
10
A/C relay
11
TCV*2
Engine switch
12
PCM
13
Glow plug
14
NE sensor
15
Idle switch*2
16
Starter
ECT sensor
17
DLC
F237
CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
ZCF4040W045
PCM
14
MAF/IAT sensor
15
16
Boost sensor
17
ECT sensor
18
TDC sensor
19
A/C relay
20
DLC
Idle switch
21
Battery
Clutch switch
22
A/C switch
10
23
Engine switch
11
24
Starter
12
25
13
TCV
26
Neutral switch
F238
CONTROL SYSTEM
POWERTRAIN CONTROL MODULE (PCM)
REMOVAL/INSTALLATION
WL / WLT Models
1. Disconnect the battery negative cable.
2. Remove the drivers side front side trim. (Refer to
Section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
8.912.7 Nm
{90130 kgfcm, 78112 inlbf}
PCM connector
PCM
F239
CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
1. Disconnect the battery negative cable.
2. Remove the passengers side front side trim.
3. Remove in the order indicated in the table.
ZCF4040W050
PCM cover
PCM connector
PCM
Bracket
F240
CONTROL SYSTEM
Set bolt removal note
1. Using a chisel and a hammer, cut a groove on the
head of the set bolt so that a screwdriver can be
inserted.
2. Loose the set bolt by using an impact screwdriver
or pliers.
ZCF4040W051
ZCF4040W052
F241
CONTROL SYSTEM
Terminal Voltage (Reference)
Europe and UK
S
T
Terminal
A
A*1
B
C
Q
R
Signal
Constant
voltage
System
ground
FICD
control
O
P
E C
Connected
to
D Control
lever
position
sensor
D EGR
valve
position
sensor
O M K I G E C A
P N L J H F D B
Test condition
Engine
switch
ON
OFF
Idle
Ground
Constant
Idle
Start
ECT
Engine
switch
(Starter)
ECT sensor
Engine
switch is on.
While cranking
ECT is 20C {68F}.
After warm-up
Engine
speed
(Input)
NE sensor
A/C
(With A/C)
Temperature
control dial
H
H*1
*1:
Idle (Control
lever open
or close)
Idle switch
Engine
switch is on.
Below
1.0
Action
D Inspect PCM.
D Inspect related harness.
Approx.
5.0
Voltage
(V)
Approx.
5.0
Europe and UK
F242
Below
1.0
Below
1.0
B+
Below
1.0
Approx.
10
Approx.
3.1
Approx.
0.8
Approx.
0
Approx.
0.05
B+
Below
1.0
B+
Below
1.0
valve No.1.
+ FUEL SYSTEM, FICD
SOLENOID VALVE No.1,
No.2 INSPECTION
D Inspect related harness
D Inspect related harness
temperature sensor.
+ ECT SENSOR
INSPECTION
D Inspect related harness
D Inspect NE sensor.
+ NE SENSOR
INSPECTION
D Inspect related harness
D Inspect microswitch.
+ Section U, CONTROL
SYSTEM, HEATER
CONTROL UNIT
INSPECTION
D Inspect fan switch.
+ Section U, CONTROL
SYSTEM, HEATER
CONTROL UNIT
INSPECTION
D Inspect related harness
CONTROL SYSTEM
Terminal
Signal
Glow plug
voltage
Connected
to
Glow plug
Test condition
ECT is below 60C
{140F}.
ECT is
above 60C
{140F}.
J*1
L*1
L*2
Power
supply
Engine
switch
Engine
switch
Engine
switch is on.
Approx.
4.2
Approx.
0.81.5
Engine
switch
Engine
switch
N*1
A/C control
(With A/C)
B+
Idle
OFF
Below
1.0
ON
B+
B+
Idle
B+
Below
1.0
Below
1.0
A/C relay
B+
B+
Idle
B+
tion sensor.
+ CONTROL LEVER
POSITION SENSOR
INSPECTION
D Inspect related harness.
D Inspect related harness.
6.97.1
N*2
B+
A/C is operating
M
Below
1.0
B+
Power
supply
A/C relay
Below
1.0
B+
B+
ON
B+
Below
1.0
Instrument
cluster
Action
Below
1.0
OFF
Engine
speed (Output)
A/C control
(With A/C)
Voltage
(V)
B+
*1:
Europe and UK
*2: Turkey and General (R.H.D., L.H.D.)
F243
Below
1.0
light
+ Section T, WARNING
AND INDICATOR
SYSTEM, WARNING
AND INDICATOR LIGHT
BULB REPLACEMENT
D Inspect related harness.
D Inspect A/C relay.
+ Section U, CONTROL
SYSTEM, A/C RELAY
INSPECTION
D Inspect related harness.
CONTROL SYSTEM
Terminal
Signal
Glow system
Connected
to
Glow plug
relay
Test condition
Engine coolant temperature is below
60C
{140F}.
FICD
control
Idle
B+
Below
1.0
B+
B+
Below
1.0
is not at OFF
D Engine coolant temperature is below 60C
{140F}.
D Temperature control dial
Below
1.0
Action
B+
While cranking
While cranking
P
Voltage
(V)
B+
Below
1.0
B+
valve No.2.
+ FUEL SYSTEM, FICD
SOLENOID VALVE No.1,
No.2 INSPECTION
D Inspect related harness.
B+
D Inspect TCV.
+ CONTROL SYSTEM,
TIMER CONTROL VALVE
(TCV) INSPECTION
D Inspect related harness.
is not at OFF
D Engine coolant temperature is above 60C
{140F}.
Q
Q*1
Timer
control
TCV
R*3
EGR valve
control
S
S*1
Diagnostic
test mode
Below
1.0
EGR
solenoid
valve
Data link
connector
(DLC) (Terminal TEN)
T*1
DTC output
Data link
connector
(DLC) (Terminal FEN)
Below
1.0
Engine
switch is on.
B+
B+
Below
1.0
No DTC output
Below
1.0
DTC output
0B+
*1:
Europe and UK
Turkey and General (R.H.D., L.H.D.)
*3: WL Turbo for Europe and UK
*2:
F244
valve.
+ EMISSION SYSTEM,
EGR SOLENOID VALVE
INSPECTION
D Inspect related harness.
CONTROL SYSTEM
WL3 / WLT3 (Euro 3 Regulation Models)
Caution
D The PCM terminal voltages vary with change in measuring conditions and vehicle conditions.
Always carry out a total inspection of the input systems, output systems, and PCM to determine the
cause of trouble. Otherwise, diagnosis will be incorrect.
Note
D PIDs for the following parts are not available on
1. Connect the WDS or equivalent to the DLC. (See
this model. Go to the appropriate part
ONBOARD DIAGNOSTIC TEST)
inspection page.
2. Turn the engine switch on.
Electronic governor
3. Measure the value.
Pump speed sensor
D If value is not within the specification, follow the
Injection pump EPROM
instructions in Action column.
EGR control solenoid valve
PID Monitor Table
Monitor item
(Definition)
ACCS (A/C relay)
Unit/
Condition
ON/OFF
ON/OFF
ARPMDES (Target
engine speed)
rpm
BARO (Barometric
pressure in PCM)
ECT (Engine
coolant
temperature)
Replace PCM.
3C
1Q
1T
4Q
4T
1F
1L
4L
PCM
terminal
EGRVP (EGR
valve position)
FLT V (Fuel
temperature signal
voltage)
EGRV (EGR
solenoid valve
(vacuum))
FLT (Fuel
temperature
sensor)
F
V
EGRA (EGR
solenoid valve
(vent))
Action
V
CS P (Control
sleeve signal
voltage)
Condition/Specification
F245
1L
CONTROL SYSTEM
Monitor item
(Definition)
Unit/
Condition
Condition/Specification
ON/OFF
Idle: ON
Engine switch is on: ON
Engine speed is above 5,100 rpm:
OFF
DTC P1182, P0251, P0606, P1226 is
detected: OFF
ON/OFF
GPL (Glow
indicator light)
ON/OFF
FSOV (FSO
solenoid control)
IASV (Intake
shutter valve)
IAT
(IAT sensor No.2)
IATDC
(IAT sensor No.1)
ON/OFF
F
V
IDLE SW
(Idle switch)
ON/OFF
MAINRLY (PCM
control relay)
ON/OFF
MAP
(Boost sensor)
PNP
(Neutral/clutch
switch)
ON/OFF
RPM (Engine
speed)
rpm
STARTER (Engine
switch)
ON/OFF
TPS (Timer
position sensor
signal)
PCM
terminal
4W
4V
4S
4Z*
1J
3D
3O
4E
3B
1P
1D
1H
1U
1K
Action
F246
CONTROL SYSTEM
TEST (TEN
terminal (in DLC))
ON/OFF
TP V (Accelerator
position signal
voltage)
TP2 V (Accelerator
position signal
voltage)
VPWR (Battery
positive voltage)
VSS (Vehicle
speed)
km/h
mph
1R
2C
4C
F247
2A
1N
CONTROL SYSTEM
Not using SSTs (WDS or equivalent) at constant
voltage terminal inspection
1. Turn the engine switch to ON.
2. Measure the voltage between the accelerator
position sensor connector (vehicle side) terminal A
and body GND using a voltmeter.
ZCF4040W017
ZCF4040W017
ZCF4040W017
ZCF4040W017
F248
CONTROL SYSTEM
D Signal circuit (MAF/IAT sensor connector terminal
C and PCM connector terminal 4E)
D GND circuit (MAF/IAT sensor connector terminal B
and PCM connector terminal 4A)
ZCF4040W009
Short circuit
D MAF/IAT sensor connector terminal A and PCM
control relay connector terminal D to GND
D MAF/IAT sensor connector terminal C and PCM
connector terminal 4E to GND
ZCF4040W057
Note
D Perform the following inspection only when
directed.
Resistance (kilo
ohm)
20 {68}
2.22.7
30 {86}
1.41.9
ZCF4040W010
MAF PID
1.62.0 V
CIrcuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (MAF/IAT sensor connector terminal
A and PCM control relay connector terminal D)
F249
CONTROL SYSTEM
NE SENSOR INSPECTION
Short circuit
D MAF/IAT sensor connector terminal D and PCM
connector terminal 3D
Note
D Perform the following test only when directed.
Note
D Perform the following test only when directed.
A
Specification
800920
3. If not as specified, replace the NE sensor.
W5U140WZC
Resistance (kilohm)
20 {68}
2.212.69
80 {176}
0.290.354
Tightening torque
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
4. If NE sensor is okay, but PCM terminal F voltage is
out of specification, inspect the following:
Open circuit
D Engine speed (input) circuit (NE sensor
connector terminal A and PCM connector
terminal F)
D GND circuit (NE sensor connector terminal B
and PCM connector terminal B)
Short circuit
D NE sensor connector terminal A and PCM
connector terminal F to GND
5. Repair or replace faulty areas.
6. Reconnect the NE sensor connector.
ZCF4040W015
Short circuit
D IAT sensor No.2 connector terminal A and PCM
connector terminal J to GND.
F250
CONTROL SYSTEM
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
INSPECTION
Note
D Perform the following test only when directed.
1. Drain the engine coolant from the radiator. (Refer
to Section E, ENGINE COOLANT, ENGINE
COOLANT REPLACEMENT.)
2. Disconnect the ECT sensor connector.
3. Remove the ECT sensor.
4. Place the sensor in water with a thermometer, and
heat the water gradually.
Open circuit
D Reference voltage circuit (ECT sensor
connector terminal A and PCM connector
terminal E through common connector)
D GND circuit (ECT sensor connector terminal B
and PCM connector terminal B through
common connector)
Short circuit
D ECT sensor connector terminal A and PCM
connector terminal E through common
connector to GND
10. Repair or replace faulty areas.
11. Reconnect the ECT sensor connector.
WL3 / WLT3 (Euro 3 Regulation Models)
D If ECT sensor is okay, but PID value is out of
specification, perform the Circuit open/short
inspection.
Circuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harness.
Open circuit
D Reference voltage circuit (ECT sensor connector
terminal A and PCM connector terminal 1T)
D GND circuit (ECT sensor connector terminal B and
PCM connector terminal 1B)
Resistance (k)
20 {68}
2.272.73
80 {176}
0.290.34
ZCF4040W016
Short circuit
D ECT sensor connector terminal A and PCM
connector terminal 1T to GND.
FUEL TEMPERATURE SENSOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
Resistance Inspection
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect the resistance between the terminals under
the following condition.
D Consult authorized BOSCH parts distributor for
repair if the fuel temperature sensor is possibly
malfunctioning.
F251
CONTROL SYSTEM
D Consult authorized BOSCH parts distributor for
repair if the pump speed sensor is possibly
malfunctioning:
D If pump speed sensor is okay, but PID value is
out of specification, perform the Circuit
open/short inspection.
ZCF4040W001
Specification
Terminal
Atmospheric
temperature C {F}
Resistance (ohm)
EK
2030 {6886}
1.42.6
ZCF4040W002
Specification
Terminal
Atmospheric
temperature C {F}
Resistance (ohm)
AB
2030 {6886}
1.461.78
ZCF4012W001
ZCF4040W003
Short circuit
D Injection pump connector A terminal K and PCM
connector terminal 1L to GND
Short circuit
D Pump speed sensor connector terminal A and
PCM connector terminal 2K to GND
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the connector C of the injection pump
auxiliary part. (See NO TAG Injection pump
auxiliary parts inspection)
3. Inspect the resistance between the terminals A and
B under the following condition.
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector A.
3. Inspect the resistance between the terminals under
the following condition.
F252
CONTROL SYSTEM
D Consult authorized BOSCH parts distributor for
repair if the CS sensor is possibly
malfunctioning:
D If the CS sensor is okay, but PID value is out of
specified, perform the CS sensor circuit
open/short inspection.
ZCF4040W001
Specification
ZCF4040W004
Terminal
Atmospheric
temperature C {F}
Resistance (ohm)
GH
1828 {66.482.4}
11.212.4
GF
1828 {66.482.4}
FH
1828 {66.482.4}
Specification
Terminal
Resistance (ohm)
Atmospheric
temperature C {F}
5.66.2
AB
76.387.7
1535 {5995}
5.66.2
AC
76.387.7
1535 {5995}
ZCF4012W001
Short circuit
D Injection pump connector A terminal G and PCM
connector terminal 1O to GND
D Injection pump connector A terminal F and PCM
connector terminal 1Q to GND
ZCF4040W005
Short circuit
D Injection pump connector B terminal C and PCM
connector terminal 1I to GND
D Injection pump connector B terminal A and PCM
connector terminal 1K to GND
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the injection pump connector B.
F253
Caution
D Do not input voltage to B terminal in the
injection pump EPROM.Doing so will cause
a malfunction of the injection pump
EPROM.
CONTROL SYSTEM
Note
D Perform the following test only when directed.
ZCF4040W005
TDC sensor
ZCF4040W043
F254
CONTROL SYSTEM
D GND circuit (EGR valve position sensor connector
terminal A and PCM connector terminal 1B)
ZCF4040W042
ZCF4040W009
Short circuit
D EGR valve position sensor connector terminal B
and PCM connector terminal 1A to GND
D EGR valve position sensor connector terminal C
and PCM connector terminal 1F to GND
Note
D Perform the following inspection only when
directed.
Note
D Perform the following test only when detected.
EGRVP PID
approx. 0.6 V
3. Start the engine and warm up the engine
completely.
4. Monitor the EGRVP PID.
D If not as specified, perform the Circuit
open/short inspection.
EGRVP PID
above 3.0V
CIrcuit open/short inspection
1. Inspect for an open or short circuit in the following
wiring harnesses.
D If there is an open or short circuit, repair or
replace wiring harnesses.
Open circuit
D Power circuit (EGR valve position sensor
connector terminal B and PCM connector terminal
1A)
D Signal circuit (EGR valve position sensor
connector terminal C and PCM connector terminal
1F)
ZCF4040W011
Short circuit
D Boost circuit (Boost sensor connector terminal B
and PCM connector terminal 1P to GND)
D Constant voltage circuit (Boost sensor connector
terminal A and PCM connector terminal 1A to
GND)
F255
CONTROL SYSTEM
PCM CONTROL RELAY INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
1. Inspect the PCM control relay. (SeeRELAY
INSPECTION.)
ACCELERATOR POSITION SENSOR INSPECTION
WL3 / WLT3 (Euro 3 Regulation Models)
Note
D Perform the following test only when directed.
1. Visually inspect all accelerator pedal components
for looseness.
2. Verify that the accelerator position sensor is
installed to the accelerator pedal properly.
3. Check the power circuit voltage.
(1) Verify that the voltage between the PCM
terminals 1A (power circuit) and 1B (ground
circuit) is 4.755.25 V.
Note
D Voltage at the PCM terminal 1R may deviate
when the power circuit voltage is abnormal.
Note
D Perform the following test only when directed.
D Accelerator position sensor adjustment is
based on the output voltage with the
accelerator pedal fully released. Therefore, be
sure to adjust according to the following
procedure. (Begin adjustment with the
accelerator pedal fully released.)
ZCF4040W019
Specification
Accelerator pedal
condition
Fully released
Gradually depressed
Increases linearly
Fully depressed
ZCF4040W019
F256
CONTROL SYSTEM
position of the accelerator position sensor
so that the PCM terminal 1R voltage is
within the specification.
Specification
: Continuity
Measuring
condition
Specification
Accelerator pedal
condition
Fully released
Gradually depressed
Increases linearly
Terminal
E
GND
Not accelerated
Other
Caution
D Turning the idle switch with its connector
connected can break the harness. Be sure
to disconnect the connector when turning
the idle switch more than one rotation.
4. If not as specified, loosen the idle switch locknut
and adjust the continuity by turning the idle switch.
5. If not as specified, replace the idle switch. If the
idle switch is okay, but PCM terminal voltage is out
of specification, inspect as follows and repair or
replace as necessary.
ZCF4040W020
Open circuit
D Power supply circuit (Idle switch connector terminal
E and PCM connector terminal 2H through
common connector)
D GND circuit (Idle switch connector terminal and
body GND)
Specification
3.43.8V (Target value: 3.6 V)
6. After completion of Steps 1. through 5, inspect the
idle switch.
IDLE SWITCH INSPECTION
Europe and UK
Continuity Inspection
WL / WLT Models
Note
D Perform the following test only when directed.
1. Disconnect the negative battery cable.
2. Disconnect the 8-pin connector of FIP.
3. Inspect for continuity between the idle switch
terminal E and ground using an ohmmeter.
Short circuit
D Power supply circuit (Idle switch connector terminal
E and PCM connector terminal H through common
connector to GND)
6. Repair or replace faulty areas.
7. Reconnect the 8-pin connector of FIP.
WL3 / WLT3 (Euro3 Regulation models)
Note
D Perform the following test only when directed.
F257
CONTROL SYSTEM
Open circuit
D Signal circuit (Idle switch connector terminal A and
PCM connector terminal 3O)
D GND circuit (Idle switch connector terminal B and
body GND)
D Power circuit (Accelerator position sensor
connector terminal A and PCM connector terminal
1A)
D Signal circuit (Accelerator position sensor
connector terminal B and PCM connector terminal
1R)
D Signal circuit (Accelerator position sensor
connector terminal C and PCM connector terminal
2C)
D GND circuit (Accelerator position sensor connector
terminal D and PCM connector terminal 1B)
Short circuit
D Idle switch connector terminal A and PCM
connector terminal 3C to GND.
D Accelerator position sensor connector terminal B
and PCM connector terminal 1R to GND.
D Accelerator position sensor connector terminal C
and PCM connector terminal 2C to GND.
ZCF4040W025
F258
CONTROL SYSTEM
D Perform the following test only when directed.
ZCF4040W025
Measuring condition
Voltage (V)
Approx. 4.2
Approx. 0.81.5
ZCF4040W026
Short circuit
D Control lever position sensor connector terminal B
and PCM connector terminal A through common
connector to GND
D Control lever position sensor connector terminal A
and PCM connector terminal J through common
connector to GND
ZCF4040W028
F259
CONTROL SYSTEM
CLUTCH SWITCH INSPECTION
WL3 / WLT3 (Euro3 Regulation models)
Inspection of Continuity
Note
D Perform the following test only when directed.
1. Inspect continuity between the clutch switch
terminals using an ohmmeter.
D If not as specified, replace the clutch switch.
D If clutch switch is okay, but PID value is out of
specification, perform the Circuit open/short
inspection.
Specification
ZCF4040W025
Voltage range
1.01.2V (Target value: 1.1 V)
ZCF4040W007
ZCF4040W026
ZCF4040W028
F260
CONTROL SYSTEM
NEUTRAL SWITCH INSPECTION
WL3 / WLT3 (Euro3 Regulation models)
Note
D Perform the following inspection only when
directed.
Continuity inspection
1. Inspect for continuity between the neutral switch
terminals using an ohmmeter.
ZCF4040W018
ZCF4040W047
F261
49 B019 9A0
DLC
49 H018 9A1A
FEN
DLC
TEN
+B
GND
F262
Indicator Pattern
Condition
09
12
36
DTC 09
DETECTION
CONDITION
POSSIBLE
CAUSE
STEP
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 1.
No
Yes
No
Troubleshooting completed.
F263
DTC 12
DETECTION
CONDITION
sec.
D When idle switch is on, input voltage from control lever position sensor is below 0.35V or above 1.39V.
D Control lever position sensor malfunction
D Idle switch malfunction
D Open circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal C to PCM termi-
POSSIBLE
CAUSE
nal B
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal A to
PCM terminal J
D Open or short circuit in wiring from control lever position sensor (FIP connector: 8pin) terminal B to
PCM terminal A
D Open or short circuit wiring from idle switch (FIP connector: 8pin) terminal E to PCM terminal H
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 1.
No
Yes
No
Troubleshooting completed.
3
4
F264
DTC 36
DETECTION
CONDITION
3
4
5
D
D
D
D
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 1.
No
Yes
No
Troubleshooting completed.
GLOW PLUG RELAY
A
A
O
A
B
(WIRE
COLOR: R)
(WIRE
COLOR: B)
F265
YMU102WBX
*: Generator Warning Light, Security Light and Glow Indicator Light Flashing
OBD READ/CLEAR DIAGNOSTIC TEST RESULTS
Euro 3 Regulation Models
D This retrieves all stored DTCs in PCM and clears
the DTC.
OBD PARAMETER IDENTIFICATION (PID) ACCESS
Euro 3 regulation Models
D The PID mode allows access to certain data
values, analog and digital inputs/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 device has a malfunction.
F266
ZCF4070W012
ZCF4070W012
Output pattern
Possible cause
P0100
(See 69
DTC
P0100)
(See 72
DTC
P0105)
(See 74
DTC
P0110)
(See 77
DTC
P0115)
(See 80
DTC
P0120)
(See 83
DTC
P0180)
(See 86
DTC
P0251)
(See 88
DTC
P0335)
(See 89
DTC
P0400)
(See 91
DTC
P0500)
WALTPX0100
P0105
WALTPX0105
P0110
WALTPX0110
P0115
WALTPX0115
P0120
WALTPX0120
P0180
WALTPX0180
P0251
WALTPX0251
P0335
WALTPX0335
P0400
WALTPX0400
P0500
WALTPX0500
F267
Page
DTC
Output pattern
Possible cause
Page
(See 93
DTC
P0510)
PCM malfunction
(See 94
DTC
P0606)
(See 95
DTC
P1110)
(See 98
DTC
P1182)
(See 99
DTC
P1189)
(See 100
DTC
P1195)
(See 101
DTC
P1226)
(See 103
DTC
P1312)
(See 105
DTC
P1318)
WALTPX1402TIF
(See 107
EGR valve position sensor circuit
DTC
malfunction
P1402)
P0510
WALTPX0510
P0606
WALTPX0606
P1110
WALTPX1110
P1182
WALTPX1182
P1189
WALTPX1189
P1195
WALTPX1195
P1226
WALTPX1226
P1312
WALTPX1312
P1318
P1402
P1602
*
Immobilizer unitPCM
communication error
(See 110
DTC
P1602)
(See 112
DTC
P1603)
(See 113
DTC
P1604)
(See 113
DTC
P1621)
(See 114
DTC
P1622)
(See 114
DTC
P1623)
WALTPX1602
P1603
*
WALTPX1603
P1604
*
WALTPX1604
P1621
*
WALTPX1621
P1622
*
WALTPX1622
P1623
*
WALTPX1623
F268
DTC
Output pattern
Possible cause
P1624
*
Immobilizer system
communication counter = 0
(See 115
DTC
P1624)
(See 115
DTC
P1649)
WALTPX1624
P1649
WALTPX1649
Page
DTC P0100
DTC P0100
DETECTION
CONDITION
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W001
F269
DTC P0100
HIGH INPUT
ZCF4070W002
ZCF4070W003
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to Step 11.
No
Go to next step.
Yes
No
Yes
Go to next step.
No
F270
STEP
5
11
12
13
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F271
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W004
HIGH INPUT
ZCF4070W005
ZCF4070W006
F272
10
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to Step 11.
No
Go to next step.
Yes
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
No
Yes
Go to next step.
No
Yes
No
F273
STEP
11
12
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0110
DTC P0110
DETECTION
CONDITION
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W052
F274
DTC P0110
HIGH INPUT
ZCF4070W053
ZCF4070W060
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 16.
Yes
No
Go to next step.
No
F275
STEP
5
10
11
12
13
14
INSPECTION
ACTION
Yes
Go to next step.
No
Go to Step 10.
Yes
No
Go to next step.
Yes
No
Go to Step 16.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
F276
STEP
15
16
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0115
DTC P0115
DETECTION
CONDITION
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W016
F277
DTC P0115
HIGH INPUT
ZCF4070W007
ZCF4070W017
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 13.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to Step 13.
No
F278
STEP
7
10
11
12
13
14
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F279
DETECTION
CONDITION
POSSIBLE
CAUSE
F280
DTC P0120
ZCF4070W18
Diagnostic procedure
STEP
1
INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?
ACTION
Yes
No
Go to next step.
F281
STEP
2
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
F282
STEP
10
11
12
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0180
DTC P0180
DETECTION
CONDITION
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W008
F283
DTC P0180
HIGH INPUT
ZCF4070W009
ZCF4070W019
Diagnostic procedure
STEP
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 15.
Yes
No
Go to next step.
Yes
Go to next step.
No
No
F284
STEP
6
10
11
12
13
14
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to Step 16.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
F285
STEP
15
16
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0251
DTC P0251
DETECTION
CONDITION
POSSIBLE
CAUSE
ZFC4070W205
Diagnostic procedure
STEP
1
INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?
ACTION
Yes
No
Go to next step.
F286
STEP
2
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
10
11
F287
POSSIBLE
CAUSE
ZCF4070W050
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Yes
No
Go to next step.
F288
STEP
4
10
INSPECTION
ACTION
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0400
DTC P0400
DETECTION
CONDITION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
VERIFY RELATED REPAIR INFORMATION
AVAILABILITY
D Check for related Service Bulletins and/or
online repair information availability.
D Is any related repair information available?
ACTION
Yes
No
Go to next step.
F289
STEP
2
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Troubleshooting completed.
F290
POSSIBLE
CAUSE
PCM malfunction
Instrument cluster (vehicle speedometer sensor) malfunction
Open circuit between PCM terminal 1N and instrument cluster terminal 1M
Short to ground between PCM terminal 1N and instrument cluster terminal 1M
VSS malfunction
Open circuit between vehicle speed sensor terminal A and instrument cluster terminal 1L
Short to ground between vehicle speed sensor terminal A and instrument cluster terminal 1L
Open circuit between vehicle speed sensor terminal B and instrument cluster terminal 1M
Short to ground between vehicle speed sensor terminal B and instrument cluster terminal 1M
ZCF4070W059
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
CHECK SPEEDOMETER
D Check speedometer.
D Does vehicle speedometer needle move?
Yes
Go to next step.
No
F291
STEP
3
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F292
POSSIBLE
CAUSE
ZFC4070W051
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
F293
STEP
5
10
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P0606
DTC P0606
DETECTION
CONDITION
POSSIBLE
CAUSE
PCM malfunction
D PCM detects internal malfunction.
D PCM malfunction
Diagnostic procedure
STEP
1
INSPECTION
ACTION
F294
POSSIBLE
CAUSE
LOW INPUT
ZCF4070W013
HIGH INPUT
ZCF4070W014
ZCF4070W015
Diagnostic procedure
STEP
1
INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?
ACTION
Yes
No
Go to next step.
F295
STEP
2
10
11
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to Step 15.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Go to Step 9.
Yes
No
Go to next step.
Yes
No
Go to Step 15.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
F296
STEP
12
13
14
15
16
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F297
ZCF4070W102
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
F298
STEP
5
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1189
DTC P1189
DETECTION
CONDITION
POSSIBLE
CAUSE
ZCF4070W100
Diagnostic procedure
STEP
1
INSPECTION
VERIFY RELATED SERVICE INFORMATION
AVAILABILITY
D Check for related Service Information
availability.
D Is any related Service Information available?
ACTION
Yes
No
Go to next step.
F299
STEP
2
INSPECTION
ACTION
Yes
Go to Step 4.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1195
DTC P1195
DETECTION
CONDITION
POSSIBLE
CAUSE
F2100
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1226
DTC P1226
DETECTION
CONDITION
POSSIBLE
CAUSE
CS sensor malfunction
PCM malfunction
Connector or terminal malfunction
Open or short to ground circuit between CS sensor terminal (injection pump connector A) F and PCM
terminal 1Q
D Open or short to ground circuit between CS sensor terminal (injection pump connector A) G and PCM
terminal 1O
D Open circuit between CS sensor terminal (injection pump connector A) H and PCM terminal 1M
ZCF4070W101
F2101
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
INSPECT CS SENSOR
D Perform CS sensor inspection.
(See NO TAG CONTROL SLEEVE (CS)
SENSOR INSPECTION)
D Is CS sensor okay?
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2102
POSSIBLE
CAUSE
ZCF4070W201
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
F2103
STEP
4
10
11
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
INSPECT TCV
D Perform TCV Inspection.
(SeeNO TAG TIMER CONTROL VALVE
(TCV) INSPECTION)
D Is TCV okay?
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2104
POSSIBLE
CAUSE
ZCF4070W203
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
F2105
STEP
4
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2106
POSSIBLE
CAUSE
ZCF4070W202
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
F2107
STEP
3
10
11
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to Step 9.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to Step 18.
No
Yes
Go to Step 15.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
F2108
STEP
12
13
14
15
16
17
18
19
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to Step 18.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2109
POSSIBLE
CAUSE
D
D
D
D
D
D
D
D
D
D
ZCF4070W301
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to step 10.
No
Go to next step.
Yes
No
Go to next step.
F2110
STEP
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to step 19.
No
Yes
Go to Step 14.
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 19.
No
14
Yes
No
Go to next step.
15
Yes
No
Go to next step.
10
11
12
13
F2111
STEP
16
17
18
19
20
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1603
DTC P1603
DETECTION
CONDITION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2112
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1621
DTC P1621
DETECTION
CONDITION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2113
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Go to Step 4.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1623
DTC P1623
DETECTION
CONDITION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2114
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
DTC P1649
DTC P1649
DETECTION
CONDITION
POSSIBLE
CAUSE
D
D
D
D
F2115
DTC P1649
ZCF4070W204
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
F2116
STEP
5
10
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
F2117
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
D Before proceeding with the following
troubleshooting:
See Section GI to understand the basic troubleshooting procedure.
Perform the DTC inspection.
If a DTC is displayed, proceed with inspection
steps for the code.
When the engine can be started, perform ENGINE TUNEUP. (See ENGINE TUNEUP.)
Y3U103WN3
Note
D If engine starts and runs, perform the following
steps at idle.
3. Access PIDs for the switch you are inspecting.
4. Shake each connector or wire harness a bit
vertically and horizontally while monitoring the PID.
D If PID value is unstable, check for poor
connection.
Y3U103WN4
F2118
TROUBLESHOOTING
D If variable click sound is heard, check for poor
connection and/or poorly mounted actuator or
relay.
Y3U103WN5
Note
D Vibrating relays too strongly may result in open
relays.
F2119
Y3U103WTJ
TROUBLESHOOTING
TROUBLESHOOTING ITEM TABLE
D Confirm trouble symptom by using the following
diagnostic index, then go to appropriate
troubleshooting chart.
No.
TROUBLESHOOTING ITEM
DESCRIPTION
Engine stalls.
Starter cranks engine at normal speed but engine will not run.
Runs on
7
8
Engine stalls/quits.
Acceleration/cruise
Acceleration/cruise
Misses
Acceleration/cruise
Buck/jerk
Acceleration/cruise/
deceleration
Hesitation/stumble
Surges
Acceleration
Acceleration/cruise
Acceleration/cruise
10
Lack/loss of power
11
12
13
Overheating
14
Runs cold
15
16
Engine noise
17
18
19
20
Intermittent concerns
Intermittent concerns
21
Constant voltage
F2120
TROUBLESHOOTING
QUICK DIAGNOSIS CHART
Y6E4080W002
F2121
TROUBLESHOOTING
ZCF4080W001
F2122
TROUBLESHOOTING
ZCF4080W002
F2123
TROUBLESHOOTING
NO.1 MELTING OF MAIN OR OTHER FUSES
1
[TROUBLESHOOTING HINTS]
Inspect condition of fuse.
Y6E4080W001
Damaged fuse
MAIN (80 A)
MAIN fuse
D Generator
D Engine switch
ENG fuse
D Blower relay
Blower fan
motor
D A/C relay
Refrigerant
pressure switch
D FIP fuse
BTN (30 A)
BTN fuse
D ROOM fuse
GLOW (60 A)
ENG (15 A)
FIP (15 A)
ROOM (10 A)
GLOW fuse
D Glow plug relay
Glow plug
ENG fuse
D PCM
FIP fuse
D PCM control relay
PCM
ROOM fuse
D PCM
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
D Verify following:
Battery connection
Battery condition
Fuses
D Are all items okay?
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
Yes
Go to next step.
No
Go to Step 6.
F2124
TROUBLESHOOTING
STEP
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
D Starter cranks engine at normal speed but engine requires excessive cranking time before start.
D Battery is in normal condition.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
D Is engine overheating?
Yes
No
Go to next step.
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
Yes
No
Go to next step.
D
D
D
D
F2125
TROUBLESHOOTING
STEP
INSPECTION
D Is idle speed correct?
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to Step 10.
No
Go to next step.
Yes
No
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
Inspect following:
D Starting signal (PCM terminal 1U)
If okay, remove and inspect injection pump.
No
10
11
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
12
POSSIBLE
CAUSE
F2126
TROUBLESHOOTING
Diagnostic procedure
STEP
1
INSPECTION
Note
D Following test should be performed on
vehicles with immobilizer system.
D Go to Step 12 for vehicles without
immobilizer system.
ACTION
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to Step 8.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
10
B+ PID
Battery positive voltage
11
F2127
TROUBLESHOOTING
STEP
12
13
INSPECTION
ACTION
Yes
Go to next step.
No
Service as necessary.
Repeat Step 12.
D Is engine overheating?
Yes
14
Note
D Ignore DTC P0120 while performing this
test.
D Disconnect accelerator position sensor
connector.
D Measure voltage at accelerator position
sensor connector VREF terminal with
engine switch ON.
No
Go to next step.
Yes
Go to next step.
No
Yes
DTC is displayed:
D Go to appropriate DTC test.
Communication error message is displayed:
D Inspect for following:
Open circuit between PCM control relay and PCM
terminal 4C
Open PCM control relay GND circuit
PCM control relay is stuck open
Open PCM GND circuit (terminal 4A or 4B)
Poor connection of vehicle body GND
No
No DTC is displayed:
D Go to next step.
Specification
4.55.5 V
D Is voltage okay?
15
D
D
D
D
16
Yes
Go to next step.
No
Go to Step 18.
17
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
18
19
Note
D The following test should be performed
on the vehicles with A/C system. If the
following test cannot be performed due
to engine stalls, go to next step.
D Go to next step for the vehicles without
A/C system.
D Connect pressure gauge to A/C lines.
D Turn blower switch on.
D Is pressure within specifications?
(See Section U)
20
F2128
TROUBLESHOOTING
STEP
21
22
23
24
25
26
27
28
29
30
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 29.
No
Go to next step.
Yes
No
Yes
Inspect following:
D Idle switch
D Neutral switch
D Start signal (PCM terminal 1U)
D MAF/IAT sensor
D IAT sensor No.2
D VSS
D Pump speed sensor
If okay, remove and inspect injection pump.
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
F2129
TROUBLESHOOTING
NO.5 CRANKS NORMALLY BUT WILL NOT START
5
DESCRIPTION
D
D
D
D
Starter cranks engine at normal speed but engine will not run.
Refer to No.4 ENGINE STALLS if this symptom appears after engine stall.
Fuel is in tank.
Battery is in normal condition.
POSSIBLE
CAUSE
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
INSPECTION
Note
D The following test should be performed
on the vehicles with immobilizer system.
D Go to Step 12 for vehicles without
immobilizer system.
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to Step 8.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Yes
No
Go to next step.
5
6
ACTION
F2130
TROUBLESHOOTING
STEP
9
10
11
12
INSPECTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Service as necessary.
Repeat Step 12.
Yes
Go to next step.
No
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
Yes
Go to Step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to Step 20.
No
Go to next step.
13
Note
D Ignore DTC P0120 while performing this
test.
D Turn engine switch to ON.
D Disconnect accelerator position sensor
connector.
D Measure voltage at accelerator position
sensor connector VREF terminal.
Specification
4.55.5 V
D Is voltage okay?
14
15
16
17
18
ACTION
D
D
D
D
F2131
TROUBLESHOOTING
STEP
INSPECTION
D Inspect timing belt for following
Chipping of gear teeth
Low tension
Breakage, damage or cracks
D Is timing belt okay?
19
ACTION
Yes
No
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
21
Yes
Go to next step.
No
22
Yes
Go to next step.
No
Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose between EGR solenoid valve
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.
Yes
Go to next step.
No
Yes
Inspect following:
D Pump speed sensor
If okay, remove and inspect injection pump.
No
20
23
24
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
25
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
D
D
D
D
ACTION
No
No DTC is displayed:
D Go to next step.
Yes
DTC is displayed:
D Go to appropriate DTC test.
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
No
Go to next step.
F2132
TROUBLESHOOTING
STEP
INSPECTION
ACTION
Yes
No
Replace thermostat.
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
D Engine speed fluctuates between specified idle speed and lower speed and engine shakes
excessively.
D Idle speed is too slow and engine shakes excessively.
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
INSPECTION
ACTION
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
D Is engine overheating?
Yes
No
Go to next step.
D
D
D
D
Yes
No DTC is displayed:
D Go to next step.
No
DTC is displayed:
D Go to appropriate DTC test.
Yes
Go to next step.
No
Go to step 6.
Yes
Go to step 7.
No
Yes
Go to next step.
No
4
5
F2133
TROUBLESHOOTING
STEP
INSPECTION
D Depress accelerator pedal slightly.
D Crank engine.
D Does engine start now?
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid valve (vent)
D EGR solenoid valve (vacuum)
D EGR valve
D Vacuum hose connection
D Wiring harness between EGR solenoid valve (vacuum)
and PCM terminal 4T
Repair or replace as necessary.
Yes
Go to Step 12.
No
Go to next step.
Yes
No
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
16
Yes
Inspect following:
D VSS
D Pump speed sensor
If okay, remove and inspect injection pump.
No
17
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
8
9
10
11
12
13
14
15
NO.8 RUNS ON
8
DESCRIPTION
POSSIBLE
CAUSE
Runs on
D Engine runs after engine switch is turned to OFF.
D FSO solenoid malfunction.
F2134
TROUBLESHOOTING
Diagnostic procedure
STEP
INSPECTION
D
D
D
D
ACTION
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
D
D
D
D
D
D
POSSIBLE
CAUSE
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
4
5
INSPECTION
D Is idle speed stable?
D Is engine overheating?
D
D
D
D
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
Yes
Go to next step.
No
Go to Step 6.
Yes
Go to next step.
No
F2135
TROUBLESHOOTING
STEP
6
INSPECTION
Note
D The following test should be performed
on the vehicles with A/C system.
D Go to next step for the vehicles without
A/C system.
ACTION
Yes
Go to next step
No
Yes
Go to next step.
No
Yes
No
Turbocharger is okay.
Go to next step.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.
Yes
No
Go to next step.
Yes
Go to next step.
No
12
Yes
No
Go to next step.
13
Yes
Go to next step.
No
Yes
Go to Step 16.
No
Go to next step.
Yes
No
10
11
14
15
F2136
TROUBLESHOOTING
STEP
16
17
INSPECTION
ACTION
Yes
Inspect following:
D Clutch for slippage
D Pump speed sensor
If okay, remove and inspect injection pump.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
Lack/loss of poweracceleration/cruise
DESCRIPTION
POSSIBLE
CAUSE
D Performance is poor under load (e.g., power down when climbing hills).
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
INSPECTION
D Is idle speed stable?
ACTION
Yes
Go to next step.
No
D Is engine overheating?
Yes
No
Go to next step.
D Is engine overheating?
Yes
No
Go to next step.
Yes
Go to next step.
No
D
D
D
D
Yes
Go to next step.
No
Yes
Go to next step.
No
F2137
TROUBLESHOOTING
STEP
7
INSPECTION
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Go to Step 16 for the vehicles without
turbocharger system.
No
Turbocharger is okay.
Go to next step.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Go to next step.
No
Replace turbocharger.
Yes
Replace turbocharger.
No
Go to next step.
10
11
ACTION
Yes
Note
D Inspect all fins on each turbine wheel.
D Is there any problem?
12
Yes
No
Go to next step.
13
Yes
Wipe oil out of vehicle and install all removed parts in Step
8. Then, go to next step.
No
Turbocharger is okay.
Install all removed parts in Step 8.
Then, go to next step.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.
Yes
No
Go to next step.
14
15
F2138
TROUBLESHOOTING
STEP
INSPECTION
ACTION
Yes
Go to next step.
No
17
Yes
Go to next step.
No
18
Yes
Go to Step 20.
No
Go to next step.
Yes
Inspect following:
D Burnt valve
D Worn piston, piston ring or cylinder
D Damaged cylinder head gasket
D Damaged valve seat
D Worn valve stem and valve guide
Repair or replace as necessary.
No
Yes
Inspect following:
D Boost sensor
D Brake system for dragging
D Clutch for slippage
If okay, remove and inspect injection pump.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
16
19
20
21
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
D
D
D
D
Yes
DTC is displayed:
Go to appropriate DTC test.
No
No DTC is displayed:
Go to next step.
F2139
TROUBLESHOOTING
STEP
3
6
7
INSPECTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoids and PCM
terminals
Repair or replace as necessary.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Replace turbocharger.
Yes
No
Go to next step.
Yes
Go to next step.
No
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Perform turbocharger inspection.
(See TURBOCHARGER INSPECTION)
D Is turbocharger okay?
9
10
ACTION
11
Yes
Go to Step 13.
No
Go to next step.
12
Yes
No
Yes
Inspect following:
D Boost sensor
D Injection pump
No
13
14
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
F2140
TROUBLESHOOTING
NO.12 HIGH OIL CONSUMPTION/LEAKAGE
12
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
D Verify following:
Proper dipstick
Proper engine viscosity
Engine oil level
D Are all items okay?
Go to next step.
No
Service as necessary.
Repeat Step 1.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Go to next step.
No
Replace turbocharger.
Yes
Replace turbocharger.
No
Go to next step.
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Remove parts necessary to inspect
turbocharger.
D Do not remove turbocharger.
D Inspect if turbocharger compressor wheel
is bent, damaged, or interfering with
housing on vehicle.
D Is there any problem?
ACTION
Yes
Note
D Inspect all fins on each turbine wheel.
D Is there any problem?
6
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Turbocharger is okay.
Install all removed parts in Step 2.
Then go to next step.
F2141
TROUBLESHOOTING
STEP
10
11
INSPECTION
D Measure engine compression.
D Is compression okay?
ACTION
Yes
No
D Verify test results. If okay, return to diagnostic index to service any advice additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
D Inspect following:
Engine coolant level
Coolant leakage
Water and antifreeze mixture
Radiator condition
Collapsed or restricted radiator hoses
Radiator pressure cap
Drive belt tension
Drive belt
Fan rotational direction
Cooling fan
D Are all items okay?
Yes
Go to next step.
No
Service as necessary.
Repeat Step 1.
D
D
D
D
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
Note
D The following test should be performed
on the vehicles with A/C system. Go to
Step 5 for vehicles without A/C system.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
F2142
TROUBLESHOOTING
STEP
6
7
8
10
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoid and PCM
terminals
Repair or replace as necessary.
Yes
Thermostat is okay.
Inspect cylinder block for leakage or blockage.
No
Replace thermostat.
D Verify test results. If okay, return to diagnostic index to service any additional symptoms
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Replace thermostat.
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
D
D
D
D
ACTION
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
F2143
TROUBLESHOOTING
STEP
2
3
4
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
Go to next step.
No
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harness between EGR solenoids and PCM
terminals
Repair or replace as necessary.
Yes
Inspect following:
D Boost sensor
D Injection pump
No
Inspect following:
D Damaged valve seat
D Worn valve stem and valve guide
D Worn or stuck piston ring
D Worn piston, piston ring or cylinder
Service as necessary.
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
POSSIBLE
CAUSE
Engine noise
D Engine noise from under hood
D
D
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
2
3
INSPECTION
D Is squeal, click or chirp sound present?
D Is rumble or grind sound present?
D Is rattle sound present?
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
F2144
TROUBLESHOOTING
STEP
4
5
6
10
11
INSPECTION
D Is hiss sound present?
No
Go to next step.
Yes
No
Go to next step.
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Inspect TCV.
(See TIMER CONTROL VALVE (TCV) INSPECTION)
If TCV is okay, adjust injection timing.
Yes
Go to next step.
No
Inspect following:
D EGR solenoid (vent)
D EGR solenoid (vacuum)
D EGR valve
D Vacuum hose connections
D Wiring harnesses between EGR solenoids and PCM
terminals
Repair or replace as necessary.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Replace turbocharger.
No
Go to next step.
Yes
Go to next step.
No
Replace turbocharger.
Yes
Replace turbocharger.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Remove turbocharger.
Inspect for cracks on centre housing inlet surface.
If cracks are found, replace turbocharger.
No
Go to next step.
Note
D The following test should be performed
on the vehicles with turbocharger
system.
D Remove parts necessary to inspect
turbocharger.
D Inspect if turbocharger compressor wheel
is bent, damaged, or interfering with casing
on vehicle.
D Is there any problem?
12
13
14
15
16
17
ACTION
Yes
F2145
TROUBLESHOOTING
STEP
18
19
20
INSPECTION
D Are any centre housing and turbine
housing attaching bolts loose?
ACTION
Yes
No
Turbocharger is okay.
Install all removed parts in Step 11.
Go to next step.
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
D Inspect following components for loose
attaching bolts or worn parts:
Cooling fan
Drive belt and pulley
Engine mounts
Exhaust system
D All items okay?
ACTION
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
D A/C compressor magnetic clutch does not engage when A/C switch is turned on.
D
D
D
D
D
D
D
D
D
D
Diagnostic procedure
STEP
1
INSPECTION
D
D
D
D
ACTION
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
F2146
TROUBLESHOOTING
STEP
2
INSPECTION
ACTION
Yes
Go to next step.
No
D
D
D
D
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
DESCRIPTION
POSSIBLE
CAUSE
D
D
D
D
D
D
Diagnostic procedure
STEP
1
INSPECTION
D
D
D
D
ACTION
Yes
DTC is displayed:
D Go to appropriate DTC test.
No
No DTC is displayed:
D Go to next step.
F2147
TROUBLESHOOTING
STEP
2
INSPECTION
D
D
D
D
D
ACTION
Yes
Go to next step.
No
Yes
No
D Verify test results. If okay, return to diagnostic index to service any additional symptoms.
Intermittent concerns
D Symptom occurs randomly and is difficult diagnose.
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
D Talk to customer.
D Retrieve vehicle service history.
D Does vehicle have a number of previous
repairs and components replaced for a
certain symptom?
Yes
No
Go to next step.
Yes
No
Go to Symptom Index.
D Start engine.
D Lightly tap on suspect component, wiggle
and pull each wire/connector at suspect
component or PCM.
D Are any PID values out of range, or do they
suddenly change and go back into range?
Yes
No
Go to next step.
Yes
No
F2148
TROUBLESHOOTING
NO.21 CONSTANT VOLTAGE
21
Constant voltage
DESCRIPTION
POSSIBLE
CAUSE
Note
D Accelerator position sensor and boost sensor use constant voltage.
Diagnostic procedure
STEP
1
2
3
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Go to Step 9.
D
D
D
D
Yes
No
Go to next step.
Yes
No
Yes
No
Go to next step.
F2149
TROUBLESHOOTING
STEP
INSPECTION
Yes
No
Go to next step.
Yes
No
D
D
D
D
Yes
Go to next step.
No
Go to Step 11.
Yes
Go to next step.
No
Yes
Go to next step.
No
10
11
ACTION
F2150
TROUBLESHOOTING
SYSTEM INSPECTION
FICD System Inspection
Fast-Idle Function
1. Verify that the FICD actuator rod is not pulled.
2. Verify that the engine is cold (ECT is below 20 C
{68 F}).
3. Turn fan switch off.
4. Start the engine.
5. Verify that the FICD actuator rod is pulled.
Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
7. If there is vacuum, consult your distributor for
replacement of the FICD actuator.
8. If there is no vacuum, inspect the following.
D FICD solenoid valve No.1 and No.2
D Loose or damaged vacuum hoses between
FICD actuator, FICD solenoid valve No.1 and
No.2, and vacuum pump.
D PCM terminal C, E and P voltages (Refer to
CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
D Wiring harness between FICD solenoid valve
No.1 and PCM terminal C.
D Wiring harness between FICD solenoid valve
No.2 and PCM terminal P.
9. Warm up the engine. (ECT above 20 C {68 F}).
10. Verify that the FICD actuator rod returns for one
notch.
F2151
TROUBLESHOOTING
7. If there is no vacuum, inspect the following:
D FICD solenoid valve No.2
D PCM terminal G and P voltages (Refer to
VACUUM HOSE B
Caution
D FIP is sealed to maintain proper function.
Special tools and testers are required when
disassembling the FIP. Disassembling the
FIP without special tools and testers will
cause a malfunction.
17. If there is no vacuum, consult your distributor for
replacement of the FICD actuator.
18. If there is vacuum, inspect the following.
D FICD solenoid valve No.2
D PCM terminal E, G and P voltages (Refer to
CONTROL SYSTEM, POWERTRAIN
CONTROL MODULE (PCM) INSPECTION.)
D Wiring harness between FICD solenoid valve
No.2 and PCM terminal P.
A/C Idle-up Function
1. Start the engine.
2. Warm up the engine to normal operating
temperature and run it at idle speed.
3. Set the fan switch at 1st position.
4. Verify that the FICD rod is pulled for one notch.
5. If not, disconnect the vacuum hose B from the
FICD actuator and inspect if there is vacuum as
shown.
TO INTAKE
PIPE
VACUUM HOSE B
F2152
TCV
TROUBLESHOOTING
WL Turbo
TCV
F2153
TROUBLESHOOTING
Glow System Inspection
STEP
1
INSPECTION
ACTION
RESULTS
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between battery, glow plug relay, and glow
plug.
Inspect if glow plug relay is stuck open or closed.
Inspect glow plug relay ground circuit.
Inspect for open circuit between glow relay and PCM
terminal O.
Yes
Go to next step.
No
Is power supplied to the glow plug for maximum 10 minutes after engine started when
engine is cold?
Yes
Go to next step.
No
Inspect for open or short circuit in harnesses and connectors between NE sensor and PCM connector terminal F.
Yes
No
F2154
G
G
G
G
G
G
G
G
G
1
1
1
2
2
3
5
5
5
G
G
G
G
G 9
G10
G10
G10
CHARGING SYSTEM
BATTERY REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3.54.9
{3550, 3143}
FRONT
75D26R
FRONT
Nm {kgfcm, inlbf}
Battery clamp
+ Installation Note (RH)
Battery
Battery tray
BATTERY INSPECTION
Battery
ST
Inspect the battery in the following procedure.
Step
G1
Inspection
5
6
8
9
Action
Above
12.4 V
Go to
Step 3.
Below
12.4 V
Go to
next step.
Above
12.4 V
Go to
next step.
Below
12.4 V
Replace
battery.
Yes
Battery is
okay.
No
Replace
battery.
CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.
Load (A)
34B19R
110
55D23R
180
75D26L
195
75D26R
195
80D26R
195
95D31R
250
BATTERY
Minimum voltage(V)
21 C {70 F}
9.6
15 C {60 F}
9.5
10 C {50 F}
9.4
4 C {40 F}
9.3
1 C {30 F}
9.1
Battery type
(5hour rate)
Slow charge
(A)
Quick charge
(A)/(30 min.)
7 C {20 F}
8.9
34B19R (27)
3.04.0
20
12 C {10 F}
8.7
55D23R (48)
4.55.5
30
18 C { 0 F}
8.5
Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.
5.56.5
35
5.56.5
35
80D26R (55)
5.56.5
35
95D31R (64)
6.58.0
40
Caution
Operating electrical loads while measuring
the back-up current can damage the circuit
tester.
Specification
Above 12.4 V
75D26L (52)
75D26R (52)
Caution
When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
Do not quick charge for over 30 minutes. It
will damage the battery.
G2
CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.
Load (A)
34B19R
110
55D23R
180
75D26L
195
75D26R
195
80D26R
195
95D31R
250
BATTERY
Minimum voltage(V)
21 C {70 F}
9.6
15 C {60 F}
9.5
10 C {50 F}
9.4
4 C {40 F}
9.3
1 C {30 F}
9.1
Battery type
(5hour rate)
Slow charge
(A)
Quick charge
(A)/(30 min.)
7 C {20 F}
8.9
34B19R (27)
3.04.0
20
12 C {10 F}
8.7
55D23R (48)
4.55.5
30
18 C { 0 F}
8.5
Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.
5.56.5
35
5.56.5
35
80D26R (55)
5.56.5
35
95D31R (64)
6.58.0
40
Caution
Operating electrical loads while measuring
the back-up current can damage the circuit
tester.
Specification
Above 12.4 V
75D26L (52)
75D26R (52)
Caution
When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
Do not quick charge for over 30 minutes. It
will damage the battery.
G2
CHARGING SYSTEM
1. Place a battery in a pan of water to prevent it from
overheating. The water level should come up about
halfway on the battery. Keep water off the top of
the battery.
Load (A)
34B19R
110
55D23R
180
75D26L
195
75D26R
195
80D26R
195
95D31R
250
BATTERY
Minimum voltage(V)
21 C {70 F}
9.6
15 C {60 F}
9.5
10 C {50 F}
9.4
4 C {40 F}
9.3
1 C {30 F}
9.1
Battery type
(5hour rate)
Slow charge
(A)
Quick charge
(A)/(30 min.)
7 C {20 F}
8.9
34B19R (27)
3.04.0
20
12 C {10 F}
8.7
55D23R (48)
4.55.5
30
18 C { 0 F}
8.5
Back-up Current
1. Verify that the ignition switch (engine switch) is at the
OFF position and that the key has been removed.
2. Disconnect the negative battery cable.
5.56.5
35
5.56.5
35
80D26R (55)
5.56.5
35
95D31R (64)
6.58.0
40
Caution
Operating electrical loads while measuring
the back-up current can damage the circuit
tester.
Specification
Above 12.4 V
75D26L (52)
75D26R (52)
Caution
When disconnecting the battery, remove
the negative cable first and install it last to
prevent damage to electrical components
or the battery.
To avoid deformation or damage to the
battery, remove the battery plugs while
charging the battery.
Do not quick charge for over 30 minutes. It
will damage the battery.
G2
CHARGING SYSTEM
G6
WL, WL Turbo
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
2030
{2.03.1, 1522}
A
B
C
1925
{1.92.6,
1418}
3851
{3.85.3,
2838}
A
5.06.8 Nm
{5070 kgfcm,
4460 inlbf}
3851
{3.85.3, 2838}
C
3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
F2 CARB, F2 CIS
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
1622
{1.62.3,
1216}
Terminal B wire
Connector
Generator
GENERATOR INSPECTION
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on and
verify that the generator warning light illuminates.
4. If not, inspect the generator warning light and
wiring harnesses between the battery and
generator warning light and between the battery
and generator terminal L (G6, F2 CARB, F2 CIS), I
(WL, WL Turbo).
3851
{3.85.3, 2838}
ST
G6, F2 CARB, F2 CIS
Nm {kgfm, ftlbf}
G3
CHARGING SYSTEM
G6
WL, WL Turbo
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
2030
{2.03.1, 1522}
A
B
C
1925
{1.92.6,
1418}
3851
{3.85.3,
2838}
A
5.06.8 Nm
{5070 kgfcm,
4460 inlbf}
3851
{3.85.3, 2838}
C
3851
{3.85.3, 2838}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
F2 CARB, F2 CIS
5.06.8 Nm
{5070 kgfcm, 4460 inlbf}
1622
{1.62.3,
1216}
Terminal B wire
Connector
Generator
GENERATOR INSPECTION
Generator Warning Light
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Turn the ignition switch (engine switch) on and
verify that the generator warning light illuminates.
4. If not, inspect the generator warning light and
wiring harnesses between the battery and
generator warning light and between the battery
and generator terminal L (G6, F2 CARB, F2 CIS), I
(WL, WL Turbo).
3851
{3.85.3, 2838}
ST
G6, F2 CARB, F2 CIS
Nm {kgfm, ftlbf}
G3
CHARGING SYSTEM
Standard voltage
WL, WL Turbo
WL, WL Turbo
WL, WL Turbo
B+
14.0514.85
B+
14.0514.85
7.0257.425
2.04.0
13.0014.85
Terminal
Current
1. Verify that the battery is fully charged.
2. Verify that the drive belt deflection/tension is
correct. (Refer to Section B1B3, DRIVE BELT,
DRIVE BELT INSPECTION.)
3. Disconnect the negative battery cable.
4. Connect an ammeter, capable of reading 120 A or
over, between generator terminal B and the wiring
harness.
5. Connect the negative battery cable.
6. Turn all electrical loads off.
7. Start the engine and increase the engine speed to
2,0002,500 rpm.
8. Turn the following electrical loads on and verify that
the current reading increases.
Headlights
Blower motor
Rear window defroster
Note
Current required for generating power varies
with electrical loads applied.
Measuring conditions
Room temperature: 20 C {68 F}
Voltage: 13.5 V
Engine hot
Engine speed
(rpm)
Standard voltage
Ignition switch ON (V)
B+
14.114.7
Approx. 1
13.014.0
B+
14.114.7
Terminal
*:
G6, F2 CARB,
F2 CIS
WL, WL Turbo
1,000
Approx. 043
Approx. 058
2,000
Approx. 062
Approx. 074
Must not be 0 A.
WL, WL Turbo
G4
IGNITION SYSTEM
IGNITION SYSTEM
G6, F2 CIS
8.912.7
{90130, 79112}
IGNITER INSPECTION
G6, F2 CIS
1. Disconnect the igniter connector.
2. Turn the ignition switch on and measure the
voltage at connector terminal A using the
voltmeter.
1.51.9
{1520, 1417}
G6, F2 CIS
Specification
Battery positive voltage
6.879.80
{70100, 60.886.8]
Nm {kgfcm, inlbf}
F2 CARB
8.912.7
{90130, 79112}
Specification
Approx. 0.5 V
5. If voltage and continuity are okay, replace the
igniter. (Refer to IGNITION SYSTEM, IGNITION
COIL REMOVAL/INSTALLATION.)
2.02.9
{2030, 1826}
6.879.80
{70100, 60.886.8]
ST
Nm {kgfcm, inlbf}
Center lead
Connector
Condenser
Ignition coil
Igniter
G5
IGNITION SYSTEM
IGNITION SYSTEM
G6, F2 CIS
8.912.7
{90130, 79112}
IGNITER INSPECTION
G6, F2 CIS
1. Disconnect the igniter connector.
2. Turn the ignition switch on and measure the
voltage at connector terminal A using the
voltmeter.
1.51.9
{1520, 1417}
G6, F2 CIS
Specification
Battery positive voltage
6.879.80
{70100, 60.886.8]
Nm {kgfcm, inlbf}
F2 CARB
8.912.7
{90130, 79112}
Specification
Approx. 0.5 V
5. If voltage and continuity are okay, replace the
igniter. (Refer to IGNITION SYSTEM, IGNITION
COIL REMOVAL/INSTALLATION.)
2.02.9
{2030, 1826}
6.879.80
{70100, 60.886.8]
ST
Nm {kgfcm, inlbf}
Center lead
Connector
Condenser
Ignition coil
Igniter
G5
IGNITION SYSTEM
2. Measure the resistance at the primary coil using an
ohmmeter.
F2 CARB
(+)
G6, F2 CIS
F2 CARB
G6
G6
IGNITION SYSTEM
2. Measure the resistance at the primary coil using an
ohmmeter.
F2 CARB
(+)
G6, F2 CIS
F2 CARB
G6
G6
IGNITION SYSTEM
Distributor Installation Note
Verify that the No.1 cylinder is at top dead center,
and align the distributor matching marks.
F2 CARB
MATCHING MARKS
Nm {kgfm, ftlbf}
F2 CIS
ST
Nm {kgfm, ftlbf}
Vacuum hose
High-tension lead
+ HIGH-TENSION LEAD
REMOVAL/INSTALLATION
Connector
Distributor
+ Installation Note
G7
IGNITION SYSTEM
DISTRIBUTOR DISASSEMBLY/ASSEMBLY
G6, F2 CARB, F2 CIS
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
F2 CIS
G6
F2 CARB
Cap
Coupling set
Rotor
Governor set
Cover
10
Oil seal
Signal rotor
11
Bearing
12
Distributor body
13
O-ring
Breaker
G8
IGNITION SYSTEM
DISTRIBUTOR INSPECTION (F2 CARB)
Centrifugal Spark Advance Control
1. Warm up the engine to the normal operating
temperature.
2. Check to be sure that the idle speed and ignition
timing are correct. (Refer to Section F4, ENGINE
TUNE-UP.)
3. Turn off all electrical loads.
4. Disconnect the vacuum hose to the vacuum control
unit, and plug the end of the hose.
TIMING LIGHT
DIAPHRAGM A
( ) 1115
VACUUM HOSE
02
20
0
53.3
ADVANCE (DEGREE)
{150, 5.9} {400, 15.7}
1923
()
913
02
ADVANCE 0(DEGREE)
1,200 2,200
6,000
ENGINE SPEED ( rpm )
ST Resistance
9001,200
G9
Caution
The high-tension leads must be reinstalled
to their original positions. Incorrect
installation can damage the leads and
cause power loss, and negatively affect the
electronic components.
STARTING SYSTEM
STARTING SYSTEM
WL, WL Turbo
STARTER REMOVAL/INSTALLATION
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}
Warning
When the battery cables are connected,
touching the vehicle body with starter
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.
1. Disconnect the negative battery cable.
2. Remove the battery. (WL, WL Turbo) (Refer to
CHARGING SYSTEM, BATTERY
REMOVAL/INSTALLATION.)
3. Remove the intake manifold bracket. (G6)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
G6, F2 CARB, F2 CIS
3851 {3.85.3, 2838}
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}
Nm {kgfm, ftlbf}
Terminal B wire
Terminal S wire
Starter
STARTER INSPECTION
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. Crank the engine and verify that the starter turns
smoothly without any noise.
3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engine
switch) is at START position.
Specification
Above 8 V
4. If the voltage is within the specification, remove the
starter and inspect the magnetic switch and the
starter.
5. If the voltage is not as specified, inspect the wiring
harness, ignition switch (engine switch).
Nm {kgfm, ftlbf}
No Load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, voltmeter, and
ammeter as shown.
A
B
M
IGNITION
SWITCH
(ENGINE
SWITCH)
V
STARTER
BATTERY
TERMINAL S
G10
STARTING SYSTEM
STARTING SYSTEM
WL, WL Turbo
STARTER REMOVAL/INSTALLATION
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}
Warning
When the battery cables are connected,
touching the vehicle body with starter
terminal B will generate sparks. This can
cause personal injury, fire, and damage to
the electrical components. Always
disconnect the battery before performing
the following operation.
1. Disconnect the negative battery cable.
2. Remove the battery. (WL, WL Turbo) (Refer to
CHARGING SYSTEM, BATTERY
REMOVAL/INSTALLATION.)
3. Remove the intake manifold bracket. (G6)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
G6, F2 CARB, F2 CIS
3851 {3.85.3, 2838}
9.911.7 Nm
{100120 kgfcm,
87104 inlbf}
Nm {kgfm, ftlbf}
Terminal B wire
Terminal S wire
Starter
STARTER INSPECTION
On-vehicle Inspection
1. Verify that the battery is fully charged.
2. Crank the engine and verify that the starter turns
smoothly without any noise.
3. If not as specified, measure the voltage at
terminals S and B when the ignition switch (engine
switch) is at START position.
Specification
Above 8 V
4. If the voltage is within the specification, remove the
starter and inspect the magnetic switch and the
starter.
5. If the voltage is not as specified, inspect the wiring
harness, ignition switch (engine switch).
Nm {kgfm, ftlbf}
No Load Test
1. Verify that the battery is fully charged.
2. Connect the starter, battery, voltmeter, and
ammeter as shown.
A
B
M
IGNITION
SWITCH
(ENGINE
SWITCH)
V
STARTER
BATTERY
TERMINAL S
G10
STARTING SYSTEM
3. Operate the starter and verify that it turns
smoothly.
4. Measure the voltage and current while the starter
is operating.
Specification
Engine type
Item
G6
F2 CARB,
F2 CIS
WL,
WL Turbo
Voltage (V)
11.5
11.5
11
Current (A)
Below 100
Below 60
Below 130
G11
CLUTCH
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
CLUTCH FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH FLUID INSPECTION . . . . . . . . . . . . .
CLUTCH FLUID REPLACEMENT/AIR
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL INSPECTION/
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH PEDAL DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
CLUTCH MASTER CYLINDER
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
H 1
H 1
H 1
H 1
H 2
H 2
H 3
H 4
H 5
H 5
H 5
GENERAL PROCEDURES
CLUTCH FLUID
49 0259 770B
H1
CLUTCH PEDAL
CLUTCH PEDAL INSPECTION/ADJUSTMENT
Clutch Pedal Height
1. Measure the distance from the upper surface of the
pedal pad to the carpet.
Pedal height
241.6246.6 mm {9.529.70 in}
A 1417
{1.41.8, 1113}
PEDAL HEIGHT
CARPET
Nm {kgfm, ftlbf}
H2
CLUTCH PEDAL
CLUTCH PEDAL INSPECTION/ADJUSTMENT
Clutch Pedal Height
1. Measure the distance from the upper surface of the
pedal pad to the carpet.
Pedal height
241.6246.6 mm {9.529.70 in}
A 1417
{1.41.8, 1113}
PEDAL HEIGHT
CARPET
Nm {kgfm, ftlbf}
H2
CLUTCH PEDAL
CLUTCH PEDAL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2.Remove in the order indicated in the table.
3.Install in the reverse order of removal.
4.After installation, adjust the clutch pedal.
(Refer to CLUTCH PEDAL
INSPECTION/ADJUSTMENT)
L.H.D.
D
1925
{1.92.6,
1418}
C
1216
{1.21.7,
8.712.3}
1925
{1.92.6,
1418}
PEDAL
FREE PLAY
Nm {kgfm, ftlbf}
6.99.80 Nm
{70100 kgfcm,
6186.8 inlbf}
Spring pin
Clevis pin
Nut
R.H.D.
G6, F2 CIS, F2 Carb
Refer to section F1, F3, or F4, INTAKE-AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION.
Standard distance
A: 14.637.5 mm {0.581.47 in}
(reference value)
A
WL, WL Turbo
Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDAL
REMOVAL/INSTALLATION.
RELEASE
POINT
FULL
STROKE
END
POSITION
Nm {kgfm, ftlbf}
PEDAL STROKE
H3
CLUTCH PEDAL
CLUTCH PEDAL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2.Remove in the order indicated in the table.
3.Install in the reverse order of removal.
4.After installation, adjust the clutch pedal.
(Refer to CLUTCH PEDAL
INSPECTION/ADJUSTMENT)
L.H.D.
D
1925
{1.92.6,
1418}
C
1216
{1.21.7,
8.712.3}
1925
{1.92.6,
1418}
PEDAL
FREE PLAY
Nm {kgfm, ftlbf}
6.99.80 Nm
{70100 kgfcm,
6186.8 inlbf}
Spring pin
Clevis pin
Nut
R.H.D.
G6, F2 CIS, F2 Carb
Refer to section F1, F3, or F4, INTAKE-AIR
SYSTEM, ACCELERATOR PEDAL
REMOVAL/INSTALLATION.
Standard distance
A: 14.637.5 mm {0.581.47 in}
(reference value)
A
WL, WL Turbo
Refer to section F2, INTAKE-AIR SYSTEM,
ACCELERATOR PEDAL
REMOVAL/INSTALLATION.
RELEASE
POINT
FULL
STROKE
END
POSITION
Nm {kgfm, ftlbf}
PEDAL STROKE
H3
CLUTCH PEDAL
CLUTCH PEDAL DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
Note
Apply lithium-based grease to the spring and
bush when assembling.
2. Assemble in the reverse order of disassembly.
1216
{1.21.7, 8.712.3}
1417
{1.41.8,
1113}
Nm {kgfm, ftlbf}
Nut
Stopper rubber
Retaining ring
Washer
Bush
Pin
Fork
10
Push rod
11
Nut
12
Pedal pad
13
H4
SST *
12.821.5
{130220, 113190}
* 49 0259 770B
Nm {kgfcm, inlbf}
Clutch pipe
Nut
Gasket
84112 Nm
{8.511.5 kgfm,
61.583.1 ftlbf}
H5
SST *
12.821.5
{130220, 113190}
* 49 0259 770B
Nm {kgfcm, inlbf}
Clutch pipe
Nut
Gasket
84112 Nm
{8.511.5 kgfm,
61.583.1 ftlbf}
H5
Snap ring
+ Disassembly Note
+ Assembly Note
Piston
Protector
Primary cap
Return spring
Tank cap
Reservoir
Bushing
Joint bolt
10
Gasket
11
12
Return spring
13
14
H6
E-clip
Bolt
Clutch hose
Nm {kgfm, ftlbf}
G6
5.98.8 Nm
{6090 kgfcm,
5378 inlbf}
EXCEPT
G6
Boot
Bleeder cap
Push rod
Bleeder screw
Steel ball
Return spring
H7
CLUTCH UNIT
CLUTCH UNIT
CLUTCH UNIT REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
G6
:9298 {9.310.0, 67.372.3}
EXCEPT G6 :97102 {9.810.5, 70.975.9}
ENGINE SIDE
TRANSMISSION SIDE
SST
SST
SST
SST
(MOLYBDENUM SULFIDE)
Nm {kgfm, ftlbf}
Transmission
+ Section J1, MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION
+ Section J2, MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION
Clutch disc
+ Installation Note
Pilot bearing
+ Removal Note
+ Installation Note
Clutch cover
+ Removal Note
+ Installation Note
Flywheel
+ Removal Note
+ Installation Note
H8
CLUTCH UNIT
Clutch Cover Removal Note
1. Install the SSTs.
2. Loosen each bolt one turn at a time in a crisscross
pattern until spring tension is released.
49 E011 1A0
49 SE01 310A
49 E011 1A0
4
6
EXCEPT G6
1
6
49 E011 1A0
4
5
2
49 1285 071
G6
PILOT BEARING
CRANK
SHAFT
49 E011 1A0
EXCEPT G6
1
6
49 E011 1A0
5
2
H9
CLUTCH UNIT
WL, WL Turbo
Install a new pilot bearing using a pipe until
protrusion height is as follows:
Protrusion height
00.2 mm {00.008 in}
DEPTH
PILOT BEARING
FLY WHEEL
Clearance
0.5 mm {0.020 in} max.
49 SE01 310A
49 E011 1A0
Misalignment
0.6 mm {0.030 in} max.
49 SE01 310A
H10
CLUTCH UNIT
WL, WL Turbo
Install a new pilot bearing using a pipe until
protrusion height is as follows:
Protrusion height
00.2 mm {00.008 in}
DEPTH
PILOT BEARING
FLY WHEEL
Clearance
0.5 mm {0.020 in} max.
49 SE01 310A
49 E011 1A0
Misalignment
0.6 mm {0.030 in} max.
49 SE01 310A
H10
CLUTCH UNIT
CLUTCH DISC INSPECTION
1. Using vernier calipers, measure the thickness of
the lining at a rivet head on both sides.
2. If clutch disc thickness is less than the minimum,
replace the clutch disc.
FLYWHEEL
PILOT BEARING INSPECTION
1. Without removing the pilot bearing from the
flywheel, turn the bearing while applying force in
the axial direction.
Thickness
0.3 mm {0.012 in} min.
0.3 mm
{0.012 in}
FLYWHEEL INSPECTION
1. Install a dial indicator on the cylinder block.
2. Measure the flywheel runout using a dial indicator.
Runout
0.7 mm {0.027 in} max.
Runout
0.2 mm {0.079 in} max.
Caution
Cleaning the clutch release collar with
cleaning fluids or a steam cleaner can wash
the grease out of the sealed bearing.
Otherwise, clutch release collar may not
operate properly.
1. Turn the collar while applying force in the axial
direction.
H11
MANUAL TRANSMISSION
(R15MD, R15MXD)
MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . .
TRANSMISSION OIL INSPECTION . . . . . . . . .
TRANSMISSION OIL REPLACEMENT . . . . . .
OIL SEAL (R15MD) REPLACEMENT . . . . . .
VEHICLE SPEEDOMETER SENSOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
J21
J21
J21
J22
J22
TRANSMISSION OIL REPLACEMENT
1. Remove drain plugs A and B, and drain the oil into
a container.
2. Clean the drain plug A.
3. Install the drain plug A with new washer and a new
drain plug B.
MANUAL TRANSMISSION
TRANSMISSION OIL INSPECTION
1. Remove the filler plug.
FILLER PLUG
Tightening torque
A: 4058 Nm {4.06.0 kgfm, 2943 ftlbf}
B: 2131 Nm {2.13.2 kgfm, 1623 ftlbf}
FILLER PLUG
2. Verify that the oil is at the brim of the filler plug hole
as shown. If it is low, add the specified oil from the
filler plug hole.
DRAIN PLUG A
Specified oil
Grade:
API service GL4 or GL5
Viscosity:
SAE 75W90 (All season) or
SAE 80W90 (Above 10C {50F})
DRAIN PLUG B
J21
MANUAL TRANSMISSION
1. Install a new filler plug.
Tightening torque
2539 Nm {2.64.0 kgfm, 1928 ftlbf}
OIL SEAL (R15MD) REPLACEMENT
1. Drain the transmission oil.
2. Remove the propeller shaft.
(Refer to section L, PROPELLER SHAFT (4x2),
PROPELLER SHAFT REMOVAL/INSTALLATION.)
3. Remove the oil seal using a screwdriver.
PIPE
J22
MANUAL TRANSMISSION
MANUAL TRANSMISSION REMOVAL/INSTALLATION
4 2 (R15MD)
1. Disconnect the negative battery cable.
2. Drain the transmission oil into a container.
3. Remove the propeller shaft. (Refer to section L, PROPELLER SHAFT (4x2), PROPELLER SHAFT
REMOVAL/INSTALLATION.)
4. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Add the specified amount and type of transmission oil. (Refer to MANUAL TRANSMISSION, TRANSMISSION
OIL REPLACEMENT.)
8. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
F2
6988
{7.09.0,
5165}
6988
{7.09.0,
5165}
1622
{1.62.3,
1216}
3851
{3.85.3,
2838}
6988
{7.09.0,
5165}
6988
{7.09.0,
5165}
1622
{1.62.3,
1216}
ST
3851
{3.85.3,
2838}
3851
{3.85.3,
2838}
7.910.7 Nm
{80110 kgfcm, 69.595.4 inlbf}
3846
{3.84.7,
2833}
Nm {kgfm, ftlbf}
12
Console
13
Dust boot
14
15
Boot
16
Dust boot
17
Gasket
Crossmember
+ Removal Note
Wave washer
18
Change bush
19
10
Change lever
Transmission
+ Removal note
+ Installation note
11
Change seat
J23
MANUAL TRANSMISSION
WL, WL TURBO
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
3851
{3.85.3,
2838}
A
1622
{1.62.3,
1216}
1622
{1.62.3,
1216}
3846
{3.84.7, 2833}
Nm {kgfm, ftlbf}
11
Change seat
Console
12
Dust boot
13
14
Boot
15
Dust boot
16
Gasket
Crossmember
+ Removal Note
Wave washer
17
Change bush
18
10
Change lever
Transmission
+ Removal note
+ Installation note
J24
MANUAL TRANSMISSION
ZCF5210W001
12
Console
13
Dust boot
14
15
Boot
16
Dust boot
17
Gasket
Crossmember
See NO TAG Crossmember removal note
Wave washer
18
Change bush
19
10
Change lever
Transmission
See NO TAG Transmission removal note
See NO TAG Transmission installation note
11
Change seat
J25
MANUAL TRANSMISSION
Crossmember removal note
D Securely support the transmission on a
transmission jack, then remove the crossmember.
Transmission removal note
Warning
D Do not allow the transmission to fall from
the transmission jack.
D Maintain the stability of the transmission while
removing it.
ST
J26
MANUAL TRANSMISSION
4 4 (R15MXD)
1. Disconnect the negative battery cable.
2. Drain the transmission and transfer oil into a container.
3. Remove the front and rear propeller shaft.
(Refer to section L, FRONT PROPELLER SHAFT (4x4), FRONT PROPELLER SHAFT
REMOVAL/INSTALLATION.)
(Refer to section L, REAR PROPELLER SHAFT (4x4), REAR PROPELLER SHAFT
REMOVAL/INSTALLATION.)
4. Remove the front pipe. (G6 engine)
(Refer to section F1, EXHAUST SYSTEM, EXHAUST SYSTEM REMOVAL/INSTALLATION.)
5. Remove the starter. (Refer to section G, STARTING SYSTEM, STARTER REMOVAL/INSTALLATION.)
6. Remove in the order indicated in the table.
7. Install in the reverse order of removal.
8. Add the specified type and amount of transmission and transfer oil.
(Refer to MANUAL TRANSMISSION, TRANSMISSION OIL REPLACEMENT.)
(Refer to section J3, TRANSFER, TRANSFER OIL REPLACEMENT.)
9. Warm up the engine and transmission, inspect for oil leakage, and verify the transmission operation.
G6
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
R
R
1925
{1.92.6,
1418}
A
3851 {3.85.3, 2838}
1622
{1.62.3,
1216}
6988
{7.09.0,
5165}
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
3750
{3.75.1,
2736}
Nm {kgfm, ftlbf}
J27
MANUAL TRANSMISSION
14
Console
15
Dust boot
16
17
Boot
18
Dust boot
19
Gasket
20
Wave washer
Crossmember
+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,
4 2 (R15MD), Crossmember removal note
Change bush
10
Change lever
21
11
Change seat
22
12
13
WL, WL TURBO
7.910.7 Nm
{80110 kgfcm,
69.595.4 inlbf}
R
R
3851
{3.85.3,
2838}
1925
{1.92.6, 1418}
ST
3851
{3.85.3, 2838}
A
3246
{3.24.7, 2433}
1622
{1.62.3,
1216}
3750
{3.75.1,
2736}
4453
{4.45.3, 3239}
2228
{2.22.9, 1620}
Nm {kgfm, ftlbf}
J28
MANUAL TRANSMISSION
14
Console
15
Dust boot
16
17
Boot
18
Dust boot
19
Gasket
Wave washer
Crossmember
+ MANUAL TRANSMISSION, MANUAL
TRANSMISSION REMOVAL/INSTALLATION,
4 2 (R15MD), Crossmember removal note
Change bush
20
10
Change lever
21
11
Change seat
12
13
ZCF5210W003
Dust boot
Console
J29
MANUAL TRANSMISSION
Boot
16
Dust boot
17
Gasket
18
Wave washer
19
Change bush
20
Crossmember
10
Change lever
21
11
Change seat
22
12
13
14
15
J210
PROPELLER SHAFT
PROPELLER SHAFT (42) . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROPELLER SHAFT INSPECTION . . . . . . . . . .
FRONT PROPELLER SHAFT (44) . . . . . . . . . . .
FRONT PROPELLER SHAFT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
L1
L1
L2
L2
L2
L3
L3
L5
L5
L5
SST
Bolt, nut
Nut
+ Installation Note
Propeller shaft
+ Removal Note
+ Installation Note
WL TURBO, G6:
49 S120 440
49 0259 440
MARK
MARK
L1
Runout
0.4 mm {0.016 in} max.
2830
{2.83.1, 2122}
Nm {kgfm, ftlbf}
Bolt, nut
TAG
MARK
L2
Runout
0.4 mm {0.016 in} max.
2830
{2.83.1, 2122}
Nm {kgfm, ftlbf}
Bolt, nut
TAG
MARK
L2
TAG
MARK
Snap ring
+ Disassembly Note
Universal joint
+ Disassembly Note
+ Assembly Note
Sliding yoke
Propeller shaft
MARK
Note
Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}
ST
BEARING CUP
L3
TAG
MARK
Snap ring
+ Disassembly Note
Universal joint
+ Disassembly Note
+ Assembly Note
Sliding yoke
Propeller shaft
MARK
Note
Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}
ST
BEARING CUP
L3
TAG
MARK
Snap ring
+ Disassembly Note
Universal joint
+ Disassembly Note
+ Assembly Note
Sliding yoke
Propeller shaft
MARK
Note
Starting torque
0.30.7 Nm
{3.08.0 kgfcm, 2.76.9 inlbf}
ST
BEARING CUP
L3
SPIDER
1.32 {0.0520}
1.24 {0.0488}
1.34 {0.0528}
1.26 {0.0496}
1.36 {0.0536}
1.28 {0.0504}
1.38 {0.0543}
1.30 {0.0512}
BEARING CUP
YOKE
SNAP RING
CLEARANCE
SPIDER
L4
TAG
MARK
5058
{5.06.0, 3743}
3752
{3.75.4, 2739}
5058
{5.06.0, 3743}
Nm {kgfm, ftlbf}
Bolt, nut
Nut
+ PROPELLER SHAFT (42), PROPELLER
SHAFT REMOVAL/INSTALLATION, Nut
Installation Note
ST
MARK
L5
STANDARD DIFFERENTIAL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
STANDARD DIFFERENTIAL ASSEMBLY . . .
LIMITED SLIP DIFFERENTIAL
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
LIMITED SLIP DIFFERENTIAL
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL FREEEWHEEL (MFW)
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON-VEHICLE INSPECTION . . . . . . . . . . . . . . .
REMOTE FREEWHEEL (RFW)
MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 4 INDICATOR SWITCH INSPECTION . . .
TRANSFER NEUTRAL SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
RFW SWITCH INSPECTION . . . . . . . . . . . . . .
RFW MAIN SWITCH REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
RFW MAIN SWITCH INSPECTION . . . . . . . .
ONE-WAY CHECK VALVE INSPECTION . . .
LOCK AND FREE SOLENOID VALVES
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
RFW ACTUATOR INSPECTION . . . . . . . . . . .
RFW CONTROL MODULE INSPECTION . . . .
RFW CONTROL MODULE
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT
REMOVAL/INSTALLATION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .
JOINT SHAFT INSPECTION . . . . . . . . . . . . . .
JOINT SHAFT COMPONENT ASSEMBLY . . .
CONTROL BOX REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX DISASSEMBLY/
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT FORK INSPECTION . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL OIL SEAL
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL REMOVAL
/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . .
FRONT DIFFERENTIAL DISASSEMBLY . . . .
FRONT DIFFERENTIAL ASSEMBLY . . . . . . .
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .
REMOTE FREEWHEEL (RFW) . . . . . . . . . . . .
M1
M37
M40
M44
M46
M48
M48
M48
M48
M48
M49
M49
M49
M50
M50
M50
M51
M51
M53
M54
M55
M56
M58
M59
M60
M61
M61
M61
M61
M62
M64
M67
M72
M72
GENERAL PROCEDURES
FRONT AXLE (4 2)
Caution
D Brake fluid will damage painted surfaces. If
brake fluid gets on a painted surface, wipe
it off immediately.
Preload Adjustment
1. Verify that the tire rotates smoothly when rotated
strongly, and that there is no rough feeling or is
abnormal noise from the bearing.
2. Remove the brake caliper component and suspend
it by a rope.
3. Remove the hub cap, pull out the cotter pin and
remove the set cover.
4. Loosen the locknut to the extent that it can be
turned by hand.
5. Attach a pull scale to a hub bolt and measure the
frictional force.
6. Tighten the locknut until the reading reaches the
specified amount.
Preload
Frictional force plus
5.910.7 N {0.61.1 kgf, 1.42.4 lbf}
7. Install the set cover, and secure with a new cotter
pin.
8. Install the hub cap and brake caliper component.
Note
D Unloaded: Fuel tank is full. Engine coolant and
engine oil are at a specified level. Spare tire,
jack and tools are in designated position.
Connectors disconnection/connection
D Disconnect the negative battery cable before doing
any work that requires the handling of connectors.
Reconnect the negative battery cable only after the
work is completed.
M2
FRONT AXLE (4 2)
WHEEL HUB, STEERING KNUCKLE REMOVAL/INSTALLATION (VEHICLES BUILT UP 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
SST
SST
R
SST
R
SST
R
R
R
SST
SST
1925
{1.92.6,
1418}
Nm {kgfm, ftlbf}
Hub cap
Cotter pin
11
Set cover
Locknut
Washer
12
13
Steering knuckle
Dust cover
14
Disc plate
+ Removal Note
15
Wheel hub
+ Removal Note
16
Hub bolt
+ Removal Note
+ Installation Note
10
Knuckle arm
M3
FRONT AXLE (4
17
18
Oil seal
+ Installation Note
19
20
21
2)
OUTSIDE BEARING
49 H033 101
INSIDE BEARING
49 B025 001
49 F019 001
MARK
M4
FRONT AXLE (4
Hub and Disc Plate Component Installation Note
1. Apply grease to the areas indicated in the figure.
M5
2)
FRONT AXLE (4
2)
Hub cap
11
Cotter pin
12
Set cover
13
Steering knuckle
Locknut
14
Disc plate
Washer
15
Wheel hub
16
Hub bolt
17
Dust cover
18
Oil seal
19
10
Knuckle arm
20
M6
FRONT AXLE (4
21
22
M7
2)
FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE
PREINSPECTION (VEHICLES BUILT FROM
08/2002)
Wheel Bearing Play Inspection
1. Position a dial indicator against the wheel hub.
FRONT AXLE (4 4)
WHEEL HUB, STEERING KNUCKLE INSPECTION
(VEHICLES BUILT UP TO 07/2002)
Wheel Bearing Play Inspection
(Refer to FRONT AXLE (4 2), WHEEL HUB,
STEERING KNUCKLE INSPECTION, Wheel Bearing
Play Inspection.)
Preload Adjustment
Caution
D When replacing the locknut, tighten it using
the SST and turn the wheel hub a few times
to seat the bearing. Then, perform the
preload adjustment.
1. For RFW model, remove the hub cap and drive
shaft end flange. For MFW model, remove the
freewheel hub component.
2. Remove the spacer and set plate.
3. Remove the brake caliper component, and
suspend it by a rope.
4. Loosen the locknut to the extent that it can be
turned by hand using the SST.
49 S231 635
2. Install the hub bolt into the wheel hub and install a
washer and hub nut on the hub bolt.
3. Tighten the hub nut while holding the wheel hub
using a brass bar.
M8
FRONT AXLE (4
4)
R
SST
R
SST
SST
5567
{5.66.9,
4149}
5468 {5.57.0}
SST
3051
{3.05.2,
2237}
R
SST
R
R
R
SST
SST
SST
R
SST
R
(RFW MODEL)
(MFW MODEL)
2529 {2.53.0, 1921}
Nm {kgfm, ftlbf}
Hub cap
Dust cover
10
Spacer
Set plate
Locknut
+ Removal Note
+ Installation Note
11
Disc plate
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Disc Plate
Removal Note
12
Wheel hub
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Wheel
Hub Removal Note
M9
FRONT AXLE (4 4)
13
Hub bolt
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt
Removal Note
+ FRONT AXLE (4 2), WHEEL HUB, STEERING
KNUCKLE REMOVAL/INSTALLATION, Hub Bolt
Installation Note
14
15
Oil seal
+ Installation Note
16
17
18
19
Nut
+ Section R, FRONT SUSPENSION, TORSION
BAR SPRING AND LOWER ARM (4 2)
REMOVAL/INSTALLATION, Nut Installation Note
20
21
22
23
24
Oil seal
+ Removal Note
+ Installation Note
25
Spacer
26
Needle bearing
+ Removal Note
+ Installation Note
27
49 S033 108
Steering knuckle
M10
FRONT AXLE (4
Oil Seal Installation Note
1. Install the new oil seal using the SST and a press.
2. Apply grease to the oil seal lip.
4)
49 S033 107
49 F027 005
49 F027 007
49 S033 106
M11
4)
FRONT AXLE (4
4)
Locknut
+ See Locknut Removal Note
+ See Locknut Installation Note
Brake caliper component
+ See Brake Caliper Component Removal Note
Disc plate
Bolt (stabilizer)
M12
10
Oil seal
+ See Oil Seal Removal Note
+ See Oil Seal Installation Note
FRONT AXLE (4
11
12
Retaining ring
13
Wheel Bearing
+ See Wheel Bearing Removal Note
+ See Wheel Bearing Installation Note
14
Dust cover
+ See Dust Cover Removal Note
+ See Dust Cover Installation Note
15
Steering Knuckle
16
Hub bolt
+ See Hub Bolt Removal Note
+ See Hub Bolt Installation Note
4)
M13
FRONT AXLE (4
4)
M14
FRONT AXLE (4
Wheel Hub Component Installation Note
1. Install the wheel hub component using the SSTs
and a press.
M15
4)
REAR AXLE
4. If not as specified, adjust the bearing play. (Refer
to REAR AXLE, AXLE SHAFT
REMOVAL/INSTALLATION, Bearing Inner Race,
Bearing Locknut Installation Note, Bearing play
adjustment.)
REAR AXLE
REAR AXLE INSPECTION
Wheel Bearing Play Inspection
1. Jack up the rear end and support it with safety
stands.
2. Verify that there is no abnormal noise and that the
tire rotates smoothly when forcefully rotated by
hand.
3. With a hand on top of the tire, inspect the bearing
play.
Wheel bearing axial play
0.050.25 mm {0.0020.010 in}
SST
*
SST
1621 Nm
{1.62.2 kgfcm,
1215 inlbf}
SST
R
SST
SST
SST
R
108127
{1113, 8094}
SST
R
*49
0259 770B
Nm {kgfm, ftlbf}
M16
REAR AXLE
Bearing Housing Removal Note
D Remove the bearing and bearing housing using the
SSTs.
Brake drum
Brake pipe
Nut
Shim
Bearing locknut
+ Removal Note
+ Installation Note
Lock washer
Bearing housing
+ Removal Note
10
11
Bearing spacer
12
13
14
15
Axle shaft
16
Hub bolt
17
Baffle
18
49 S026 204
49 S026 205
49 S026 208
OIL SEAL
49 0603 635A
49 S120 645A
49 H025 001
M17
AXLE CASING
REAR AXLE
Bearing Outer Race, Oil Seal
(Bearing Housing Side) Installation Note
D Press the bearing outer race and the oil seal using
the SSTs.
OIL SEAL
BEARING
OUTER
RACE
49 U027 003
49 F027 004
PINION SHAFT
A
1. Set the SST and then press the bearing inner race
in until 3 to 5 threads of the bearing locknut
mounting screw of the axle shaft are visible above
the top of the bearing outer race.
49 S120 748
49 0603 635A
49 S120 645A
M18
SHIM
THRUST
BLOCK
REAR AXLE
AXLE SHAFT (WITH ABS) REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Brake drum
Brake pipe
4
5
Bearing locknut
+ See Bearing Locknut Removal Note
+ See Bearing Inner Race, Bearing Locknut
Installation Note
Nut
Lock washer
10
Bearing housing
+ See Bearing Housing Removal Note
11
12
Bearing spacer
13
14
Shim
+ See Axle Shaft and Back Plate Component,
Shim Installation Note (Bearing play adjustment)
ABS sensor rotor
+ See ABS Sensor Rotor Removal Note
+ See ABS Sensor Rotor Installation Note
M19
REAR AXLE
15
16
Axle shaft
17
Hub bolt
18
Baffle
19
M20
REAR AXLE
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.
M21
REAR AXLE
ABS Sensor Rotor Installation Note
Note
D Install the ABS sensor rotor in the direction
shown in the figure
M22
DRIVE SHAFT
DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION (VEHICLES BUILT UP TO 07/2002)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Snap ring
Clip
+ Installation Note
Drive shaft
+ Removal Note
+ Installation Note
OPENING
28 mm {1.1 in}
M23
DRIVE SHAFT
DRIVE SHAFT REMOVAL/INSTALLATION (VEHICLES BUILT FROM 08/2002)
Caution
D Performing the following procedures without first removing the ABS wheelspeed sensor may
possibly cause an open circuit in the harness if it is pulled by mistake. Before performing the
following procedures, remove the ABS wheelspeed sensor (axle side) and fix it to an appropriate
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.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Drive shaft
+ See Drive Shaft Removal Note
+ See Drive Shaft Installation Note
Clip
M24
DRIVE SHAFT
Drive Shaft Installation Note
28 mm {1.1 in}
Caution
D 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.
D The oil seals are damaged easily if this
M25
DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY (VEHICLES BUILT UP TO 07/2002)
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of removal.
R
RIGHT SIDE
R
R
R
R
LEFT SIDE
Boot band
+ Disassembly Note
+ Assembly Note
Inner ring
+ Disassembly Note
+ Assembly Note
Clip
Outer ring
+ Disassembly Note
+ Assembly Note
Cage
+ Disassembly Note
+ Assembly Note
Snap ring
+ Assembly Note
Boot
+ Disassembly Note
+ Assembly Note
Balls
+ Disassembly Note
+ Assembly Note
10
Drive shaft
M26
DRIVE SHAFT
Boot Band Disassembly Note
Note
D The wheel side boot band does not need to be
removed unless replacing it.
30_
Caution
D Mark with paint; do not use a punch.
1. Mark the cage and outer ring for proper assembly.
2. Remove the clip using a screwdriver.
3. Remove the outer ring from the inner ring and the
balls.
4. Clean the grease away.
TAPE
MARKS
WHEEL SIDE
99.2 mm
{3.9 in}
DIFFERENTIAL SIDE
MARKS
M27
DRIVE SHAFT
Cage, Inner Ring, Balls, Snap Ring Assembly Note
1. Align the marks, and install the balls and cage to
the inner ring in the direction shown in the figure.
Caution
D Install the cage with the offset facing the
snap ring groove. If incorrectly installed,
the drive shaft may become disengaged.
LEFT SIDE
RIGHT SIDE
Standard length
Right side : 619.0629.0 mm {24.424.7 in}
Left side : 551.0561.0 mm {21.722.0 in}
3. Release trapped air from inside the boot using a
screwdriver covered with a rag.
SNAP RING
GROOVE
INNER
RING
Wheel side
: 110130 g {3.84.6 oz}
Differential side : 95105 g {3.43.7 oz}
2. Align the marks, and install the outer ring onto the
shaft.
3. Install a new clip.
MARKS
M28
DRIVE SHAFT
DRIVE SHAFT DISASSEMBLY/ASSEMBLY (VEHICLES BUILT FROM 08/2002)
Caution
D 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.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of removal.
Boot band
+ See Boot Band Disassembly Note
+ See Boot Band Assembly Note
Clip
Outer ring
+ See Outer Ring Disassembly Note
+ See Outer Ring Assembly Note
Snap ring
+ See Cage, Inner Ring, Balls, Snap Ring Assembly Note
Balls
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Cage, Inner Ring, Balls, Snap Ring Assembly Note
M29
Inner ring
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Cage, Inner Ring, balls, Snap Ring Assembly Note
Cage
+ See Balls, Inner Ring, Cage Disassembly Note
+ See Inner ring, Balls, Snap Ring Assembly
Note
Boot
+ See Boot Disassembly Note
+ See Boot Assembly Note
10
Drive shaft
DRIVE SHAFT
D Do not strip the tape until the boot is
assembled.
1. Wrap the shaft splines with tape.
Caution
D Do not touch the grease with your hand.
Apply it from the tube to prevent foreign
matter from entering the boot.
Note
D The wheel side and differential side boots are
different.
D Use the specified grease supplied in the boot.
Grease amount
110130 g {3.884.58 oz}
2. With the splines of the shaft still wrapped in tape
from disassembly, install the boot.
3. Remove the tape.
M30
DRIVE SHAFT
Outer Ring Assembly Note
1. Fill the outer ring and boot with the specified
grease.
Caution
D Do not touch the grease with your hand.
Apply it from the tube to prevent foreign
matter from entering the boot.
Note
D Use the specified grease supplied in the boot
kit.
2. Lock the end of the band by bending the locking
clips.
Grease amount
95115 g {3.364.05 oz}
2. Align the marks, and install the outer ring on to the
shaft.
3. Install a new clip.
4. Install the boot,
5. Set the drive shaft to the standard length.
Standard length
Right side: 593.5603.5 mm {23.3723.75 in}
Left side: 525.5535.5 mm {20.6921.08 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
D Be careful not to allow the grease to leak.
D Do not damage the boot.
M31
DRIVE SHAFT
OUTPUT SHAFT (MFW) REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3757
{3.75.5, 2739}
Nm {kgfm, ftlbf}
Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION
Bolt
M32
Screw
DRIVE SHAFT
OUTPUT SHAFT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
R
SST
R
R
R
Clip
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Clip Assembly Note
Bearing
+ Disassembly Note
+ Assembly Note
Output shaft
Bearing housing
Oil seal
+ Assembly Note
O-ring
Oil seal
+ Assembly Note
M33
DRIVE SHAFT
Bearing Disassembly Note
D Remove the bearing from the output shaft
component using a press.
49 M005 796
M34
REAR DIFFERENTIAL
Specified oil
Type
Standard differential:
API service GL5, SAE 90
LSD:
API service GL6, SAE 90
Capacity:
4 2:
1.40 L {1.48 US qt, 1.23 lmp qt}
4 4:
1.85 L {1.96 US qt, 1.63 lmp qt}
REAR DIFFERENTIAL
REAR DIFFERENTIAL OIL INSPECTION
Caution
D Position the vehicle level.
1. Remove the filler plug.
2. Verify that the oil is at the brim of the filler plug
hole. If it is low, add the specified oil.
Specified oil
Type
Standard differential:
API service GL5, SAE 90
LSD:
API service GL6, SAE 90
Capacity
4 2:
1.40 L {1.48 US qt, 1.23 lmp qt}
4 4:
1.85 L {1.96 US qt, 1.63 lmp qt}
FILLER PLUG
WASHER
M35
REAR DIFFERENTIAL
REAR DIFFERENTIAL REMOVAL/INSTALLATION
Caution
D Clean away the old sealant before applying the new sealant.
D Install the differential carrier within 10 minutes after applying sealant.
D Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oil.
1. Drain the differential oil. (Refer to REAR DIFFERENTIAL, REAR DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the rear propeller shaft. (Refer to section L, REAR PROPELLER SHAFT (4 4), REAR PROPELLER
SHAFT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
5058
{5.06.0, 3743}
Nm {kgfm, ftlbf}
M36
Differential
+ Removal Note
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.
SST
SST
SST
SST
SST
Differential component
+ Disassembly Note
14
Adjusting shim
15
Bearing cap
+ Disassembly Note
16
Oil buffle
Adjusting shim
17
18
Carrier
19
Hex screw
Pinion nut
+ Disassembly Note
20
Ring gear
21
Roll pin
+ Disassembly Note
22
Pinion shaft
23
Thrust block
Companion flange
+ Disassembly Note
Oil seal
+ Disassembly Note
Thrust washer
24
Pinion gear
10
Drive pinion
+ Disassembly Note
25
26
Side gear
11
27
12
Collapsible spacer
28
Case
13
M37
REAR DIFFERENTIAL
Differential Component Disassembly Note
D Mount a carrier component to the SST or
equivalent.
T57L500B
MARK
308047
T77F1102A
the SST.
M38
REAR DIFFERENTIAL
Rear Bearing Cone Disassembly Note
Note
D Mark or otherwise distinguish between the front
and rear cones so that they are not mixed up at
the time of reassembly.
D Remove the rear bearing cone using the SST.
205D064
D84L1123A
3308047
T77F1102A
M39
REAR DIFFERENTIAL
STANDARD DIFFERENTIAL ASSEMBLY
D Assemble in the order indicated in the table.
SST
SST
SST
130150
{13.215.3,
96110}
R
SST
R
R
SST
R
SST
R
R
SST
298500
{30.350.9, 220368}
Nm {kgfm, ftlbf}
Case
+ Assembly Note
16
Adjusting shim
+ Assembly Note
17
Side gear
18
Drive pinion
+ Assembly Note
Pinion gear
19
Collapsible spacer
Thrust block
20
Pinion shaft
21
Thrust washer
Roll pin
22
Ring gear
Oil seal
+ Assembly Note
10
Hex screw
23
Companion flange
11
24
Pinion nut
25
12
Carrier
13
Oil buffle
26
Adjusting shim
+ Assembly Note
14
27
Bearing cap
+ Assembly Note
15
M40
REAR DIFFERENTIAL
Adjusting Shim Assembly Note
Pinion height Adjustment
1. Assemble the rear bearing cone over the SST and
insert it into the rear bearing cup of the carrier.
2. Assemble the front bearing cone into the front
bearing cup and assemble the SSTs.
205456
205110, T76P4020A10
205457
205105, T76P4020A3
205090
T75L1165B
205109, T76P4020A9
205111, T76P4020A11
Note
D There should be drag on the feeler gauge
when it is inserted between the SSTs
(205110, T76P4020A10 and 205456).
Caution
D Never loosen pinion nut to decrease drive
pinion preload torque, and never exceed
specified preload torque. If preload torque
is exceeded, a new collapsible spacer must
be installed and the torque sequence
repeated.
205456
M41
REAR DIFFERENTIAL
Case Assembly Note
D Assemble the side gears, thrust washer, thrust
block, pinion gears, pinion shaft and knock pin.
After assembling the knock pin, make a crimp so
that the pin will not come out of the gear case.
205007
T56T4676B
Standard backlash
00.1 mm {00.004 in}
(4) If the backlash exceeds the standard, use the
thrust washers to adjust.
Side Bearing Cone Assembly Note
Caution
D Bearings should be assembled to the
original positions.
D Press the side bearings into the gear case using
the SST.
205092
T75L1165DA
M42
REAR DIFFERENTIAL
DIAL INDICATOR
WITH BRACKETRY
RING
GEAR
M43
REAR DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.
SST
SST
SST
SST
SST
SST
SST
Differential component
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Differential
Component Disassembly
Bearing cap
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Bearing Cap
Disassembly Note
SST
Oil seal
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Oil Seal
Disassembly Note
Thrust washer
10
Drive pinion
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Drive Pinion
Disassembly Note
Adjusting shim
11
12
Collapsible spacer
13
14
Adjusting shim
15
16
Oil buffle
Pinion nut
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Pinion nut
Disassembly Note
Companion frange
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Companion
Frange Disassembly Note
M44
REAR DIFFERENTIAL
17
18
Carrier
19
Hex screw
20
Ring gear
21
Roll pin
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL DISASSEMBLY, Roll Pin
Disassembly Note
22
Pinion shaft
23
Thrust block
24
25
Pinion gear
26
Side gear
27
28
T83T4205A3
T83T4205A2
T83T4205A4
T83T4205A4
RETAINING CLIP
DIFFERENTIAL
CLUTCH PACK
9. Remove the top side gear and clutch pack. Keep the
stack of 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.
M45
REAR DIFFERENTIAL
LIMITED SLIP DIFFERENTIAL ASSEMBLY
D Assemble in the order indicated in the table.
SST
SST
SST
130150
{13.215.3,
96110}
R
R
SST
SST
R
R
R
SST
SST
SST
R
R
298500
{30.350.9, 220368}
Nm {kgfm, ftlbf}
Case
14
Oil buffle
15
Side gear
Pinion gear
16
Thrust block
Pinion shaft
17
Roll pin
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Roll Pin
Assembly Note
Adjusting shim
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Adjusting Shim
Assembly Note
18
Ring gear
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Ring Gear
Assembly Note
19
Drive pinion
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Drive Pinion
Assembly Note
20
Collapsible spacer
10
11
Hex screw
12
13
Carrier
M46
REAR DIFFERENTIAL
21
22
Thrust washer
23
Oil seal
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Oil Seal
Assembly Note
24
Companion frange
25
Pinion nut
26
27
Adjusting shim
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Adjusting Shim
Assembly Note
28
Bearing cap
+ REAR DIFFERENTIAL, STANDARD
DIFFERENTIAL ASSEMBLY, Bearing Cap
Assembly Note
THRUST WASHER
Note
D During assembly, be sure the holes of the
thrust washers and gears are lined up exactly
with those of the differential case.
T83T4205A3
T83T4205A4
T83T4205A2
M47
REMOTE FREEWHEEL
(RFW) MECHANISM
ON-VEHICLE INSPECTION
1. Jack up the front of the vehicle and support it on
safety stands.
2. Set the select lever in 2H position.
3. Set the freewheel hub control handle to the FREE
position, then turn the handle clockwise and
counterclockwise by hand, and inspect that it turns
smoothly.
4. Set the freewheel hub control handle to LOCK
position and inspect that the wheel turns with
considerable force applied to make it turn.
5. If not as specified, replace the freewheel hub
component as necessary.
Switch
Yes
Depressed (ON)
No
Released (OFF)
M48
Switch
Yes
Depressed (ON)
No
Released (OFF)
OFF
ON
12 mm {0.472 in}
13 mm {0.512 in}
Terminal
A
OFF
ON
Switch
Yes
Depressed (ON)
No
Released (OFF)
123456567
M49
AIR FILTER
M50
Connector
Nut
Bolt
M51
Signal name
Connected to
Lock solenoid
Lock solenoid
Ground
Body
Free solenoid
Free solenoid
Condition
Inspection point
Solenoid OFF
B+
Solenoid ON
Below 0.5 V
D Lock solenoid
CM)
Voltage
Below 0.5 V
Solenoid OFF
B+
Solenoid ON
Below 0.5 V
D Free solenoid
CM)
D Harness (4
4 4 indicator
light
4 4 indicator
light
B+
4 4 indicator light ON
Below 0.5 V
4 indicator
lightRFW CM)
D 4 4 indicator light
Lock indicator
light
LOCK
indicator light
B+
Below 0.5 V
Battery
Battery
Ignition swtich ON
B+
Below 0.5 V
RFW main
switch
B+
RFW main
switch
Below 0.5 V
RFW switch
RFW switch
B+
RFW switch ON
Below 0.5 V
4 4 indicator switch
OFF
B+
D Harness (4
4 4 indicator switch
ON
Below 0.5 V
4 indicator
switchRFW CM)
D 4 4 indicator switch
B+
Below 0.5 V
4 4 indicator
switch
4 4 indicator
switch
Transfer
neutral switch
Transfer
neutral switch
lightRFW CM)
M52
switchRFW CM)
switchRFW CM)
SST
Nm {kgfm, ftlbf}
Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION
Vacuum hose
49 0813 215A
M53
Snap pin
Gear sleeve
Output shaft
+ Removal Note
SST
SST
SST
Control box
Clip
Bearing
+ Disassembly Note
10
Oil seal
+ Disassembly Note
Spacer
11
Joint shaft
Retaining ring
12
Needle bearing
Ball bearing
+ Disassembly Note
13
Clip
14
Casing
15
Dust seal
M54
49 U027 004
49 0710 520
49 W027 001
M55
SST
SST
SST
R
R
SELECTIVE
SST
SELECTIVE
SST
SST
SST
Nm {kgfm , ftlbf}
Casing
Spacer
+ Assembly Note
Oil seal
+ Assembly Note
10
Adjustment shim(s)
+ Assembly Note
11
Clip
12
Ball bearing
+ Assembly Note
Dust seal
+ Assembly Note
13
Needle bearing
14
Clip
15
Control box
Joint shaft
+ Assembly Note
Bearing
+ Assembly Note
Retaining ring
M56
49 U027 006
49 U027 006
49 U027 005
49 U027 006
49 U027 006
49 U027 005
M57
49 M005 796
1622
{1.62.3, 1216}
Vacuum hose
Control box
Nm {kgfm , ftlbf}
M58
R
SST
Nm {kgfm , ftlbf}
Snap pin
Change rod
Washer
10
Shift fork
RFW actuator
11
Boot
+ Assembly Note
Spring cap
12
Oil seal
+ Assembly Note
Washer
13
Control box
Roll pin
+ Disassembly Note
+ Assembly Note
M59
49 U027 007
M60
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL OIL INSPECTION
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL INSPECTION.)
Specified oil
Type
Above 18 C {0 F}: API GL5, SAE 90
Below 18 C {0 F}: API GL5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL REPLACEMENT
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL REPLACEMENT.)
Specified oil
Type
Above 18 C {0 F}: API GL5, SAE 90
Below 18 C {0 F}: API GL5, SAE 80
Capacity
MFW: 1.2 L {1.3 US qt, 1.1 lmp qt}
RFW: 1.5 L {1.6 US qt, 1.3 lmp qt}
FRONT DIFFERENTIAL OIL SEAL REPLACEMENT
1. Remove the drive shaft.
(Refer to DRIVE SHAFT, DRIVE SHAFT
REMOVAL/INSTALLATION, Drive shaft removal
Note.)
2. Drain the differential oil.
(Refer to REAR DIFFERENTIAL, REAR
DIFFERENTIAL OIL REPLACEMENT.)
3. Remove the oil seal using a screwdriver.
4. Tap in the new oil seal to the differential using the
SST.
49 G030 795
M61
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL REMOVAL/INSTALLATION
1. Drain the differential oil. (Refer to FRONT DIFFERENTIAL, FRONT DIFFERENTIAL OIL REPLACEMENT.)
2. Remove the propeller shaft. (Refer to section L, FRONT PROPELLER SHAFT (4 4), FRONT PROPELLER
SHAFT REMOVAL/INSTALLATION.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
MFW
Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note
M62
Differential bracket
FRONT DIFFERENTIAL
RFW
2830
{2.83.1, 2122}
2326
{2.32.7, 1719}
94.2115.7
{9.511.8, 68.885.3}
62.893.1
{6.49.5, 46.368.7}
3753
{3.75.5, 2739}
APPLY SCREW
LOCK AGENT
Nm {kgfm, ftlbf}
Drive shaft
+ DRIVE SHAFT, DRIVE SHAFT REMOVAL/
INSTALLATION, Drive Shaft Removal Note
Vacuum hose
Front differential
M63
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL DISASSEMBLY
D Disassemble in the order indicated in the table.
SST
SST
SST
SST
SST
SST
Bolt
Adjusting screw
Differential casing
Oil baffle
Differential component
+ Disassembly Note
Locknut
+ Disassembly Note
10
Washer
Lock plate
11
Bearing cap
+ Disassembly Note
Companion flange
+ Disassembly Note
M64
FRONT DIFFERENTIAL
Locknut Disassembly Note
D Hold the companion flange using the SST and
remove the locknut.
12
Oil seal
+ Disassembly Note
13
Drive pinion
+ Disassembly Note
14
15
Collapsible spacer
16
17
Spacer
18
19
20
Carrier
21
Bolt
22
Ring gear
23
Knock pin
+ Disassembly Note
24
Pinion shaft
25
Pinion gear
26
Thrust washer
27
Side gear
28
Thrust washer
29
30
Gear case
49 S120 710
49 0839 425C
49 0107 680A
MARK
M65
FRONT DIFFERENTIAL
Rear Bearing Inner Race Disassembly Note
Note
D Mark or otherwise distinguish between the front
and rear inner races so that they are not mixed
up at the time of reassembly.
D Remove the rear bearing inner race using the SST.
49 H027 002
49 0839 425C
Note
D Mark or otherwise distinguish between the front
and rear outer races so that they are not mixed
up at the time of reassembly.
D Remove the bearing outer races using the two
M66
FRONT DIFFERENTIAL
FRONT DIFFERENTIAL ASSEMBLY
Caution
D Clean away the old sealant before applying the new sealant.
D Install the differential carrier within 10 minutes after applying sealant.
D Allow the sealant to set at least 30 minutes after installation before filling the differential with the
specified oll.
D Assemble in the order indicated in the table.
184284
{1329, 95209}
2327
{2.32.7, 1719}
R
SST
1451
{3.85.3, 2838}
R
R
1825
{1.82.6, 1418}
SST
SST
R
SST
6983
{7.08.5,
5161}
SST
SST
SST
R
SST
SST
R
Nm {kgfm, ftlbf}
Gear case
+ Assembly Note
Thrust washer
+ Assembly Note
10
Bolt
11
Carrier
Side gear
12
Thrust washer
Pinion gear
13
Pinion shaft
Knock pin
14
Ring gear
+ Assembly Note
Spacer
+ Assembly Note
15
M67
FRONT DIFFERENTIAL
16
Drive pinion
+ Assembly Note
17
Collapsible spacer
18
19
Oil seal
+ Assembly Note
20
Companion flange
21
Washer
22
Locknut
+ Assembly Note
23
24
Adjusting screw
+ Assembly Note
25
Bearing cap
+ Assembly Note
26
Lock plate
27
Baffle plate
28
Differential casing
29
Bolt
Standard backlash
00.1 mm {00.004 in}
4. If the backlash exceeds the standard, use the
thrust washers to adjust.
Ring Gear Assembly Note
1. Coat the ring gear and gear case facing surfaces
with locking agent.
2. Install the ring gear and tighten the bolt to the
specified torque.
Side Bearing Inner Race Assembly Note
Caution
D Bearings should be assembled to the
original positions.
D Press the side bearings into the gear case using
the SST.
49 G030 338
49 F027 005
49 F027 004
M68
FRONT DIFFERENTIAL
Spacer Assembly Note
Pinion height adjustment
49 0727 570
Notes
D Use the same spacer and nut.
D Be careful to install collars A and B in the
correct position and facing in the correct
direction.
1. Assemble the spacer, rear bearing inner race and
SST (49 8531 568) on to the SST (49 8531 565).
Secure the collar with the O-ring. Then install this
to the carrier.
2. Assemble the front bearing inner race, SST (49
8531 567), companion flange, washer and nut to
the SST (49 8531 565).
3. Tighten the nut to the extent that the SST (49 8531
565) can be turned by hand.
49 0350 555
49 0350 555
49 8531 565
pinion height
0.06+0.04
2 = 0.07 =
adjustment value
2
100
SPACER
REAR BEARING
49 8531 568
O RING
49 8531 567
FRONT BEARING
4. Place the SST on the surface plate and set the dial
indicator to zero.
49 0727 570
SSTs.
SPACER
5. Place the SST (49 0350 555) on top of the SST (49
8531 565), and then set the SST (49 0727 570) on
top of the SST (49 0350 555).
6. Place the measuring probe of the dial indicator so
that it contacts the place where the side bearing is
installed in the carrier. Then measure left and right
side of the lower position.
M69
49 F401 331
49 G030 338
FRONT DIFFERENTIAL
Drive Pinion Assembly Note
Drive pinion preload adjustment
Caution
D Do not install the oil seal.
1. Install the drive pinion, spacer, front bearing,
collapsible spacer and companion flange to the
carrier, and temporarily tighten the locknut.
2. Adjust the preload of the drive pinon bearing as
follows.
(1) Turn the companion flange by hand to seat the
bearing.
(2) Use a torque wrench to tighten the locknut
temporarily tightened in Step 1, and confirm
that the specified preload can be obtained
within the specified tightening torque range.
The torque applied at this time will be used
after the oil seal is installed.
Locknut tightening torque
128284 Nm {1329 kgfm, 95209 fflbf}
Drive pinion preload
0.913.4 Nm {914 kgfcm, 7.912.1 inlbf}
49 S120 710
Preload
0.91.3 Nm {914 kgfcm, 7.912.1 inlbf}
49 S120 710
49 0259 720
49 0259 720
49 U027 003
M70
FRONT DIFFERENTIAL
(3) Inspect for the backlash at the three other
marked points and make sure that the
minimum backlash is more than 0.05 mm
{0.002 in} and difference of the maximum and
minimum backlash value is less than 0.07 mm
{0.0028 in}.
FLANK CONTACT
HEEL CONTACT
Standard distance
185.43185.50 mm {7.3007.303 in}
3. The inspection and adjustment procedure is as
follows:
(1) Coat both surfaces of 68 teeth of the ring
gear uniformly with a thin red lead coating.
(2) While moving the ring gear back and forth by
hand, rotate the drive pinion several times and
inspect the tooth contact.
(3) If the tooth contact is good, wipe off the red
lead coating.
(4) If it is not good, adjust the pinion height, then
adjust the backlash.
RED LEAD
M71
FACE CONTACT
TROUBLESHOOTING
TROUBLESHOOTING
REMOTE FREEWHEEL (RFW)
Foreword
D Refer to section GI, HOW TO USE THIS MANUAL, TROUBLESHOOTING PROCEDURE and thoroughly read
and understand the basic flow of troubleshooting in order to properly perform the basic procedures.
Precaution
D This section only mentions unique symptoms of the trouble caused by RFW. Inspect and repair as necessary
for trouble caused by other sources.
D Inspect the connector and terminal connections when inspecting the wiring harnesses. (The cause of the
malfunction may be a poor connection in the connectors, terminals, or wiring harnesses.)
Diagnostic Index
No
TROUBLESHOOTING ITEM
DESCRIPTION
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Noise
Oil leakage
M72
TROUBLESHOOTING
Oil leakage
Symptom Troubleshooting
1
NO RFW OPERATION FROM FREE TO LOCK (RFW INDICATOR LIGHT DOES NOT ILLUMINATE)
DESCRIPTION
[TROUBLESHOOTING HINTS]
D
D
D
D
D
D
D
STEP
1
D
D
D
D
D
D
D
INSPECTION
ACTION
Yes
Go to Step 6.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go to Step 8.
No
M73
Noise
Vacuum hose
Joint shaft
RFW hub
4 x4 indicator swiitch
METER 15 A fuse
ENGINE 15 A fuse
RFW actuator
RFW switch
Troubleshooting item
Possible factor
TROUBLESHOOTING
STEP
7
INSPECTION
ACTION
Yes
No
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 19.
No
Go to next step.
16
Yes
No
Go to next step.
17
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 23.
No
Go to next step.
Yes
No
Go to next step.
10
11
12
13
14
15
18
19
20
M74
4 indicator
TROUBLESHOOTING
STEP
21
22
23
24
25
26
27
28
29
30
31
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 27
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
4 indicator
NO RFW OPERATION FROM LOCK TO FREE (RFW INDICATOR LIGHT DOES NOT GO OFF)
DESCRIPTION
[TROUBLESHOOTING HINTS]
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Go to Step 3.
M75
TROUBLESHOOTING
STEP
2
INSPECTION
ACTION
Yes
No
Yes
Go to Step 5.
No
Yes
No
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go next step.
No
Yes
Go next step.
No
Yes
Go to next step.
No
Yes
Go to Step 16.
No
Go to next step.
13
Yes
No
Go to next step.
14
Yes
Go to next step.
No
10
11
12
M76
TROUBLESHOOTING
STEP
15
16
17
18
19
20
21
22
23
24
25
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to Step 20.
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 28.
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to Step 28.
No
Go to next step.
Yes
No
Go to next step.
4 indicator switch
26
Yes
Go to next step.
No
27
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
28
29
30
M77
TROUBLESHOOTING
STEP
31
32
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
NOISE
DESCRIPTION
[TROUBLESHOOTING HINTS]
D Joint shaft bearing abrasion or damage
D RFW hub abrasion
STEP
1
2
3
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
OIL LEAKAGE
DESCRIPTION
[TROUBLESHOOTING HINTS]
D Poor installation of the RFW control box
STEP
1
INSPECTION
Is RFW control box installed completely?
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Troubleshooting completed.
Explain repairs to customer.
M78
STEERING SYSTEM
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N11
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N12
STEERING SHAFT INSPECTION . . . . . . . . . . . N12
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N13
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N14
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N15
POWER STEERING OIL PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N16
POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N18
POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N20
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N 1
MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N 3
STEERING SHAFT INSPECTION . . . . . . . . . . . N 4
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N 5
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N 7
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 9
ENGINE SPEED SENSING POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
POWER STEERING FLUID INSPECTION . . . N10
GENERAL PROCEDURES
MANUAL STEERING
Connectors disconnection/connection
Disconnect the negative battery cable before doing
any work that requires handling of connectors.
Reconnect the negative battery cable only after the
work is completed.
N1
STEERING SYSTEM
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N11
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N12
STEERING SHAFT INSPECTION . . . . . . . . . . . N12
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N13
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N14
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N15
POWER STEERING OIL PUMP
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N16
POWER STEERING OIL PUMP (F2 CIS, F2 CARB,
G6) DISASSEMBLY/ASSEMBLY . . . . . . . . . . . N18
POWER STEERING OIL PUMP (WL, WL TURBO)
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N20
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . . N 1
MANUAL STEERING . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 1
STEERING WHEEL AND COLUMN
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . N 3
STEERING SHAFT INSPECTION . . . . . . . . . . . N 4
STEERING GEAR AND LINKAGE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . N 5
STEERING GEAR AND LINKAGE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . N 7
STEERING GEAR AND LINKAGE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . N 9
ENGINE SPEED SENSING POWER
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . N10
POWER STEERING FLUID INSPECTION . . . N10
GENERAL PROCEDURES
MANUAL STEERING
Connectors disconnection/connection
Disconnect the negative battery cable before doing
any work that requires handling of connectors.
Reconnect the negative battery cable only after the
work is completed.
N1
MANUAL STEERING
Steering Wheel Effort Inspection
1. With the vehicle on a hard, level surface, put the
wheels in the straight-ahead position.
2. Remove the air bag module, if equipped.
(Refer to section T, AIR BAG SYSTEM,
DRIVER-SIDE AIR BAG MODULE
REMOVAL/INSTALLATION.)
3. Measure the steering wheel effort using a torque
wrench.
N2
MANUAL STEERING
STEERING WHEEL AND COLUMN REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
4050
{4.05.0,
2936}
4050
{4.05.0, 2936}
1622
{1.62.3, 1216}
1622
{1.62.3, 1216}
2026
{2.02.7,
1519}
1824
{1.82.5, 1418}
2026
{2.02.7, 1519}
Nm {kgfm, ftlbf}
Horn cap
Combination switch
Steering shaft
+ Installation Note
Universal joint
Locknut
Boot
Steering wheel
+ Removal Note
+ Installation Note
10
Intermediate shaft
11
Column cover
N3
MANUAL STEERING
Steering Wheel Removal Note
Caution
Do not try to remove the steering wheel by
hitting the shaft with a hammer. The column
will collapse.
Set the wheels in the straight-ahead position,
N4
MANUAL STEERING
Steering Wheel Removal Note
Caution
Do not try to remove the steering wheel by
hitting the shaft with a hammer. The column
will collapse.
Set the wheels in the straight-ahead position,
N4
MANUAL STEERING
STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION
1. With the wheels in the straight-ahead position, remove in the order indicated in the table.
2. Install in the reverse order of removal.
3754
{3.75.5, 2739}
2026
{2.02.7, 1519}
4558
{4.56.0,
3343}
SST
6978
{7.08.0, 5157}
4558
{4.56.0,
3343}
SST
79157
{8.016.0,
58115}
4558
{4.56.0, 3343}
SST
3754
{3.75.5,
2739}
4558
{4.56.0, 3343}
SST
SST
Nm {kgfm, ftlbf}
Cotter pin
Washer
Nut
10
Ball joint
+ Removal Note
11
12
Locknut
13
Bolt
Tie rod
14
Center link
Idler arm
+ Removal Note
15
Bushing
Dust boot
+ Removal Note
+ Installation Note
N5
MANUAL STEERING
Ball Joint, Idler Arm, Steering Gear and Pitman
Arm Removal Note
Remove the ball joint from the knuckle and center
link, the idler arm from the center link, and steering
gear and pitman arm from the center link using the
SST.
49 T028 3A0
49 1243 785A
N6
MANUAL STEERING
STEERING GEAR AND LINKAGE DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
2534
{2.53.5, 2534}
1521
{1.52.2, 1115}
1524
{1.52.5, 1118}
128166
{13.017.0, 95122}
R
SST
R
R
197235
{20.024.0, 145173}
SST
Nut
Adjusting screw
Pitman arm
+ Disassembly Note
10
Oil seal
11
Retaining ring
Clip
12
Dust boot
+ Assembly Note
Locknut
+ Disassembly Note
13
Oil seal
14
Adjusting nut
+ Disassembly Note
Sector shaft
+ Disassembly Note
+ Assembly Note
15
Bearing
16
17
Bearing
Side cover
Adjusting shim
N7
Nm {kgfm, ftlbf}
MANUAL STEERING
Pitman Arm Disassembly Note
Separate the pitman arm from the steering gear
using the SST.
49 UB39 585A
49 U032 3A0
49 0180 510B
49 U032 201
49 U032 201
N8
MANUAL STEERING
(2) Tighten the locknut to the specified torque
using the SST.
Tightening torque
128166 Nm {1317 kgfm, 95122 ftlbf}
49 U032 201
49 U034 209
backlash.
Backlash
0 mm
ADJUSTING
SHIM
N9
MANUAL STEERING
(2) Tighten the locknut to the specified torque
using the SST.
Tightening torque
128166 Nm {1317 kgfm, 95122 ftlbf}
49 U032 201
49 U034 209
backlash.
Backlash
0 mm
ADJUSTING
SHIM
N9
R.H.D.
L.H.D.
F2 CIS
F2 CARB
F2 CIS
F2 CARB
WL
WL TURBO
WL
WL TURBO
G6
G6
N10
R.H.D.
L.H.D.
F2 CIS
F2 CARB
F2 CIS
F2 CARB
WL
WL TURBO
WL
WL TURBO
G6
G6
N10
49 1232 670A
49 H002 671
GAUGE
CLOSE VALVE
COMPLETELY
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.
49 B032 304
THERMOMETER
5060 C {122140 F}
49 G032 3A4
GAUGE
OPEN VALVE
COMPLETELY
49 H002 671
N11
N12
N12
2026
{2.02.7, 1519}
SST
6978
{7.08.0, 5157}
SST
79157
{7.016.0, 58115}
R
3754
{3.75.5, 2739}
4558
{4.56.0, 3343}
SST
R
4558
{4.56.0, 3343}
SST
SST
Nm {kgfm, ftlbf}
Cotter pin
11
Locknut
12
Pressure pipe
Ball joint
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Ball
Joint Removal Note
13
Return pipe
14
Bolt
15
Locknut
16
Tie rod
Center link
Idler arm
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Idler
Arm Removal Note
17
Bushing
Washer
Dust boot
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Dust
Boot Disassembly Note
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE REMOVAL/INSTALLATION, Dust
Boot Assembly Note
10
N13
R
R
R
R
R
R
R
R
5663
{5.76.5, 4247}
SST
R
197235
{20.024.0,
145173}
SST
Nut
O-ring
Pitman arm
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Pitman
Arm Disassembly Note
Y packing
10
Back up ring
11
Oil seal
Clip
12
Back up ring
Dust boot
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Dust
Boot Assembly Note
13
Y packing
14
Dust cover
15
Snap ring
16
Washer
17
Oil seal
18
19
O-ring
20
Seal ring
21
Gear housing
Locknut
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut
(Side Cover), Sector Shaft Disassembly Note
Sector shaft
+ MANUAL STEERING, STEERING GEAR AND
LINKAGE DISASSEMBLY/ASSEMBLY, Locknut
(Side Cover) Sector Shaft Disassembly Note
Side cover
N14
Nm {kgfm, ftlbf}
housing.
N15
housing.
N15
3044
{3.04.5, 2232}
3039
{3.04.0, 2228}
SST
5059
{5.06.0, 3743}
Nm {kgfm, ftlbf}
N16
G6
1925
{1.92.6, 1418}
3246
{3.24.7, 2433}
3247
{3.24.8, 2434}
5059
{5.06.0, 3743}
SST
CLAMP
POSITION
30 mm
{1.2 in}
Nm {kgfm, ftlbf}
Drive belt
Return hose
Locknut
+ Removal Note
49 G032 354
N17
WL, WL TURBO
3044
{3.04.5, 2232}
1925
{1.92.6, 1418}
1925
{1.92.6,
1418}
Nm {kgfm, ftlbf}
Pressure pipe
Return hose
O-ring
N18
9.913.7 Nm
{100140 kgfcm,
87121 inlbf}
1519
{1.52.0,
1114}
7.911.7 Nm
{80120 kgfcm,
70104 inlbf}
G6
2225
{2.22.6, 1618}
R
F2 CIS
5068
{5.07.0,
3750}
F2 CARB
1821
{1.82.2, 1416}
1623
{1.62.4, 1217}
2225
{2.22.6, 1618}
Nm {kgfm, ftlbf}
SST
13
Rear body
+ Assembly Note
14
O-ring
O-ring
15
Nut (G6)
Cam ring
+ Assembly Note
Connector (G6)
16
Rotor
Connector bolt
17
O-ring
Vane
+ Assembly Note
18
Pin
Spring
19
Side plate
+ Assembly Note
10
Suction pipe
20
O-ring
11
O-ring
21
Oil seal
12
Shaft component
22
Front body
N19
Caution
To secure the oil pump in a vise, use the SST
as shown to prevent damage to the pump.
ROUND EDGE
49 F032 301
2. Install the rotor with the mark facing the rear body.
MARK
N20
7.911.7 Nm
{80120 kgfcm,
69.5104.1 inlbf}
2225
{2.22.6, 1618}
R
SST
R
R
5068
{5.07.0, 3750}
Nm {kgfm, ftlbf}
10
Cam ring
+ ENGINE SPEED SENSING POWER
STEERING POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Cam Ring
Assembly Note
2
3
Suction pipe
11
Rotor
O-ring
12
Vane
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Vane
Assembly Note
Connector
O-ring
Control valve
7
8
Spring
13
Rear body
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Rear Body
Assembly Note
Side plate
+ ENGINE SPEED SENSING POWER
STEERING, POWER STEERING OIL PUMP
(G6) REMOVAL/INSTALLATION, Side Plate
Assembly Note
14
O-ring
O-ring
15
Front body
N21
BRAKING SYSTEM
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
CONVENTIONAL BRAKE SYSTEM . . . . . . . . . . .
AIR BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM LINE INSPECTION . . . . . . . . . . . . . .
BRAKE PEDAL INSPECTION . . . . . . . . . . . . . .
BRAKE PEDAL REMOVAL/INSTALLATION . .
BRAKE SWITCH INSPECTION . . . . . . . . . . . . .
MASTER CYLINDER REMOVAL/
INSTALLATION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER REMOVAL/
INSTALLATION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
FLUID LEVEL SENSOR INSPECTION . . . . . .
MASTER CYLINDER DISASSEMBLY/
ASSEMBLY (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER CYLINDER DISASSEMBLY/
ASSEMBLY (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
POWER BRAKE UNIT INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
POWER BRAKE UNIT INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
POWER BRAKE UNIT REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
VACUUM SWITCH INSPECTION (DIESEL) . .
VACUUM SWITCH
REMOVAL/INSTALLATION (DIESEL) . . . . . .
VACUUM PUMP INSPECTION (DIESEL) . . . .
VACUUM PUMP REMOVAL/INSTALLATION
(DIESEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE INSPECTION (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE INSPECTION (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE ADJUSTMENT
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE ADJUSTMENT
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
LOAD SENSING PROPORTIONING
VALVE REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
FRONT BRAKE (DISC) INSPECTION . . . . . . .
FRONT BRAKE (DISC) REMOVAL/
INSTALLATION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . .
DISC PAD (FRONT) REPLACEMENT
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
FRONT BRAKE (DISC) REMOVAL/
INSTALLATION (4x4) (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . . . .
P
P
P
P
P
P
P
2
3
3
3
3
4
5
P 5
P 8
P10
P11
P13
P14
P15
P16
P16
P17
P17
P17
P18
P19
P20
P21
P22
P23
P24
P25
P26
P27
P1
P69
P71
P71
P72
P72
P73
P73
P74
GENERAL PROCEDURES
Wheel and tires removal/installation
D The removal and installation procedures for the
wheels and tires are not mentioned in this section.
When a wheel is removed, retighten the wheel nuts
to the specified torque. (See TD Wheels and Tires.
Brake lines disconnection/connection
Caution
D Brake fluid will damage painted surfaces. If
brake fluid get on a painted surface, wipe it
off immediately.
D If any brake line has been disconnected anytime
Fluid specification
SAE J1703 or FMVSS116 DOT3 or DOT4
P2
CHECK VALVE
ENG
Tightening torque
Front:
914 Nm {92142 kgfcm, 80123 inlbf}
Rear:
5.98.8 Nm {6090 kgfcm, 5378 inlbf}
Pedal height
L.H.D.: 214219 mm {8.438.81 in}
R.H.D.:219224 mm {8.638.81 in}
PEDAL HEIGHT
49 0259 770B
P3
Specification
0.11.0 mm {0.0040.039 in}
Tightening torque
1417 Nm {140180 kgfcm, 122156 inlbf}
5. Connect the brake switch connector.
6. After adjustment, inspect the pedal play and the
brake light operation.
Clearance
105 mm {4.2 in} min.
C
PEDAL-TO-FLOOR
CLEARANCE
Pedal play
38 mm {0.120.31 in}
Tightening torque
2434 Nm {2.43.5 kgfm, 1825 ftlbf}
P4
R.H.D.
Terminal
Condition
SST
SST *
12.921.5
{130220, 113190}
9.8115.6
{100160, 87138}
B
* 49 0259 770B
Nm {kgfcm, inlbf}
Brake pipe
Bracket (R.H.D.)
Master cylinder
+ Installation Note
O-ring
SST
9.8115.6
{100160, 87138}
SST *
12.921.5
{130220, 113190}
* 49 0259 770B
Nm {kgfcm, inlbf}
49 B043 001
P5
Clearance at B
1. Measure and record the height D1 of the gauge
rod.
(D1)
TOUCHING
49 B043 001
49 B043 001
TOUCHING
ADJUSTING NUT
Push rod
Clearance at B
Too long
Clearance at C
Too short
No clearance at B or C
Okay
ADJUSTING NUT
(D2)
CLEARANCE (B)
49 B043 001
CLEARANCE (C)
49 B043 001
49 E043 003A
CLEARANCE (B)
P6
CLEARANCE (C)
49 B043 001
49 E043 003A
P7
Bracket
Brake pipe
Master cylinder
(See Master Cylinder Installation Note)
Caution
D When pushing the SST gauge rod into the
master cylinder piston, only use enough
pressure to push the rod to the bottom of
the piston. If too much pressure is applied,
a false reading will occur.
P8
Push rod
Too short
Too long
Note
D The threads of the push rod are specially
designed so that the bolt becomes harder to
turn past a certain point. This is to prevent the
bolt from coming loose. Turn the bolt only
within this range when adjusting.
1. Push lightly on the end of the SST gauge rod, and
measure the clearance between the adjusting nut
and the SST body.
P9
Fluid level
Below MIN.
Above MIN.
A
B
P10
1.01.5
{1015, 8.713}
R
2.02.4 {2025, 1821}
Nm {kgfcm , inlbf}
Cap set
10
Cup
2
3
Screw
11
Reservoir
12
Primary piston
Joint bushing
13
Stop screw
+ Assembly Note
Snap ring
14
O-ring
Spacer
15
Secondary piston
Piston guide
16
O-ring
P11
P12
Cap set
11
Cup
Pin
12
Reservoir
13
Primary piston
Joint bushing
14
15
Snap ring
Spacer
16
Gasket
Piston guide
17
Secondary piston
10
Oring
18
P13
49 U043 004
A
A
49 U043 006
49 U043 005
PEDAL DEPRESSION
FORCE
GAUGE
VACUUM GAUGE
Loaded condition
1. Start the engine.
2. Depress the brake pedal with a force of 196 N {20
kgf, 44 lbf}.
3. With the brake pedal depressed, stop the engine
when the vacuum gauge reading reaches 66.7 kPa
{500 mmHg, 19.7 inHg}.
4. Observe the vacuum gauge for 15 seconds. If the
gauge shows 63.366.7 kPa {475500 mmHg,
18.719.7 inHg}, the unit is operating.
b) Inspection for hydraulic pressure
1. When the engine is stopped (vacuum 0 kPa {0
mmHg, 0 inHg}) and the fluid pressure is within
the specification, the unit is operating.
Note
D If a problem is found, inspect for damage on
the check valve or vacuum hose, and examine
the installation. Repair as necessary, and
inspect it again.
Step 3
1. Start the engine.
2. Depress the pedal with the usual force.
3. Stop the engine with the pedal held depressed.
4. Hold the pedal down for about 30 seconds.
5. If the pedal height does not change, the unit is
operating.
(Inspection using the testers)
1. Connect the SSTs, vacuum gauge, and pedal
depression force gauge as shown in the figure.
Note
D Use commercially available gauges and pedal
depression force gauge.
D Bleed the air from the SST at gauge A.
P14
Pedal force
Fluid pressure
196 N
{20 kgf, 44 lbf}
Fluid pressure
196 N
{20 kgf, 44 lbf}
8,240 kPa
{84 kgf/cm2, 1,200 psi} min
Fluid pressure
196 N
{20 kgf, 44 lbf}
Fluid pressure
196 N
{20 kgf, 44 lbf}
P15
L.H.D.
1925
{1.92.6, 1418}
2434
{2.43.5, 1825}
Brake warning
light
ON
OFF
Nm {kgfm, ftlbf}
R.H.D.
1925
{1.92.6, 1418}
2434
{2.43.5, 1825}
Nm {kgfm, ftlbf}
Vacuum hose
Snap pin
Clevis pin
Nut
Gasket
Fork
Nut
P16
L.H.D.
2024
{2.02.5, 1518}
Nm {kgfm, ftlbf}
R.H.D.
2024
{2.02.5, 1518} Nm {kgfm, ftlbf}
Vacuum switch
+ Installation Note
R
DO NOT APPLY
SEALANT ON
THIS AREA
P17
Vacuum hose
Bolt
Vacuum pump
O-ring
Note
D When applying the specified pressure, the brake
pedal must not be double pumped or released.
D Approximately two seconds after setting the front
wheel cylinder fluid pressure, read the rear pressure.
5. Bleed the air from the brake system.
6. Slowly depress the brake pedal until the front
pressure gauge indicates the specified pressure
shown in the table, then note the reading on the
rear pressure gauge.
kPa {kgf/cm2, psi}
Front pressure
Rear pressure
LOADED
A PERSON IN
DRIVERS SEAT
REAR PRESSURE
4,900 {50, 711} 9,810 {100, 1,422}
FRONT PRESSURE
kPa {kgf/cm2, psi}
P18
Specification
kPa {kgf/cm2, psi}
Type
Without ABS
4x2
With ABS
Without ABS
4x4
With ABS
P19
MAIN SPRING
ADJUSTMENT LINK
AXLE CASING
BOLT
P20
Type
4x4
Note
D A change of 5mm {0.197 in} in dimension L
results in a change of the following.
Specification
Dimension L
mm {in}
4x2
4x4
without ABS
Dimension L
with ABS
147.5154.5
{5.816.08}
without ABS
175.5182.5
with ABS
{6.917.18
without ABS
with ABS
without ABS
with ABS
Type
4x2
Change
P21
SST * 12.821.5 Nm
SST *
{130220 kgfcm,
113190 inlbf}
1925
{1.92.6, 1418}
* 49 0259 770B
Brake pipe
Nut
Bolt
Nm {kgfm, ftlbf}
P22
Brake pipe
(See Brake Pipe Installation Note)
Nut
P23
Bolt
P24
Runout limit
0.05 mm {0.002 in} max.
2229
{2.23.0, 1629}
R
2934
{2.93.5, 2125}
108127
{10.414.0, 8094}
SST
Nm {kgfm, ftlbf}
Brake hose
Bolt
3
4
5
Disc pad
+ Installation Note
Guide pin
Plate
Dust boot
Guide plate
Caliper
Mounting support
P25
49 0221 600C
2934
{2.93.5, 2125}
SST
Nm {kgfm, ftlbf}
Bolt
Caliper
Disc pad
+ CONVENTIONAL BRAKE SYSTEM, FRONT
BRAKE (DISC) REMOVAL/INSTALLATION,
Disc Pad Installation Note
Plate
Guide plate
P26
Flexible hose
Guide pin
Caliper
Disc pad
(See Disc Pad Installation Note)
Guide plate
(See Guide Plate Removal Note)
10
Mounting support
11
Disc plate
(See Disc Plate Removal Note)
(See Disc Plate Installation Note)
P27
P28
*
SST
914
{92143, 80123}
SST
Bolt
Caliper
Guide pin
Disc pad
(See Disc Pad Installation Note)
Guide plate
(See Guide Plate Removal Note)
Piston
+ Disassembly Note
Dust seal
Piston seal
+ Disassembly Note
Caliper body
Nm {kgfcm, inlbf}
P29
Dust seal
Piston
(See Piston Disassembly Note)
Piston seal
(See Piston Seal Disassembly Note)
Bleeder cap
Bleeder screw
Caliper
P30
9.812.7
{100130, 87112}
* SST
12.821.5
{130220, 113190}
APPLY
TO SHADED EREA
Nm {kgfcm, inlbf}
Brake drum
Adjust strut
Brake shoe
Hold pin
10
11
Operating lever
12
Brake pipe
13
Wheel cylinder
Pawl lever
14
Gasket
P31
Maximum diameter
4 2: 271.5 mm {10.68 in}
4 4: 296.5 mm {11.67 in}
2. Apply chalk to the inside of the brake drum.
3. Inspect for scratches and uneven or abnormal
wear inside the drum as shown in the figure.
Stroke
17 notches
3. If not as specified, adjust the parking brake lever
stroke.
PARKING BRAKE (STICK TYPE) ADJUSTMENT
Parking Brake Lever Stroke Adjustment
1. Before adjustment, depress the brake pedal
several times while the vehicle is moving in
reverse.
2. Loosen the locknut A and turn the adjustment nut
B so that the stroke is within the above range.
3. After adjustment, tighten the locknut A.
Tightening torque
6.99.8 Nm {70100 kgfcm, 4386 inlbf}
B
A
R
SST *
5.98.8
{ 6090 , 5378 }
* 49 0259 770B
Dust boot
Piston
Piston cap
Spring
Cylinder body
Nm { kgfcm , inlbf }
P32
6.99.8
{70100, 4386}
Nm {kgfcm, inlbf}
Clip
Joint pin
10
Spring
Cable connector
11
Rachet pawl
12
Stopper
Clip
13
Fork joint
Pin
14
Spring
15
Guide
Lever
16
Rod
P33
1622
{1.62.3,
1216}
6.99.8 Nm
{70100 kgfcm,
4386 inlbf}
4x4
1622
{1.62.3, 1216}
6.99.8 Nm
{70100 kgfcm,
4386 inlbf}
1622
{1.62.3, 1216}
1622
{1.62.3, 1216}
1622
{1.62.3,
1216}
1622
{1.62.3, 1216}
Nut
Grommet
Bolt
Bolt
Spring
Spring (4
10
Clip
Bolt (4
11
Bracket (4
12
4)
4)
P34
4)
Nm {kgfm, ftlbf}
ABS HU/CM
(See ABS HU/CM SYSTEM INSPECTION)
(See ABS HU/CM REMOVAL/
INSTALLATION)
(See ABS HU/CM INSPECTION)
ABS wheel speed (front)
(See FRONT ABS WHEELSPEED SENSOR
REMOVAL/INSTALLATION)
(See FRONT ABS WHEELSPEED SENSOR
INSPECTION)
P35
G sensor (4x4)
(See G SENSOR REMOVAL/INSTALLATION)
(See G SENSOR INSPECTION)
COMMAND NAME
OPERATION
PMP
MOTOR
RF
OUTLET
RF
INLET
Pressure
retention
OFF
OFF
ON
Pressure
reduction
ON
COMMAND
TYPE
Manual
ON
OFF
P36
Note
D If Steps 4 and 5 show correct operation, the
following systems are okay:
Brake piping to ABS HU/CM.
Braking system, including ABS HU/CM.
Electrical system in ABS HU/CM (solenoid,
ABS motor, etc.)
D The following are not inspected with above
steps:
Input system and harness of ABS HU/CM.
Intermittent failure.
Fluid leakage from brake including the ABS
HU/CM and master cylinder.
P37
Connector
(See Connector Removal Note)
(See Connector Installation Note)
Stud
Bushing
Joint bolt
Gasket
10
Joint
(See Joint Installation Note)
Nut
11
Gasket
Bracket
12
ABS HU/CM
P38
P39
Terminal
A
B
Signal
Connected to
RR wheelspeed
RR wheel
speed sensor
C
F
LR wheelspeed
LR wheel
speed sensor
C
F
LR wheelspeed
LR wheel
speed sensor
Test condition
Voltage (V)
Vehicle is stopped.
0 (AC)
RF wheelspeed
RF wheel
speed sensor
LR wheelspeed
LR wheel
speed sensor
G sensor input
G sensor
sensor.
0 (AC)
H*1
Vehicle is stopped.
I
E
0 (AC)
Vehicle is stopped.
G
D
Action
2.42.6
2.51.0
2.54.0
J*1
G sensor ground
Onboard
diagnostic
KLN terminal of
DLC
No need to
check
DLC
No need to
check
U*2
G sensor
Onboard
diagnostic
TBS terminal of
DLC
1014
Power supply
Ignition switch
(engine switch)
B+
P40
Terminal
*1:
*2:
Signal
Connected to
Test condition
Voltage (V)
AA
Power supply
(Solenoid valve)
Battery
B+
AB
Power supply
(ABS motor)
Battery
B+
AC
Ground
Ground
AD
Ground
Ground
4x4 only.
Use this terminal at factory only, not used for inspection and repair at field.
Note
D As vehicle speed increases, period of wave
shortens.
D There is a malfunction is in the sensor rotor,
the wave profile warps.
P41
Action
D Inspect related harness.
Connector
Bolt
P42
Connector
Bolt
Resistance Inspection
1. Disconnect the ABS wheelspeed sensor
connector.
2. Inspect the resistance at the ABS wheelspeed
sensor.
D If not as specified, replace the ABS
wheelspeed sensor.
Clearance Inspection
1. Inspect the clearance between the wheelspeed
sensor and the sensor rotor.
Clearance
0.31.1 mm {0.0120.043 in}
Resistance
1.21.6 kilohm
Voltage Inspection
1. Jack up the vehicle on level ground and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
D If not as specified, replace the ABS
wheelspeed sensor.
Voltage
0.151.2 V (AC)
P43
P44
Connector
Bolt
P45
Resistance Inspection
1. Disconnect the ABS wheelspeed sensor
connector.
2. Inspect the resistance at the ABS wheelspeed
sensor.
D If not as specified, replace the ABS
wheelspeed sensor..
Resistance
1.21.6 kilohm
Voltage Inspection
1. On level ground, jack up the vehicle and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Inspect each sensor by rotating each wheel one
revolution per second.
D If not as specified, replace the ABS
wheelspeed sensor.
Voltage
0.151.2 V (AC)
Voltage Pattern Inspection
1. Jack up the vehicle on level ground and support it
evenly on safety stands.
2. Disconnect the ABS wheelspeed sensor
connector.
3. Using an oscilloscope, inspect voltage pattern for
distortion and noise by rotating each wheel.
D If there is distortion or noise, inspect the ABS
sensor rotor.
P46
G SENSOR REMOVAL/INSTALLATION
Caution
D Do not drop the G sensor, Replace it if it is
subjected to an impact.
Voltage
1.31.7 V
Connector
G sensor
P47
10
Instrument cluster
11
ABS HU/CM
12
4x4 only
13
G sensor
14
DLC
Solenoid valve
15
KLN
ABS motor
16
TBS
Brake switch
17
GND
Battery
P48
Caution
D Connecting to the wrong DLC terminal may
cause a malfunction. Carefully connect
only to the specified terminal.
(1) Connect the TBS terminal at the DLC to body
ground using a jumper wire.
(2) Turn the ignition key (engine key) to ON
(engine OFF).
(3) Output all stored DTCs.
(4) After verifying that the first code is repeated,
depress the brake pedal 10 times or more at
intervals of less than 1 second.
(5) Turn the ignition key (engine key) to OFF and
disconnect the jumper wire.
Note
D DTCs cannot be cleared if the following occur:
If intervals of depressing the brake pedal
exceed 1 second.
The brake switch has failed.
P49
P50
ABS
warning
light
B1318
63
ABS HU/CM
power supply
B1342
61
ABS HU/CM
C1095
54
Motor relay,
pump motor
C1096
53
Motor relay,
pump motor
C1140
30
ABS HU/CM
(pump)
C1145
11
C1148
41
C1155
12
C1158
42
C1165
13
C1168
43
C1175
14
C1178
44
P51
Diagnostic
system
component
Action
ABS
warning
light
C1186
51
Valve relay
C1194
24
C1198
25
C1202
26
R outlet solenoid
valve
C1206
27
R inlet solenoid
valve
C1210
22
C1214
23
C1233
46
C1234
45
Right front
wheelspeed
sensor/sensor
rotor
C1235
47
Right rear
wheelspeed
sensor/sensor
rotor
P52
Diagnostic
system
component
Action
*:
SST
(WDS
or
equivalent)
ABS
warning
light
C1236
48
C1266
52
Valve relay
C1414
64
ABS HU/CM
mismatched
installation
C1510
32
C1511
33
C1512
34
R solenoid
valve, motor or
right rear wheel
speed sensor/
sensor rotor
C1513
35
R solenoid
valve, motor or
left rear wheel
speed sensor/
sensor rotor
C1949*
03*
G sensor
C1950*
04*
G sensor
Diagnostic
system
component
Action
4x4 only
Unit/Condition
Condition/Specification
D ABS warning light is
ON/OFF
illuminated: ON.
D ABS warning light is not
illuminated: OFF.
D Ignition key at ON: B+
D Idle: Approx. 1316 V
P53
Action
ABS HU/CM
terminal
PID Name
(Definition)
Unit/Condition
Condition/Specification
D During ABS control: ON/
ABSLF_I
(LF ABS inlet valve
output state)
ON/OFF
ABSPMPRLY
(ABS pump motor
relay output state)
ON/OFF
ON/OFF
ON.
D Motor relay is deactivated:
OFF.
D During ABS control: ON/
ABSR_I
(R ABS inlet valve
output state)
ON/OFF
ABSR_O
(R ABS outlet valve
output state)
ON/OFF
ABSR_I
(RF ABS inlet valve
output state)
ON/OFF
ABSRF_O
(RF ABS inlet valve
output state)
ABSVLVRLY
(ABS valve relay
output state)
ON/OFF
ON/OFF
ON.
D Valve relay is deactivated:
OFF
D Vehicle is stopped or
ACCLMTR*
(Accelerometer)
ACCELERATION
driving at a constant
speed: 0 G.
D Vehicle is driving at a
acceleration: Changes
between 0 1.28 G.
D Vehicle is driving at a
deceleration: Changes
between 0 1.27 G.
D Brake pedal is depressed:
BOO_ABS
(Brake pedal switch
ON/OFF
ON.
D Brake pedal is released:
OFF.
P54
Action
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Inspect ABS HU/CM.
(See ABS HU/CM
INSPECTION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Internal fault of ABS HU/
CM. Replace ABS
HU/CM. (See ABS HU/
CM REMOVAL/
INSTALLATION
Inspect ABS HU/CM.
(See ABS HU/CM
INSPECTION
ABS HU/CM
terminal
H, J
PID Name
(Definition)
Unit/Condition
CCNTABS
(Number of continuous
trouble code set)
LF_WSPD
(LF wheelspeed
sensor input)
LR_WSPD
(LR wheelspeed
sensor input)
Condition/Specification
D DTC is detected: 1255.
D DTC is not detected: 0.
D Vehicle is stopped: 0 KPH
KPH or MPH
{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Vehicle is stopped: 0 KPH
KPH or MPH
{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Pump motor is activated:
PMPSTAT
(ABS motor status)
RF_WSPD
(RF wheelspeed
sensor input)
RR_WSPD
(RR wheelspeed
sensor input)
*:
ON/OFF
{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
D Vehicle is stopped: 0 KPH
KPH or MPH
{0 MPH}.
D Vehicle is driving:
Indicates vehicle speed.
ABS HU/CM
terminal
Inspect wheelspeed
sensor/sensor rotor.
Inspect wheelspeed
sensor/sensor rotor.
E, I
C, F
ON.
D Pump motor is
deactivated: OFF
D Vehicle is stopped: 0 KPH
KPH or MPH
Action
Inspect wheelspeed
sensor/sensor rotor.
Inspect wheelspeed
sensor/sensor rotor.
D, G
A, B
4x4 only
ABS OUTPUT
CONTROL
Command name
Operation/unit
(SST (WDS or
equivalent display))
ABS_POWER
Valve relay
ON/OFF
LF_INLET
ON/OFF
LF_OUTLET
ON/OFF
PMP_MOTOR
ABS motor
ON/OFF
REAR_INLET
ON/OFF
REAR_OUTLET
ON/OFF
RF_INLET
ON/OFF
RF_OUTLET
ON/OFF
P55
Note
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Go to Step 3.
Yes
Go to Step 5.
No
If there is no continuity:
D Repair or replace harness for open between
ABS HU/CM and ground, then go to Step 5.
D Repair or replace harness for poor ground then
go to Step 5.
Yes
Go to next step.
No
INSPECT GENERATOR
D Inspect generator.
D Is it okay?
Yes
Go to next step.
No
P56
STEP
5
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
ABS HU/CM
D The onboard diagnostic program detects computer malfunction.
D Malfunction of ABS HU/CM (CM part)
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
D C1095 (54): ABS motor is stuck OFF when vehicle is started or during ABS operation, ABS motor ON is
DETECTION
CONDITION
commanded.
D C1096 (53): ABS motor is stuck ON when vehicle is started or during ABS operation, ABS motor OFF is
commanded.
POSSIBLE
CAUSE
D
D
D
D
Open circuit, or short power or short to ground of motor relay and/or ABS motor in ABS HU/CM
Stuck motor relay and/or ABS motor
Open circuit of ABS motor power supply
Open circuit of ABS motor ground
P57
Diagnostic procedure
STEP
1
2
3
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
P58
STEP
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P59
C1145 (11)
C1155 (12)
C1165 (13)
C1175 (14)
DETECTION
CONDITION
POSSIBLE
CAUSE
P60
INSPECTION
ACTION
Yes
Go to next step.
No
Go to Step 3.
Yes
No
Go to Step 5.
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P61
D C1148 (41), C1158 (42), C1168 (43), C1178 (44): ABS wheelspeed signal is out of specification when
DETECTION
CONDITION
D
D
D
D
P62
INSPECTION
ACTION
Yes
Go to Step 5.
No
Go to next step.
Yes
Go to next step.
No
Go to Step 4.
Yes
No
Yes
Go to Step 8.
No
Yes
Go to Step 8.
No
Go to next step.
P63
STEP
6
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P64
Valve relay
D C1186 (51): Valve relay in ABS HU/CM is stuck OFF when ignition switch (engine switch) is turned ON,
DETECTION
CONDITION
D Open circuit, short to power or short to ground circuit of valve relay in ABS HU/CM
D Stuck ON or OFF of valve relay in ABS HU/CM
D Open circuit of valve relay power supply circuit
P65
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P66
C1202 (26)
C1206 (27)
C1210 (22)
C1214 (23)
C1194 (24)
C1198 (25)
DETECTION
CONDITION
POSSIBLE
CAUSE
Diagnostic Procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P67
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
2
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
P68
STEP
6
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
G sensor
D C1949 (03):
DETECTION
CONDITION
POSSIBLE
CAUSE
sensor terminal B
D Open circuit in harness between ABS HU/CM terminal J and G sensor terminal A
D Malfunction of G sensor
P69
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Go to next step.
INSPECT G SENSOR
D Inspect G sensor.
(See G SENSOR INSPECTION)
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Troubleshooting completed.
P70
10
2
3
Instrument cluster
11
ABS HU/CM
12
4x4 only
13
G sensor
14
DLC
Solenoid valve
15
KLN
ABS motor
16
TBS
Brake switch
17
GND
Battery
P71
Remedy
If ABS is operating,
stop control after
operation. If ABS is not
operating, stop control
immediately.
Operate control.
* : If battery voltage drops below about 9 to 10 V while vehicle speed is greater than 6 kmh {3.7 mph}, ABS
HU/CM records DTC B1318 (DTC 63).
(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.
D Malfunction in electrical system
The ABS control module (ABS HU/CM) has an onboard diagnostic function. With this function, the ABS
warning light will turn on 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. Turn the ignition switch (engine switch) to ON position, shorting the TBS terminal of
the data link connector and the body ground, or connecting the SST (WDS or equivalent) to the DLC, and
approximately 5 seconds later the stored malfunctions will be displayed in the order of occurrence. To
find out the causes of ABS malfunctions, use these onboard diagnostic results.
If a malfunction occurred in the past but is now normal, the cause is likely a temporary poor connection of
the harness. The ABS HU/CM usually operates normally. Be careful when searching for the cause of
malfunction.
After repair, it is necessary to erase 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 wheelspeed sensor or ABS sensor rotor, or after replacing the ABS HU/CM (ABS
motor or ABS motor relay or solenoid valve), the ABS warning light may not go off even when the ignition
switch (engine switch) is turned to ON position. IN this case, drive the vehicle at a speed of more than 10
kmh {6.2 mph}, make sure the ABS warning light goes off, and then erase the DTC.
When repairing, if the ABS related connectors are disconnected and the ignition switch (engine switch) is
turned to ON position, the ABS HU/CM will mistakenly detect a fault and record it as a malfunction.
To protect the ABS HU/CM, make sure the ignition is off before connecting or disconnecting the ABS HU/
CM connector.
D 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 materials get 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 materials do not get inside
when servicing the ABS (e.g. brake fluid replacement, pipe removal).
P72
Symptom
ABS warning light does not illuminate with ignition switch (engine switch) on.
ABS warning light stays on for more than 4 seconds with ignition switch (engine switch) on.
There is a malfunction in the system even though ABS warning light indicates that the system is normal.
NO.1 ABS WARNING LIGHT DOES NOT ILLUMINATE WITH IGNITION SWITCH (ENGINE SWITCH) ON
D 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
connected correctly and undamaged.
1
Air bag system warning light does not illuminate when ignition switch is turned to ON position.
[TROUBLESHOOTING HINTS]
D ABS warning light circuit open or shorted to ground
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to step 4.
No
Go to next step.
Yes
Go to next step.
No
P73
STEP
*3
*7
INSPECTION
ACTION
Yes
No
Yes
Go to next step.
No
Go to step 6.
Yes
Yes
Go to next step.
No
Yes
No
No
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Disconnect ABS HU/CM connector and
instrument cluster connectors. Is there continuity
between instrument cluster connector terminal 2B
and ABS HU/CM connector terminal W?
NO.2 ABS WARNING LIGHT STAYS ON FOR MORE THAN 4 SECONDS WITH IGNITION SWITCH (ENGINE
SWITCH) ON
Using SST (WDS or equivalent)
D 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
connected correctly and undamaged.
2
ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.
[TROUBLESHOOTING HINTS]
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below about 9 to 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)
Diagnostic procedure
STEP
1
INSPECTION
INSPECT ABS HU/CM IGNITION POWER
SUPPLY FUSE
Is ABS HU/CM power supply fuse okay?
ACTION
Yes
Go to next step.
No
P74
STEP
2
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 16.
No
Go to next step.
INSPECT BATTERY
Is battery voltage normal?
Yes
No
Yes
Go to Step 9.
No
Yes
No
Go to next step.
Yes
No
Go to Step 11.
Yes
No
Go to next step.
3
4
*9
10
P75
STEP
*11
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
No
Go to Step 18.
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
Is voltage approximately 12 V at ABS HU/CM
terminal Z?
*12
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal AC and ground?
*13
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal T and data link connector
(DLC)?
*14
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to ON
position.
Is voltage approximately 12 V at ABS HU/CM
connector terminal T?
*15
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal T and ground?
16
P76
STEP
17
*18
*19
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
ABS warning stays on for more than 4 seconds with ignition switch (engine switch) on.
[TROUBLESHOOTING HINTS]
D ABS HU/CM detects ABS system malfunction
D ABS HU/CM detects low voltage in power supply (ABS HU/CM ignition terminal Z voltage is below 10 V)
D ABS HU/CM does not operate
D ABS warning light circuit open or shorted to high voltage (approximately 12 V)
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
INSPECT BATTERY
Is battery voltage normal?
Yes
Go to next step.
No
Yes
Go to Step 6.
No
Yes
No
Go to next step.
Yes
No
Go to Step 8.
*6
P77
STEP
7
*8
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Turn ignition switch (engine switch) to LOCK
position.
Disconnect ABS HU/CM connector.
Is voltage approximately 12 V at ABS HU/CM
terminal Z?
*9
Caution
D Attach a wire to the tester lead to avoid
damaging the ABS HU/CM terminal.
Is there continuity between ABS HU/CM
connector terminal AC and ground?
*10
*11
NO.3 THERE IS A MALFUNCTION IN SYSTEM EVEN THOUGH ABS WARNING LIGHT INDICATES THAT
THE SYSTEM IS NORMAL
3
There is a malfunction in the system even though ABS warning light indicates that the system is normal.
[TROUBLESHOOTING HINTS]
There is a mechanical malfunction in system.
Diagnostic procedure
STEP
1
INSPECTION
CHECK FOR DTCS IN ABS HU/CM
Have DTCs been recorded in memory?
ACTION
Yes
No
Go to next step.
P78
Yes
No
P79
SUSPENSION
GENERAL PROCEDURES . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . .
WHEEL ALIGNMENT PREINSPECTION . . . . .
FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . .
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . .
VEHICLE HEIGHT ADJUSTMENT . . . . . . . . . .
FRONT SHOCK ABSORBER REMOVAL/
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SHOCK ABSORBER INSPECTION . .
FRONT SHOCK ABSORBER DISPOSAL
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
TORSION BAR SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2) . . . . . . . . .
R
R
R
R
R
R
1
1
1
2
3
3
R 5
R 6
R 6
R 7
GENERAL PROCEDURES
WHEEL ALIGNMENT
R1
WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT
Specifications
Specification
Item
4 2
(mm {in})
Total toe-in
Maximum steering
angle
3"3 {0.12"0.12}
0 16 "16
(degree)
Inner
35 00
+2
3
Outer
33 00
+2
3
Camber angle*2
Caster
angle*3
4 4
0 14 "14
33 30
+2
3
30 00
+2
3
0 56 "30
1 06 "30
1 37 "45
2 02 "45
8 04
10 15
Fuel tank is full. Engine coolant and engine oil are at specified level. Spare tire, jack, and tools are in designated
position.
Difference between left and right must not exceed 30.
Difference between left and right must not exceed 45.
Tightening torque
4058 Nm {4.06.0 kgfm, 2943 ftlbf}
4 2
ADJUSTING BOLT
4 4
ADJUSTING BOLT
R2
FRONT SUSPENSION
VEHICLE HEIGHT ADJUSTMENT
No.15
Caution
D 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.
No.611
FRONT
Adjustment shim
No.
No.
1.0 {0.039}
1.0 {0.039}
1.6 {0.063}
1.6 {0.063}
2.0 {0.079}
2.0 {0.079}
3.2 {0.126}
10
3.2 {0.126}
4.0 {0.157}
11
4.0 {0.157}
0.6 {0.024}
Left/right difference
10 mm {0.39 in} max.
Standard vehicle height
Drive
type
Note
D Shims No.15 are used on either side. Do not
use more than two.
D Shims No.611 are used at the front and rear
of either sides. Do not use more than one.
D Camber: A change of shim thickness (at front
and rear) of 1 mm {0.039 in} results in a
change of about 15.
D Caster: A change of shim thickness (at front or
rear only) of 1 mm {0.039 in} results in a
change of about 30.
4x2
Cab type
Tire size
Regular
Cab,
Stretch Cab*
ALL
Double Cab
4x4
Tightening torque
94116 Nm {9.511.9 kgfm, 6986 ftlbf}
Double Cab
427.0 {16.81}
422.0 {16.61}
205R16
Regular
Cab,
Stretch Cab*
Vehicle
height (mm
{in})
235/75R15
P235/75R15
519.0 {20.43}
515.0 {20.28}
265/70R15
518.0 {20.39}
205R16
510.0 {20.08}
235/75R15
P235/75R15
265/70R15
506.0 {19.92}
509.0 {20.04}
R3
WHEEL ALIGNMENT
Caution
D Adjust the vehicle height at the left and
right wheels at the same time. Otherwise,
the vehicle height may not be adjusted
correctly.
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
D Vehicle height increasedecreases per one
anchor bolt rotation as follows:
4x2: 3.5 mm {0.14 in}
4x4: 3.3 mm {0.13 in}
4 2
4 4
ANCHOR BOLT
ANCHOR BOLT
R4
FRONT SUSPENSION
FRONT SHOCK ABSORBER REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
68 mm
{0.240.31 in}
Nm {kgfm, ftlbf}
Nut
+ Installation Note
Bolt
Retainer, bushing
Shock absorber
R5
FRONT SUSPENSION
FRONT SHOCK ABSORBER INSPECTION
1. Remove the front shock absorber from the vehicle.
2. Inspect for damage and oil leakage.
3. Inspect the rubber bushing for deterioration and
wear.
4. Compress and extend the shock absorber piston at
least three (3) times. Verify that the operational
force does not change and that there is no unusual
noise.
5. Compress the shock absorber piston and release
it. Verify that the piston extends fully at a normal
speed.
FRONT SHOCK ABSORBER DISPOSAL (VEHICLES
BUILT FROM 08/2002)
Warning
D 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 23 mm {0.080.12 in) hole at a point
2030 mm {0.81.2 in} from the bottom of the
tube, so that the gas can escape.
R6
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 2)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the vehicle height and adjust it as necessary.
APPLY THREAD
LOCKING COMPOUND
APPLY THREAD
LOCKING COMPOUND
SST
R
Nm {kgfm, ftlbf}
Cotter pin
11
Torque plate
Nut
12
13
Rubber bushing
+ Removal Note
+ Installation Note
Anchor bolt
+ Removal Note
+ Installation Note
14
15
Anchor swivel
16
Lower arm
17
18
Anchor arm
19
10
20
Clip
+ Installation Note
21
R7
FRONT SUSPENSION
Lower Arm Ball Joint/Knuckle Arm Removal Note
D Separate the ball joint from the knuckle arm using
the SST.
KNUCKLE
49 T028 3A0
49 U034 208
MATCHING MARK
1821 mm
{0.710.82 in}
MATCHING MARK
MATCHING MARK
49 UB39 615
49 UB39 615
R8
FRONT SUSPENSION
Torsion Bar Spring Installation Note
1. Before installation, check the identification mark on
the end of the torsion bar spring.
L: Left bar, R: Right bar
2. Align the marks made during removal, and connect
the torsion bar spring to the torque plate.
MATCHING MARK
MATCHING MARK
MATCHING MARK
Note
D If the anchor bolt was not marked during
removal, install it as follows:
(1) Lower the front suspension until the upper
arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
34 "4.5.
(3) Install the anchor bolt and tighten it 27.3
turns.
R9
FRONT SUSPENSION
TORSION BAR SPRING AND LOWER ARM REMOVAL/INSTALLATION (4 4)
1. Remove the driveshaft snap ring.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
4. Inspect the vehicle height and adjust it as necessary.
118156
{12.016.0, 87115}
SST
APPLY THREAD
LOCKING COMPOUND
Cotter pin
13
Nut
14
15
Lower arm
16
17
Anchor swivel
18
19
Anchor arm
+ Removal Note
+ Installation Note
Clip
+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Clip
Installation Note
10
20
21
11
Torque plate
12
R10
FRONT SUSPENSION
Anchor Arm Removal Note
D Mark the anchor arm and body for reference during
installation.
R11
FRONT SUSPENSION
Anchor Bolt Installation Note
D Install the anchor bolt, and tighten it until the marks
made during removal are aligned.
Note
D If the anchor bolt was not marked during
removal, install it at follows:
(1) Lower the front suspension until the upper
arm contacts the rebound stopper.
(2) Install the anchor arm so that the angle A is
60"4.5.
(3) Install the anchor bolt and tighten it 26.9
turns.
R12
FRONT SUSPENSION
UPPER ARM REMOVAL/INSTALLATION
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3. Inspect the wheel alignment and adjust it as necessary.
R
SST
Clip
Clip
+ Installation Note
Adjustment shim
+ Removal Note
10
49 T028 3A0
49 U034 209
KNUCKLE
R13
FRONT SUSPENSION
UPPER ARM INSPECTION
1. Remove the upper arm from the vehicle.
2. Inspect for damage, cracks, and bending.
3. Check the ball joint rotation torque.
(1) Rotate the ball joint five times.
(2) Connect the SST to the ball stud, and measure
the rotation torque using a pull scale.
(3) Replace it if not within the specification.
49 0180 510B
APPLY THREAD
LOCKING COMPOUND
Nut
+ FRONT SUSPENSION, TORSION BAR
SPRING AND LOWER ARM
REMOVAL/INSTALLATION (4 2), Stabilizer
Bolt, Bushing, Retainer, Spacer, And Nut
Installation Note
Stabilizer bracket
Bushing
Stabilizer bar
Retainer
10
Bolt
11
Bolt
12
Tension rod
Bolt
R14
FRONT SUSPENSION
Tension Rod Nut Installation Note
D Tighten the tension rod nuts so that length L is 98.5
mm {3.88 in}.
STABILIZER REMOVAL/INSTALLATION (4 4)
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
Nm {kgfm, ftlbf}
Nut
+ FRONT SUSPENSION, STABILIZER AND
TENSION ROD REMOVAL/INSTALLATION
(4 2), Nut Installation Note
Bolt
Stabilizer bracket
Bushing
Bolt
Stabilizer bar
R15
REAR SUSPENSION
REAR SUSPENSION
REAR SHOCK ABSORBER AND LEAF SPRING REMOVAL/INSTALLATION
1. Support the frame with safety stands and place a jack under the differential casing. Remove in the order
indicated in the table. While supporting the differential casing with a jack, raise or lower the jack as necessary.
2. Install in the reverse order of removal.
4 2
6478
{6.58.0, 4857}
7898
{8.010.0, 5872}
R
2026 {2.02.7, 1519.5}
Nm {kgfm, ftlbf}
10
Spring pin
11
Shock absorber
12
Shackle pin
13
Shackle plate
14
U-bolt
15
Spring clamp
Stopper rubber
R16
REAR SUSPENSION
4 4
APPLY THREAD
LOCKING COMPOUND
6478
{6.58.0, 4857}
R
7898 {8.010.0, 5872}
Nm {kgfm, ftlbf}
11
12
Spring pin
13
Shock absorber
14
Shackle pin
15
Shackle plate
16
U-bolt
17
Set plate
Spring clamp
10
Stopper rubber
R17
REAR SUSPENSION
Leaf Spring Bushing Removal Note
D Secure the leaf spring in a vise and remove the
bushing using a chisel.
R18
BODY
BONNET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S 3
BONNET REMOVAL/INSTALLATION . . . . . . . . S 3
BONNET ADJUSTMENT . . . . . . . . . . . . . . . . . . S 4
FRONT FENDER PANEL . . . . . . . . . . . . . . . . . . . . S 4
FRONT FENDER PANEL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S 4
DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S 5
FRONT DOOR REMOVAL/INSTALLATION . . . S 5
FRONT DOOR DISASSEMBLY/ASSEMBLY . . S 6
FRONT DOOR ADJUSTMENT . . . . . . . . . . . . . S 7
REAR DOOR REMOVAL/INSTALLATION . . . . S 7
REAR DOOR DISASSEMBLY/ASSEMBLY . . . S 8
REAR DOOR ADJUSTMENT . . . . . . . . . . . . . . . S 9
DOOR LOCK STRIKER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S 9
REGULATOR HANDLE REMOVAL . . . . . . . . . . S 9
REGULATOR HANDLE INSTALLATION . . . . . S 9
POWER WINDOW SYSTEM . . . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
INSPECTION (VEHICLES BUILT
UP TO 07/2002) . . . . . . . . . . . . . . . . . . . . . . . . . S10
POWER WINDOW MAIN SWITCH
INSPECTION (VEHICLES BUILT
FROM 08/2002) . . . . . . . . . . . . . . . . . . . . . . . . . S13
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S15
POWER WINDOW SUBSWITCH
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S15
POWER WINDOW SUBSWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S16
POWER WINDOW SUBSWITCH INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S16
FRONT POWER WINDOW REGULATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S16
FRONT POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S17
REAR POWER WINDOW REGULATOR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S17
REAR POWER WINDOW REGULATOR
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . S17
POWER WINDOW MOTOR INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S18
POWER WINDOW MOTOR INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . S18
POWER DOOR LOCK SYSTEM . . . . . . . . . . . . . . S20
DOOR KEY CYLINDER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . S20
DOOR KEY CYLINDER SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . S20
DOOR LOCK-LINK SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . S20
DOOR LOCK-LINK SWITCH INSPECTION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . . S20
DOOR LOCK-LINK SWITCH INSPECTION
(VEHICLES BUILT FROM 08/2002) . . . . . . . . . S21
S1
S16
S22
S22
S22
S23
S24
S25
S25
S26
S27
S27
S29
S29
S29
S29
S29
S29
S30
S30
S30
S30
S30
S30
S32
S32
S33
S33
S34
S35
S35
S36
S36
S36
S36
S36
S36
S36
S37
ROOF MOLDING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . .
OUTSIDE MIRROR . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR INSPECTION . .
POWER OUTSIDE MIRROR SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
POWER OUTSIDE MIRROR SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
REARVIEW MIRROR . . . . . . . . . . . . . . . . . . . . . . . .
REARVIEW MIRROR
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER SWITCH
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER SWITCH
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILAMENT INSPECTION . . . . . . . . . . . . . . . . . .
FILAMENT REPAIR . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER RELAY
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER RELAY
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINDSHIELD REMOVAL . . . . . . . . . . . . . . . . . .
WINDSHIELD INSTALLATION . . . . . . . . . . . . . .
QUARTER WINDOW GLASS
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
QUARTER WINDOW GLASS
REMOVAL/INSTALLATION (STRETCH CAB
4 DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW GLASS REMOVAL . . . . . . . .
REAR WINDOW GLASS INSTALLATION . . . .
DASHBOARD AND CONSOLE . . . . . . . . . . . . . . .
DASHBOARD REMOVAL/INSTALLATION . . .
DASHBOARD DISASSEMBLY/ASSEMBLY . .
DASHBOARD MEMBER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
COLUMN COVER
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT CONSOLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT CONSOLE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
REAR CONSOLE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR CONSOLE
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
GLOVE COMPARTMENT
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
METER HOOD
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
TRIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
A-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
B-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002) . . . . . . . .
S37
S37
S37
S37
S37
S38
S38
S39
S39
S39
S39
S39
S39
S40
S40
S40
S41
S41
S42
S44
S45
S45
S45
S47
S47
S48
S49
S49
S49
S49
S49
S50
S50
S50
S51
S51
S51
S51
B-PILLAR TRIM
REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/2002) . . . . . . . .
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
ROOF SIDE TRIM
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
FRONT SIDE TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT SCUFF PLATE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR SCUFF PLATE
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR SCUFF PLATE
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
C-PILLAR TRIM REMOVAL/INSTALLATION . .
QUARTER UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
QUARTER LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BACK UPPER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
BACK LOWER TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
FRONT DOOR TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR DOOR TRIM
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR ACCESS PANEL TRIM
REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEADLINER REMOVAL/INSTALLATION . . . . .
FLOOR COVERING . . . . . . . . . . . . . . . . . . . . . . . . .
FLOOR COVERING
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEAT BELT REMOVAL/INSTALLATION . . . . . .
SEAT BELT REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR) . . . . . . . . . . . . . .
SEAT BELT INSPECTION . . . . . . . . . . . . . . . . .
BUCKLE REMOVAL/INSTALLATION . . . . . . . . .
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT SEAT REMOVAL/INSTALLATION . . . .
FRONT SEAT DISASSEMBLY/ASSEMBLY . . .
CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . .
REAR SEAT REMOVAL/INSTALLATION . . . . .
REAR SEAT DISASSEMBLY/ASSEMBLY . . . .
SEAT WARMER SWITCH REMOVAL . . . . . . .
SEAT WARMER SWITCH INSTALLATION . . .
SEAT WARMER SWITCH INSPECTION . . . . .
SEAT WARMER UNIT INSPECTION . . . . . . . .
BODY SHELL (STRETCH CAB 4 DOOR) . . . .
REAR ACCESS PANEL
REMOVAL/INSTALLATION . . . . . . . . . . . . . . .
REAR ACCESS PANEL
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . .
STRIKER REMOVAL/INSTALLATION . . . . . . .
TROUBLESHOOTING (POWER WINDOW
SYSTEM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTERMITTENT CONCERN
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .
S2
S51
S52
S52
S52
S52
S53
S53
S53
S53
S53
S54
S54
S54
S55
S55
S55
S56
S56
S56
S56
S58
S58
S60
S60
S60
S62
S62
S63
S65
S65
S65
S68
S68
S68
S68
S69
S69
S70
S70
S71
S71
S72
S72
S73
S73
S73
S74
S74
S76
S77
S78
S78
S78
S79
S80
S81
S81
S82
S84
BONNET
3.03.9
{3040,
2734}
Warning
D Removing the bonnet without supporting it
can be dangerous. The bonnet may fall and
injure you. Always perform these
procedures together with at least another
person.
A
A
BONNET REMOVAL/INSTALLATION
1. Pull out the windshield washer pipe.
2. To remove the bonnet hinge, remove the front
fender panel. (Refer to FRONT FENDER PANEL,
FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
3. To remove the bonnet lock, remove the radiator
grille.
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
6. Adjust the bonnet. (Refer to BONNET
ADJUSTMENT.)
7.910.7
{80110,
69.595.4}
Nm {kgfcm, inlbf}
S3
Bonnet
Bonnet hinge
Bonnet stay
Bonnet lock
Height Adjustment
1. Loosen the bonnet lock installation bolts and move
the bonnet lock to reposition the bonnet.
BOLT
Clearance
a: 2.75.3 mm {0.110.20 in}
b: 1.80.8 mm {0.070.03 in} (sec. AA)
c: 2.30.8 mm {0.090.03 in} (sec. BB)
d: 2.30.3 mm {0.090.01 in} (sec. CC)
e: 6.010.0 mm {0.240.39 in}
f: 7.013.0 mm {0.280.51 in}
50 {2.0}
A A
30 {1.2}
E
D
D
B B
C C
a
e
b , c, d
SEC. AA
SEC. BB
SEC. CC
f
SEC. DD
SEC. EE
B
mm {in}
Gap Adjustment
1. Loosen the bonnet installation bolts and reposition
the bonnet.
A
BOLT
6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
Mud guard
S4
12345678
DOOR
DOOR
FRONT DOOR REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the door screen. (Refer to FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
3. To remove the front door hinge, remove the front
fender panel. (Refer to FRONT FENDER PANEL,
FRONT FENDER PANEL
REMOVAL/INSTALLATION.)
4. To remove the checker, remove the speaker.
(Refer to section T, AUDIO, SPEAKER
REMOVAL/INSTALLATION.)
5. Remove in the order indicated in the table.
6. Install in the reverse order of removal.
7. Adjust the front door. (Refer to FRONT DOOR
ADJUSTMENT.)
Symbol
Drivers side
Passengers side
Power window
subswitch
Power outside
mirror
Speaker
DOOR HARNESS
CLIP
C
2230
{2.23.1, 1622}
CLIP CLIP
(WITHOUT
SPEAKER)
(WITH SPEAKER)
Nm {kgfm, ftlbf}
Checker pin
Front door
Checker
CLIP
CLIP
8.912.7 Nm
{90130 kgfcm, 79112 inlbf}
S5
DOOR
FRONT DOOR DISASSEMBLY/ASSEMBLY
1. Raise the rear edge of the front door glass 80 mm {3.1 in} from the fully lowered position.
2. Disconnect the negative battery cable.
3. Remove the front door trim. (Refer to TRIM, FRONT DOOR TRIM REMOVAL/INSTALLATION.)
4. To remove the inner handle, peel off the door screen partially.
5. Disassemble in the order indicated in the table.
6. Assemble in the reverse order of disassembly.
WITHOUT POWER WINDOW SYSTEM AND POWER DOOR LOCK SYSTEM
B
B
A
D
6.879.80
{70100, 60.886.7}
4.36.1
{4363,
3854}
C
6.879.80 {70100, 60.886.7}
D
H
8.912.7
{90130, 79112}
G
I
4.36.1
{4363,
3854}
6.879.80
{70100, 60.886.7}
J
I
Nm {kgfcm, inlbf}
Inner handle
Door screen
Outer handle
10
Retainer
11
12
13
14
S6
DOOR
FRONT DOOR ADJUSTMENT
1. Measure the clearance between the door and the
body.
2230
{2.23.1, 1622}
Clearance
a: 4.06.0 mm {0.160.23 in}
b: 1.51.0 mm {0.0590.039 in}
c: 2.00.5 mm {0.0780.019 in}
d: 4.58.5 mm {0.180.33 in}
e: 1.2 mm {0.047 in}
f: 3.56.5 mm {0.140.25 in}
g: 2.7 mm {0.11 in}
h: 5.5 mm {0.22 in}
E E
8.912.7 Nm
{90130 kgfcm,
79112 inlbf}
A A
B B
(+)
Nm {kgfm, ftlbf}
F
F
e
(+)
a
b
()
SEC. BB
SEC. AA
(+)
b
()
SEC. CC
g
()
SEC. DD
h
SEC. EE
SEC. FF
S7
Connector
Checker pin
Rear door
Checker
DOOR
REAR DOOR DISASSEMBLY/ASSEMBLY
1. Close the rear door glass completely.
2. Disconnect the negative battery cable.
3. Remove the rear door trim. (Refer to TRIM, REAR DOOR TRIM REMOVAL/INSTALLATION.)
4. Disassemble in the order indicated in the table.
5. Assemble in the reverse order of disassembly.
WITH POWER WINDOW SYSTEM
6.879.80
{70100, 60.886.7}
E
WITHOUT POWER WINDOW SYSTEM
6.879.80
{70100,
60.886.7}
2.53.5
{2536, 2231}
4.36.1
{4363, 3854}
D
A
C
6.879.80
{70100, 60.886.7}
Nm {kgfcm, inlbf}
Inner handle
Door screen
Ashtray bracket
Glass guide
10
11
12
Outer handle
S8
DOOR
Rear Door Glass Removal Note
D Draw out the rear door glass through the glass
hole.
SCREW
1826
{1.82.7,
1419}
REAR DOOR
DD
A A
E E
B B
RAG
C
C
(+)
(+)
b
()
b
()
SEC. AA
SEC. BB
a
(+)
b
CLIP
(+)
c
SEC. CC
b
()
()
SEC. DD
SEC. EE
CLIP
S9
FRONT
SWITCH PANEL
POWER
WINDOW
MAIN SWITCH
SWITCH PANEL
BODY
SCREW
BODY
CLIP
HOOK
S10
Switch
position
A (H)
B (I)
Manual close
Off
Auto open
Manual open
Double Cab
1. Remove the switch panel. (Refer to POWER
WINDOW MAIN SWITCH
REMOVAL/INSTALLATION.)
2. Inspect for continuity between the power window
main switch terminals using an ohmmeter.
3. When inspecting the drivers side, connect the
battery positive voltage to terminal A (L.H.D.) or F
(R.H.D.) and connect the ground to terminal H.
4. When inspecting the passengers side and rear,
turn the power-cut switch to ON.
Power window switch
Drivers side
( ): R.H.D.
: Continuity
Passengers side
: Continuity
Switch
position
Terminal
Switch
position
H (A)
I (B)
Terminal
A (F)
L (D)
J (B)
Manual close
Close
Off
Off
Auto open
Manual open
Open
( ): R.H.D.
( ): R.H.D.
Passengers side
: Continuity
Power-cut switch
Switch
position
: Continuity
Switch
position
Terminal
D
A (H)
B (I)
H (A)
I (B)
Terminal
A (F)
D (L)
B (J)
Close
ON
Off
OFF
( ): R.H.D.
Open
( ): R.H.D.
Rear left
F
: Continuity
POWER-CUT SWITCH
Switch
position
MANUAL
OPEN
MANUAL
CLOSE
OPEN
CLOSE
Close
AUTO
OPEN
AUTO
CIRCUIT
Terminal
Off
Open
I (B)
H (A)
PASSENGERS
SIDE
( ): R.H.D.
Rear right
OPEN
CLOSE
: Continuity
Switch
position
A (H) B (I)
DRIVERS SIDE
H
I
A
D
Close
Off
( ) : R.H.D.
Open
( ): R.H.D.
S11
Terminal
A
L
(D
)
J
(B
)
D
(L
)
B
(J)
ON
OFF
( ): R.H.D.
L.H.D.
A
H
D
B
PASSENGERS
C
RIGH
T
R.H.D.
F
H
J
PASSENGERS
D
S12
Terminal
1F
1H
Signal
Door
switch
IG1
Connected to
Door switch
P. WIND 30 A
fuse
Power
supply
P. WIND 15 A
fuse
1L
(1D)
Close
output
Power window
motor
1M
Ground
GND
1N
(1B)
Close
output
Power window
motor
1J
2A
2B
Ground
SEN2
Test condition
Any door is open (door switch is
on): inspect for continuity to
ground
Yes
No
B+
SEN1
Below 1.0
B+
Yes
Below 1.0
B+
Power window
motor
2D
Power
supply
Power window
motor
B+
2C
Below 1.0
Action
harness
D Inspect P.WIND 30 A
fuse
D Inspect relate
harness
D P. WIND 15 A fuse
D Inspect related
harness
Power window
motor
Power window
motor
Voltage (V)/
Continuity
Yes
harness
D Inspect GND
D Power window motor
D Inspect related
harness
D Power window motor
D Inspect related
harness
Alternates
between 0
and 9
0 or 9
Alternates
between 0
and 9
0 or 9
9
harness
D Power window motor
D Inspect related
harness
D Power window motor
D Inspect related
harness
( ) : R.H.D.
S13
Rear right
Rear left
Powercut switch
S14
Rear
1. Disconnect the negative battery cable.
2. Disengage the clip using a tape-wrapped flathead
screwdriver.
3. Pull the power window subswitch panel forward to
disengage the hook.
CLIP
POWER
WINDOW
SUBSWITCH
BODY
HOOK
HOOK
POWER WINDOW
SUBSWITCH
S15
Switch position
Off
Close
Open
E
CLOSE
OPEN
Rear
: Continuity
Terminal
Switch position
Close
B
Off
Open
8.912.7
{90130, 79112}
D
C
B
A
B
F
CLOSE
OPEN
E
D
C
6.879.80
{70100, 60.886.7}
S16
Bolt
Nut
D
C
3.04.9 Nm
{3050 kgfcm,
2743 inlbf}
Bolt
Frame
6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
Bolt
GEAR
S17
Bolt
Frame
Voltage
Pulse wave: MAX. 5V, MIN. 0V
MARK
Motor operation
BASE
Terminal
2A
2B
UP
GND
B+
DOWN
B+
GND
GEAR
Motor operation
B+
GND
Up
Down
UP
Motor operation
UP
GND
B+
DOWN
B+
GND
DOWN
A
B
S18
Note
D A driverside window will not fully close
automatically under the following conditions:
The battery has been disconnected during
vehicle maintenance or for other reasons.
The power window main switch connector,
or driverside power window motor
connector has been disconnected.
Carry out the following procedure to
resume operation:
1. Turn the ignition switch to the ON position.
2. Press the driver side power window main switch
and fully open the driverside window.
S19
SCREW
Terminal
Key cylinder
position
Neutral
Lock
Rear
UK only
Unlock
Note
D The rear door lock-link switch is mounted to the
rear door lock actuator.
R: 9501050
B
UNLOCK
FRONT DOOR
LOCK-LINK SWITCH
LOCK
Lock knob
position
Note
D The front door lock-link switch is mounted to
the driver-side door lock.
Lock
Unlock
S20
Terminal
A
UNLOCK
LOCK
Rear
UK only
1. Disconnect the negative battery cable.
2. Remove the door screen.(Refer to DOOR, REAR
DOOR DISASSEMBLY/ASSEMBLY.)
3. Disconnect the rear door lock-link switch
connector.
4. Inspect for continuity between the rear door
lock-link switch terminals using an ohmmeter.
: Continuity
Note
D The front door lock actuator is mounted to the
passenger-side door lock.
1. Disconnect the negative battery cable.
2. Remove the passenger-side door lock. (Refer to
DOOR, FRONT DOOR
DISASSEMBLY/ASSEMBLY.)
3. Remove the screws.
4. Remove the front door lock actuator from the front
door lock.
Terminal
Lock
Unlock
FRONT DOOR LOCK
UNLOCK
123456567
SCREW
S21
Actuator operation
Connectio
B+
GND
Lock
Unlock
SCREW
ROD
REAR DOOR
LOCK ACTUATOR
Actuator operation
GND
B+
Lock
B+
GND
Unlock
FRONT, REAR
UNLOCK
LOCK
A
S22
Nut
Bracket
Terminal
Signal
Connection
Test condition
Voltage (V)
/Continuity
Inspection area
GND
Body ground
Yes
Power supply
D/L 30 A fuse
Constant
B+
No
Unlock input
Door lock-link
switch
Yes
Yes
No
E
F
Lock input
Lock output
Unlock output
G
H
GND
Door lock-link
switch
Door lock
actuator
Door lock
actuator
Other
Other
Not used
Terminal A of
door lock timer
unit
S23
D/L 30 A fuse
Door lock-link
switch
Door lock-link
switch
Door lock
actuator
Door lock
actuator
Yes
Terminal
Signal
Power
supply
Unlock
output
Lock
output
Lock/
Unlock
input
Connected to
D/L 30 A fuse
Test condition
Voltage (V)/
Continuity
B+
Action
D Inspect D/L 30 A fuse
D Inspect related har-
ness
Door lock
actuator
Door lock
actuator
Keyless unit
0 B+ 0
Other
Below 1.0
0 B+ 0
Other
Below 1.0
B+ 5 B+
B+ 0 B+
B+
actuator
D Inspect related
harness
D Inspect door lock
actuator
D Inspect related
harness
D Inspect keyless unit
D Inspect transmitter
D Inspect related
harness
Yes
Lock
input
Unlock
input
Power
ground
Door locklink
switch
Door locklink
switch
GND
No
No
S24
Yes
Yes
switch
D Inspect related
harness
D Inspect door locklink
switch
D Inspect related
harness
D Inspect GND
Nut
Keyless unit
S25
Terminal
Signal
Connected to
Test condition
Ignition switch is at ON position
IG1
METER 15 A
fuse
Voltage (V)/
Continuity
Action
B+
D Inspect METER 15 A
fuse
Ignition switch is at LOCK or ACC
position
Below 1.0
D Inspect related
harness
D Inspect ROOM 10 A
Power
supply
ROOM 10 A
fuse
B+
fuse
D Inspect related
harness
Door
open/
closed
Door switch
Below 1.0
B+
harness
*1 H
Hazard
Flasher unit
B+ Below
1.0 B+
B+ Below
1.0 B+
Below
1.0 B+
B+
harness
Yes
Ground
GND
S26
Terminal
Signal
Connected to
Test condition
Transmitter LOCK button is
pressed
Lock/
unlock
output
Voltage (V)/
Continuity
Action
B+ 6 B+
*2 5
2.5 5
B+ Below
1.0 B+
*25 Below
1.0 5
timer unit
D Inspect related
harness
B+
*2 5
Battery specification
Lithium CR2025 X 1
Note
D The batteries will last about 2 years when used
10 times a day.
TRANSMITTER BATTERY INSPECTION
Caution
D Since the battery voltage does not drop
fully if the button is pushed for only 4
seconds or less, it can not be properly
examined to see whether it is good or bad.
Always push the button for 5 seconds.
Note
D A correct measurement can not be obtained if
the battery temperature is low. Make sure the
battery is at 18 _C {64 _F} or more for at least
30 minutes before reinspecting if a
measurement value is under the standard
voltage.
1. Remove the transmitter cover.
2. Apply the circuit tester leads to the positions
indicated in the figure.
S27
S28
BUMPER
Fuel-filler lid
6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
Clearance
a: 3.55.5 mm {0.140.21 in}
b: 0.52.0 mm {0.010.07 in}
A
a
b
A
Front bumper
SEC.AA
12345678
Nm {kgfcm, inlbf}
S29
BUMPER
REAR BUMPER REMOVAL/INSTALLATION
With Step
1. Remove the bolts, then remove the rear bumper.
6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
3246
{3.24.7,
2433}
A
A
A
B
BOLT
79116
{8.011.9,
58.086.0}
6.879.80 Nm
{70100 kgfcm,
60.886.7 inlbf}
REAR BUMPER
A
B
0.300.78 Nm
{3.08.0 kgfcm,
2.76.9 inlbf}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Rear bracket
Set plate
79116
{8.011.9,
58.086.0}
1622
{1.62.3,
1216}
Nm {kgfm, ftlbf}
CLIP A
S30
SCREW
B
A
SCREW
A
SCREW
CLIP B
EXTERIOR ATTACHMENT
RADIATOR GRILLE REMOVAL/INSTALLATION
1. Pull the radiator grille toward you, then disengage
clips A to remove the radiator grille.
SCREW
CLIP A
A
CLIP
RADIATOR GRILLE
SCREW
COWL GRILLE
WEATHERSTRIP
S31
EXTERIOR ATTACHMENT
CENTER SIDE
PROTECTOR
(REGULAR CAB)
b
c
d
ca
a
e
SCREW
c
DOUBLE-SIDED ADHESIVE TAPE
CENTER SIDE
REAR SIDE PROTECTOR
PROTECTOR
(STRETCH CAB)
d
d
d
b
c
c a
a
WINDSHIELD
GARNISH
COWL GRILLE
e e
a c
c
HOOK
Clearance
a : 4.85.8 mm {0.190.22 in}
b : 5.06.0 mm {0.200.23 in}
c : 13.014.0 mm {0.510.55 in}
d : 16.517.0 mm {0.650.66 in}
e : 12.313.3 mm {0.490.52 in}
f : 6.08.0 mm {0.240.31 in}
Regular Cab
Note
D The side protector is installed with
double-sided adhesive tape. If the side
protector is difficult to remove, soften the
double-sided adhesive tape using a hot air
blower.
Clearance
a : 03.0 mm {00.11 in}
b : 37.5 mm {1.48 in}
c : 10.0 mm {0.39 in}
d : 2.05.0 mm {0.080.19 in}
e : 25.0 mm {0.98 in}
A
A
REAR SIDE
PROTECTOR
SEC. AA
A
A
SEC. AA
S32
EXTERIOR ATTACHMENT
Clearance
a : 4.85.8 mm {0.190.22 in}
b : 5.06.0 mm {0.200.23 in}
c : 3.977.97 mm {0.160.31 in}
Double Cab
SEC. AA
A
A
A
OVER FENDER
FASTENER
REAR
A
A
SCREW
A
CLIP
A
OVER FENDER
SCREW
FASTENER
S33
EXTERIOR ATTACHMENT
OVER FENDER REMOVAL/INSTALLATION
(VEHICLES BUILT FROM 08/20002)
Front
1. To remove the front over fender No.1, remove the
front bumper.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Rear
1. To remove the front over fender No.1, remove the
front bumper.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
CLIP A
A
A
A
A
A
7
3
VUE0035454
DOUBLE CAB
2
7
EXCEPT
DOUBLE CAB
CLIP A
5
A
8
1
Rivet
VUE0035455
Fastener
Rivet A
Screw A
Screw A
Screw B
Screw B
Nut
Fastener
Screw D
10
11
Rivet B
12
S34
5
A
EXTERIOR ATTACHMENT
Rear flap removal note
1. While cutting the doublesided adhesive tape
using a screw driver or a razor, separate the rear
flap from the rear over fender No. 2.
TAILGATE DISASSEMBLY/ASSEMBLY
1. Remove the cover.
2. Remove the nuts attaching the tailgate lock.
3. Disconnect the rods from the tailgate lock.
4. Remove the tailgate lock.
Warning
D Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
NUT
TAILGATE LOCK
ROD
ROD
Note
D Doublesided adhesive tape has already been
attached to the new rear flap.
LATCH
Warning
D Using a razor with bare hands can cause
injury. Always wear gloves when using a
razor.
1. When installing a new rear flap, follow the
procedure below:
(1) Remove the adhesive remaining on the rear
over fender No. 2 using a razor.
(2) Remove any grease or dirt from the adhesion
surface of the rear over fender No. 2.
2. When reusing the rear flap, follow the procedure
below:
(1) Remove the adhesive remaining on the rear
flap and the rear over fender No. 2 using a
razor.
(2) Remove any grease or dirt from the adhesion
surface of the rear flap and the rear over
fender No. 2.
(3) Apply primer to the bonding area of the rear
flap.
(4) Attach doublesided adhesive tape to the rear
flap as shown.
3. Peel off the backing of the doublesided adhesive
tape, install the rear flap to the rear over fender No.
2.
S35
BOLT
STRIKER
ROPE HOOK
SCREW
MOLDING
WINDSHIELD UPPER MOLDING REMOVAL
D Remove the windshield upper molding from the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD REMOVAL.)
WINDSHIELD UPPER MOLDING INSTALLATION
D Install the windshield upper molding to the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD INSTALLATION.)
WINDSHIELD SIDE MOLDING REMOVAL
D Remove the windshield side molding from the
windshield. (Refer to WINDOW GLASS,
WINDSHIELD REMOVAL.)
ROPE HOOK
BOLT
HOOK
BELTLINE
MOLDING
CLIP
A
S36
OUTSIDE MIRROR
MANUAL OUTSIDE MIRROR
REMOVAL/INSTALLATION
1. Remove the inner garnish.
2. Remove the front door trim. (Refer to TRIM,
FRONT DOOR TRIM REMOVAL/INSTALLATION.)
3. Remove the screws.
4. Remove the manual outside mirror.
HOOK
BELTLINE
MOLDING
CLIP
A
SCREW
ROOF MOLDING
ROOF MOLDING
CLIP
BODY
A
S37
OUTSIDE MIRROR
B+: Battery positive voltage
Connection
B+
GND
Mirror
operation
Up
Down
Left
Right
: Continuity
Switch
position
Terminal
I
Up
Down
LH
Left
Right
Up
DOWN UP
M
LEFT
Down
*
123456567
RH
RIGHT
Left
Right
S38
REARVIEW MIRROR
Note
D The rearview mirror is attached to the interior
light. (Refer to section T, INTERIOR LIGHTING
SYSTEM, INTERIOR LIGHT
REMOVAL/INSTALLATION, Regular Cab.)
Stretch Cab, Double Cab
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
HOOK
REAR WINDOW
DEFROSTER
SWITCH
2.03.9
{2040, 1834}
Nm {kgfcm, inlbf}
Cover
Screw
Rearview mirror
METER HOOD
Terminal
A
ON
OFF
S39
FILAMENT
ALUMINUM FOIL
(1) (2)
Approx. 12 V Approx. 0 V
(2)
NEGATIVE
SIDE
REAR
WINDOW
DEFROSTER
RELAY
REAR WINDOW
DEFROSTER RELAY CONNECTOR
(1)
POSITIVE
SIDE
Terminal
Step
B)
GND
1
2
TAPE
SECTION TO BE REPAIRED
S40
WINDOW GLASS
Reusing Windshield
1. Make a hole through the sealant from the inside of
the vehicle using an awl.
2. Pass the SST (piano wire) through the hole.
WINDOW GLASS
WINDSHIELD REMOVAL
1. Remove the cowl grille.(Refer to EXTERIOR
ATTACHMENT, COWL GRILLE
REMOVAL/INSTALLATION.)
2. Apply protective tape to the headliner, the body
and the dashboard.
PROTECTIVE TAPE
WINDSHIELD UPPER
MOLDING
R
Warning
D Using a razor knife with bare hands can
cause injury. Always wear gloves when
using a razor knife.
SEALANT
HEADLINER
PROTECTIVE TAPE
PROTECTIVE
TAPE
WINDSHIELD
DAM
Note
D The windshield upper molding and windshield
side molding are replacement parts.
49 0305 870A
WINDSHIELD
UPPER MOLDING
Note
D Use the entire length of piano wire to prevent it
from breaking when cutting through the
sealant.
4. Working with another person, saw through the
sealant around the edge of the glass, being careful
not to damage the body.
LIP
49 0305 870A
Note
D For the areas of the sealant that are difficult to
cut, use a piano wire and follow the procedures
under Reusing Windshield.
DAM
SPACER
S41
WINDOW GLASS
GLASS MARK
WINDSHIELD
WINDSHIELD
SIDE MOLDING
WINDSHIELD
WINDSHIELD INSTALLATION
Warning
D Using a razor knife with bare hands can
cause injury. Always wear gloves when
using a razor knife.
CENTER
8.5 {0.33}
Caution
D To prevent the sealant from cracking or the
glass from being pushed out by air
pressure if a door is closed, open all of the
windows and leave them open until the
sealant has hardened.
1. Cut away the old sealant using a razor knife so that
12 mm {0.040.07 in} thickness of sealant
remains around the circumference of the frame. If
all the sealant has come off in any one place, apply
some primer after degreasing, and allow it 30
minutes to dry. Then put on new sealant to create
a 2 mm {0.08 in} layer.
2. Clean and degrease an approximately 50 mm
{1.97 in} wide strip around the circumference of
the glass and the bonding area on the body.
3. Align the center mark on the windshield upper
molding with the glass mark.
4. Install the windshield upper molding from the
center toward both sides.
14.5 {0.57}
6.0 {0.24}
DAM
SPACER
14.5 {0.57}
14.5 {0.57}
CERAMIC
PARTING
LINE
mm {in}
CENTER
MARKING
BODY
SPACER
GLASS MARK
mm {in}
Caution
D Keep the area free of dirt and grease, and
do not touch the surface or the primer may
not properly bond to the surface of the
glass and body, which may cause leaks to
occur.
S42
WINDOW GLASS
8.5 {0.33}
UPPER
GLASS
PRIMER
14.5 {0.57}
BODY
WINDSHIELD
GLASS
PRIMER
BODY
PRIMER
BODY
PRIMER
13.0 {0.51}
UPPER
SEALANT
SIDE
14.5 {0.57}
ADJUST SEALANT
IN THIS AREA
SIDE
GLASS
PRIMER
BODY
PRIMER
DAM
19.0 {0.75}
BODY
PRIMER
19.0
{0.75}
WINDSHIELD
BODY
16.0 {0.63}
LOWER
DAM
WINDSHIELD
SIDE MOLDING
WINDSHIELD
UPPER MOLDING
BODY PRIMER
ADJUST SEALANT
IN THIS AREA
mm {in}
5.0
{0.20}
11.0
{0.43}
Temperature
Surface
hardening time
Time required
until car can be
put into service
5 C {41 F}
Approx. 1.5 h
Approx. 12 h
20 C {68 F}
Approx. 1 h
Approx. 4 h
35 C {95 F}
Approx. 10 min
Approx. 2 h
DAM
mm {in}
S43
WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION
(STRETCH CAB 2 DOOR)
1. To remove the quarter window hinge, remove the quarter upper trim. (Refer to TRIM, QUARTER UPPER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Hinge cover
S44
WINDOW GLASS
QUARTER WINDOW GLASS REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the rear access panel trim. (See REAR ACCESS PANEL TRIM REMOVAL/INSTALLATION.)
2. Remove the upper latch. (See REAR ACCESS PANEL DISASSEMBLY/ASSEMBLY.)
3. Remove in the order indicated in the table.
4. Install in the reverse order of the removal.
Weatherstrip
LIP
49 0259 866A
S45
WINDOW GLASS
3. Fit the SST into the rear window weatherstrip and
cross the ends as shown, leave 200 mm {7.87 in}.
REAR WINDOW WEATHERSTRIP
49 0259 866A
200 {7.87}
mm {in}
SOAPY WATER
49 0259 866A
S46
7.911.7
{80120, 70104}
Nm {kgfcm, inlbf}
Bolt
S47
Dashboard
Defroster nozzle
Duct
Center duct
S48
DASHBOARD MEMBER
1622
{1.62.3, 1216}
1622
{1.62.3,
1216}
1622
{1.62.3,
1216}
BOLT
1622
{1.62.3, 1216}
Nm {kgfm, ftlbf}
COLUMN
COVER
Screw
Front console
Boot
Set plate
SCREW
REAR CONSOLE
Caution
D In order to prevent noise caused by
interference with the dashboard, install the
screws to the rear of the front console
before installing the front of the front
console.
FRONT CONSOLE
SCREW
SCREW
S49
A B
A B
A
B A
CLIP
B PIN
A
Screw
Rear console
A
CLIP
A
GLOVE COMPARTMENT
S50
TRIM
TRIM
A-PILLAR TRIM REMOVAL/INSTALLATION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the quarter upper trim. (Regular cab,
stretch cab) (Refer to QUARTER UPPER TRIM
REMOVAL/INSTALLATION.)
2. Remove the B-pillar upper trim. (Double cab)
(Refer to B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION.)
3. Pull the A-pillar trim toward you, then disengage
clips A and pin B.
4. Pull the A-pillar trim upward, then disengage the
hook.
A
B
A A
CLIP
A
A
A
PIN
B-PILLAR TRIM
A-PILLAR TRIM
B
A
CLIP
CLIP C
PIN
A
HOOK
A
S51
TRIM
B-PILLAR LOWER TRIM REMOVAL/INSTALLATION
Double Cab
1. Remove the front scuff plate.
2. Remove the rear scuff plate.
3. Turn over the seaming welt.
4. Pull the B-pillar lower trim indicated by the arrow,
then disengage clips A and pin B.
5. Remove the seat belt from B-pillar trim.
6. Pull the B-pillar lower trim upward, then disengage
hooks C from the body.
NUT
CLIP
FRONT SIDE
TRIM
A
A
PIN
A
B
A
B-PILLAR
LOWER TRIM
HOOK
C
C
A
B
CLIP
A
HOOK
A
B
B-PILLAR
UPPER TRIM
FASTENER
S52
TRIM
FRONT SCUFF PLATE REMOVAL/INSTALLATION
1. Remove the screws.
2. Pull the front scuff plate upward, then disengage
pin A.
SCREW
A
PIN
A
FRONT SCUFF PLATE
A
B
CLIP
A
PIN
B
SCREW
REAR SCUFF PLATE
C-PILLAR TRIM
CLIP
PIN
FASTENER
S53
TRIM
B
CLIP
HOOK
A
PIN
A
A
B
FASTENER
FASTENER
B
A
A
A
A
CLIP
PIN
S54
TRIM
FRONT DOOR TRIM REMOVAL/INSTALLATION
1. Disconnect the negative battery cable if equipped
with a power window system.
2. Remove the regulator handle if equipped.
3. Remove the inner garnish.
4. Remove the power window switch if equipped.
5. Remove the screws and the fastener.
6. Pull the front door trim toward you, then disengage
clips A.
7. Pull the front door trim upward, then disengage
hook B.
FASTENER
A
A
CLIP
A
A
A
SCREW
A
A
FASTENER
HOOK
A
A
A
SCREW
CLIP
A
A
B
A
A
A
A
HOOK
SCREW
A
CLIP
A
A
A
ASHTRAY
A
A
A
A
A
B
HOOK
S55
HEADLINER
FLOOR COVERING
HEADLINER REMOVAL/INSTALLATION
1. Remove the A-pillar trims.
2. Remove the B-pillar upper trims. (Refer to TRIM,
B-PILLAR UPPER TRIM
REMOVAL/INSTALLATION, Double Cab.)
3. Remove the quarter upper trims. (Refer to TRIM,
QUARTER UPPER TRIM
REMOVAL/INSTALLATION, Stretch Cab.)
4. Remove the C-pillar trims. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION,
Double Cab.)
5. Remove the assist handle.
6. Remove the rearview mirror.
7. Remove the sunvisors and adapters.
8. Remove the interior light. (Refer to section T,
INTERIOR LIGHTING SYSTEM, INTERIOR
LIGHT REMOVAL/INSTALLATION.)
9. Remove the fasteners, then remove the headliner.
HEADLINER
FASTENER
ASSIST HANDLE
FASTENER
ADAPTER
SUNVISOR
FLOOR COVERING
HEADLINER
Double cab
1. Remove the dashboard member. (Refer to
DASHBOARD AND CONSOLE, DASHBOARD
MEMBER REMOVAL/INSTALLATION.)
2. Remove the B-pillar lower trims. (Refer to TRIM,
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION.)
3. Remove the C-pillar trims. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)
S56
FLOOR COVERING
4. Remove the front seats and rear seat. (Refer to
SEAT, SEAT REMOVAL/INSTALLATION, Stretch
Cab, Double cab, Front.) (Refer to SEAT, SEAT
REMOVAL/INSTALLATION, Stretch Cab, Double
cab, Rear.)
5. Remove the rear console bracket.
6. Remove the lower anchor installation bolts of front
seat belts and rear seat belts.
7. Remove the front side trim.
8. Remove the air outlet duct. (Refer to section U,
BASIC SYSTEM, AIR OUTLET DUCT
REMOVAL/INSTALLATION.)
9. Remove the footrest.
10. Remove the fasteners, then remove the floor
covering.
Type 1
FASTENER
FLOOR COVERING
Type 2
FLOOR COVERING
FASTENER
S57
SEAT BELT
SEAT BELT
SEAT BELT REMOVAL/INSTALLATION
Caution
D The ELR has a spring that will unwind if the
retractors cover is removed. The spring
cannot be rewound by hand. If this occurs,
the ELR will not work properly. Therefore,
do not disassemble the retractor.
Stretch Cab
Front
1. Remove the quarter lower trim. (Refer to TRIM,
QUARTER LOWER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}
Regular Cab
Drivers side and passengers side
1. Remove the B-pillar trim if equipped with a B-pillar
trim. (Refer to TRIM, B-PILLAR TRIM
REMOVAL/INSTALLATION, Regular Cab.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Anchor cover
Seat belt
Anchor cover
Seat belt
Rear
1. Remove the quarter lower trim. (Refer to TRIM,
QUARTER LOWER TRIM
REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Seat belt
S58
SEAT BELT
Rear
1. Remove the C-pillar trim. (Refer to TRIM,
C-PILLAR TRIM REMOVAL/INSTALLATION.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Anchor cover
Seat belt
Nm {kgfm, ftlbf}
Double Cab
Front
1. Remove the B-pillar lower trim. (Refer to TRIM,
B-PILLAR LOWER TRIM
REMOVAL/INSTALLATION, Double Cab.)
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
Anchor cover
Seat belt
Nm {kgfm, ftlbf}
S59
Anchor cover
Seat belt
SEAT BELT
FRONT SEAT BELT REMOVAL/INSTALLATION
(STRETCH CAB 4 DOOR)
1. Remove the cover.
2. Remove the lower anchor bolt.
3. Remove the anchor cover.
4. Remove the upper anchor bolt.
5. Rear access panel trim. (See REAR ACCESS
PANEL TRIM REMOVAL/INSTALLATION.)
6. Remove the front seat belt through the seat belt
hole.
7. Remove the bolts from the retractor.
3. Remove the retractor.
4. Make sure that the seat belt does not lock when
the retractor is tilted slowly up to 15 from the
mounted position. Make sure that the seat belt
locks when the retractor is tilted 40 or more.
RETRACTOR
3978
{3.98.0, 2957}
ELR
1. Verify that the belt can be pulled out smoothly, and
that it moves smoothly when worn.
2. Verify that the retractor locks when the belt is
quickly pulled.
S60
Buckle
SEAT BELT
Except drivers side and passengers side
Except Europe and UK
1. Remove as indicated in the table.
2. Install in the reverse order of removal.
3978
{3.98.0, 2957}
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
1
Nm {kgfm, ftlbf}
Buckle
Bucket Seat
Front
1. Disconnect the negative battery cable.
2. Remove the side cover. (Refer to SEAT, FRONT
SEAT DISASSEMBLY/ASSEMBLY, Bucket Seat.)
3. Remove as indicated in the table.
4. Install in the reverse order of removal.
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Front buckle
Stretch Cab
Rear
1. Remove as indicated in the table.
2. Install in the reverse order of removal.
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Rear buckle
Double Cab
Rear
1. Remove the seat cushion. (Refer to SEAT, REAR
SEAT REMOVAL/INSTALLATION, Double Cab.)
2. Remove as indicated in the table.
3. Install in the reverse order of removal.
S61
Rear buckle
SEAT
Bucket Seat
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
SEAT
FRONT SEAT REMOVAL/INSTALLATION
Bench Seat
1. Remove as indicated in the table.
2. Install in the reverse order of removal.
3563
{3.56.5, 2647}
3563
{3.56.5, 2647}
3563
{3.56.5, 2647}
3563
{3.56.5, 2647}
Nm {kgfm, ftlbf}
Nm {kgfm, ftlbf}
Front seat
+ Installation note
LEFT
SIDE
Connector
Cover
Front seat
+ Installation note
RIGHT
SIDE
DOOR
SIDE
TUNNEL
SIDE
S62
SEAT
FRONT SEAT DISASSEMBLY/ASSEMBLY
Bench Seat
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
A
3246
{3.24.7, 2433}
Nm {kgfm, ftlbf}
Headrest
Pole guide
Recliner lever
10
Side cover
11
Lower cover
12
Cable
13
Slide adjuster
14
Connecting rod
S63
SEAT
Bucket Seat
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. When removing the cable (passengers seat), adjust the cable. (Refer to CABLE ADJUSTMENT.)
PASSENGERS SEAT
3753
{3.75.5, 2739}
B
A
C
B
3978
{3.98.0, 2957}
Nm {kgfm, ftlbf}
Headrest
11
Recliner lever
12
Pole guide
Side cover
13
Front buckle
14
15
16
Wire
17
Connecting rod
18
19
10
S64
SEAT
CABLE ADJUSTMENT
D Verify the slide adjuster slides and locks smoothly
when the slide adjuster lever is operated.
SEAT BACK
LEVER
BOLT
1622
{1.62.3, 1216}
SLIDE
LOCK
SCREW
2.02.9 Nm
{2030 kgfcm,
1826 inlbf}
LEVER
Nm {kgfm, ftlbf}
Hinge
1. Remove the back lower trim. (Refer to TRIM,
BACK LOWER TRIM REMOVAL/INSTALLATION.)
2. Remove the fasteners, and then turn over the floor
covering.
3. Remove the bolts, and then remove the hinge.
BOLT
1622
{1.62.3, 1216}
SEAT BACK
HOOK
HOOK
HOOK
HINGE
BOLT
6.879.80
{70100, 60.886.7}
Nm {kgfm, ftlbf}
Nm {kgfcm, inlbf}
Seat cushion
1. Lift up the rear seat cushion.
2. Remove the screws.
3. Remove the bolts, and then remove the seat
cushion.
S65
SEAT
Double Cab
1. Remove in the order indicated in the table.
2. Install in the reverse order of removal.
3563
{3.56.5,
2647}
1622
{1.62.3,
1216}
PULL
1622
{1.62.3,
1216}
1622
{1.62.3, 1216}
3563
{3.56.5,
2647}
Nm {kgfm, ftlbf}
Seat cushion
Seat back
+ Installation note
Hinge
Striker
S66
SEAT
Double Cab
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Headrest
Side cover
Pole guide
Stopper
10
S67
SEAT
SEAT WARMER SWITCH REMOVAL
1. Disconnect the negative battery cable.
2. Insert your hand under the dashboard near the
fuse block, grasp the hooks of the seat warmer
switch and pull it forward to remove it.
3. Disconnect the seat warmer switch connector, and
then remove the seat warmer switch.
HOOK
A
B
SEAT WARMER
SWITCH
CONNECTOR
THERMOMETER
: Bulb
Terminal
Switch position
On
Off
S68
THERMOMETAL
SWITCH
BODY SHELL
REAR ACCESS PANEL REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
Checker
Connector
S69
Upper latch
Outer handle
Lower latch
Weatherstrip
STRIKER REMOVAL/INSTALLATION
Upper striker
1. Remove the bolts.
2. Remove the upper lock striker.
Lower Striker
1. Remove the screw.
2. Remove the lower striker.
S70
TROUBLESHOOTING [POWER
WINDOW SYSTEM]
INTERMITTENT CONCERN TROUBLESHOOTING
Vibration Method
D If malfunction occurs or becomes worse while
driving on a rough road or when engine is
vibrating, perform the steps below.
Note
D There are several reasons why vehicle or
engine vibration could cause an electrical
malfunction. Some of the things to check for:
Connectors not fully seated.
Wire harnesses not having full play.
Wires laying across brackets or moving
parts.
Wires routed too close to hot parts.
D An improperly routed, improperly clamped, or
loose harness can cause wiring to become
pinched between parts.
D The connector joints, points of vibration, and
places where wire harnesses pass through the
firewall, body panels, etc. are the major areas
to be checked.
D Check for DTCs or malfunctions by shaking
harnesses and connectors that are suspected
to be causing malfunction.
FOREWORD
D Always perform basic power window system
inspection before troubleshooting.
D Troubleshooting gives content unique to trouble
caused by problems in the automatic window
return function.
S71
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
D Go to next step.
No
Yes
No
down?
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
D Go to next step.
No
Yes
No
S72
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
No
INSPECTION
ACTION
main switch for driverside front window. Window should go down within approximately 42
seconds from ignition switch OFF position.
D In manual mode (finger continuously
depressing power window main switch),
window should go down within approximately
42 seconds from ignition switch OFF position.
D Does driverside front window go down?
2
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
D Go to next step.
S73
STEP
INSPECTION
ACTION
Yes
No
TROUBLESHOOTING INDEX
No.
TROUBLESHOOTING ITEM
PAGE
NO. 1 DRIVERSIDE FRONT WINDOW DOES NOT GO UP AND DOWN IN AUTOMATIC MODE
1
POSSIBLE
CAUSE
D Open or short to B+ circuit in position sensor 1 signal, ground signal from wiring harness (between
power window main switch and driverside front power window motor), inner power window main
switch, or inner motor: Steps 36
D Open or short to B+/ground circuit in position sensor 2 signal from wiring harness (between power
window main switch and driverside front power window motor), inner power window main switch, or
inner motor: Steps 711
Note
D The automatic function and the ignition off timer function do not operate while power window main
switch is in failsafe mode. The failsafe operates when position sensor 1, and/or position sensor 2,
and/or position sensor 2 power supply malfunctions.
D Position sensor 1 and/or 2 malfunction
When driverside front window is kept up down, main switch can not sense a pulse signal from
position sensor 1 during that can sense 5 pulses (2.5 cycles) from position 2.
When driverside front window is kept up down, main switch can not sense a pulse signal from
position sensor 2 during that can sense 5 pulses (2.5 cycles) from position 1.
There are 3 abnormal pulse from a pulse signal during driverside front window is kept up or down.
There are 20 cycle pulses from a close position during driverside front window is kept up.
There is no pulse signal during 1 sec. after down is operated.
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Yes
Go to Step 7.
No
Go to next step.
S74
STEP
3
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
S75
STEP
INSPECTION
10
11
12
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
D Troubleshooting completed.
D Explain repairs to customer.
No
NO. 2 DRIVERSIDE FRONT WINDOW DOES NOT REVERSE, EVEN WHEN ENCOUNTERING A FOREIGN
OBJECT IN ITS PATH
2
Driverside front window does not reverse, even when encountering a foreign object in its path.
POSSIBLE
CAUSE
D Automatic window return range did not reset after battery disconnect: Step 2
Diagnostic procedure
STEP
INSPECTION
ACTION
Yes
D System normal.
D Explain to customer that automatic window
return power window system does not operate
when nearing of complete close.
No
Go to next step.
Yes
D Troubleshooting completed.
D Explain to customer that misadjustment of
automatic window return range was the
problem.
No
S76
3
POSSIBLE
CAUSE
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
D Troubleshooting completed.
D Explain repairs to customer.
No
S77
TROUBLESHOOTING [KEYLESS
ENTRY SYSTEM]
FOREWORD
D Go to troubleshooting after identifying the specific
malfunction by doing a keyless entry system
preliminary inspection.
Flowchart
S78
STEP
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
S79
STEP
4
INSPECTION
ACTION
Yes
No
5
Yes
Go to next step.
No
Yes
No
S80
TROUBLESHOOTING ITEM
DESCRIPTION
ACTION
(See NO. 1 ONE OR MORE
ONBOARD DIAGNOSTIC
FUNCTIONS INOPERATIVE)
(See NO. 2 ALL ONBOARD
DIAGNOSTIC FUNCTIONS
INOPERATIVE)
(See NO. 3 TRANSMITTER ID
CODE CANNOT BE
REPROGRAMMED)
DESCRIPTION
POSSIBLE
CAUSE
D Malfunction in hazard warning light system (except vehicle with theftdeterrent system), or door lock
linkage system, drivers door key cylinder switch system.
D Malfunction in hazard warning light system (except vehicle with theftdeterrent system)
Hazard warning light circuit
Keyless unit malfunction
Malfunction in wiring harness between keyless unit and flasher unit
D Malfunction in door lock linkage
D Malfunction in keyless unit door lock/unlock signal circuit
Keyless unit malfunction
Malfunction in wiring harness between keyless unit and door lock timer unit
Diagnostic procedure
Note
D For with theftdeterrent system, follow the procedure from Step 4.
STEP
1
*3
INSPECTION
ACTION
Yes
Go to Step 4.
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
Go to next step.
No
S81
STEP
INSPECTION
*6
*7
ACTION
Yes
No
Yes
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
DESCRIPTION
POSSIBLE
CAUSE
D Malfunction in keyless unit power supply circuit, door switch circuit or keyless unit ground
circuit.
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
S82
STEP
*3
*4
*5
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
S83
DESCRIPTION
D Malfunction in transmitter battery, transmitter keyless unit bracket, keyless unit bracket ground screw
or keyless unit circuit.
POSSIBLE
CAUSE
D Malfunction in transmitter battery, transmitter, keyless unit bracket, keyless unit bracket ground screw
or keyless unit circuit
Transmitter battery, transmitter, keyless unit bracket, keyless unit bracket ground screw or keyless
unit malfunction
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
Troubleshooting completed.
Explain repairs to customer.
No
S84
T1
T13
T13
T13
T14
T14
T15
T16
T17
T17
T17
T17
T19
T19
T19
T20
T20
T20
T21
T22
T21
T22
T22
T22
T23
T23
T23
T23
T23
T24
T24
T24
T24
T24
T25
T25
T25
T25
T27
T27
T27
T28
T28
T28
T28
T28
T28
T29
T29
T29
T29
T29
T29
T30
T30
T30
T31
T31
T31
T31
T32
T32
T33
T33
T33
T33
T33
T33
T33
T33
T33
T2
T36
T38
T41
T42
T41
T42
T43
T44
T50
T52
T52
T53
T53
T54
T55
T55
T55
T56
T56
T59
T60
T61
T61
T61
T62
T62
T62
T63
T64
T64
T65
T66
T66
T73
T73
POWER SYSTEM
POWER SYSTEM
FUSE SERVICE CAUTION
Caution
D Determine and correct the cause of the
burnt fuse before replacing it with the
specified type. If the fuse is replaced before
doing this, it may burn again.
Terminal
2A
2B
1D
1C
1B
1A
LOCK
ACC
ON
START
2A
2B
2B
2A
123456567
START
START
LOCK
LOCK
ON
ON ACC
ACC
1A 1B
1C 1D
1C
1A
1D
1B
F2 CARB
Nut
Bolt
Main fuse
STEERING
LOCK
IGNITION
SCREW
SWITCH
CONNECTOR
IGNITION
SWITCH
T3
POWER SYSTEM
KEY REMINDER SWITCH INSPECTION
1. Remove the column cover.
2. Disconnect the key reminder switch connector.
3. Inspect for continuity between the key reminder
switch terminals using an ohmmeter.
: Continuity
Key position
Terminal
A
Inserted
Removed
A
Connector
Socket
+ Removal Note
Ring
T4
POWER SYSTEM
RELAY LOCATION
ZCF8110W101
T5
POWER SYSTEM
D If not as specified, replace the relay.
RELAY INSPECTION
Relay Type
Terminal type
Fourterminal
Parts name
Type A
Starter relay
Type B
Note
D The inspection of theftdeterrent relay has not
been changed.
Y5A8110W151
Fourterminal
Type A
1. Remove the relay.
2. Inspect for continuity between the relay terminals
using an ohmmeter.
ZCF8110W102
Z5U914WAK
Type B
1. Remove the relay.
2. Inspect for continuity between the relay terminals
using an ohmmeter.
ZCF8110W103
T6
ADJUSTING
SCREW
SCREW
ADJUSTING
SCREW
HEADLIGHT AIMING
1. Adjust the tire air pressure to the specification.
2. Position the unloaded vehicle on a level surface.
3. Seat one person in the drivers seat.
4. Start the engine and charge the battery fully.
5. Position the vehicle straight ahead and
perpendicularly to a wall.
6. Set the headlights 7.6 m {25 ft} from the wall.
7. While adjusting one headlight, disconnect the
connector of the other.
1
Spring
Caution
D Always tighten the adjusting screws last.
When loosening the adjusting screws, loosen
the screws first and then tighten them.
If the adjusting screws are tightened first,
then loosened, they will continue to loosen
when the vehicle is in motion and may
cause the headlights to become misaligned.
ADJUSTING
SCREW
OUTWARD
INWARD
UP
HOOK
DOWN
SCREW
T7
Cover
+ Installation Note
Headlight bulb
Screw
TOP MARK
Socket
FRONT
Socket
REAR
T8
Socket
Screw
Screw
Lens
+ Removal Note
Nut
Spring washer
Screw
T9
Screw
Lens
COMBINATION SWITCH
DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Screw
Screw
Light switch
Socket
Body
Screw
Light switch
Screw
Combination switch
Note
D When the flash-to-pass switch is on, the
contact of the low-high switch is at neutral.
2. Inspect for continuity between the light switch
terminals using an ohmmeter.
T10
Dimmer
OFF
TNS
Headlight
Low
Terminal
Flashto-pass
P
(B)
D
(N)
L
(H)
F
(J)
H
(L)
Off
On
Off
On
Off
On
High
(N)
OFF
OFF
TNS
FLASH
-TO
-PASS
HIGH
HOOK
HEADLIGHT
HEADLIGHT TNS
(L)
(H)
(B)
*
(O)
*
(M)
*
(K)
P
(*)
LOW
(*)
*
(J)
F
(*)
(*)
*
(B)
Terminal
Switch
position
(*)
Off
On
Terminal
C (M)
A (K)
E (O)
Right
Off
Left
*
*
* (M)
(O)
(K)
* H
P
N
L (J)
(*)
A
(*)
F
(*)
(*)
(*)
*
(B)
(K)
(O)
( ): LIGHT SWITCH RIGHT SIDE LEVER
T11
HOOK
HOOK
CONNECTOR
CONNECTOR
REAR FOG
LIGHT SWITCH
HEADLIGHT
LEVELING SWITCH
Switch position
Terminal
A
Terminal
Switch position
Off
Neutral
0
1
2
R3
R1:1600
R2+R3
R1+ R2+ R3
On
3:300
3
*
R1 R2 R3
560
2:
T12
DRIVER-SIDE
FRONT SIDE TRIM
Nm {kgfm, ftlbf}
Gasket
Shift lever
position
Reverse
Other
T13
Nut
Flasher unit
Terminal
Signal
Connection
Voltage (V)
/Continuity
Test condition
Alternates
B+ and 0
Flasher unit
output
Hazard warning
switch
Hazard warning
switch off
Ignition switch at
ON position
B+
Ignition switch at
LOCK or ACC
position
Power supply
Flasher unit
ground
Hazard warning
switch
GND
Hazard warning
switch off
Ignition switch at
LOCK or ACC
position
D Hazard
warning switch
D Turn signal
light
B+
Ignition switch at
ON position
Inspection area
B+
D HAZARD 10 A
fuse
D METER 15 A
fuse
0
Yes
D Hazard
warning switch
GND
Terminal
Signal
Power supply
Connected to
HAZARD 10 A
fuse
Test condition
Under any
condition
T14
Voltage (V)/
Continuity
Action
D Inspect HAZARD 10 A
B+
fuse
D Inspect related harness
Terminal
Signal
Connected to
Test condition
Turn signal light
(LH) flashes
Turn signal
flasher (LH)
Turn signal
light (LH)
Hazard warning
switch at on
position
Other
Flasher unit
ground
Turn signal
flasher (RH)
Turn signal
light (RH)
Hazard warning
on
Combination
switch
Hazard warning
switch at on
position
Combination
switch
Yes
Alternates
below 1.0 and
B+
Other
Below 1.0
Hazard warning
switch at on
position
Below 1.0
B+
Ignition switch is at
ON and turn switch
(RH) on
B+
(LH)
D Inspect related harness
D Inspect GND
(RH)
D Inspect related harness
Below 1.0
Ignition switch is at
ON and turn switch
(LH) on
Other
switch
Hazard warning
switch at off
position
Other
Turn switch on/off
(LH)
Alternates
below 1.0 and
B+
Action
Below 1.0
Constant: inspect
for continuity to
ground
GND
Voltage (V)/
Continuity
B+
Below 1.0
HEADLIGHT
LEVELING
ACTUATOR
HEADLIGHT LEVELING
ACTUATOR CONNECTOR
T15
Terminal
Signal
Headlight
leveling
actuator
power supply
Headlight
leveling switch
position
Headlight
leveling
actuator
ground
Connection
Combination
switch
Headlight
leveling switch
GND
Test condition
Headlight illuminated
Voltage ( V )
/Continuity
Inspection area
B+
Combination switch
Headlight unilluminated
Headlight
switch on
Headlight leveling
switch at 0
6.2
Headlight leveling
switch at 1
4.2
Headlight leveling
switch at 2
2.1
Headlight leveling
switch at 3
T16
Yes
GND
Note
D Because the lock section of the relay is
damaged easily, do not remove the relay from
the bracket unless replacement is necessary.
Always perform an inspection of the rear fog
light relay before removal.
NUT
RUNNING LIGHT
RELAY WITH COVER
REAR FOG
LIGHT RELAY
COVER
BRACKET
RUNNING LIGHT
RELAY
Step
B+
GND
1
2
RUNNING LIGHT
RELAY CONNECTOR
Test
condition
Constant
Terminal
A
B
B
T17
T18
4.0 mm
{0.2 in}
Lens
+ Removal Note
Screw
Spacer
Interior light
+ Installation Note
SPACER
INTERIOR LIGHT
Terminal
Step
Body GND
ON
DOOR
OFF
B
A
OFF
ON
DOOR
A
Regular cab
D Push the areas indicated by the arrows to pull out
the lens.
T19
Screw
Door switch
Switch condition
Body GND
Pressed
Released
BODY GND
HOOK
T20
Terminal
A
B
D
F
G
H
Signal
Panel light
control
output
Connection
Each
illumination
Power
supply
Light switch
Voltage (V)/
Continuity
Test condition
Inspect using an oscilloscope
+ A terminal inspection
Not used
Not used
Not used
D Light switch
D TAIL 10 A fuse
A Terminal Inspection
1. Measure the wave pattern of the A terminal on the
panel light control switch using an oscilloscope.
Each illumination
B+
GND
Inspection area
Panel light
control
switch
ground
Yes
GND
PANEL LIGHT
CONTROL SWITCH
OSCILLOSCOPE
V
B+
0
13.2 ms
515.4 ms
T21
1619
{1.62.0,
1214}
Nm {kgfm, ftlbf}
CONNECTOR
WINDSHIELD
WIPER LINK
BOLT
4.06.8 {4070, 3560}
Cap
Nut
Rubber brush
Nm {kgfcm, inlbf}
Operation
High
Low
A
B
WINDSHIELD WIPER
ARM CONNECTOR SHAFT
C
D
T22
CERAMIC SECTION
MARK
Grommet
Bolt
M
A
WINDSHIELD
WASHER TANK
CONNECTOR
WINDSHIELD
WASHER PIPE
B
A
BRACKET
T23
SCREW
WINDSHIELD
WIPER AND
WASHER
SWITCH
CENTER
320 {12.6}
CONNECTOR
390 {15.4}
100 100
{3.9} {3.9}
290
{11.4} 290
{11.4}
270
{10.6}
180
{7.1}
WINDSHIELD
GLASS END LINE
MOLDING
END LINE
Switch position
Wiper
switch
L(F)
G(E
)
M(C
)
N(D
)
C(M
)
123
Off
OFF
mm {in}
Terminal
Onetouch
On
INT
LO
HI
Washer
switch
On
OFF
HI
LO
INT
INT
LO
CLIP
INT
RELAY
WINDSHIELD
WASHER PIPE
L
(F)
H
(J)
M
(C)
G
(E)
C
(M)
WASHER
SWITCH
0
(*)
*
G
(*)
M
N
(*)
L
(*)
*
(J)
H
(*)
*
(E)
*
(F)
*
(A)
*
(D)
T24
Screw
Instrument cluster
20
1822
40
3644
60
5466
80
7288
100
90110
120
108132
140
126154
160
144176
180
162198
INSTRUMENT CLUSTER
DISASSEMBLY/ASSEMBLY
Caution
D If the print plate on the back of the
instrument cluster is damaged, the system
will not operate properly and it may become
the cause of trouble or malfunction.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
Speedometer tester
indication (km/h)
Tachometer
Using the SSTs (NGS kit) or a dwell tacho tester
Caution
D If the engine speed exceeds the allowable
range, the engine could be damaged.
Therefore, when inspecting the tachometer,
do not allow the engine speed to exceed the
allowable range indication on the
tachometer.
1. Follow the appropriate procedure for using the
SSTs (NGS kit) or dwell tacho tester.
Screw
Bulb
Alarm
Front lens
Instrument cluster
NGS KIT
T25
: Resistance
Step
1
FUEL
GND
COM
R1
R2
GND
FUEL+
COM
Terminal
FUEL +
FUEL
650
583705
1000
9261060
2000
19542120
3000
29803180
4000
40084240
Fuel Gauge
1. Disconnect the fuel gauge sender unit connector.
2. Connect the red lead of SST (Fuel And
Thermometer checker) to terminal B of the fuel
gauge sender unit connector and black lead to
ground.
3. Set the resistance of SST (Fuel And Thermometer
checker) to 180 .
49 N088 0A0
49 0839 285
T26
Step
1
2
Terminal
TEMP +
TEMP
V+
COM
R1
R2
TEMP+
COM
V+
TEMP
BULB
SPEEDOMETER
SPEEDOMETER
Resistance ()
Full
18.426.4
1/2
81.593.5
Empty
136154
WL, WL TURBO
87.0 {3.43} *
65.5 {2.58}
* DOUBLE CAB
2WD, STRETCH
CAB 2WD
FULL
169.7 {6.681} *
158.1 {6.224}
1/2
253.7 {9.988}
EMPTY
T27
*
B C
mm {in}
FULL
160.1 {6.303}
1/2
A B
255.7 {10.067}
EMPTY
Water temperature (C {F })
Resistance ()
49.850.2 {121.7122.3}
189.4259.6
mm {in}
WATER
TEMPERATURE
SENDER UNIT
BOLT
THIRD THREAD
68
{0.240.31}
mm { in }
HORN
HORN
CONNECTOR
T28
AUDIO
AUDIO UNIT REMOVAL
1. Disconnect the negative battery cable.
2. With the beveled parts of the SST (Removing tool)
facing inward, insert them into the unit.
3. Pull the SST (Removing tool) outward and
rearward to slide out the unit.
49 D066 801A
Nut
Horn relay
Terminal
Step
B+
GND
1
2
A
C
CLOCK
SCREW
P29
AUDIO
Screw
Screw
Speaker
+ Installation Note
Connector
Rear speaker
Connector
Double cab
1. Disconnect the negative battery cable.
2. Remove the rear door trim.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
Terminal
A
B
R
Constant
R: 4
123456567
Armrest
Connector
Rear speaker
T30
AUDIO
5. Inspect for continuity between the roof antenna
terminals using an ohmmeter.
: Continuity
Terminal
Step
2
C
D
D
B
B
A
A
123456567
SCREW
ROOF ANTENNA
T31
Clip
Antenna feeder
AUDIO
ANTENNA FEEDER INSPECTION
1. Disconnect the negative battery cable.
2. Remove the driver-side front side trim. (Refer to
section S, TRIM, FRONT SIDE TRIM
REMOVAL/INSTALLATION.)
3. Disconnect the connection between the antenna
feeder and the roof antenna.
4. Verify that there is no continuity between the
antenna feeder terminals A and B using an
ohmmeter.
5. Inspect for continuity between the antenna feeder
terminals using an ohmmeter.
: Continuity
Terminal
Step
1
2
B
D
A
123456567
IGNITION
COIL
Screw
Clip
Nut
Condenser
T32
THEFT-DETERRENT SYSTEM
THEFT-DETERRENT SYSTEM
STRUCTURAL VIEW
10
Flasher unit
2
3
Theft-deterrent relay
11
Security light
12
Ignition switch
13
Door switch
14
Bonnet switch
15
16
Theft-deterrent horn
17
Terminal
A
Closed
Open
Bolt
Nut
Connector
Bonnet switch
T33
123
THEFT-DETERRENT SYSTEM
THEFT-DETERRENT HORN RELAY
REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the washer tank from the bracket.
3. Remove in the order indicated in the table.
4. Install in the reverse order of removal.
Nut
Connector
Bolt
Connector
Theft-deterrent relay
Step
B+
GND
1
2
Terminal
Step
B+
GND
1
2
E
F
C
C
F E
A
:
123456567
123456567
T34
THEFT-DETERRENT SYSTEM
Nut
Bracket
T35
THEFT-DETERRENT SYSTEM
THEFT-DETERRENT CONTROL MODULE INSPECTION
(VEHICLES BUILT UP TO 07/2002)
1. Remove the theft-deterrent control module without disconnecting the connectors.
2. Measure the voltage at the theft-deterrent control module terminals as indicated below.
3. Disconnect the theft-deterrent control module connectors before inspecting for continuity at terminals 1F, 2K,
2M, 2N and 2R.
4. If not as specified, inspect the parts listed under inspection area and related wiring harnesses.
5. If the parts and wiring harnesses are okay but the system still does not work properly, replace the theft-deterrent
control module.
Terminal Voltage List (Reference)
B+: Battery positive voltage
1F 1E 1D 1C 1B 1A
Terminal
Signal
2S 2Q 2O 2M 2K 2I 2G 2E 2C 2A
2T 2R 2P 2N 2L 2J 2H 2F 2D 2B
Connection
Test condition
Ignition switch at ON position
1A
1B
IG1
Power supply
ENGINE 15 A fuse
ROOM 10 A fuse
1C
Flasher input
D Turn switch
D Hazard warning
switch
D Flasher unit
Turn (LH)
1F
Turn (RH)
Theft-deterrent
control module
ground
GND
0
B+
Turn switch on
Alternates 0
and B+
0
Alternates 0
and B+
Alternates 0
and B+
Turn switch on
Alternates 0
and B+
Inspection area
D Ignition switch
D ENGINE 15 A
fuse
ROOM 10 A fuse
D Turn switch
D Hazard warning
switch
D Flasher unit
Alternates 0
and B+
Turn light (LH)
0
Alternates 0
and B+
Ignition
switch
at ON
position
1E
B+
Ignition
switch
at ON
position
1D
Voltage ( V )
/Continuity
Turn switch on
Alternates 0
and B+
Alternates 0
and B+
Turn light (RH)
0
Alternates 0
and B+
T36
Yes
THEFT-DETERRENT SYSTEM
B+: Battery positive voltage
Terminal
Signal
Connection
2A
Not used
2B
Not used
2C
Theft-deterrent
horn on/off
Theft-deterrent horn
relay
2D
Key reminder
switch on/off
Test condition
Voltage ( V )
/Continuity
Inspection area
Alternates 0
and B+
Theft-deterrent horn
relay
B+
B+
2E
Not used
2F
Not used
2G
Not used
2H
Not used
2I
Not used
2J
Not used
2K
Lock/unlock
unit
D Drivers door
lock-link switch
2L
2M
2N
Lock/unlock
Bonnet
open/closed
2O
2P
2Q
2R
2S
2T
Security light
on/off
Door open/closed
Theft-deterrent
relay on/off
No
Yes
Not used
Bonnet switch
cylinder switch
D Passengers
door key cylinder
switch
No
Yes
Yes
No
2.5
Other
Not used
Security light
Door switch
Theft-deterrent relay
B+
Yes
No
0
B+
T37
D Drivers or
passengers door
key cylinder
switch
Security light
Door switch
Bonnet switch
Security light on
Not used
Theft-deterrent relay
THEFT-DETERRENT SYSTEM
THEFT-DETERRENT CONTROL MODULE INSPECTION
(VEHICLES BUILT FROM 08/2002)
1. Remove the theft-deterrent control module without disconnecting the connectors.
2. Measure the voltage at the theft-deterrent control module terminals as indicated below.
3. Disconnect the theft-deterrent control module connectors before inspecting for continuity at terminals 1F, 2K,
2M, 2N and 2R.
4. If not as specified, inspect the parts listed under Action.
D If the parts and wiring harnesses are okay but the system still does not work properly, replace the theft-deterrent
control module.
Terminal Voltage List (Reference)
Terminal
1A
1B
Signal
Connected to
ENGINE 15 A
fuse
IG1
Power supply
ROOM 10 A
fuse
Test condition
Engine switch at ON
position
Engine switch a
LOCK or ACC
position
Under any condition
Voltage (V)/
Continuity
B+
Below 1.0
B+
Action
D ROOM 10 A fuse
1C
1D
1E
Yes
1F
Theftdeterrent
control module
ground
GND
2A
2B
2C
2D
Theftdeterrent
horn on/off
Theftdeterrent
horn relay
Key reminder
switch on/off
Key reminder
switch
Theftdeterrent
system alarm 1:
Other
B+
Theftdeterrent
system alarm 1:
Active
Alternates
below 1.0
and
B+
D Inspect theftdeterrent
B+
horn relay
D Inspect related harness
switch
Below 0.1
2E
2F
2G
2H
2I
T38
THEFT-DETERRENT SYSTEM
Terminal
2J
2K
2L
Signal
Keyless entry
system
discemment
signal input
Lock/unlock
Connected to
Test condition
Keyless unit
D Door lock
No
timer unit
D Drivers
door lock
link switch
D Passengers
2M
2N
Lock/unlock
Bonnet open/
closed
door lock
link switch
D Rear door
locklink
switch
Bonnet switch
D Drivers
2O
2P
2Q
2R
Door open/closed
Voltage (V)/
Continuity
door key
cylinder
switch
Passengers
door key
cylinder
switch
keyless unit
Instrument
cluster
Door lock
timer unit
Security light
Door switch
Rear
door
closed
locklink switch
D Inspect related harness
Yes
Passengers
and rear
door lock
link switch
locked:
inspect for
continuity to
ground
No
D Inspect passengers or
Passengers
and rear
door lock
link switch
unlocked:
inspect for
continuity to
ground
Yes
Yes
No
Drivers or passengers
door locked with key or
transmitter
2.5
Other
Drivers or passengers
door unlocked with key
or transmitter
Action
D Inspect drivers or
Below 1.0
Security light on
Below 0.1
B+
Yes
No
T39
THEFT-DETERRENT SYSTEM
Terminal
2S
2T
Signal
Hazard warning
signal output
Connected to
Flasher unit
Test condition
Voltage (V)/
Continuity
Theftdeterrent system
alarm 1: Active
Below 1.0
Theftdeterrent system
alarm 1: Other
B+
T40
Action
D Inspect flasher unit
IMMOBILIZER SYSTEM
IMMOBILIZER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove in the order indicated in the table.
3. Install in the reverse order of removal.
Caution
D After replacing the immobilizer unit with a
new one, the engine cannot be started
without reprogramming the ID number of
the keys of the new immobilizer unit. Input
the ID number. (Refer to IMMOBILIZER
SYSTEM REPROGRAM PROCEDURE.)
Bolt
Connector
Theft-deterrent horn
P41
Immobilizer unit
IMMOBILIZER SYSTEM
IMMOBILIZER UNIT INSPECTION
1. Measure the voltage at the immobilizer unit terminals as indicated below.
2. Disconnect the immobilizer unit connector before inspecting for continuity at terminal C.
D If not as specified, inspect the parts listed under Action.
D If the parts and wiring harnesses are okay but the system still does not work properly, replace the
immobilizer unit.
Terminal Voltage Table (Reference)
ZCF8170W103
Terminal
Signal
Communication with
PCM
B
C
Connected to
PCM
GND
GND
Coil
Coil
Key reminder
switch
Battery
M
N
Power supply
Starter relay
Engine switch
Security light
Test condition
Voltage
(V)/continuity
Engine switch at
ON position
B+
Engine switch at
LOCK position
Below 1.0
Under any
condition: inspect
for continuity to
ground
Yes
Below 1.0
Cannot be
measured
Below 1.0
Cannot be
measured
Below 1.0
B+
B+
Engine switch at
ON position
Below 1.0
Engine switch at
LOCK position
Engine switch at
ON position
B+
Engine switch at
OFF position
Below 1.0
Security light
neither illuminates
nor blinks
T42
B+
Action
D Inspect PCM
D Inspect related harness
D Inspect GND
D Inspect coil
D Inspect related harness
D Inspect coil
D Inspect related harness
IMMOBILIZER SYSTEM
COIL REMOVAL/INSTALLATION
Note
D Do not remove the coil unless you are
replacing it.
D When the coil only is replaced, the immobilizer
system reprogram procedure is not necessary.
Connector
Coil
+ Installation Note
T43
IMMOBILIZER SYSTEM
VEHICLES BUILT BEFORE SEPTEMBER 2001
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE
Note
D 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.
D When an error occurs during the reprogram procedures, except when both the immobilizer unit and the
DDS1 are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many
keys can start the engine.
Then, perform the key replacement or addition reprogram procedure according to the valid key number.
D To make a copy of the key or replace the immobilizer system component parts (the key(s), steering lock,
immobilizer unit and/or the DDS1), the customer should bring all keys she/he has to the dealer. This is
because the previously programmed key IDs are erased when reprogramming the key IDs into the
immobilizer unit and the DDS1.
D To replace the DDS1, there should be at least one valid key. Otherwise, both the immobilizer unit and the
DDS1 should be replaced.
D The immobilizer unit and the DDS1 cannot be changed from one car to another. If an immobilizer unit or the
DDS1 is replaced with one from another car, the engine will not start. Reprogramming of the IDs and code
word of an immobilizer unit that has already been programmed as a set is not possible.
D The immobilizer unit and the DDS1 should not be replaced with a new one as a trial during troubleshooting.
If this is done, the ID and code word will be programmed into the new unit and it cannot be used for other
cars even if you find that the old unit was normal.
D The immobilizer system cannot be deactivated.
D Confirm that all keys registered can start the engine after the reprogramming procedure. When confirming,
wait for more than 5 seconds before inserting the next key.
D When the customer does not need to register more than two keys, the following procedures can be stopped
after registering two keys.
Key Replacement or Addition
When customer has brought two or more valid keys
VALID KEYS
KEY 1
NEW KEY
KEY 3
KEY 2
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s).
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. The key should not
remain at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe illumination of security light in instrument cluster.
(2) Turn key 1 to LOCK position and remove key 1 from steering lock. Observe security light goes out.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. If there are 48 keys (valid and/or new keys), repeat Step 3.
6. Wait for 30 seconds to quit reprogram mode.
T44
IMMOBILIZER SYSTEM
When customer has brought only one or no valid key (code word is required)
KEY 1
NEW KEYS
KEY 2
VALID KEY OR
NEW KEY
KEY 3
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s).
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. The key should not
remain at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe flashing of security light (300 ms ON300 ms OFF) in instrument
cluster.
(2) Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to
1.2 seconds.
(3) Input code word. (Refer to CODE WORD INPUT PROCEDURE.)
(4) Observe security light stops flashing and illuminates (1 second), then goes out.
(5) Turn key 1 to LOCK position and remove from steering lock.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. If there are 48 keys (valid and/or new keys), repeat Step 3.
6. Wait for 30 seconds to quit reprogram mode.
Steering Lock Replacement
When customer has brought two or more valid keys for old steering lock
Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
IMMOBILIZER UNIT
KEY 3, 4, 5
KEY 1, 2
DDS1
VALID KEYS
(ORIGINAL
KEYS)
NEW KEYS
OLD
NEW
TO VEHICLE HARNESS
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Remove old steering lock.
2. Connect new steering lock to ignition switch connector.
3. Connect old steering lock to coil connector as shown in figure.
4. Insert key 1 into old steering lock.
T45
IMMOBILIZER SYSTEM
5. Insert key 3 into new steering lock and turn to ON position then back to LOCK position five times. The key
should not remain at ON position or LOCK position for more than one second.
(1) Turn key 3 back to ON position. Observe illumination of security light in instrument cluster.
(2) Turn key 3 to LOCK position. Observe that security light goes out.
Note
D Perform next two steps within 30 seconds of Step 5(2).
6. Remove key 1 from old steering lock and insert key 2 into old steering lock.
7. Using key 3 of new steering lock, turn to ON position. Observe that security light illuminates (for 12 seconds)
and goes out.
(1) Turn key 3 to LOCK position.
Note
D Perform next two steps within 30 seconds of Step 7(1).
8. Disconnect coil connector from old steering lock, and reconnect coil connector to new steering lock.
9. Using key 3 of new steering lock, turn to ON position. Observe that security light illuminates (for 12 seconds)
and goes out.
(1) Turn key 3 to LOCK position and remove from steering lock.
10. Repeat Step 9 with key 4.
11. Repeat Step 9 with key 5.
12. Wait for 30 seconds to quit reprogram mode.
13. Install new steering lock.
When customer has brought only one or no valid key (code word is required)
KEY 1
NEW KEYS
KEY 2
KEY 3
Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace steering lock.
2. Using key 1, turn ignition switch to ON position then back to LOCK position five times. Key should not remain
at ON position or LOCK position for more than one second.
(1) Turn key 1 back to ON position. Observe flashing of security light (300 ms ON300 ms OFF) in instrument
cluster.
(2) Turn key 1 to LOCK position and wait for 5 minutes until security light decreases in flashing frequency to
1.2 seconds.
(3) Input code word. (Refer to CODE WORD INPUT PROCEDURE.)
(4) Observe the security light stops flashing and illuminates (1 second), then goes out.
(5) Turn key 1 to LOCK position and remove from steering lock.
3. Using key 2, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
4. Repeat Step 3 with key 3.
5. Wait for 30 seconds to quit reprogram mode.
T46
IMMOBILIZER SYSTEM
Immobilizer Unit Replacement
When customer does not have valid key or when customer has brought at least one valid key
KEY 1
VALID OR
NEW KEYS
KEY 2
KEY 3
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit. (Refer to IMMOBILIZER UNIT REMOVAL/INSTALLATION.)
3. Using key 1, turn to ON position. Observe that security light illuminates (for 12 seconds) and goes out.
(1) Wait for 16 minutes until security light begins to blink with a flashing frequency of 300 ms. (The light will
blink for 60 seconds.)
(2) Turn key 1 to LOCK position while the light is flashing and remove from steering lock.
4. Using key 2, turn to ON position while the light is flashing. Observe that security light illuminates (for 12
seconds) and goes out.
(1) Turn key 2 to LOCK position and remove from steering lock.
5. Repeat Step 4 with key 3.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
DDS1 Replacement
Note
D 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.
When customer does not have valid key
D Immobilizer unit needs to be replaced with the DDS1. Perform Replacement of Both Immobilizer unit and
DDS1 of the immobilizer system reprogram procedure.
When customer has brought at least one valid key
VALID KEY
KEY 1
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace the DDS1. (Refer to section F2, FUEL SYSTEM, FUEL INJECTION PUMP (FIP)
REMOVAL/INSTALLATION.)
2. Using key 1, turn ignition switch to ON position, and observe that security light illuminates (for 12 seconds) in
instrument cluster.
(1) Turn key 1 to LOCK position.
3. Wait for 30 seconds to quit reprogram mode.
T47
IMMOBILIZER SYSTEM
Replacement of Both Immobilizer Unit and DDS1
Note
D Keys may be valid or new keys.
D When an error occurs in Steps 1 to 4, repeat the procedure from Step 1.
D When an error occurs in Step 5, perform the Reprogram error recovery procedure for replacement of both
immobilizer unit and DDS1.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit (Refer to IMMOBILIZER UNIT REMOVAL/INSTALLATION.) and DDS1. (Refer to
section F2, FUEL SYSTEM, FUEL INJECTION PUMP (FIP) REMOVAL/INSTALLATION.)
3. Using key 1, turn ignition switch to ON position. Observe security light illuminates and then goes out in
instrument cluster.
(1) Turn key 1 to LOCK position. Observe security light blinks once repeatedly.
4. Using key 2, turn ignition switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 2 to LOCK position. Observe security light blinks twice repeatedly.
5. Using key 3, turn ignition switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 3 to LOCK position. Observe security light blinks three times repeatedly.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
Reprogram error recovery procedure for replacement of both immobilizer unit and DDS1
Note
D If no specific time interval is given, step should be performed within 30 seconds of the previous step.
1. Using key 1, turn ignition switch to ON position then back to LOCK position five times. Key should not remain
at ON position or LOCK position for more than one second.
2. Using key 1, turn ignition switch to ON position (Security light illuminates).
3. Turn key 1 to LOCK position and remove from steering lock (Security light goes out).
4. Using key 2, turn to ON position. Observe that security light illuminates (about 12 seconds) and goes out.
5. Turn key 2 to LOCK position and remove from steering lock.
6. Repeat Step 4 and 5 with key 3.
7. If there are 48 keys (valid and/or new keys), repeat Step 4 and 5.
8. Wait for 30 seconds to quit reprogram mode.
T48
IMMOBILIZER SYSTEM
VEHICLES BUILT FROM SEPTEMBER 2001
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE
Note
D When an error occurs during the reprogram procedures, except when both the immobilizer unit and PCM
are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many keys can
start the engine. Then, perform the key replacement or additional reprogram procedure according to the
valid key number.
D To make a copy of the key or replace the immobilizer system component parts (the key(s), steering lock,
immobilizer unit, and/or PCM), the customer should bring all keys to the dealer. This is because the
previously programmed key IDs are erased when reprogramming the key IDs into the immobilizer unit and
PCM.
D If the customer has only one valid key when replacing the immobilizer system component parts, the dealer
should contact a distributor to obtain the code word.
D To replace the immobilizer unit or PCM, there should be at least one valid key. Otherwise, both the
immobilizer unit and PCM should be replaced.
D The immobilizer unit and PCM cannot be changed from one car to another. If an immobilizer unit or PCM is
replaced with one from another car, the engine will not start. Reprogramming of the IDs and code word of
an immobilizer unit that has already been programmed is not possible.
D The immobilizer unit and PCM should not be newly replaced as a trial during troubleshooting. If this is done,
the ID and code word will be programmed into the new unit and it cannot be used for other cars even if you
find that the old unit was normal.
D The immobilizer system cannot be deactivated.
D Confirm that all keys registered can start the engine after the reprogram procedure. When confirming, wait
for more than 5 seconds before inserting the next key.
D When the customer does not need to register more than two keys, the following procedures can be stopped
after registering two keys.
D If the key cannot be registered in spite of the fact that the immobilizer system operates normally, there may
be a malfunction with the key reminder switch or wiring harness.
Key Replacement or Addition
When the customer has two or more valid keys
Y5A8122W102
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s).
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.
T49
IMMOBILIZER SYSTEM
When the customer has only one or no valid key (code word is required)
Y5A8122W103
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s).
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.
8. After reprogramming, clear DTCs stored in the PCM.
Steering Lock Replacement
When the customer has two or more valid keys from the old steering lock
ZCF8122W101
Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Remove the steering lock.
2. Connect the engine switch connector and key reminder switch connector to a new steering lock.
3. Connect the coil connector to the removed steering lock as shown in the figure.
4. Insert key 1 into the removed steering lock.
5. Insert key 3 into the new steering lock and hold for 1 second or more.
6. Remove and insert key 3 five times at no more than 1second intervals.
T50
IMMOBILIZER SYSTEM
(1) After the final key insertion, verify that the
security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
Note
D Perform Steps 7, 8 and 9 within 30 seconds after Step 6(2).
7. Remove key 1 from the steering lock.
8. Insert key 2 into the removed steering lock.
9. Insert key 3 into the new steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
10. After verifying that the security light goes off, turn the key to the LOCK position.
Note
D Perform Steps 11 and 12 within 30 seconds after Step 10.
11. Disconnect the coil connector from the removed steering lock and connect to the new steering lock.
12. Turn key 3 to the ON position and verify that the security light illuminates.
13. After verifying that the security light goes off, turn key 3 to the LOCK position and remove from the steering
lock.
14. Insert key 4 into the new steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
15. Insert key 5 into the new steering lock and turn the key to the ON position.
(1) After verifying that the security light goes off, turn the key to the LOCK position.
16. Wait for 30 seconds.
17. Install the new steering lock to the vehicle.
When the customer has only one or no valid key (code word is required)
Y5A8122W105
Note
D When replacing the steering lock, the coil and keys should be replaced as a set.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Replace the steering lock.
2. Insert key 1 into the steering lock and hold for 1 second or more.
3. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12
seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
5. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
T51
IMMOBILIZER SYSTEM
6. If there are 48 keys (valid and/or new keys), repeat Step 5 with each key.
7. Wait for 30 seconds.
8. After reprogramming, clear DTCs stored in the PCM.
Immobilizer Unit Replacement
When the customer does not have valid key
D PCM needs to be replaced with immobilizer unit. Perform Both Immobilizer unit and PCM Replacement of the
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See 54 Both Immobilizer Unit and PCM
Replacement.)
When the customer has at least one valid key (code word is required)
Y5A8122W106
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace immobilizer unit.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
4. After the security light goes off, turn key 1 to the LOCK position.
(1) Remove the key from the steering lock and wait for 2 seconds or more.
5. Insert key 2 into the steering lock and hold 1 second or more.
6. Remove and insert key 2 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
7. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
8. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After the security light goes off, turn the key to the LOCK position.
9. If there are 48 keys (valid and/or new keys), repeat Step 8 with each key.
10. Wait for 30 seconds.
11. After reprogramming, clear DTCs stored in the PCM.
T52
IMMOBILIZER SYSTEM
PCM Replacement
When the customer does not have valid key
D Immobilizer unit needs to be replaced with PCM. Perform Both Immobilizer Unit and PCM Replacement of the
IMMOBILIZER SYSTEM REPROGRAM PROCEDURE. (See 54 Both Immobilizer Unit and PCM
Replacement.)
When the customer has two or more valid keys
Y5A8122W107
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace the PCM.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
4. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
5. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
6. Repeat Step 5 with key 1.
7. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
8. If there are 48 keys (valid and/or new keys), repeat Step 7 with each key.
9. Wait for 30 seconds.
When the customer has only one valid key (code word is required)
Y5A8122W108
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponderequipped key(s) if necessary.
2. Replace the PCM.
3. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
T53
IMMOBILIZER SYSTEM
4. After verifying that the security light goes off, turn key 1 to the LOCK position.
(1) Remove the key from the steering lock and wait for 2 seconds or more.
5. Insert key 2 into the steering lock and wait for 1 second or more.
6. Remove and insert key 2 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light flashes. (300 ms ON300 ms OFF)
(2) Wait for 5 minutes until the security light flashes at 1.2second intervals.
(3) Input the code word. (See 56 CODE WORD INPUT PROCEDURE.)
(4) After verifying that the security light has switched from flashing to straight illumination, turn the key to the
ON position.
(5) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
7. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
8. If there are 48 keys (valid and/or new keys), repeat Step 8 with each key.
9. Wait for 30 seconds.
10. After reprogramming, clear DTCs stored in the PCM.
Both Immobilizer Unit and PCM Replacement
When the customer has two or more valid keys
Note
D Keys may be valid or new.
D When an error occurs in Steps 1 to 3, repeat the procedure from Step 1.
D When an error occurs in Step 4, perform the Reprogram error recovery procedure for both immobilizer unit
and PCM replacement.
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Cut new transponder equipped key(s) if necessary.
2. Replace immobilizer unit and PCM.
3. Using key 1, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 1 to LOCK position. Observe security light blinks once repeatedly.
4. Using key 2, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 2 to LOCK position. Observe security light blinks twice repeatedly.
5. Using key 3, turn engine switch to ON position. Observe security light illuminates and then goes out.
(1) Turn key 3 to LOCK position. Observe security light blinks three times repeatedly.
6. If there are 48 keys (valid and/or new keys), repeat Step 4.
7. Wait for 30 seconds to quit reprogram mode.
Reprogram error recovery procedure for both immobilizer unit and PCM replacement
Note
D If no specific time interval is given, each step should be performed within 30 seconds of the previous step.
1. Insert key 1 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
2. Remove and insert key 1 five times at no more than 1second intervals.
(1) After the final key insertion, verify that the security light illuminates.
(2) Remove the key from the steering lock and verify that the security light goes off.
3. Insert key 2 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position and remove from the
steering lock.
4. Insert key 3 into the steering lock and turn the key to the ON position.
(1) Verify that the security light illuminates for 12 seconds.
(2) After verifying that the security light goes off, turn the key to the LOCK position.
5. Wait for 30 seconds.
T54
IMMOBILIZER SYSTEM
VEHICLES BUILT BEFORE SEPTEMBER 2001
CODE WORD INPUT PROCEDURE
Note
D A code word is composed of five digits from 19 and is part of the immobilizer unit from the manufacturer.
Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number,
then ask the distributor.
D To input the code word into the DDS1, turn the ignition key and count the number of flashes of the security
light. The calculation of the number of flashes of the security light comes with the timing of the turning of the
key.
1. Wait for 5 minutes until security light flashes slowly. (300 ms ON, 300 ms OFF
2. Input the code word as in the example shown below.
SECURITY LIGHT
ON
OFF
ON
IGNITION SWITCH
LOCK
WITHIN 30 SECONDS
(1) Turn ignition switch to ON position while security light is off and count three illumination cycles. As the light
goes out after the third illumination, turn key to LOCK position.
(2) Wait at least one illumination cycle and within 30 seconds of turning key to LOCK position, turn ignition
switch to ON position while security light is off and count one illumination cycle. As the light goes out after
the first illumination, turn key to LOCK position.
(3) Repeat Step (2) for rest of three digits.
3. When code word is registered correctly in the DDS1. The security light stops flashing and illuminates.
4. As soon as the security light stops flashing and illuminates, the following immobilizer system reprogram
procedure should be started.
Note
D If the code word is not input correctly, the security light goes out after all five digits are input. In this case,
perform the Code Word Input Error Recovery Procedure.
T55
IMMOBILIZER SYSTEM
VEHICLES BUILT FROM SEPTEMBER 2001
CODE WORD INPUT PROCEDURE
Note
D A code word is composed of eight digits from 19 and is part of the immobilizer unit from the manufacturer.
Each unit has its own code word. To obtain the code word, you need to have the immobilizer serial number,
then ask the distributor.
D To input the code word into the PCM, turn the engine key and count the number of flashes of the security
light. The calculation of the number of flashes of the security light comes with the timing of the turning of the
key.
1. Wait for 5 minutes until security light flashes slowly. (300 ms ON300 ms OFF
2. Input the code word as shown in the example below.
ZCF8122W102
(1) Turn engine switch to ON position while security light is off and count three illumination cycles. As the light
goes out after the third illumination, turn key to LOCK position.
(2) Wait at least one illumination cycle and within 30 seconds of going to LOCK position, turn engine switch to
ON position while security light is off and count one illumination cycle. As the light goes out after the first
illumination, turn key to LOCK position.
(3) Repeat Step (2) for rest of six digits.
3. When code word is registered correctly in the PCM, the security light stops flashing and illuminates.
4. As soon as the security light stops flashing and illuminates, the following immobilizer system reprogram
procedure should be started.
Note
D If the code word is not input correctly, the security light goes out after all eight digits are input. In this case,
perform the Code Word Input Error Recovery Procedure.
Examples of Incorrect Input of Code Word
Note
D The security light must flash one or more times between the digits of the code word.
D If the code word is input incorrectly, the security light goes out. Remove and insert key five times and
repeat the procedure to input all eight figures for the code word.
D When an error occurs during the reprogram procedures except when both the immobilizer unit and PCM
are replaced, repeat the procedure from Step 1. If you still cannot reprogram, confirm how many keys can
start the engine. Then, perform the key replacement or addition reprogram procedure according to the valid
key number.
D The security light flashes ten or more times while the engine switch is at ON position.
ZCF8122W103
T56
IMMOBILIZER SYSTEM
D The engine switch is turned to ON position and LOCK position while the security light is off.
ZCF8122W104
D The engine switch is turned to LOCK position and ON position while the security light is on.
ZCF8122W105
D The engine switch is turned to LOCK position and ON position while the security light is off.
ZCF8122W106
T57
RIGHT
WRONG
RIGHT
WRONG
T58
7.911.7 Nm
{80120 kgfcm, 70104 inlbf}
Bolt
+ Installation Note
Connector
+ Installation Note
Component Reusing
D Even if an air bag module does not deploy in a
collision and does not have any external signs
of damage, it may have been damaged
internally, which may cause improper
operation. Improper operation may cause
serious injury. Always self-check the
undamaged air bag module to determine
whether it can be reused. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION, AIR BAG SYSTEM.)
Bolt Installation Note
D Tighten the bolts in the order shown in the figure.
T59
Warning
D Handling the air bag module improperly can
accidentally deploy the air bag module,
which may seriously injure you. Read
SERVICE WARNINGS before handling the
air bag module. (Refer to SERVICE
WARNINGS.)
1. Turn the ignition switch to LOCK position.
2. Disconnect the negative battery cable and wait for
more than 1 minute.
3. Remove the glove compartment.
4. Remove in the order indicated in the table.
Note
D When a new SAS unit has been installed, the
air bag system warning light flashes
continuously if there arent any malfunctions in
the system. Perform the air bag module
deployment authorization procedure. (Refer to
AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE.)
8. If the air bag system warning light remains on, off,
or repeats flashing after servicing, there are
malfunctions in the system. Perform the inspection
again. (Refer to ON-BOARD DIAGNOSTIC
FUNCTION, AIR BAG SYSTEM.)
6.879.80 Nm
{70100 kgfcm, 60.886.7 inlbf}
A
B
A
6.879.80 Nm
{70100 kgfcm, 60.886.7 inlbf}
Connector
Bolt
Connector
Nut
+ Installation Note
SAS unit
T60
0.81.1 Nm
{812 kgfcm, 710 inlbf}
Connector
Screw
+ Installation Note
Clock spring
ALIGNMENT MARKS
Terminal
1A
1B
2D
3A
3B
4D
Constant
123456567
T61
HORN CIRCUIT
2D
VEHICLESIDE
4D
AIR BAG CIRCUIT (GND)
1B
1A
3B
1A
2D 2C 2B 2A
3A
3A
VEHICLE-SIDE
1B
AIR BAG
MODULESIDE
4D 4C 4B 4A
Note
D When the vehicle-side connector of clock
spring is disconnected, terminals 1A and 1B
are shorted to prevent unexpected deployment
of the air bag module.
CLOCK SPRING
CONNECTOR
49 D066 002
49 D066 002
Caution
D Deploying the air bag modules inside the
vehicle may cause damage to the vehicle
interior. When the vehicle is not to be
scrapped, always deploy the air bag
modules outside the vehicle.
T62
49 D066 002
49 H066 002
DRIVER-SIDE
AIR BAG MODULE
WIRE
HARNESS
49 H066 002
ACTIVATION
SWITCH
GREEN LIGHT
RED LIGHT
49 D066 002
5. Stack three tires on top of the tire with the air bag
module. Stack another tire that has a wheel on top
of the four tires.
TIRE WITH
WHEEL
BOLT
DRIVER-SIDE
AIR BAG MODULE
TIRE WITH
DRIVER-SIDE
AIR BAG
MODULE
T63
PASSENGER-SIDE
AIR BAG MODULE
BOLT
Warning
D If the air bag module is not properly
installed to the tire, serious injury may
occur when the module is deployed.
When installing the air bag module to the
tire, make sure the module is facing the
center of the tire.
49 H066 002
49 D066 002
49 H066 002
ACTIVATION
SWITCH
WIRE HARNESS
GREEN LIGHT
RED LIGHT
PASSENGER-SIDE
AIR BAG MODULE
T64
49 H066 002
ACTIVATION
SWITCH
TIRE WITH
WHEEL
GREEN LIGHT
RED LIGHT
TIRE WITH
PASSENGER-SIDE
AIR BAG MODULE
Warning
D The air bag module is very hot immediately
after it deploys. You can get burned. Do not
touch the air bag module for at least 15
minutes after deployment.
Warning
D Pouring water on a deployed air bag
module is dangerous. The water will mix
with residual gases to form a gas that can
make breathing difficult. Do not pour water
on the deployed air bag module.
Warning
D A deployed air bag module 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, wear gloves and
safety glasses.
49 D066 002
T65
CLIP
CONNECTOR A
GREEN LIGHT
CONNECTOR B
ACTIVATION SWITCH
RED LIGHT
Inspection Procedure
1. Follow the steps below to verify that the SST
(Deployment Tool) is operating correctly.
Step
Light condition
Inspection procedure
Green
Red
On
Off
Off
On
On
Off
RED
BLACK
49 H066 002
ACTIVATION
SWITCH
CONNECTOR A
49 H066 002
CONNECTOR B
T66
Output pattern
Description
01
WALTPX0001
02
Page
WALTPX0002
03
WALTPX0003
11
WALTPX0011
21
WALTPX0021
24
WALTPX0024
30
WALTPX0030
Note
D Perform the following if the security light stays on:
If engine stalls, go to symptom troubleshooting NO.7 ENGINE RUNS ROUGH/ROLLING IDLE. (See
NO.7 ENGINE RUNS ROUGH/ROLLING IDLE.)
If engine will not start, go to symptom troubleshooting NO.5 CRANKS NORMALLY BUT WILL NOT
START. (SeeNO.5 CRANKS NORMALLY BUT WILL NOT START)
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.
T67
ID number unregistered in immobilizer unit is input after engine switch is turned to ON position or
engine cranking.
D ID number is unregistered in immobilizer unit.
Diagnostic procedure
STEP
INSPECTION
ACTION
DTC 02
DTC 02
POSSIBLE
CAUSE
Diagnostic procedure
STEP
INSPECTION
ACTION
DTC 03
DTC 03
POSSIBLE
CAUSE
ID number is not input into immobilizer unit after engine switch is turned to ON position or
cranking engine.
D
D
D
D
ZCF8170W102
Diagnostic procedure
STEP
INSPECTION
ACTION
Yes
Go to DTC 11.
No
Go to next step.
Yes
Go to DTC 30.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Troubleshooting is completed.
T68
Coil or wiring harness between immobilizer unit and coil is open circuit.
D
D
D
D
ZCF8170W101
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Replace coil.
Yes
No
Note
D Vehicle harness which is connected to
immobilizer unit terminals D and F, uses
a twisted pair wire. Because twisted pair
wire does not have polarity, immobilizer
unit connector terminal D 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.
T69
Diagnostic procedure
STEP
INSPECTION
INSPECT IMMOBILIZER UNIT
D Turn engine switch from LOCK position to
START position for 2 seconds.
D Does security light indicate DTC 21 again?
ACTION
Yes
No
DTC 24
DTC 24
POSSIBLE
CAUSE
Open or short circuit in wiring harness between immobilizer unit and PCM
D
D
D
D
ZCF8170W103
Diagnostic procedure
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
T70
STEP
4
INSPECTION
INSPECT COMMUNICATION CIRCUIT
D Connect PCM connector.
D Turn engine switch to ON position.
D Measure voltage at immobilizer unit
connector terminal A.
D Is voltage more than 10 V?
ACTION
Yes
No
DTC 30
DTC 30
POSSIBLE
CAUSE
Diagnostic procedure
STEP
INSPECTION
INSPECT INNER CIRCUIT OF IMMOBILIZER
UNIT
D Replace immobilizer unit and reprogram
immobilizer system.
(See NO TAG Immobilizer Unit
Replacement )
D Does engine start?
ACTION
Yes
No
T71
No
Yes
Does air bag system warning light illuminate for
approximately 6 seconds and then go off?
No
Yes
No
Does air bag system warning light remain off?
Yes
END
Note
D When a malfunction has occurred in the air bag system and the air bag system warning light doesnt turn on
after the ignition switch is turned to ON position, the warning buzzer built into the SAS unit sounds 5 times
for 5 cycles.
Diagnostic trouble code table
DTC
Output pattern
Diagnosed circuit
ON
SAS unit
OFF
ON
Continuously flashes
Caution
D When the output pattern continuously flashes (standby code), perform the deployment
authorization procedure. (Refer to AIR BAG SYSTEM, AIR BAG MODULE DEPLOYMENT
AUTHORIZATION PROCEDURE.)
T72
DETECTION
CONDITION
POSSIBLE
CAUSE
STEP
1
INSPECTION
VERIFY THAT SAS UNIT CONNECTOR IS
CONNECTED WITH SAS UNIT
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
ACTION
Yes
Go to next step.
No
Yes
No
DTC 2
DETECTION
CONDITION
SAS UNIT
Warning
D Detection conditions are for understanding DTC outline before performing inspection.
Performing inspection with only detection conditions may cause injury due to operating error
or damage the system. When performing inspection, always follow inspection procedure.
Malfunction in SAS unit inner circuit
POSSIBLE
CAUSE
STEP
INSPECTION
ACTION
Replace SAS unit.
+ AIR BAG SYSTEM, SAS UNIT
REMOVAL/INSTALLATION
T73
DTC 3
DETECTION
CONDITION
POSSIBLE
CAUSE
Note
D Diagnostic trouble code 3 is indicated when voltage simultaneously drops in the harness of both of
following circuits.
1. Harness between METER 15 A fuse and terminal AB of SAS unit connector.
2. Harness between ENGINE 15 A fuse and terminal Z of SAS unit connector.
D Weak battery
D Malfunction in wiring harness between battery and SAS unit
D Damaged SAS unit
STEP
1
INSPECTION
ACTION
INSPECT BATTERY
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
Yes
Go to next step.
No
Battery is weak.
Inspect charge/discharge system.
+ Section G, CHARGING SYSTEM, BATTERY
INSPECTION
Yes
No
AA
AB
T74
DTC 6
DETECTION
CONDITION
POSSIBLE
CAUSE
STEP
1
D
D
D
D
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove driver-side air bag module.
+ AIR BAG SYSTEM, DRIVER-SIDE AIR
BAG MODULE REMOVAL/INSTALLATION
Is clock spring pin okay?
2
T75
STEP
5
INSPECTION
ACTION
3A
No
3B
DTC 7
DETECTION
CONDITION
Yes
AA
AB
POSSIBLE
CAUSE
STEP
1
D
D
D
D
ACTION
Yes
Go to next step.
No
Go to step 5.
T76
STEP
2
INSPECTION
INSPECT PASSENGER-SIDE AIR BAG
MODULE CONNECTOR PIN
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Warning
D Handling air bag system components
improperly can accidentally deploy air
bag modules, which may seriously
injure you. Read SERVICE WARNINGS
before handling air bag system
components.
+ AIR BAG SYSTEM, SERVICE
WARNINGS
Turn ignition switch to LOCK position.
Disconnect negative battery cable and wait for
more than 1 minute.
Remove glove compartment.
Disconnect passenger-side air bag module
connector.
Is passenger-side air bag module connector
pin okay?
3
T77
STEP
5
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
AA
AB
T78
TROUBLESHOOTING
TROUBLESHOOTING
AIR BAG SYSTEM
Foreword
D Refer to section GI and thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
D For the steps that have an asterisk (*) , inspect the connector/terminal connection for continuity and damage. If
the connection is poor, reconnect it, or repair or replace the appropriate parts if necessary.
Troubleshooting Index
D Use the chart below to verify the symptoms of the trouble in order to diagnose the appropriate area.
No.
Malfunction symptom
Air bag system warning light does not illuminate when ignition switch is turned to ON position.
Air bag system warning light illuminates immediately after ignition switch is turned to ON position and remains illuminated.
Symptom Troubleshooting
Note
D The following may be the cause of trouble if the symptom does not go away after the symptom
troubleshooting steps are followed.
1. Poor contact at terminal G of short connector (6pin) between instrument cluster and SAS unit.
2. Simultaneous poor contact at terminals D and F of short connector (6pin) between METER 15 A fuse and SAS
unit, and ENGINE 15 A fuse and SAS unit, respectively.
3. Simultaneous poor contact at terminals S and X of SAS unit connector (21pin).
4. Simultaneous poor contact at terminals AB and Z of SAS unit connector (21pin).
5. Simultaneous poor contact in wiring harness between terminal S of SAS unit connector (21pin) and ground,
terminal X of SAS unit connector (21pin) and ground.
6. Simultaneous poor contact in wiring harness between METER 15 A fuse and SAS unit, ENGINE 15 A fuse and
SAS unit.
1
Air bag system warning light does not illuminate when ignition switch is turned to ON position.
TROUBLESHOOTING HINTS
Malfunction in SAS unit power supply/ground circuit
1 Air bag system warning light does not illuminate
D SAS unit malfunction
D Instrument cluster (print plate) malfunction
D Terminal 1J of instrument cluster connector (16pin) malfunction
D Terminal 2J of instrument cluster connector (14pin) malfunction
D Terminal Q of SAS unit connector (21pin) malfunction
D Air bag system warning light bulb malfunction
D Poor installation of air bag system warning light bulb
D Poor connection at terminal 1J of instrument cluster connector (16pin)
D Poor connection at terminal 2J of instrument cluster connector (14pin)
D Poor connection at terminal Q of SAS unit connector (21pin)
D Poor contact in instrument cluster connectors (14, 16pin)
D Open or short circuit in wiring harness between instrument cluster and SAS unit
STEP
1
2
3
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
T79
TROUBLESHOOTING
STEP
INSPECTION
ACTION
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
*9
Yes
No
10
Yes
No
T80
TROUBLESHOOTING
Air bag system warning light illuminates immediately after ignition switch is turned to ON position and
remains illuminated.
TROUBLESHOOTING HINTS
Malfunction in air bag system warning light circuit
1 Air bag system warning light remains illuminated
D SAS unit malfunction
D Malfunction of short bar between terminals Q and S of SAS unit connector (21pin)
D No connection in SAS unit connector (21pin)
D Short circuit in wiring harness between instrument cluster and SAS unit
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
No
Yes
No
*4
T81
U1
SERVICE WARNINGS
SERVICE CAUTIONS
HANDLING REFRIGERANT
Avoid breathing air conditioning refrigerant or
lubricant vapor. Exposure may irritate eyes,
nose and throat. If accidental system discharge
occurs, ventilate work area before resuming
service.
Do not pressure test or leak test R-134a service
equipment and/or vehicle air conditioning
system with compressed air. Some mixtures of
air and R-134a have been shown to be
combustible at elevated pressures. These
mixtures, if ignited, may cause injury or
property damage. Additional health and safety
information may be obtained from refrigerant
manufacturers.
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 40 C
{104 F}.
MINERAL OIL
MOISTURE ABSORPTION
U2
TIME
49 C061 001
49 C061 005
49 C061 004
REFRIGERANT
TANK
SCALE
VACUUM PUMP
49 C061 001
Caution
Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.
49 C061 002
49 C061 003
49 C061 006A
CAP
49 C061 007
CAP
CHARGING VALVE OF
LOW-PRESSURE SIDE
CHARGING
VALVE OF
HIGH-PRESSURE
SIDE
RECOVERY
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
CLOSE
CHARGING
Charging Recycled R-134a Refrigerant
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
Charging New R-134a Refrigerant
Caution
Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant
550 g {19.4 oz}
49 C061 001
U3
49 C061 001
49 C061 005
49 C061 004
REFRIGERANT
TANK
SCALE
VACUUM PUMP
49 C061 001
Caution
Close the SST (49 C061 001) valve
immediately after stopping the vacuum
pump. If the valve is left open, the vacuum
pump oil will flow back into the refrigeration
cycle and cause a decrease in the efficiency
of the air conditioner.
49 C061 002
49 C061 003
49 C061 006A
CAP
49 C061 007
CAP
CHARGING VALVE OF
LOW-PRESSURE SIDE
CHARGING
VALVE OF
HIGH-PRESSURE
SIDE
RECOVERY
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
CLOSE
CHARGING
Charging Recycled R-134a Refrigerant
Connect an R-134a recovery/recycling/recharging
device to the vehicle and follow the device
manufacturers instructions.
Charging New R-134a Refrigerant
Caution
Do not exceed the specification when
charging the system with refrigerant. Doing
so will decrease the efficiency of the air
conditioner or damage the refrigeration
cycle parts.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
6. Place the refrigerant tank on the scale.
Regular amount of refrigerant
550 g {19.4 oz}
49 C061 001
U3
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.
17. Open the high-pressure side valve of the SST (49
C061 001) and charge with refrigerant until the
weight of refrigerant tank has decreased 300 g
{10.6 oz} from the amount in step 13.
49 C061 001
OPEN
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.
19. Start the engine and actuate the A/C compressor.
20. Open the low-pressure side valve of the SST (49
C061 001) and charge with refrigerant until the
refrigerant tank is empty.
U4
49 C061 001
49 C061 001
OPEN
49 C061 005
49 C061 004
REFRIGERANT
TANK
VACUUM PUMP
49 C061 006A
49 0061 007
CAP
CAP
49 C061 001
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.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
U5
49 C061 001
49 C061 001
OPEN
49 C061 005
49 C061 004
REFRIGERANT
TANK
VACUUM PUMP
49 C061 006A
49 0061 007
CAP
CAP
49 C061 001
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.
1. Install the SSTs (Manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Connect the tap pin side of the SST (49 C061 004)
to the air purge valve of the SST (49 C061 001).
3. Connect the SST (49 C061 005) to the center joint
of the SST (49 C061 001).
4. Connect the SST (49 C061 005) to the vacuum
pump.
5. Connect the SST (49 C061 004) to the refrigerant
tank.
U5
49 C061 007
49 C061 006A
CAP
49 C061 001
OPEN
CAP
SIGHT GLASS
SIGHT GLASS
R.H.D.
(WL turbo)
SIGHT GLASS
U6
49 C061 007
49 C061 006A
CAP
49 C061 001
OPEN
CAP
SIGHT GLASS
SIGHT GLASS
R.H.D.
(WL turbo)
SIGHT GLASS
U6
Amount
Condition of
sight glass
Other conditions
Mpa
{kgf/cm2, psi}
Insufficient
Bubbles
2.0
{21, 299}
pipe is warm;
low-pressure side cooler
pipe is cool.
High- and low-pressure
side readings are lower
than normal.
Air cooling ability is low.
1.5
{15, 213}
1.0
{10, 142}
0.2
{2.0, 28}
Clear
Correct
Milky white
Over
Clear
LOW-PRESSURE SIDE
0.1
{1.0, 14}
25
{77}
30
{86}
35
{95}
40
C
{104} {F}
AMBIENT TEMPERATURE
HIGH-PRESSURE SIDE
C {F}
6 {43}
5 {41}
4 {39}
3 {37}
2 {36}
1 {34}
0 {32}
20
{68}
25
{77}
30
{86}
35
{95}
CENTER VENTILATOR
TEMPERATURE
AMBIENT TEMPERATURE
40
C
{104} {F}
U7
Amount
Condition of
sight glass
Other conditions
Mpa
{kgf/cm2, psi}
Insufficient
Bubbles
2.0
{21, 299}
pipe is warm;
low-pressure side cooler
pipe is cool.
High- and low-pressure
side readings are lower
than normal.
Air cooling ability is low.
1.5
{15, 213}
1.0
{10, 142}
0.2
{2.0, 28}
Clear
Correct
Milky white
Over
Clear
LOW-PRESSURE SIDE
0.1
{1.0, 14}
25
{77}
30
{86}
35
{95}
40
C
{104} {F}
AMBIENT TEMPERATURE
HIGH-PRESSURE SIDE
C {F}
6 {43}
5 {41}
4 {39}
3 {37}
2 {36}
1 {34}
0 {32}
20
{68}
25
{77}
30
{86}
35
{95}
CENTER VENTILATOR
TEMPERATURE
AMBIENT TEMPERATURE
40
C
{104} {F}
U7
BASIC SYSTEM
BASIC SYSTEM
STRUCTURAL VIEW
BLOWER UNIT
L.H.D. (G6)
COOLING UNIT
HEATER UNIT
COOLER
PIPE
(LOW)
COOLER
PIPE
(HIGH)
HEATER
HOSE
A/C
COMPRESSOR
COOLER
HOSE
(LOW)
BLOWER UNIT
COOLING UNIT
CONDENSER
HEATER UNIT
RECEIVER/DRIER
COOLER
PIPE
(LOW)
HEATER
HOSE
COOLER
PIPE
(HIGH)
A/C
COMPRESSOR
COOLER
HOSE
(HIGH)
CONDENSER
RECEIVER/DRIER
COOLER
PIPE
(LOW)
HEATER
COOLER
HOSE
PIPE
A/C
(HIGH) COMPRESSOR
COOLER
HOSE
(HIGH)
CONDENSER
RECEIVER/DRIER
U8
BASIC SYSTEM
R.H.D. (G6)
HEATER UNIT
COOLING UNIT
HEATER
HOSE
A/C
COMPRESSOR
BLOWER UNIT
COOLER
HOSE
(LOW)
COOLER
PIPE
(HIGH)
CONDENSER
COOLER
HOSE (HIGH)
RECEIVER/DRIER
COOLING UNIT
A/C
COMPRESSOR
BLOWER UNIT
COOLER
HOSE (LOW)
COOLER
PIPE
(HIGH)
SIGHT GLASS
CONDENSER
RECEIVER/DRIER
HEATER UNIT
HEATER
HOSE
COOLING UNIT
A/C
COMPRESSOR
BLOWER UNIT
COOLER
HOSE (LOW)
COOLER
PIPE
(HIGH)
CONDENSER
RECEIVER/DRIER
U9
COOLER
HOSE (HIGH)
WL turbo
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
4. Remove the passengers side front side trim
(L.H.D. only.)
5. Remove as indicated in the table.
6. Install in the reverse order of removal.
R.H.D.
B
C
A
A
B
C
Connector
Blower unit
Blower motor
Resistor
Blower harness
Polyurethane protector
10
11
B
C
A
B
C
U10
BASIC SYSTEM
BLOWER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Remove the glove compartment.
3. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
4. Remove the passengers side front side trim
(L.H.D. only.)
5. Remove as indicated in the table.
6. Install in the reverse order of removal.
R.H.D.
B
C
A
A
B
C
Connector
Blower unit
Blower motor
Resistor
Blower harness
Polyurethane protector
10
11
B
C
A
B
C
U10
BASIC SYSTEM
5. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
6. Install in the reverse order of removal.
7. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)
Connector
Cooling unit
+ Removal Note
+ Installation Note
L.H.D.
1521 Nm
{1.52.2 kgfm,
130.2190.9 inlbf}
6.99.8 Nm
{0.71.0 kgfm,
60.886.7 inlbf}
R.H.D.
2029 Nm
{2.03.0 kgfm,
1521 ftlbf}
R
9.8119.61 Nm
{100200 kgfcm,
86.8173.5 inlbf}
U11
BASIC SYSTEM
COOLING UNIT DISASSEMBLY/ASSEMBLY
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.
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
L.H.D.
Thermoswitch clip
Thermoswitch
+ Assembly Note
Evaporator
Expansion valve
+ Assembly Note
11.814.7 Nm
{120150 kgfcm,
105130 inlbf}
R.H.D.
HEAT-SENSING TUBE
40 mm
{1.6 in}
U12
BASIC SYSTEM
EVAPORATOR INSPECTION
1. Remove the cooling unit. (Refer to COOLING UNIT
REMOVAL/INSTALLATION.)
2. Remove the evaporator from the cooling unit.
3. Inspect for cracks, damage, and oil leakage. If any
problems are found, replace the evaporator.
4. Inspect for bent fins. If they are bent, use a
flat-head screwdriver to straighten them.
HEATER UNIT REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Drain the engine coolant. (Refer to section E,
ENGINE COOLANT, ENGINE COOLANT
REPLACEMENT.) (With heater core only)
3. Remove the dashboard. (Refer to section S,
DASHBOARD AND CONSOLE, DASH BOARD
REMOVAL/INSTALLATION.)
4. Remove in the order indicated in the table.
5. Install in the reverse order of removal.
Heater hose
Heater unit
U13
BASIC SYSTEM
HEATER UNIT DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
*
*
*
Heater core
10
11
12
13
14
15
16
U14
BASIC SYSTEM
HEATER CORE INSPECTION
1. Remove the heater unit. (Refer to HEATER UNIT
REMOVAL/INSTALLATION.)
2. Remove the heater core from the heater unit.
3. Inspect for cracks, damage, and coolant leakage. If
any are found, replace the heater core.
4. Inspect for bent fins. If any are bent, use a flathead
screwdriver to straighten them.
5. Verify that the heater core inlet and outlet are not
distorted or damaged. Repair with pliers if necessary.
2435
{2.43.6,
1826}
Nm {kgfm, ftlbf}
F2, F2 Cab
R
3039
{3.04.0,
2228}
Nm {kgfm, ftlbf}
Connector
A/C compressor
+ Installation Note
U15
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the radiator grille.
4. Remove the charge air cooler and air hose. (WL
turbo only)
(Refer to section F2, INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the receiver/drier. (Refer to
RECEIVER/DRIER REMOVAL/INSTALLATION.)
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.
RECEIVER/DRIER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,
RECOVERY.) (Refer to REFRIGERANT SYSTEM
SERVICE PROCEDURES, CHARGING.)
3. Remove the radiator grille.
1521 Nm
{1.52.2 kgfm,
1115 ftlbf}
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.
6.859.80 Nm
{70100 kgfcm, 60.886.7 inlbf}
B
C
C
D
R
Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note
Condenser
+ Installation Note
U16
BASIC SYSTEM
CONDENSER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, RECOVERY.) (Refer to
REFRIGERANT SYSTEM SERVICE
PROCEDURES, CHARGING.)
3. Remove the radiator grille.
4. Remove the charge air cooler and air hose. (WL
turbo only)
(Refer to section F2, INTAKE-AIR SYSTEM,
INTAKE-AIR SYSTEM
REMOVAL/INSTALLATION.)
5. Remove the receiver/drier. (Refer to
RECEIVER/DRIER REMOVAL/INSTALLATION.)
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.
RECEIVER/DRIER REMOVAL/INSTALLATION
1. Disconnect the negative battery cable.
2. Discharge the refrigerant from the system. (Refer to
REFRIGERANT SYSTEM SERVICE PROCEDURES,
RECOVERY.) (Refer to REFRIGERANT SYSTEM
SERVICE PROCEDURES, CHARGING.)
3. Remove the radiator grille.
1521 Nm
{1.52.2 kgfm,
1115 ftlbf}
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.
6.859.80 Nm
{70100 kgfcm, 60.886.7 inlbf}
B
C
C
D
R
Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note
Condenser
+ Installation Note
U16
BASIC SYSTEM
Connector
Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note
Condenser
+ CONDENSER REMOVAL/INSTALLATION,
Condenser Installation Note
Receiver/drier
+ Installation Note
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.
3. Remove the radiator grille.
4. Remove the front bumper. (Refer to section S,
BUMPER, FRONT BUMPER
REMOVAL/INSTALLATION.)
5. Remove the radiator. (WL turbo only)
6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)
B
C
D
F
R
R
D
F
A
C
B
A
R
R
R
B
A
U17
BASIC SYSTEM
Connector
Cooler pipe
+ REFRIGERANT LINES
REMOVAL/INSTALLATION, Refrigerant Lines
Installation Note
Condenser
+ CONDENSER REMOVAL/INSTALLATION,
Condenser Installation Note
Receiver/drier
+ Installation Note
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.
3. Remove the radiator grille.
4. Remove the front bumper. (Refer to section S,
BUMPER, FRONT BUMPER
REMOVAL/INSTALLATION.)
5. Remove the radiator. (WL turbo only)
6. Remove in the order indicated in the table. Do not
allow compressor oil to spill.
7. Install in the reverse order of removal.
8. Carry out the refrigerant system performance test.
(Refer to REFRIGERANT SYSTEM SERVICE
PROCEDURES, PERFORMANCE TEST.)
B
C
D
F
R
R
D
F
A
C
B
A
R
R
R
B
A
U17
BASIC SYSTEM
R.H.D.
B
R
R
D
E
B
R
B
C
A
R
A
D
B
A
D
C
U18
CONTROL SYSTEM
CONTROL SYSTEM
STRUCTURAL VIEW
L.H.D.
A/C RELAY No.2*
MAGNETIC CLUTCH
CLIMATE
CONTROL UNIT
THERMOSWITCH
RESISTOR
BLOWER MOTOR
R.H.D.
CLIMATE
CONTROL UNIT
THERMOSWITCH
RESISTOR
BLOWER MOTOR
* F2 Cab only
U19
CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (Refer to
MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT.)
10.115.0 N
{102153
89132
kgf
inlbf}
49 H061 005
Bolt
+ Removal/Installation Note
Pressure plate
+ Installation Note
Shim
Snap ring
Stator
+ Removal Note
+ Installation Note
A/C COMPRESSOR
U20
CONTROL SYSTEM
MAGNETIC CLUTCH DISASSEMBLY/ASSEMBLY
1. Disassemble in the order indicated in the table.
2. Assemble in the reverse order of disassembly.
3. Adjust the magnetic clutch clearance. (Refer to
MAGNETIC CLUTCH CLEARANCE
ADJUSTMENT.)
10.115.0 N
{102153
89132
kgf
inlbf}
49 H061 005
Bolt
+ Removal/Installation Note
Pressure plate
+ Installation Note
Shim
Snap ring
Stator
+ Removal Note
+ Installation Note
A/C COMPRESSOR
U20
CONTROL SYSTEM
3. If not within the specification, remove the pressure
plate and adjust the clearance by changing the
shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5
mm {0.020 in}) or the number of shims.
Clearance
0.350.75 mm {0.0140.029 in}
MEASURING POINT
A
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.
U21
Connector
CONTROL SYSTEM
3. If not within the specification, remove the pressure
plate and adjust the clearance by changing the
shim (0.1 mm {0.004 in}, 0.3 mm {0.012 in}, 0.5
mm {0.020 in}) or the number of shims.
Clearance
0.350.75 mm {0.0140.029 in}
MEASURING POINT
A
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.
U21
Connector
CONTROL SYSTEM
A/C RELAY No.1 INSPECTION
1. Remove the A/C relay No.1.
2. Inspect for continuity between the A/C relay No.1
terminals using an ohmmeter.
: Continuity B+: Battery positive voltage
B
C
Terminal
Step
B+
GND
B
123456567
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.
5.97.8 Nm
{6080 kgfcm,
5369 inlbf}
Connector
Terminal
B
1
2
B+
GND
Connector
123456567
U22
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION
1. Install the SSTs (manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Disconnect the refrigerant pressure switch
connector.
3. Verify the high-pressure side reading of the SST
(Manifold gauge).
4. Inspect for continuity between the terminals of the
refrigerant pressure switch using an ohmmeter.
0.180.21
{1.82.2, 2631}
WITH HEATER
CORE
A
WITHOUT
HEATER CORE
A
3.03.3
{3034, 427483}
CONTINUITY
NO CONTINUITY
0.02 {0.25, 3.56}
OR LESS
0.40.7
{4.08.0, 57113}
MPa { kgf/cm2 , psi }
: Continuity
Water temperature
temperat re
: Continuity
Temperature
control dial
position
MAX COLD
Terminal
A
1C {34F} or less
: Continuity
Magnetic clutch
cl tch
Terminal
3C {37F} or more
1/2
On
Off
MAX WARM
Water temperature
temperat re
Terminal
A
03C {3237F}
3C {37F} or more
711C {4552F}
123456567
: Continuity
Magnetic clutch
cl tch
Terminal
A
B
123456567
On
Off
123456567
U23
CONTROL SYSTEM
REFRIGERANT PRESSURE SWITCH INSPECTION
1. Install the SSTs (manifold gauge set). (Refer to
MANIFOLD GAUGE SET INSTALLATION.)
2. Disconnect the refrigerant pressure switch
connector.
3. Verify the high-pressure side reading of the SST
(Manifold gauge).
4. Inspect for continuity between the terminals of the
refrigerant pressure switch using an ohmmeter.
0.180.21
{1.82.2, 2631}
WITH HEATER
CORE
A
WITHOUT
HEATER CORE
A
3.03.3
{3034, 427483}
CONTINUITY
NO CONTINUITY
0.02 {0.25, 3.56}
OR LESS
0.40.7
{4.08.0, 57113}
MPa { kgf/cm2 , psi }
: Continuity
Water temperature
temperat re
: Continuity
Temperature
control dial
position
MAX COLD
Terminal
A
1C {34F} or less
: Continuity
Magnetic clutch
cl tch
Terminal
3C {37F} or more
1/2
On
Off
MAX WARM
Water temperature
temperat re
Terminal
A
03C {3237F}
3C {37F} or more
711C {4552F}
123456567
: Continuity
Magnetic clutch
cl tch
Terminal
A
B
123456567
On
Off
123456567
U23
CONTROL SYSTEM
WITH HEATER
CORE
A
WITHOUT
HEATER CORE
A
Connector
Blower motor
U24
Connector
Resistor
CONTROL SYSTEM
WITH HEATER
CORE
A
WITHOUT
HEATER CORE
A
Connector
Blower motor
U24
Connector
Resistor
CONTROL SYSTEM
RESISTOR INSPECTION
1. Remove the glove compartment.
2. Disconnect the resistor connector.
3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal
Resistance ()
1A1B (2A)
R1: 0.430.47
1A1C
R2: 1.041.16
1C1D
R3: 1.471.63
R3
1D
R2
1C
R1
1A
1B
2A
1C
1A
1D
1B
2A
49 D066 801A
U25
CONTROL SYSTEM
RESISTOR INSPECTION
1. Remove the glove compartment.
2. Disconnect the resistor connector.
3. Verify that the resistance between the terminals of
the resistor is as shown in the table.
Terminal
Resistance ()
1A1B (2A)
R1: 0.430.47
1A1C
R2: 1.041.16
1C1D
R3: 1.471.63
R3
1D
R2
1C
R1
1A
1B
2A
1C
1A
1D
1B
2A
49 D066 801A
U25
CONTROL SYSTEM
WITHOUT HEATER CORE
SET HOLE
R.H.D.
AIR INTAKE WIRE
Dial
Knob
+ Removal Note
A/C switch
Panel
Fan switch
Illumination bulb
A/C amplifer
10
11
11
Cap
13
Body
SET HOLE
SET HOLE
WIRE
KNOB
U26
CONTROL SYSTEM
WITHOUT HEATER CORE
SET HOLE
R.H.D.
AIR INTAKE WIRE
Dial
Knob
+ Removal Note
A/C switch
Panel
Fan switch
Illumination bulb
A/C amplifer
10
11
11
Cap
13
Body
SET HOLE
SET HOLE
WIRE
KNOB
U26
CONTROL SYSTEM
Airflow Mode Wire
1. Set the airflow mode control dial at DEF.
2. Set the airflow mode link to DEF in the direction of
the arrow and insert a screwdriver into the set hole.
SET HOLE
Fan Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the fan switch
terminals using an ohmmeter.
: Continuity
Terminal
Switch
position
0
1
2
3
AIRFLOW
MODE
WIRE
Switch
position
OFF
ON
123456567
U27
B C
123456567
E C A
CONTROL SYSTEM
Airflow Mode Wire
1. Set the airflow mode control dial at DEF.
2. Set the airflow mode link to DEF in the direction of
the arrow and insert a screwdriver into the set hole.
SET HOLE
Fan Switch
1. Remove the climate control unit. (Refer to
CLIMATE CONTROL UNIT REMOVAL.)
2. Inspect for continuity between the fan switch
terminals using an ohmmeter.
: Continuity
Terminal
Switch
position
0
1
2
3
AIRFLOW
MODE
WIRE
Switch
position
OFF
ON
123456567
U27
B C
123456567
E C A
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
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.
The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
No.
Malfunction symptom
Insufficient blown air volume and/or no blown air depending on airflow mode.
No cool air.
SYMPTOM TROUBLESHOOTING
1
Insufficient blown air volume and/or no blown air depending on airflow mode.
TROUBLESHOOTING HINTS
1 Malfunction in VENT mode system
Steps 14
2 Malfunction in HEAT mode system
Step 5
3 Malfunction in DEFROSTER mode system
Steps 68
STEP
1
2
3
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to Step 5.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Is vent clogged?
Is duct in dashboard properly installed?
Yes
Go to next step.
No
Yes
No
Go to next step.
Is vent clogged?
Yes
No
Go to next step.
Yes
No
U28
TROUBLESHOOTING
TROUBLESHOOTING
FOREWORD
Refer to section GI. Thoroughly read and understand the basic flow of troubleshooting in order to properly
perform the procedures.
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.
The areas for inspection (steps) are given according to various circuit malfunctions. Use the chart below to
verify the symptoms of the trouble in order to diagnose the appropriate area.
TROUBLESHOOTING INDEX
No.
Malfunction symptom
Insufficient blown air volume and/or no blown air depending on airflow mode.
No cool air.
SYMPTOM TROUBLESHOOTING
1
Insufficient blown air volume and/or no blown air depending on airflow mode.
TROUBLESHOOTING HINTS
1 Malfunction in VENT mode system
Steps 14
2 Malfunction in HEAT mode system
Step 5
3 Malfunction in DEFROSTER mode system
Steps 68
STEP
1
2
3
4
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to Step 5.
No
Go to next step.
Yes
No
Go to next step.
Yes
No
Is vent clogged?
Is duct in dashboard properly installed?
Yes
Go to next step.
No
Yes
No
Go to next step.
Is vent clogged?
Yes
No
Go to next step.
Yes
No
U28
CONTROL SYSTEM
STEP
9
INSPECTION
ACTION
Yes
No
TROUBLESHOOTING HINTS
1 Blower motor, resistor, fan switch malfunction
Step 1
2 Blower unit malfunction
Steps 24
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Go to Step 4.
Yes
Go to next step.
No
Yes
No
Yes
No
TROUBLESHOOTING HINTS
1 Malfunction in heater units airflow mode main link, airflow mode rod, airflow mode cranks, airflow mode sub link, airflow
mode wire or wire clamp
Steps 1, 2
2 Bevel gear set (2) in climate control unit, airflow mode wire or wire clamp malfunction
Step 3
3 Malfunction in one or more heater unit doors
Steps 4, 5
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
U29
TROUBLESHOOTING
STEP
2
4
5
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
No
TROUBLESHOOTING HINTS
1 Malfunction in blower units air intake crank, air intake link, air intake wire or wire clamp
Steps 1, 2
2 Climate control unit air intake wire or wire clamp malfunction
Step 3
3 Blower unit air intake door malfunction
Steps 4, 5
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
No
U30
CONTROL SYSTEM
TROUBLESHOOTING HINTS
1 Malfunction in heater units air mix rod, air mix link, air mix cranks, air mix shaft, air mix wire or wire clamp
Steps 2, 3
2 Bevel gear set (2) in climate control unit, air mix wire or wire clamp malfunction
Step 4
3 Heater unit air mix door malfunction
Steps 5, 6
STEP
INSPECTION
ACTION
Yes
Go to next step.
No
Inspect heater units air mix rod, air mix link, air
mix cranks, air mix shaft and wire clamp.
Is there grease
g
on air mix rod,, air mix link and
air mix cranks?
Are air mix rod, air mix link, air mix cranks, and
air mix shaft securely installed in their proper
positions?
Is wire clamp free of deformation?
Are above items okay?
Yes
Go to next step.
No
Apply grease or install air mix rod, air mix link, air
mix cranks, and air mix shaft securely in their
proper positions, repair wire clamp, then go to
Step 7.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
No
TROUBLESHOOTING HINTS
1 Drive belt malfunction
Step 1
2 Malfunction in blower unit or condenser
Steps 4, 5
3 Malfunction in receiver/drier or expansion valve (valve closes too much)
Steps 8, 9
4 Malfunction in refrigerant lines
Steps 10, 11
5 Malfunction in piping connections
Steps 1, 2, 13
6 A/C compressor system malfunction, insufficient compressor oil
Steps 15, 16
7 Compressor oil over-full, malfunction in expansion valve or heater unit air mix link system
Steps 1720
U31
TROUBLESHOOTING
STEP
1
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
Go to next step.
No
Go to Step 6.
Yes
No
Go to next step.
Inspect condenser.
+ BASIC SYSTEM, CONDENSER INSPECTION
Is it okay?
Yes
No
Yes
Go to next step.
No
Go to Step 14.
Yes
Go to next step.
No
Go to Step 10.
Turn A/C switch off and let air conditioner stop for
10 minutes.
min tes
Start engine.
Turn both A/C switch and fan switch on.
Does malfunction occur after A/C compressor
turns on?
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
6
7
10
U32
CONTROL SYSTEM
STEP
11
12
13
14
15
16
17
18
INSPECTION
ACTION
Yes
No
Yes
No
Yes
No
Yes
No
Go to Step 17.
Yes
Return to Step 3.
No
Go to next step.
Yes
No
Yes
Go to Step 20.
No
Go to next step.
Yes
Go to next step.
No
Repair or install air mix rod, air mix link, air mix
cranks and air mix shaft securely in proper
position, then go to Step 21.
Are heater units air mix rod, air mix link, air mix
cranks and air mix shaft securely and properly
installed?
U33
TROUBLESHOOTING
STEP
19
20
21
INSPECTION
ACTION
1.
2.
3.
4.
5.
6.
Yes
Go to Step 21.
No
Yes
No
Yes
No
No cool air.
TROUBLESHOOTING HINTS
1 A/C compressor system malfunction
Step 2
2 Incorrect amount of refrigerant
Step 3
3 A/C switch indicator light malfunction
Steps 46
4 A/C relay system malfunction
(WL, WL turbo, F2 Cab) Steps 7, 1113
(G6, F2) Steps 7, 11, 12
5 Refrigerant pressure switch malfunction
Step 8
6 PCM A/C cut-off control system
(WL, WL turbo) Steps 9, 26
(G6, F2) Step 9
7 PCM (IG1 signal) system malfunction
Steps 10, 25
8 Magnetic clutch system malfunction
Step 14
9 PCM (A/C signal) system malfunction
(WL, WL turbo) Steps 15, 20
(G6, F2) Steps 15, 19, 20
(F2 Cab) Step 15
10 Thermoswitch, A/C switch malfunction
(WL, WL turbo, G6, F2) Steps 2124
(F2 Cab) Steps 1618
U34
CONTROL SYSTEM
STEP
1
2
4
*5
*6
*8
*9
*10
INSPECTION
ACTION
Yes
Go to next step.
No
Start engine.
Turn both A/C switch and fan switch on
on.
Does A/C compressor operate?
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to Step 7.
No
Go to next step
Yes
Go to next step.
No
Yes
No
Yes
Go to next step.
No
Yes
No
Yes
No
Go to next step.
Yes
Go to Step 15.
No
Go to next step.
U35
TROUBLESHOOTING
STEP
*11
*12
*13
*14
*15
*16
*17
*18
*19
INSPECTION
ACTION
Yes
Go to next step.
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Yes
No
Go to next step.
U36
CONTROL SYSTEM
STEP
*20
*21
22
*23
*24
*25
*26
27
INSPECTION
ACTION
Yes
No
Yes
No
Go to Step 23.
Yes
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Yes
No
Yes
No
U37
TROUBLESHOOTING
TROUBLESHOOTING HINTS
1 Magnetic clutch operation noise
Step 3
2 A/C compressor operation noise
Steps 48
3 A/C compressor slippage noise
Steps 911
4 Hose or refrigerant line interference noise
Step 12
STEP
1
INSPECTION
ACTION
Yes
Go to Step 9.
No
Go to next step.
Yes
Go to Step 12.
No
Go to next step.
Yes
No
Go to next step.
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
Go to next step.
No
Yes
No
Go to next step.
Yes
No
Yes
Go to next step.
No
Yes
No
Go to next step.
10
U38
CONTROL SYSTEM
STEP
INSPECTION
ACTION
11
Yes
No
12
Yes
No
Yes
No
13
U39
TECHNICAL DATA
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LUBRICATION SYSTEM . . . . . . . . . . . . . . . . .
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . .
FUEL AND EMISSION CONTROL
SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE ELECTRICAL SYSTEM . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MANUAL TRANSMISSION . . . . . . . . . . . . . . .
PROPELLER SHAFT . . . . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
FRONT AND REAR AXLES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
TD
TD
TD
TD
1
1
4
4
TD 5
TD 6
TD10
TD10
TD11
TD11
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
BRAKING SYSTEM (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT UP TO 07/2002) . . . . . . . . . . . . . . . . .
WHEELS AND TIRES (VEHICLES
BUILT FROM 08/2002) . . . . . . . . . . . . . . . . .
BODY ELECTRICAL SYSTEM . . . . . . . . . . .
HEATER AND AIR
CONDITIONER SYSTEMS . . . . . . . . . . . . .
TD12
TECHNICAL DATA
ENGINE
Engine
Item
Generator
Drive belt deflection
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})
P/S
A/C
Generator
P/S
A/C
Compression
G6
New
10.012.0 {0.400.47}
Used
12.014.0 {0.480.55}
New
6.67.2 {0.260.28}
Used
7.28.0 {0.290.31}
New
8.510.0 {0.340.39}
Used
10.011.5 {0.400.45}
New
Used
New
Used
New
Used
Standard
Minimum
(mm {in})
(mm {in})
TD1
00.7 {00.027}
00.5 {00.019}
TD13
TD13
TD14
TD15
TD15
TD17
TD18
TD18
TECHNICAL DATA
Specification
Item
WL
WL Turbo
Type
WLT3
Diesel, 4-cycle
Inline, 4-cylinder
Combustion chamber
Swirl type
Valve system
Displacement
Bore
WL3
stroke
(mm {in})
Generator
93.0
92.0 {3.66
3.62}
New
7.09.0 {0.280.35}
Used
8.010.0 {0.320.39}
Limit
16.0 {0.63}
A/C (measuring
Drive belt deflection
[Applied pressure 98 N {10 kgf, point a)
22 lbf}]
(mm {in})
New
5.06.2 {0.200.24}
Used
6.06.5 {0.240.25}
Limit
11.3 {0.44}
A/C (measuring
point b)
New
9.511.8 {0.380.46}
Used
11.012.5 {0.440.49}
Limit
18.0 {0.71}
New
Used
Limit
New
Used
Limit
Generator
A/C
(mm {in})
Standard
9.010.0 {0.360.39}
Standard
101.2101.8 {3.9854.007}
Minimum
102.5 {4.035}
Standard
113.2113.8 {4.4574.480}
Minimum
114.5 {4.508}
(mm {in})
0.51.0 {0.020.03}
(mm {in})
00.4 {00.01}
(mm {in})
Compression ratio
21.9,
Compression pressure
IN
Valve timing
EX
(kPa
{kgf/cm2,
psi} [rpm])
20.1, 19.8*1
21.6
19.9
Open
BTDC ()
10
Close
ABDC ()
28
24
23
Open
BBDC ()
61
Close
ATDC ()
IN
Valve
clearance
00.5 {00.01}
21.6*1
(mm {in})
EX
Engine cold
0.050.15 {0.00200.0059}
(0.10 0.05 {0.0039 0.0019})
Engine hot
(Reference)
0.15 {0.0059}
Engine cold
0.150.25 {0.00600.0098}
(0.20 0.05 {0.0078 0.0019})
Engine hot
(Reference)
0.25 {0.0098}
TD2
TECHNICAL DATA
Engine
Item
Generator
Drive belt deflection
[Applied pressure
98 N {10 kgf, 22 lbf}]
(mm {in})
P/S
A/C
Generator
P/S
A/C
Compression
F2 CARB
F2 CIS
New
7.08.0 {0.280.31}
Used
8.09.0 {0.320.35}
New
5.06.0 {0.200.23}
Used
5.56.5 {0.220.25}
New
10.012.0 {0.400.47}
Used
12.014.0 {0.480.55}
New
Used
New
Used
New
Used
Standard
Minimum
New
8.09.0 {0.320.35}
Used
9.010.0 {0.360.39}
(mm {in})
(mm {in})
TD3
0 {0}
00.5 {00.019}
TECHNICAL DATA
LUBRICATION SYSTEM
Engine
Item
F2
G6
WL
WL Turbo
295392
{3.04.0,
4356}
[3000]
305402
{3.14.1,
4558}
[3000]
452529
{4.65.4,
6676}
[3000]
402480
{4.14.9,
5969}
[3000]
Oil replacement
Oil pressure
(kPa
Oil capacity
(L {US qt, lmp qt})
{kgf/cm2,
psi} [rpm])
Engine oil
API service CD
SAE 40
0C40_C {32_F104F}
SAE 30
10C20_C {14_F68F}
SAE 20W-20
API service SG
SAE
10W-30*,
10W-40, 10W-50
SAE 5W-20
SAE
15C40_C {5_F104F}
5W-30*
SAE 10W-30
D European specification vehicles use only those oils marked with an asterisk
SAE 5W-30
COOLING SYSTEM
Engine
Item
F2
G6
Cooling system
Coolant capacity (Approximate
quantity)
(L {US qt, lmp qt})
Water
pump
WL
9.4 {9.9,8.3}
Without
heater
Type
Centrifugal,
timing belt
driven
Type
Wax, flow
control
Wax,
twostage
83.589.5
{183193}
Sub:
83.589.5
{183193}
Main:
86.589.5
{188193}
8084 {176183}
Opening
temperature
(_C {_F})
Full-open
temperature
(_C {_F})
WLT3
100 {212}
8.5 {0.33}
min
Full-open lift
(mm {in})
95 {203}
Sub: 1.5
{0.06} min
Main: 8.0
{0.31} min
Type
74102
{0.751.05, 10.714.9}
Type
Cooling
fan
WL turbo
With
heater
Thermo
stat
Radiator
WL3
Outer diameter
Blade
(mm {in})
Number
380 {15.0}
410 {16.1}
440 {17.3}
10
TD4
TECHNICAL DATA
FUEL AND EMISSION CONTROL SYSTEMS
CIS vehicles
Engine
Item
Idle speed
(rpm)
F2
730770 (750"20)
730770 (750"20)
46/750
57/750
(BTDC /rpm)
Injection timing
Idle speed*1
G6
(rpm)
A/C
ON*2
700800 (750"50)
P/S ON*3
780880 (830"50)
700800 (750"50)
CO concentration
HC concentration
Fuel pressure
(kPa {kgf/cm2, psi})
Hold pressure
Fuel leakage
Less than 1
(drop/2 minutes)
Injection volume
(ml {cc, fl oz}/15 sec.)
Fuel injector
Resistance
1216
() [20C {68F}]
Pressure regulator
*1:
*2:
*3:
*4:
Excludes temporary idle speed drop just after the loads (A/C, P/S) are turned on.
A/C switch and fan switch are turned on.
Steering wheel is fully turned.
Hot condition at start.
DIESEL vehicles
Engine
Item
WL Turbo
WL
(780"20)*1
(rpm)
760800
700740 (720"20)*2
107115 {1.091.18,
15.516.8}
825875 (850"25)
805855 (830"25)
825875 (850"25)*3
Idle speed
Injection timing
ATDC 10
Idle-up speed
(rpm)
Injection nozzle
Cam lift
12001500 (1350"150)
(mm {in})
Diesel smoke
2.48 {0.098}
Nozzle leakage
*1:
*2:
*3:
700740 (720"20)
(%)
General (L.H.D.)
Europe and UK
Europe
TD5
TECHNICAL DATA
CARB vehicles
Engine
Item
F2 CARB
Idle speed
(rpm)
Injection timing
(BTDC)
Idle-up speed
(rpm)
57 (6"1)
A/C Operated
14001600 (1500"100)
P/S Operated
D/P Operated
19002100 (2000"100)
T/P Operated
CO concentration
HC concentration
Fuel pump
Carburetor
(ppm)
Discharge pressure
(kPa
Discharge amount
Float level
(mm {in})
{kgf/cm2,
psi})
1150 {70.2}
89 {0.3150.354}
10501250 (1150"100)
1
2
2.02.5 (2.0 +0.5
0 )* , 2.03.0 (2.5"0.5)*
(%)
4445 {1.7321.772}
()
4852 {50"2}
GULF
General
Item
G6
Electrolyte gravity
1.271.29
Back-up current *1
Test load chart
(mA)
Max. 20
Battery type
80D26R
(A)
Battery type
(5-hour rate)
80D26R (55)
5.56.5
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
80D26R (55)
35
(A)
Battery
Slow charge
195
()
Standard
Brush length
Brush spring force
(mm {in})
Standard
(N {kgf, lbf})
Minimum
(N {kgf, lbf})
Terminal
Standard voltage
(V)
Idle
[20_C {68_F}]
Generated current*2
(Reference)
(A)
18.5 {0.73}
Minimum
Ignition switch
ON
Generator
(mm {in})
3.74.4
Engine speed
Terminal
5.0 {0.20}
B+
Approx. 1
B+
14.114.7
13.014.0
14.114.7
1000
Approx. 043
2000
Approx. 062
(rpm)
*1:
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
*2: Must not be 0 A.
TD6
TECHNICAL DATA
Engine
Item
Ignition
coil
G6
Primary coil
Resistance
[20_C {68_F}]
()
Secondary coil
(k)
NGK
DENSO
Plug gap
(mm {in})
(k)
)
Resistance
Tightening torque
Hightension
lead
Commutator
diameter
Brush length
Starter
1.01.1 {0.0400.043}*5,
0.70.8 {0.0280.031}
3.07.5
DENSO
No.1 lead
2.97.7
No.2 lead
4.310.8
No.3 lead
5.413.5
No.4 lead
6.616.2
Center lead
4.511.2
Standard
(mm {in})
29.4 {1.16}
Minimum
(mm {in})
28.8 {1.14}
Standard
(mm {in})
12.3 {0.48}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
Minimum
(N {kgf, lbf})
Pinion gap
No load test
NGK
(Nm {kgfm, ftlbf})
Resistance
1016
ZFR5F11*3, *5, ZFR6F11*4, *5,
BKR5E*3, BKR6E*4
Type
Spark
plug
0.810.99
(mm {in})
7.0 {0.28}
3.0 {1.118}
Voltage
(V)
11.5
Current
(A)
Below 100
*3:
Standard plug
*4: Cold type plug
*5: Europe
TD7
TECHNICAL DATA
Engine
Item
F2 CARB
F2 CIS
Electrolyte gravity
Back-up current
Test load chart
(A)
Battery
1.271.29
*1
(mA)
Battery type
34B19R
180
(A)
Battery type
(5-hour rate)
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
34B19R (27)
3.04.0
4.55.5
20
30
()
18.5 {0.73}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
Minimum
(N {kgf, lbf})
B+
Approx. 1
B+
14.114.7
13.014.0
14.114.7
Terminal
(V)
Idle
[20_C {68_F}]
Ignition
coil
Engine speed
Terminal
1000
Approx. 043
2000
Approx. 062
(rpm)
Primary coil
Resistance
[20_C {68_F}]
()
Secondary coil
02/1200, 913/2200,
1923/6000
BKR5E*5
BKR6E*3
BKR7E*4
BPR5ES11*3
BPR6ES11*4
K16PRU*5
K20PRU*3
K22PRU*4
W16EXRU11*3
W20EXRU11*4
0.70.8 {0.0280.031}
1.01.1 {0.0400.043}
NGK
Type
DENSO
Spark
plug
Plug gap
(mm {in})
(k)
)
Tightening torque
Hightension
lead
Resistance
(k
) [20 _C {68 _F}]
NGK
*2:
*3:
*4:
*5:
3.07.5
DENSO
(Nm {kgfm, ftlbf})
No.1 lead
2.757.07
No.2 lead
4.1910.43
No.3 lead
4.3810.88
No.4 lead
Center lead
*1:
0.810.99
1016
/rpm
Distributor
Vacuum spark advance
1.0351.265
(k)
Resistance
3.74.4
(mm {in})
Standard voltage
Generated current*2
(Reference)
(A)
55D23R (48)
Standard
Ignition switch
ON
Generator
55D23R (48)
55D23R
34B19R (27)
Slow charge
Max. 20
110
5.7314.08
2.005.33
3.99.9
Back-up current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the ignition
switch is at OFF position and the ignition key is removed.
Must not be 0 A.
Standard plug
Cold type plug
Hot type plug
TD8
TECHNICAL DATA
Engine
Item
Commutator
diameter
Brush length
Starter
F2 CARB
Standard
(mm {in})
32.0 {1.26}
Minimum
(mm {in})
31.4 {1.24}
Standard
(mm {in})
17.0 {0.67}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
Minimum
(N {kgf, lbf})
Pinion gap
11.5 {0.46}
(mm {in})
No load test
0.52.0 {0.0200.078}
Voltage
(V)
11.5
Current
(A)
Below 60
Engine
Item
WL, WL Turbo
Electrolyte gravity
1.271.29
Back-up current *1
Test load chart
(A)
(mA)
Battery type
Battery
Slow charge
(A)
Quick charge
(A/30 min.)
Battery type
(5-hour rate)
Battery type
(5-hour rate)
195
75D26R
195
95D31R
250
75D26L (52)
5.56.5
75D26R (52)
5.56.5
95D31R (64)
6.58.0
75D26L (52)
35
75D26R (52)
35
95D31R (64)
40
()
(mm {in})
17.9 {0.70}
Minimum
(mm {in})
5.0 {0.20}
Standard
(N {kgf, lbf})
(N {kgf, lbf})
Minimum
B+
B+
2.04.0
14.0514.85
14.0514.85
7.0257.425
13.0014.85
1000
Terminal B
current
Approx. 058
2000
Terminal B
current
Approx. 074
Terminal
Standard voltage
(V)
Idle
[20_C {68_F}]
Generated current*2
(Reference)
(A)
2.50
Standard
Engine switch
ON
Generator
20 max.
75D26L
F2 CIS
Engine speed
(rpm)
Terminal
*1: Back-up
current is the constant flow of current present (for the audio unit, clock, PCM, etc.) when the engine
switch is at OFF position and the engine key is removed.
*2: Must not be 0 A.
TD9
TECHNICAL DATA
Engine
Item
Commutator
diameter
Brush length
Starter
WL, WL Turbo
Standard
(mm {in})
29.5 {1.16}
Minimum
(mm {in})
27.3 {1.07}
Standard
(mm {in})
17.7 {0.70}
Minimum
(mm {in})
Standard
(N {kgf, lbf})
Minimum
(N {kgf, lbf})
Pinion gap
(mm {in})
No load test
8.7 {0.34}
3.0 {0.12}
Voltage
(V)
11
Current
(A)
Below 130
CLUTCH
Item
Specification
Clutch pedal
Height
(mm {in})
241.6246.6 {9.529.70}
(mm {in})
3.08.0 {0.120.31}
(mm {in})
Clutch disc
Runout limit
Clutch fluid
Type
MANUAL TRANSMISSION
M15M-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
M15MX-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
Type
Transfer oil
Viscosity
Capacity
All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
R15M-D
Item
Specification
Type
Transmission oil
Viscosity
Capacity
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
TD10
TECHNICAL DATA
R15MX-D
Item
Specification
Type
Transmission oil
Viscosity
All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
Capacity
Type
Transfer oil
Viscosity
All-season
SAE 75W-90
Above
10 _C {50 _F}
SAE 80W-90
Capacity
PROPELLER SHAFT
Item
0.4 {0.016}
0.4 {0.016}
0.4 {0.016}
0.31.1
{3.012.0, 2.710.4}
0.30.7
{3.08.0, 2.76.9}
0.31.1
{3.012.0, 2.710.4}
Propeller shaft (4
Runout limit
(mm {in})
2)
4 2
Play
0 {0}
Preload
Front axle
Wheel bearing
(N {kgf, lbf})
Rear axle
Drive shaft
Shaft length
(mm {in})
(mm {in})
0.050.25 {0.0020.010}
Left side
551.0561.0 {21.722.0}
Right side
619.0629.0 {24.424.7}
Pinion height
(mm {in})
Front
0.0320.032 {0.0010.001}
Rear
0.2540.254 {0.0100.010}
Front
00.1 {00.003}
Rear
Front
Rear
Standard
Minimum
Allowance variation
Differential
4.444
4.100
WL3
F2 CIS
F2 CARB
WL
Grade
Front
Viscosity
SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]
Front
Rear
Grade
Viscosity
Capacity
4.777
WLT3
WL TURBO
G6
WL
Rear
Capacity
(L {US qt, lmp qt})
LSD
4.444
Standard
Oil
4 4
(mm {in})
SAE 90
(L {US qt, lmp qt})
TD11
TECHNICAL DATA
FRONT AND REAR AXLES (VEHICLES BUILT FROM 08/2002)
Item
Specification
Drive type
Play
(mm {in})
Preload
Front axle
Wheel bearing
Drive shaft
(mm {in})
0.050.25 {0.0020.010}
525.5535.5
{20.6921.08}
Right side
593.5603.5
{23.3723.75}
(mm {in})
Front
0.0320.032 {0.0010.001}
Rear
0.2540.254 {0.0100.010}
Front
00.1 {00.003}
Rear
Front
Rear
Standard
Minimum
Allowance variation
Differential
0.05 {0.002}
Left side
Pinion height
Backlash of drive
pinion and ring
gear
(mm {in})
0 {0}
(N {kgf, lbf})
Wheel bearing play
4x4
Rear axle
4x2
4.444
4.100
WL3
F2 CIS
F2 CARB
WL
Grade
Front
Standard
Rear
Capacity
(L {US qt, lmp qt})
SAE 90
1.20 {1.27, 1.06} [MFW]
1.50 {1.59, 1.32} [RFW]
Front
Rear
Grade
LSD
Viscosity
Capacity
4.777
WLT3
WL TURBO
G6
WL
Viscosity
Oil
4.444
SAE 90
(L {US qt, lmp qt})
TD12
TECHNICAL DATA
STEERING SYSTEM
Item
Play
Steering wheel
(mm {in})
Effort
030 {01.18}
Backlash
(mm {in})
Steering gear
Grade
Capacity
Power steering
oil pump
1.01.3
{1014, 8.712.1}
0.71.2
{6.512.5, 5.710.8}
8.99.3
{9095, 12801350}
8.99.3
{9095, 12801350}
Manual steering
Item
F2, G6
4 4
WL, WL Turbo
Brake pedal
Brake pedal height
(mm {in})
(mm {in})
38 {0.120.31}
(mm {in})
Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm]
(kPa {mmHg, in Hg})
Maximum vacuum
[When engine speed 3,000 rpm]
(kPa {mmHg, in Hg})
LSPV
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
22 {0.87}
Runout limit
(mm {in})
0.05 {0.002}
(mm {in})
1.0 {0.04}
(mm {in})
Disc plate
296.5 {11.67}
Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)
17
Brake fluid
Type
TD13
TECHNICAL DATA
BRAKING SYSTEM (VEHICLES BUILT FROM 08/2002)
Item
Specification
Drive type
4x2
4x4
Brake pedal
Brake pedal height
(mm {in})
(mm {in})
38 {0.120.31}
(mm {in})
Vacuum pump
Vacuum specification [In 20 seconds]
[When engine speed 1,500 rpm]
(kPa {mmHg, in Hg})
Maximum vacuum
[When engine speed 3,000 rpm]
(kPa {mmHg, in Hg})
Fluid pressure
(kPa {kgf/cm2, psi})
When front
pressure is 4,900
kPa {50 kgf/cm2,
711 psi}
When front
pressure is 9,800
kPa {100 mmHg,
19.7 in Hg}
(mm {in})
2.0 {0.08}
Thickness limit
(mm {in})
Runout limit
(mm {in})
0.05 {0.002}
(mm {in})
1.0 {0.04}
(mm {in})
271.5 {10.68}
Disc plate
22 {0.87}
26 {1.02}
Parking brake
Parking brake lever stroke
[When pulled at 98 N {10 kgf, 22 lbf}]
(notches)
17
Brake fluid
Type
TD14
TECHNICAL DATA
SUSPENSION
Suspension
Item
4 2
(mm {in})
Total toe-in
Front wheel
alignment
[unloaded*1]
4 4
3"3 {0.12"0.12}
0_16 "16
(Degree)
0_14 "14
Camber angle
+2_
35_00 3_
33_00 +2_
3_
0_56"30
33_30 +2_
3_
30_00 +2_
3_
1_ 06"30
Caster angle*2
1_37"45
2_02"45
Inner
Maximum
steering angle
Outer
(mm {in})
(N {kgf, lbf})
(N {kgf, lbf})
68 {0.240.31}
1444 {0.74.5, 1.69.9}
3.432.5 {0.43.2, 0.97.0}
(mm {in})
1821 {0.710.82}
*1:
Fuel tank is full. Engine coolant and engine oil are at specified levels. Spare tire, jack, and tools are in
designated positions.
Adjust to the median when carrying out wheel alignment.
*2: Difference between left and right must not exceed 45.
Wheels and Tires
(Vehicles built up to 07/2002)
Europe
Item
4 2
Front
Size
Front
Tire
195R14C-8PR
Rear
Air pressure
(kPa {kgf/cm2, psi})
Rear
Wear limit
Up to full
passenger
Full
loaded
Up to full
passenger
Full
loaded
Offset
(mm {in})
(mm {in})
235/75R15 105S
205R16C-8PR
180 {1.8, 26}
1.6 {0.06}
14 5J
14 5 1/2J
Tightening torque
Wheel
and tire
205/75R14C
(mm {in})
Size
Wheel
4 4
14 5 1/2J
40 {1.57}
15 6 1/2JJ
16 6JJ
25 {0.98}
35 {1.38}
139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059}
Imbalance limit
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on either side of the wheel.
TD15
TECHNICAL DATA
General
Item
4 2
Front
Size
185R14C8PR
Rear
Unloaded
(Up to
full
passenger
Front )
Tire
Air pressure
(kPa {kgf/cm2, psi})
Loaded
(Full
loaded)
200
{2.0, 28}
180
{1.8, 26}
180 {1.8, 26}
200
{2.0, 28}
Size
(mm {in})
(mm {in})
Tightening torque
(Nm {kgfcm, inlbf})
240
{2.4, 34}
260
{2.6, 36}
1.6 {0.06}
14 5J
Offset
250
{2.5, 35}
(mm {in})
(mm
Unloaded
(Up to
full
passenger
Rear )
Wheel
Wheel
and tire Runout limit
{in})
195R14C8PR
180
{1.8, 26}
Loaded
(Full
loaded)
Wear limit
4 4
14 5J
14 5
1/2J
40 {1.57}
16 6JJ
15 6 1/2JJ
35 {1.38}
25 {0.98}
139.7 {5.45}
Standard wheel: 89117 {912, 6586}
Styled wheel (16 6JJ): 118147 {1215, 87108}
Horizontal
2.0 {0.078}
Vertical
1.5 {0.059}
Imbalance limit
(g {oz})
10 {0.35}
D One balance weight: max. 60 g {2.1 oz}.
D If the total weight exceeds 100 g {3.5 oz} on one side, rebalance after moving the tire around on the rim.
D Do not use more than two balance weights on the inner or outer side of the wheel.
TD16
TECHNICAL DATA
Wheels and Tires
(Vehicles built from 08/2002)
L.H.D
Item
Specification
Drive type
4x2
Front
195R14
C8PR
Size
Rear
Air Pressure
Front
Tire
(kPa {kgf/cm2,
psi})
Wheel
Wheel
and
tire
4x4
205/75
R14C
235/75
R15
105S
205R16
C8PR
P235/7
5R15
108S
265/70
R15
110S
Unloaded
Loaded
Unloaded
Rear
Loaded
Wear limit
(mm {in})
Size
(mm {in})
Offset
(mm {in})
(mm {in})
240
{2.4, 35}
1.6 {0.06}
14x5
1/2JJ
14x5J
40 {1.57}
16x6JJ
15x6 1/2JJ
16x7JJ
35
{1.38}
25 {0.98}
10 {0.39}
139.7 {5.50}
Standard wheel: 89117 {912, 6586}
Styled wheel (16x6JJ): 118147 {1215, 87108}
Vertical: 1.5 {0.059} max.
Horizontal: 2.0 {0.079} max.
(mm {in})
imbalance limit
250
{2.5, 36}
Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit
265/70
R15
112S
(g {oz})
10 {0.35} max.
R.H.D
Item
Specification
Drive type
Size
Air Pressure
4x2
Front
Tire
(kPa {kgf/cm2,
psi})
Wheel
and
tire
235/75
R15 105S
P235/75
R15 108S
265/70
R15 110S
Rear
265/70
R15 112S
Unloaded
Loaded
Unloaded
Wear limit
Wheel
205/75
R14C
Rear
Front
4x4
Loaded
450
{4.6, 65}
250
{2.5, 36}
(mm {in})
240
{2.4, 35}
1.6 {0.06}
Size
(mm {in})
14x5 1/2JJ
15x6 1/2JJ
15x7JJ
Offset
(mm {in})
40 {1.57}
25 {0.98}
10 {0.39}
(mm {in})
139.7 {5.50}
Tightening torque
(Nm {kgfcm, ftlbf})
Runout limit
imbalance limit
(mm {in})
(g {oz})
10 {0.35} max.
TD17
TECHNICAL DATA
BODY ELECTRICAL SYSTEM
Item
Specification
Headlight
(W)
(W)
(W)
60/55 2
Parking light
5 2
21 2
Brake light/taillight
21/5 2
21 2
Back-up light
21 2
21 1
5 2
Stretch cab, Double cab
Interior light
10 1
Regular cab
8 1
3.4 4
1.4 1
1.4 1
1.4 1
1.4 1
1.4 1
1.4 1
1.4 1
1.4 2
1.4 1
4 4 indicator light
1.4 1
1.4 1
Item
Refrigerant
Regular amount
Lubricating oil
A/C compressor
G6, WL
(g {oz})
Sealed volume
(ml {cc, fl oz})
F2
550 {19.4}
180 {180, 6.08}
0.350.75 {0.0140.029}
TD18
0.30.6 {0.0120.023}
SPECIAL TOOLS
SPECIAL TOOLS
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST2
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . ST6
TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . ST10
FRONT DIFFERENTIAL . . . . . . . . . . . . . . . . . ST15
REMOTE FREE WHEEL (4x4) . . . . . . . . . . . ST18
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . ST20
ST1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . .
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . .
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ST21
ST30
ST32
ST33
ST34
ST35
SPECIAL TOOLS
Engine
Mazda Tool Number
49 L010 1A0
49 S013 102
Commercially available
Not
applicable
49 S010 1A0
Commercially available
Not
applicable
49 9014 001
Commercially available
Not
applicable
49 0636 100B
49 B012 0A2
ST2
SPECIAL TOOLS
49 S120 170
49 L012 0A0A
49 0249 010A
Commercially available
Not
applicable
49 G011 001
Commercially available
Not
applicable
49 S015 1A1
Commercially available
Not
applicable
49 S120 215A
49 S010 301
ST3
SPECIAL TOOLS
49 0259 749
Commercially available
Not
applicable
49 S010 001
49 S011 103
49 S011 102A
49 E011 1A0
49 0187 280
Commercially available
Not
applicable
ST4
SPECIAL TOOLS
49 G014 001
49 L011 2A0
49 S120 710
49 S011 103
ST5
Graphic
not
available
Graphic
not
available
SPECIAL TOOLS
Transmission
Mazda Tool Number
49 SE01 310A
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
Center Screw
205-034 (15-002)
ST6
Graphic
not
available
SPECIAL TOOLS
49 H017 101
49 1243 465A
49 0710 520
Remover, Bearing/Gear
205-310 (15-091)
49 F027 005
49 F027 007
ST7
Graphic
not
available
SPECIAL TOOLS
49 F401 331
49 0862 350
Commercially available
Not
applicable
49 F017 101
49 G030 795
ST8
Graphic
not
available
SPECIAL TOOLS
49 F401 335A
49 U027 003
49 S120 440
Screwdriver
Not
applicable
49 S017 401
Gears
Not
applicable
ST9
SPECIAL TOOLS
Transfer Box
Mazda Tool Number
49 S120 710
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
ST10
SPECIAL TOOLS
49 F401 331
Remover, Bearing/Gear
205-310 (15-091)
49 0727 415
ST11
SPECIAL TOOLS
49 0727 415
49 0727 415
49 G030 370
49 G030 797
49 G026 102
ST12
SPECIAL TOOLS
49 0258 749
49 S231 395A
49 0500 330
Graphic
not
available
Remover, Bearing/Gear
205-310 (15-091)
Depth Gauge
Commercially available
Not
applicable
49 U017 3A0A
Graphic
not
available
Commercially available
Not
applicable
49 F401 336B
ST13
SPECIAL TOOLS
49 0636 145
Remover, Bearing/Gear
205-310 (15-091)
ST14
SPECIAL TOOLS
Front Differential
Mazda Tool Number
49 M005 581
49 S120 710
49 H027 002
Remover, Bearing/Gear
205-310 (15-091)
49 0727 570
49 8531 565
49 0305 555
Preload Sleeve
205-060 (15-023)
49 0259 720
ST15
SPECIAL TOOLS
49 0839 425C
Remover, Bearing/Gear
205-310 (15-091)
49 G030 338
Graphic
not
available
49 F027 004
Commercially available
Not
applicable
49 F027 005
ST16
Graphic
not
available
SPECIAL TOOLS
49 U027 003
49 G030 795
49 0350 555
49 0350 565
49 0350 567
49 0350 568
ST17
Graphic
not
available
SPECIAL TOOLS
49 U027 006
49 U027 004
49 U027 004
49 M005 796
Graphic
not
available
Graphic
not
available
Graphic
not
available
49 0813 215 A
Commercially available
Not
applicable
49 W027 001
ST18
SPECIAL TOOLS
49 U027 007
ST19
Graphic
not
available
SPECIAL TOOLS
Front Axle
Mazda Tool Number
49 T028 3A0
49 H033 101
49 B025 001
49 F019 001
ST20
SPECIAL TOOLS
Rear Axle
Mazda Tool Number
49 S120 645A
49 0603 635A
49 S126 204
Remover, Bearing/Gear
205-311 (15-092)
T57L-500-B
308-047 (T77F-1102-A)
ST21
Graphic
not
available
Graphic
not
available
SPECIAL TOOLS
205-D064 (D84L-1123-A)
Remover, Bearing/Gear
205-310 (15-091)
Remover, Bearing/Gear
205-311 (15-092)
205-456
205-110 (T76P-4020-A10)
ST22
SPECIAL TOOLS
205-457
ST23
SPECIAL TOOLS
205-105 (T76P-4020-A3)
ST24
SPECIAL TOOLS
205-109 (T76P-4020-A9)
ST25
SPECIAL TOOLS
205-111 (T76P-4020-A11)
205-090 (T75L-1165-B)
ST26
SPECIAL TOOLS
205-024 (T76P-4616-A)
205-092 (T57L-1165-DA)
205-007 (T56T-4676-B)
ST27
SPECIAL TOOLS
49 S126 205
49 S126 208
Remover, Bearing/Gear
205-310 (15-091)
49 S120 748
Commercially available
Not
applicable
49 F027 004
Commercially available
Not
applicable
49 U027 003
ST28
SPECIAL TOOLS
49 H025 001
Commercially available
Not
applicable
T83T-4205-A1
Not essential
Not
applicable
T83T-4205-A2
Not essential
Not
applicable
T83T-4205-A3
Not essential
Not
applicable
T83T-4205-A4
Not essential
Not
applicable
ST29
SPECIAL TOOLS
Steering
Mazda Tool Number
49 T028 3A0
49 1232 670 A
49 H002 671
49 G032 3A4
49 T028 3A0
49 B032 304
ST30
SPECIAL TOOLS
49 0180 510B
49 0223 695E
ST31
Graphic
not
available
SPECIAL TOOLS
Brakes
Mazda Tool Number
49 0259 770B
Commercially available
Not
applicable
49 U043 0A0
Commercially available
Not
applicable
49 0221 600C
49 0208 701A
49 B043 001
49 EC43 003A
Commercially available
Not
applicable
49 B043 004
Commercially available
Not
applicable
ST32
SPECIAL TOOLS
Suspension
Mazda Tool Number
49 U034 2AO
49 U039 615
ST33
Graphic
not
available
SPECIAL TOOLS
Air Conditioning
Mazda Tool Number
49 C081 0A0A
Commercially available
Not
applicable
49 C061 012
Commercially available
Not
applicable
49 C061 013
Commercially available
Not
applicable
49 H061 005
ST34
SPECIAL TOOLS
General
Mazda Tool Number
49 0305 870A
Commercially available
Not
applicable
49 9140 074
49 9200 146
49 9200 147
49 0259 888A
Commercially available
Not
applicable
49 01670280
Commercially available
Not
applicable
49 N088 0A0
Commercially available
Not
applicable
ST35
SPECIAL TOOLS
49 L018 901
Commercially available
Not
applicable
ST36
Z
SECTION TITLE
RANGER
2000 2002
lefthanddrive
(LHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.
SECTION
General Information
GI
Ground points
Schematic
A~U
Connectors
Parts index
PI
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN) and
related materials shown on the following page.
Z
Vehicle identification numbers (VIN)
(Chassis numbers)
European specifications (LHD)
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
BMF:30WW
BME:30WW
DMF:30WW
DME:30WW
LMF:30WW
LME:30WW
BMD:30WW
BMC:30WW
DMD:30WW
DMC:30WW
LMD:30WW
LMC:30WW
BMB:30WW
BMA:30WW
DMB:30WW
DMA:30WW
LMB:30WW
LMA:30WW
100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001100001-
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
BMFE:40WW 100001BMEE:40WW 100001DMFE:40WW 100001DMEE:40WW100001LMFE:40WW 100001LMEE:40WW 100001BMD:40WW 100001BMC:40WW 100001DMD:40WW 100001DMC:40WW 100001LMD:40WW 100001LMC:40WW 100001BMB:40WW 100001BMA:40WW 100001DMB:40WW 100001DMA:40WW 100001LMB:40WW 100001LMA:40WW 100001-
MNC
MNC
MNC
MNC
BSB:30WW
BSA:30WW
BSB:3WWW
BSA:3WWW
BSF:30WW
BSE:30WW
BSF:3WWW
BSE:3WWW
100001100001100001100001-
WF0
WF0
WF0
WF0
WF0
WF0
WF0
WF0
BMBD20:W
BMDD20:W
BMDE40:W
LMAD20:W
LMBD20:W
LMBE40:W
LMDE40:W
LMFE40:W
100001100001100001100001100001100001100001100001-
100001100001100001100001-
Z
Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment.
Non Euro 3 regulation models are not equipped with an EGR cooler in the engine compartment.
EGR cooler
Wire colours
Colour
Code
Colour
Code
Black
Orange
Blue
Pink
Brown
BR
Purple
Dark blue
DL
Red
Dark green
DG
Sky blue
Green
PU
R
SB
Tan
Grey
GY
Violet
Light blue
LB
White
Light green
LG
Yellow
Natural
TOCB1UK
TOCB1UK
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . Z2
Ground points (WL, WL Turbo, before
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Ground points (F2 CIS, G6) . . . . . . . . . . . . . .
Ground points (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Schematic (WL, WL Turbo, before
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Schematic (F2 CIS, G6) . . . . . . . . . . . . . . . . .
Schematic (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . . . .
Engine
Starting System / Charging System
(WL, WL Turbo, before model
year 2002) . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting System / Charging
System (F2 CIS, G6) . . . . . . . . . . . . . . . . .
Starting System / Charging
System (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .
Powertrain / Quickstart system
(WL, WL Turbo: General specifications,
before model year 2002) . . . . . . . . . . . . . .
Powertrain / Preglow system
(WL, WL Turbo: European specifications,
before model year 2002) . . . . . . . . . . . . . .
Powertrain / Ignition (G6) . . . . . . . . . . . . . .
Powertrain / Ignition (F2 CIS) . . . . . . . . . .
Powertrain / Preglow system
(WL3, WLT3, as of model year 2002) .
Fuel system (before model year 2002) . .
Fuel system (WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . .
Z12
Z14
Z16
Z18
Z19
Z20
Z21
Z23
Z25
Z27
Z31
Z35
Z41
Z49
Z47
Z55
Chassis
Remote freewheel control system
(before model year 2002) . . . . . . . . . . . . Z101
Remote freewheel control system
(WL3, WLT3, as of
model year 2002) . . . . . . . . . . . . . . . . . . . Z103
Instrument cluster
Instrument cluster (WL, WL Turbo,
before model year 2002) . . . . . . . . . . . . . . Z57
Instrument cluster (F2 CIS, G6) . . . . . . . . Z63
Instrument cluster (WL3, WLT3,
as of model year 2002) . . . . . . . . . . . . . . . Z69
Body
Front wiper/washer . . . . . . . . . . . . . . . . . . . Z75
Horns (before model year 2002) . . . . . . . . Z89
Z77
Z79
Z83
Z81
Z85
Z87
Z91
Z89
Z93
Air conditioning
Heating / Air conditioning (WL, WL
Turbo, before model year 2002) . . . . . . . . Z95
Heating / Air conditioning (F2 CIS, G6) . . Z97
TOCB1UK
Z-GI
Wiring Diagrams
GI
General Information
Ground points
Schematic
A~U
Connectors
PI
Parts index
Z-2
Z-GI
8
B
10
12
B /O
B
6
B /W
D
C
E
B
A
WITH AIRBAG SYSTEM
WITH ABS
B (E M )
B (D )
B (E M )
B (E M )
B (F )
B (E M )
B (F )
TO EACH
UNIT
B (E M )
TO EACH
UNIT
B (D )
EMISSION
HARNESS
(EM)
J C 02
11
B (D )
B (D )
B (D )
B /W ( E M )
DASH
HARNESS
(D)
B (D )
WITH AIRBAG SYSTEM
TO EACH
UNIT
FRONT
HARNESS
(F)
B
(F )
10
B (D )
B (F )
B (F )
B (D )
J C 03
B (D )
B (E M )
J C 01
B (F )
B (D )
B / O (D )
3
WITHOUT AIRBAG SYSTEM
B (F )
B (F )
B (F )
B ( I)
B ( I)
B (F )
INSTRUMENT
PANEL
HARNESS
(I)
B (F )
B ( I)
B (F )
B (IN )
INTERIOR
LIGHT
HARNESS
(IN)
12
SHORT
CORD
B (F )
Ground indication
On vehicle
Indication
IG
MAIN
100 A
F B 0 9
K E Y
X 01
F B 07
60 A
B (E )
B /W (D )
B /W ( F )
B
F B 0 5
A
B T N
40 A
IN J OR
FIP
30 A
B (F )
B (D )
J B 0 5
G
W /R ( F )
J B 0 3
W /R ( D )
R OO
1 B
10 A
X 03
8
F B 0 3
F B 0 3
Y /L (F )
X 0 6
F B 0 4
F B 0 3
L G /R
(E M )
X 09
Y
L /R ( E )
J B 0 4
L /R (E M )
SPV RELAY
(SECTION B_1b)
W /Y
(E M )
I G1I G2
A C C
X 0 3
L (D )
A A
X 0 6
O F F
S T
E N G IN E
10 A
14 J B 01
B / L (D )
MAIN
RELAY
F B 0 4
ENGINE SWITCH
L /R
(D )
F B 0 4
W /G (E M )
B /L
(E M )
L /R
(E M )
B 1 0 1
B /W
(F )
1 E
3 W
B 1 0 3
1 B
1 A
B 1 0 2
1 F
P C M
2 M
GLOW
PLUG
RELAY
3 R
3 P
L G
B R /B
( E M )
1 S
1 N
1 Q
B 1 0 1
L
B 1 02
(E M )
L
(E )
F B 0 1
F B 0 3
(E M )
L (E )
I
L
L /B
( E M )
G /B
(E M )
G /W
(E M )
B
(E )
(E )
J
B 1 0 5
X 0 9
1 1
23
22
14
A/C RELAY
(SECTION G2)
B
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)
B
(E M )
B 1 0 4
(SECTION U)
31
AD FAN RELAY
(SECTION G2)
GLOW
PLUG
G
G
B 1 01
P C M (E M )
1 U
1 S
Y
W /G
1 V
B 1 0 3
G L O W
P L U G
B /W
1 O
1 M
1 K
P /L
L /W
L /R
1 I
1 G
1 Q
W /R L /B
W /L
V /W
1 T
1 R
R E L A Y
1 C
1 A
2 O
R /Y
L /R
G /R
B /L
W /Y
1 F
1 D
1 B
2 P
1 E
L G /R
G /W
1 P
1 N
1L
1 J
1 0 4 G L O W P L U G
(S H O R T C O RD )
1 H
2 K
2 I
2 G
2 E
2 A
2 M
B 1 05
L /W
2 N
2L
E N G I N E ( E ) S H O R T
(E )
3 Y
2 C
L G / BB R / W R / L
2 J
R /Y
B R /Y L / Y
2 H
2 F
2 D
B /W
C O R D )
Z-3
3 Q
3 Z
3 X
3 O
3 M
3 K
3 G
R /B
L G
3 V
3 T
3 A
3 I
3 S
L /R
R /L
O
2 B
C O RD
(S H O R T
3 U
3 W
G Y /RP /B
3 R
V
B R / BY / B
3 P
3 N
3 E
3 C
G /Y
G /R
3L
3 J
3 H
3 F
B /O
3 D
3 B
B 1 0 2
(E)
G L O W
P L U G
R E L A Y
L /R
L
B
Z-GI
B (E )
A
System name
M A IN
100A
IG KE Y
60A
X 0 1
F B 0 7 D
B /W ( F )
F B 0 5
B (F )
IN J O R
F IP
30A
F B 0 3
GLOW
40A
F B 0 3
W /G ( E M )
F B 0 4
Y /L (F )
S
F B 0 4
M A IN R E L A Y
F B 0 3
G
D
F B 0 4
L /R ( E )
L /R ( E M )
B 1 0 1
1E
3W
B 1 0 3
B 1 0 2
2M
GLOW
PLUG
RELA Y
3R
B 1 0 1
L
(E M )
B 1 0 2
F B 0 1 F B 0 3
B
(E )
LG
(E M )
L (E )
I
L
(E )
B 1 0 5
X 0 9
L G /R
(E M )
X 0 9
B /W
(F )
23
B
B
(E M )
D A T A L IN K
( S E C T IO N U
B 1 0 4
GLOW
PL UG
G
G
B 1 0 1 P C M ( E M ) 1 U
Connector code
1O
1S
1V
B103
Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air conditioning system connectors
H : Transmission control system connectors
I : Interior light system connectors
J : Audio/radio system connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
O : Anti-lock brake system connectors
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB: Joint box connections
1K
1T
1I
1C
1G
1A
W /Y
1P
1N
B /L
1L
1J
1H
B 1 0 4 G L O W P L U G
( S H O R T C O RD )
1F
G / Y W /Y
1D
L /W
1B
2P
2N
2L
2J
Ground numbers
A harness ground is represented differently than
a unit ground.
Types of grounds
Symbol
Harness
G
G
Unit
G
G
Sensor
Z-4
2G
L G /BB R /WR /L
B
2H
B 1 0 5 E N G IN E ( E )S H O R T C O RD
(E )
(S
B /W
2I
2M
G /R
L G /R R / Y R /W
G /W
1R
2K
2O
1E
W /G W /L V / W
1M
1Q
W /R L /B P /L L /W L /R
Z-GI
System code
B-1A
Current symbol
DATA LINK
CONNECTOR (DLC)
(SECTION U)
B /W (D )
B (D )
1B
ENGINE SWITCH
17
18
G /Y
(E M )
W /Y
(E M )
R /W
(E M )
O FF
ST
A CC
IG 1 IG 2
E N G IN E
J B 0 4 1 0 A 1 4 J B 0 1
X 0 6
16
X 0 3
X 0 3
L (D )
B /L (D )
AA
B /L
(E M )
B 1 0 1
1F
1D
1I
1A
* Shielded wire:
Prevents signal disturbances from
electrical interference. Wire is
covered by a metal meshing for
grounding.
PCM
2C
2A
1S
2B
2E
R /Y
(E M )
SHIELD WIRE
B 1 0 7
W /R
(E M )
P /B G Y /R O
(E M ) (E M ) (E M )
INTAKE AIR
TEMPERATURE
SENSOR NO.1
1
B 1 0 7
O
(E M )
B
(E M )
14
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)
B 1 0 6
Connector symbols
BOOST SENSOR
3Y
3Q
3U
3W
3K
3I
L G B R /BY / B G /R
3V
3T
3A
3G
R /B
R /L
3X
3M
3S
B / W L /R
3Z
3O
3R
3P
3N
3L
3E
3C
G /Y
3J
3H
3F
Circuit
diagram symbol
L /R
L
B /O
3D
Connector
diagram symbol
3B
P / B G Y /R O
R /Y
Male
Male
Female
Female
L
R
(Example)
Connector on harness side
Symbol
(Example)
Solid colour wire
B
(F)
Black
Striped wire
W/R
(F)
White
(base
colour)
View from
harness side
Red
(stripe)
D Colours for connectors except milk-white are given in
locations.
D The harness symbol is in ( ) following the harness
symbols (refer to P-7).
Z-5
Z-GI
Routing diagram
D The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector
symbols.
Connector symbol
Component name
Ground symbol
(Example)
Connector
Symbol
Common connectors
X-9
System connectors
I-03
HARNESS SYMBOL
(F)
(E)
(R)
INSTRUMENT
CLUSTER
VACUUM
SWITCH
C-01
C-05
(F)-(I)
X-02
(F)-(I)
X-02
C-06
PARKING BRAKE SWITCH
Z-6
Z-GI
SYMBOL
DESCRIPTION OF HARNESS
SYMBOL
FRONT HARNESS
(F)
(DR1)
(F2)
(DR2)
ENGINE HARNESS
(E)
(DR3)
DASH HARNESS
(D)
(DR4)
REAR HARNESS
(R)
FLOOR HARNESS
(FR)
(R2)
(IN)
REAR A HARNESS
(RA)
A/C HARNESS
(AC)
(I)
EMISSION HARNESS
(EM)
(EM2)
(EM3)
Z-7
Z-GI
Symbols
Symbol
Meaning
Symbol
Battery
Light
Ground (1)
Meaning
3.4 W
Resistance
Motor
Pump
Remarks
D Current will not flow through a circuit if
ground is faulty.
Fuse (1)
Precautions
Cigarette lighter
(Box)
Fuse (2)
<Blade type>
<Tube type>
D Generates sound when current flows.
Horn
(Cartridge)
Main fuse/
Fusible link
<Cartridge type>
<Fusible link>
Speaker
Transistor (1)
Collector (C)
Base (B)
NPN
Emitter (E)
C
B
Transistor (2)
Collector (C)
EC B
C
PNP
Emitter (E)
Speed sensor
Ignition switch
E
B
D Reading code.
2 S C 828 A
Base (B)
Heater
Semiconductor
Number of
terminals
Revision mark
A: High-frequency PNP
B: Low-frequency PNP
C: High-frequency NPN
D: Low-frequency NPN
B 1
B 2
S T
IG 2
O FF
IG 1
Z-8
O FF
A C C
Z-GI
Meaning
Symbol
Meaning
Harness
Connection
D
B
Selection
WITH ABS
Switch (2)
A
Diversion point D
for the different
circuits according to
the vehicles
specification is
indicated by a white
dot.
Relay (1)
D
B
WITHOUT ABS
C
D Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil
Current to coil
No Flow
Flow
D Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil
Current to coil
Flow
No Flow
Diode
Sensor (thermistor)
Capacitor
Light-emitting diode
(LED)
Cathode (K)
Anode (A)
Flow of direct current
A K
A
Anode (A)
Cathode (K)
Anode (A)
Flow of current
Solenoid
Z-9
Reference diode
(Zener diode)
Z-GI
Meaning
D The wiring position can be exchanged freely within the
connector.
Abbreviations
3GR
Third Gear
CCT
Circuit
4GR
Fourth Gear
CIGAR
Cigarette
Ampere
CIS
A/C
Air Conditioning
CKP
A/F
Air Fuel
CLS
A/R
Auto Reverse
CMP
AAS
COMBI
Combination
ABS
CON
Conditioner
ACC
Accessories
CONT
Control
ACV
CPU
ADD
Additional
CSD
AIR
CTP
AIS
DEF
Defroster
ALL
DI
Distributor Ignition
AM
Amplitude Modulation
DLC
AMP
Amplifier
DLI
Distributorless Ignition
ANT
Antenna
DOHC
Double-Overhead Camshaft
AP
Accelerator Pedal
DTC
AS
Autostop
DTM
ASV
ECM
AT
Automatic Transmission
ECPS
ATX
Automatic Transaxle
ECT
B+
EGR
BAC
EI
Electronic Ignition
BARO
Barometric Pressure
ELEC
Electric
CAC
ELR
CARB
Carburetor
ETR
Electronic Tuner
Z-10
Z-GI
Front
OBD
On-board Diagnostic
F/I
Fuel Injector
OFF
Switch Off
FC
Fan Control
ON
Switch On
FICB
Power
FM
Frequency Modulation
P/S
Power Steering
FP
Fuel Pump
PAIR
FPR
PCM
GEN
Generator
PNP
Park/Neutral Position
GND
Ground
PRCV
H/D
Heater/Defroster
PRG
HEAT
Heater
PSP
HEI
High-Energy Ignition
PTC
HI
High
QSS
Quicik-Start System
HO2S
Rear
IAC
REC
Recirculation
IAT
RF
Right Front
ICM
RFW
Remote Freewheel
IG
Ignition
RH
Right Hand
ILLUMI
Illumination
RPM
Engine Speed
INT
Intermittent
RR
Rear Right
JB
Joint Box
SAPV
KS
Knock Sensor
SFI
LCD
SOL
Solenoid
LF
Left Front
ST
Start
LH
Left Hand
SW
Switch
LO
Low
TC
Turbocharger
LR
Left Rear
TCM
Motor
TCV
MAF
TEMP
Temperature
MAP
TICS
MFI
TP
Middle
TR
Transmission Range
MID
MIL
TWS
MIN
Minute
Volt
MIX
Mixture
VAF
MPX
Multiplex
VENT
Ventilation
MT
Manual Transmission
VOL
Volume
MTR
VR
Voltage regulator
MTX
Manual Transaxle
VRIS
NC
Normally Closed
VSS
NO
Normally Open
Watt(s)
O2S
Oxygen Sensor
WOT
Z-11
p12nUK
Y-1
10
14
3
B
4
B
7
15
17
B/R
6
B
B/R
16
B/R
11
B/R
B(F)
B(F)
B(F)
B(F)
B(F)
Z12
3
B/R(F)
B(F)
Front harness
B(F)
B(F)
with immobiliser
unit
16
4
B/R(F)
to each
unit
Front harness
B(F)
to each
unit
B(F)
B/R(F)
B(R2)
10
B(R2)
11
Rear harness 2
14
15
Short cord
B(FR)
17
Floor harness
6
B(R2)
B/R(F)
Wiring Diagram
p13nUK
Y-1
Harness symbol
11
14
17
Z13
WL Turbo
16
WL
15
Wiring Diagram
10
16
p14nUK
Y-2
2
5
Wiring Diagram
7
8
10
11
14
12
13
B/O
15
17
B(F)
B(R2)
10
11
B(F)
B(R2)
B(F)
B(R2)
Rear harness
2
Z14
B(F)
B(INJ)
B(F)
B(F)
12
Injection harness
B
(INJ)
to each unit
Front harness
B(F)
B(F)
to each unit
5
B/O(INJ)
13
14
Rear window
heater grid
15
Short cord
B(FR)
17
Floor harness
B(F)
B(F)
p15nUK
Y-2
Harness symbol
10
12
11
13
14
17
G6
Z15
13
12
15
F2 CIS
Wiring Diagram
Y-3
10
14
15
11
B
B/ R
16
B/ R
B/ R
B /R
B/ R
B /R
19
E
B( F)
B( F)
B/ R( F )
B( F)
B/ R( F )
B( F)
B( F)
B/ R( F )
B/ R( F )
B( F)
Front harness
B/ R( F )
Z16
B( F)
B( F)
20
B/ R( F )
B/ R( F )
to each unit
Front harness
to each unit
B/ R( F )
B/ R( F )
B( F)
JC
01
B( F )
B/ R (F)
B( R2 )
10
B( R2 )
11
Rear harness
2
14
Rear window
heater grid
15
Short cord
B( FR)
17
Floor harness
16
B( R2 )
B( F )
18
B( F )
B( F )
B( F )
19
B/ R
B/ R
B/ R
B/ R
18
17
B
5
01
Wiring Diagram
JC
p17UK
Y-3
Harness symbol
Z
Wiring Diagram
10
16
19
11
14
Stretch cabin
Regular cabin
18
Z17
17
10
11
20
14
JC-01
17
15
Double cabin
p18nUK
W-1
I2
I2
I2
I2
I3
Immobiliser system
Heated Seats
Rear defrost
Outlet
Clock
Cigar lighter
Interior lamps
Air Bags
Heating
Air conditioning
Remote freewheel
control system
Powertrain
Quickstart system
Powertrain
Glow System
Starting System
Charging System
Fuel system
System
Section
Audio Systems
B/Y
30A
(PTC)
60A
GLOW
30A
HEAD
80A
MAIN
30A
BTN
G/B
R
10A
B/W
B/W
W/R
W/R
B/Y
W/R
Z18
Reversing Lamps
F2
F1
Stop Lamps
F2
Horns
F2
Instrument Illumination
I1
E3
Headlamps
(without daytime running lamps / without
headlamp levelling)
E1
R/B
10A
(A/C)
30A
(D/L)
20A
R.DEF
HAZARD
L/Y
LG/R
W/G
W
B/W
10A
ROOM
15A
STOP
L/R
10A
G/W
Y/R
TAIL
Ignition switch
ST
OFF
R/B
IG1 IG2
ACC
Headlamp
switch
15A
L
CIGAR
40A
(HEATER)
15A
WIPER
B/R
L/W
R/Y
R/L
R/W
L
10A
L
R.FOG
R/G
Instrument cluster
Power Mirrors
R/L
15A
W
15A
ENGINE
(S.WARM)
15A
METER
30A
(P.WIND)
B/W
R/W
BR/Y
B/Y
R/G
Headlamps
(with daytime running
lamps / with headlamp levelling)
Rear fog lamps
C1a
C1b
C1c
E2
E3
R/L
Windshield Wiper/
Washer
Power Windows
D
K1
K2
Wiring Diagram
S1
G1
B1a
B1b
B2a
B2b
A1
B5
K3
Battery
p19nUK
W-2
I2
I2
I2
I2
I3
Heated Seats
Rear defrost
Outlet
Clock
Cigar lighter
Interior lamps
Air Bags
Heating
Air conditioning
Fuel system
Remote freewheel
control system
Powertrain
Ignition
(F2 CIS, G6)
Starting System
Charging System
System
Section
Audio Systems
B/Y
30A
FUEL INJ
30A
HEAD
80A
MAIN
30A
BTN
F2
F1
Stop Lamps
F2
Horns
F2
Instrument Illumination
I1
R/B
E3
R/L
Headlamps
(without daytime running lamps / without
headlamp levelling)
E1
R
10A
B/W
B/W
W/R
W/R
B/Y
W/R
Z19
Reversing Lamps
L/W
10A
(A/C)
30A
(D/L)
20A
R.DEF
HAZARD
L/Y
LG/R
W/G
W
B/W
ST
IG1 IG2
10A
ROOM
15A
STOP
L/R
10A
G/W
Y/R
TAIL
OFF
ACC
Ignition switch
Headlamp switch
15A
CIGAR
40A
(HEATER)
15A
WIPER
B/R
L/W
R/Y
R/W
L
10A
R.FOG
R/G
Instrument cluster
ENGINE
15A
(S.WARM)
15A
METER
30A
(P.WIND)
B/W
BR/Y
Headlamps
(with daytime running lamps / with
headlamp levelling)
C2a
C2b
C2c
K3
L
E2
L
R/G
E3
B/Y
R/L
Windshield Wiper/
Washer
Power Windows
D
K1
K2
Wiring Diagram
S1
G2
B5
B3a
B3b
B3c
B4a
B4b
B4c
A2
Battery
W-3
T 2
I 2
I 2
I 2
I 2
I 3
6a
6b
6c
B
B
B
K 3
Battery
System
B
30A
PT C
60A
GLOW
30A
H EAD
80A
MA IN
30A
BT N
Z20
IG 2
Reversing Lamps
R
B/ W
W/ R
W/ R
B/ W
IG 1
G/B
B/ W
W/ R
ST
Audio Systems
F 4
R/B
B/ Y
OF F
B/ Y
Section
Ignition
switch
10A
A/ C
30A
D/L
20A
R.DE F
15A
FI P
10A
ROOM
15A
ST O P
10 A HAZ A RD
L/Y
LG/R
F 3
Stop Lamps
F 4
Horns
F 4
W/ G
W
L/ W
Instrument Illumination
10A
Y/ R
L/R
I1
TA IL
G/W
R/B
C
C
C
3a
3b
3c
Headlamp
switch
AC C
B/ R
15 A CIGA R
40 A H E AT ER
15 A WI PE R
L/W
R/ Y
R/W
L
10 A R.F O G
L
Instrument cluster
R/G
Power Mirrors
L
R/L
15 A
W
15 A
E N GINE
B/ W
R/W
BR /Y
Headlamps
E
S. WAR M
15 A
ME TE R
30 A
P. WI ND
B/ Y
R/G
E 5
Windshield Wiper/
Washer
K
K
1
2
R/L
Power Windows
Wiring Diagram
Immobiliser system
Heated Seats
Rear defrost
Outlet
Clock
Cigar lighter
Interior lamps
Air Bags
Heating
Air conditioning
Remote freewheel
control system
Powertrain
Glow System
Starting System
Charging System
Fuel system
p21nUK
A-1
Starting System / Charging System (WL, WL Turbo, before model year 2002)
Battery
HEAD
B(E)
R(E)
30A
MAIN
B/W(E)
B(E)
80A
X01
B/W
(E)
A
B/W(F)
X07
ST
X02
IG1 IG2
Instrument cluster
(Section C1a)
X02
Ignition
switch
OFF
ACC
W/B
(F)
B/Y
(F)
B
(E)
X09
B/W
(E)
A101
R
(E)
W/B
(E)
A102
Z21
B/Y(E)
A101
B/Y(F)
X08
Powertrain control
module (PCM)
(Section B1b, 2b)
Regulator
Starter
A102
1B
W/R
(E)
A101
Starter (E)
A102
Generator (E)
1B
W/R
B/Y
W/B
W/R
2A
B/W
2A
W/R
(E)
Generator
Wiring Diagram
X01
p22nUK
A-1
Harness symbol
[ Black ]
(F)(E)
Wiring Diagram
[ Black ]
(F)(E)
X08
X07
Main fuse box
[ Black ]
(F)(E)
X01
X09
A101
Starter
Z22
A102
Generator
X02
Ignition switch
X02
Ignition switch
[ Blue ]
[ White ]
p23nUK
A-2
Battery
HEAD
B(E)
R(E)
30A
MAIN
B(E)
B/W(E)
80A
X01
B/W
(E)
A
B/W(F)
X07
ST
OFF
B/Y(F)
X02
IG1 IG2
Instrument cluster
(Section C2a)
X02
Ignition switch
ACC
B/Y
(F)
W/B
(F)
B
(E)
X09
X08
B/W
(E)
A201
R
(E)
W/B
(E)
B/Y
(E)
A202
Z23
B/Y(E)
A201
Regulator
Starter
A2-01
A2-02
Starter (E)
B/Y
Generator (E)
B/W
W/B
Generator
Wiring Diagram
X01
p24nUK
A-2
Harness symbol
X01
X09
X01
X09
Starter
A201
X07
(F)(E)
[ Black ]
X08
(F)(E)
[ Black ]
Z24
A202
X07
(F)(E)
[ Black ]
Generator
[ Grey ]
X08
A201
(F)(E)
[ Black ]
A202
[ Grey ]
G6
A202
Generator
X02
Generator
F2 CIS
Starter
Generator
A202
X02
Ignition switch
Ignition switch
[ Blue ]
[ White ]
Wiring Diagram
[ Black ]
(F)(E)
[ Black ]
(F)(E)
A-3
Battery
HE AD
B( E)
R( E )
30A
MA IN
B( E)
B/ W( E)
80A
01
B/ W
(E )
A
X
B/ W( F )
AB
07
X
Instrument cluster
(Section C-3a)
02
Ignition switch
02
OF F
ST
IG 1
IG 2
AC C
X 0 2
W
(F)
B
(E )
W/ B
(F )
X 0 3
B/ Y
(F )
15A
E N GINE
X
09
03
B/ W
(F )
B/ W
(E )
R
(E )
W/ B
(E )
A3 03
Starter relay
A3 0 2
Z25
A3 0 1
A3 03
B/ L
(F )
B/ L (F )
B/ L (E )
A3 0 1
R( F )
54
B/ L (F )
Immobiliser module
(Section T-2)
Regulator
08
Starter
A 3 0 1
Starter (E)
A3 0 2
B/ L
Generator (E)
B/ W
A3 0 3
W/ B
B/ W
R
B/ Y
B/ L
Generator
Wiring Diagram
X 0 1
p26UK
A-3
Harness symbol
Z
Wiring Diagram
[Grey]
(F)(E)
[Black]
X08
(F)(E)
X09
(F)(E)
X07
Main fuse box
X01
Z26
A3-01
Starter
A3-02
Generator
X02
X02
A3-03
Starter relay
Ignition switch
[Blue]
X03
Fuse block
Ignition switch
[White]
p27nUK
B-1a
Powertrain / Quickstart system (WL, WL Turbo: General specifications, before model year 2002)
Battery
MAIN
B(E)
X07
X01
X02
Ignition
switch
OFF
ST
GLOW
IG1
IG2
60A
Wiring Diagram
X01
X01
B/W(F)
B/W(E)
80A
B/W
(F)
B/W
(F)
B/W
(F)
ACC
X02
B105
W
(F)
ENGINE
B105
B/W(F)
15A
X03
B106
Fuse block
B106
X03
B/W
(F)
G
(F)
P
(F)
B101
J
BR
(F)
R
(F)
G/R
(F)
W
(F)
B/R
(F)
B101
R/B
(E)
B/W
(F)
B/R(F)
Z27
X09
B102
B103
B109
G/R
(E)
Glow plug
relay
R(F)
R(F)
No.4
No.3
B
(F)
No.2
No.1
B104
Fuel shutoff
valve
B/R
(F)
B/R(E)
B107
Glow plugs
B102
B/R
(E)
W
(E)
B108
Diesel pump
unit
B107
NE sensor
B/R(E)
6
B101
I
O
BR
GY
W/L
R/B
B/W
P
P
B106
B107
B102
G
E
R/W
G/R
B/Y
B/R
B103
B/W
B/R
G/R
B105
BR
R
R/B
B108
NE sensor (E)
B109
B/R
P
B104
B/W
B/W
p28nUK
B-1a
Harness symbol
(F)(E)
(F)(E) X09
X07
[Brown]
Glow plug relay
[Black]
[Black]
Glow plug
relay
B105
B103
B102
[Black]
FICD solenoid valve 1
(F)(E)
B105
X09
B106
B106
X01
[Black]
(F)(E)
X07
X01
B107
B107
B104
Glow plugs
Z28
B109
Diesel pump unit
B103
[Black]
B108
[Brown]
NE sensor
WL Turbo
B102
Glow plug relay
B104
[Grey]
B108
NE sensor
[Grey]
B109
Diesel pump unit
[Black]
B101
Powertrain control
module (PCM)
X02
Ignition switch
X03
Fuse block
X02
Ignition switch
[Blue]
[White]
Glow plugs
WL
Wiring Diagram
B102
[Black]
B102
[Brown]
Glow plug relay
[Brown]
Glow plug relay
p29nUK
B-1b
Z
A/C Relay 1
(Section G1)
B/Y
(F)
R/W
(F)
R/B
(F)
B101
D
GY
(F)
W/L
(F)
B101
Z29
4
Instrument cluster
(Section C1c)
B101
BR
GY
W/L
R/B
B/W
P
P
G
R/W
G/R
B/Y
B/R
Instrument cluster
(Section C1a)
Wiring Diagram
Thermo switch
(Section G1)
Ignition switch
(Section A1)
p30nUK
B-1b
Harness symbol
Z
Wiring Diagram
Z30
B101
p31nUK
B-2a
Powertrain / Preglow system (WL, WL Turbo: European specifications, before model year 2002)
MAIN
B(E)
X07
X01
X02
OFF
Ignition
switch
B/W
(F)
GLOW
IG1 IG2
60A
B/W
(F)
B/W
(F)
B/W
(F)
ACC
X02
W
(F)
B205
Fuse block
ENGINE
15A
B205
B/W(F)
X03
B206
B206
49
X03
B/W
(F)
G
(F)
P
(F)
Immobiliser module
(Section T)
B201
L
BR
(F)
R
(F)
G/R
(F)
W
(F)
B/R
(F)
BR/W
(F)
R/L
(F)
G/W
(F)
L/B
(F)
B201
R/B
(E)
B/W
(F)
B/R(F)
B209
Z31
X09
B203
B202
G/R
(E)
Glow plug
relay
W
(E)
R(F)
Engine Coolant
Temperature (ECT)
sensor
Glow plugs
B204
B/R
(F)
B209
No.4
No.3
No.2
No.1
Fuel
shutoff
valve
NE sensor
Diesel
pump
unit
C
B/R
(F)
B207
B
(F)
Injection
timing
control
valve
B/R(E)
B208
B207
B202
B/R
(E)
Idle
switch
without immobiliser
unit
B/R(F)
B/R(E)
3
B201
Powertrain
control module (PCM) (F)
K
S
BR/R
Y/B
L/B
BR
GY
W/L
R/B
B/W
<Y>
B206
B/W
B207
B202
I
G
R/W
R/L
G/W
H
G/R
BR/W
B/Y
B/R
B/R
G/R
B203
B204
B205
BR
R
R/B
B208
NE sensor (E)
B209
B/R
C
R/L
B/R
BR/W L/B
G/W
B/W
(B/R) (V/W)
F
B/W
Wiring Diagram
A
ST
X01
B/W(F)
B/W(E)
80A
X01
( )...
Battery
p32nUK
B-2a
Harness symbol
[ Black ]
(F)(E)
X07
B202
[ Black ]
(F)(E)
[ Brown ]
Glow plug relay
[ Black ]
FICD solenoid valve
1
X09
Glow plug
relay
B205
X07
B203
[ Black ]
FICD solenoid valve
1
B205
FICD solenoid valve
2
B206
B206
X01
[ Black ]
(F)(E)
X09
B202
Main fuse box
[ Black ]
(F)(E)
X01
B207
B207
B204
Glow plugs
Z32
B209
Diesel pump
unit
[ Grey ]
B203
B202
Glow plug
relay
[ Brown]
Glow plug
relay
B204
[ Grey ]
B208
NE sensor
[ Grey]
WL Turbo
B208
NE sensor
B209
Diesel pump unit
[ Grey]
B201
Powertrain control
module (PCM)
[ Black ]
X02
X03
Fuse block
X02
Ignition switch
[ Blue ]
Ignition switch
[ White ]
Glow plugs
WL
Wiring Diagram
B202
[ Brown ]
Glow plug relay
[ Brown ]
Glow plug relay
p33nUK
Powertrain / Preglow system (WL, WL Turbo: European specifications, before model year 2002)
B-2b
Thermo switch
(Section G1)
A/C Relay 1
(Section G1)
12
10
B/Y
(F)
BR/R
(F)
Y/B
(F)
R/W
(F)
R/B
(F)
B201
D
B201
GY
(F)
Y
(F)
W/L
(F)
Z33
B210
B/R
(F)
Instrument cluster
(Section C1c)
Instrument cluster
(Section C1a)
B201
Powertrain
control module (PCM) (F)
K
S
BR/R
Y/B
T
L/B
BR
GY
W/L
R/B
B/W
<Y>
R
B210
R/W
R/L
G/W
H
G/R
BR/W
B/Y
B/R
Wiring Diagram
Ignition switch
(Section A1)
p34nUK
B-2b
Harness symbol
Z
Wiring Diagram
[ Green ]
Exhaust Gas Recirculation
(EGR) valve
B210
Z34
B201
Powertrain control module (PCM)
[ Black ]
p35nUK
B-3a
X01
X01
MAIN
B/W(E)
B/W(F)
FUEL INJ
X01
BTN
L/W(E)
30A
Fuse block
X03
30A
Ignition switch
L/R(F)
X03
10A
IG1 IG2
X03
ACC
X02
X03
ENGINE
OFF
ST
ROOM
W/R(F)
specifications (LHD)
X02
Fuse block
X08
W/R(E)
W(F)
15A
B301
B/W
(F)
L/W
(F)
1A
2F
B302
W
(F)
Main relay
1E
1D
1K
2U
1B
2V
2W
2E
2C
LG/B
(F)
L/W
(F)
P
(F)
B/O
(F)
B301
LG/R
(F)
X05
W
(F)
B302
W
(F)
O
(F)
LG/R
(INJ)
B304
R/W
(F)
O
(F)
O
(F)
Y/B
(F)
Y
(F)
BR/R
(F)
B/Y
(F)
Ignition coil
9
Capacitor
Z35
Ignition
module
B305
10
11
12
Fuel injector 1
B/Y
(INJ)
B/Y
(INJ)
1T
B/Y
B310
B311
B309
B/O(F)
B/Y
(INJ)
B/Y
(F)
X05
B/Y(INJ)
B/Y(INJ)
B/O
(INJ)
X05
B/Y(F)
B/Y(F)
13
B302
1O
R/G
W/G
G/R
BR/R
BR
1P
1N
(B)
1L
1R
B305
1M
1Q
G/B
Camshaft
position
sensor
1S
1V
Fuel injector 4
B/Y
(INJ)
B311
B309
Fuel injector 2
B308
B/Y
(INJ)
B
(F)
B310
B308
B307
B/Y(F)
B304
LG/B
(INJ)
Fuel injector 3
B306
B(F)
B301
LG/B
(INJ)
B307
B306
B
(F)
LG/R
(INJ)
B303
B/Y(F)
LG/R
(INJ)
L/G
(INJ)
B310
B303
B
(F)
B/Y
(F)
LG/B
(INJ)
1K
1I
1G
1E
1C
Y/B
R/B
L/O
1J
1H
2Y
L/R
Y
1F
B/Y
W/L
1B
2Z
1D
2W
2U
L/W
LG/R
L/Y
LG/B
2X
2V
2S
2Q
2O
2M
G/W
G/B
G/Y
L
2T
2R
B306
B311
1A
R/W
B/Y
B/O
2P
2K
2I
2E
2C
BR/W
B/O
L/W
B/W
R/W
BR/B
B/Y
2N
2L
2F
2D
2B
2J
B/Y
2H
B307
B303
Capacitor (F)
2A
LG/R
2G
LG/R
B/Y
B308
LG/B
B/Y
B309
LG/B
B/Y
Wiring Diagram
X01
80A
X08
( )... European
X07
B(E)
Battery
p36nUK
B-3a
Harness symbol
Z
Wiring Diagram
[ Black ]
(F)(E)
X08
Main fuse box
X01
[ Black ]
(F)(INJ)
X05
[ Black ]
Idle air control valve (IAC)
B310
B309
Fuel injector 4
[ Grey ]
B307
Fuel injector 3
[ Grey ]
B303
Z36
Capacitor
[ Black ]
B304
B302
Ignition coil
Main relay
B305
X07
(F)(E)
Ignition module
B311
Camshaft position sensor
13
[ Black ]
[ Grey ]
B306
Fuel injector 1
[ Grey ]
B308
Fuel injector 2
[ Grey ]
[ Grey ]
B301
Powertrain control module (PCM)
[ Yellow ]
X02
Ignition switch
[ White ]
X03
Fuse block
X02
Ignition switch
[ Blue ]
p37nUK
B-3b
European specifications
(LHD)
1N
2N
1P
2D
2L
2Q
2K
2O
2M
2X
2T
B301
V
(F)
W
(F)
BR
(F)
BR/B
(F)
G
(F)
G/W
(F)
BR/W
(F)
G/Y
(F)
X09
G/B
(F)
L/Y
(F)
L
(F)
X05
B319
BR
(E)
BR/W
(INJ)
B320
Canister purge
solenoid valve
G/Y
(INJ)
B319
B312
B317
B313
Power
steering
pressure
switch
Door ajar
switch, tailgate
B314
Z37
Heated
oxygen
sensor
(HO2S),
front
B317
B315
BR/B
(F)
B316
Engine Coolant
Temperature
(ECT) sensor
Throttle Position
Sensor (TPS)
B/Y
(F)
B/Y(F)
B316
B315
BR/B
(F)
BR/B
(F)
B/Y
(F)
BR/B
(INJ)
B/Y
(F)
B/Y
(F)
G/B
(F)
B318
X05
B318
BR/B(F)
BR/B(F)
BR/B(F)
BR/B(F)
Main relay
(Section B3a)
B301
B312
1M
W/G
G/R
BR
1P
1N
1K
1I
1G
BR/R
1E
1C
Y/B
2Y
1A
L/R
2W
2U
L/W
LG/R
L/Y
LG/B
2S
2Q
2O
2M
G/W
G/B
G/Y
2K
2G
2I
2E
2C
2A
BR/W
B/O
R/W
BR/B
2N
2L
2F
2D
2B
B313
V
G/B
1V
B314
1T
1R
L/O
1J
1H
B315 Engine
Y
1F
Coolant Temperature
(ECT) sensor (F)
(B)
1L
R/B
BR/B
1D
B/Y
W/L
1B
B316
2Z
2X
2V
L
2T
B317
BR/W BR/B
B320
L/Y
B/Y
2P
2J
2H
B318
G/W
G/Y
B319
2R
B/Y
BR/B
BR
G/B
BR/B
Wiring Diagram
( )...
p38nUK
B-3b
Harness symbol
Wiring Diagram
B317
B320
[ Black ]
(F)(E)
X09
[ Black ]
Heated oxygen sensor (HO2S), front
[ Blue ]
Evaporative emission
(EVAP) canister vent
valve
[ Black ]
Intake air temperature sensor
B314
[ Black ]
Canister purge solenoid valve
Throttle Position
Sensor (TPS)
B319
B316
X05
(F)(INJ)
[ Black ]
Z38
B315
[ Black ]
B312
B318
B313
Power steering
pressure switch
B301
Powertrain control module
(PCM)
[ Yellow ]
p39nUK
B-3c
specifications (LHD)
Wiring Diagram
1Q
1J
1M
2Z
1O
L/O
(F)
R/G
(F)
R/B
(F)
G/R
(F)
W/L
(F)
W/G
(F)
2A
2B
1L
1V
B
(F)
B
(F)
B
(F)
G/B
(F)
B301
B
(F)
G/B(F)
X05
European
specifications
(LHD)
X09
G/B
(E)
G/B
(F)
Z39
B321
6
14
Coolant pressure
switch
(Section G2)
15
A/C Relay 1
(Section G2)
Brake pressure
switch
(Section F2)
Instrument cluster
(Section C2a)
B322
Clutch
switch
16
Neutral
position
switch
B321
B
(INJ)
B322
B
(F)
B
(E)
X09
B
(F)
12
B301
1T
1R
B321
1M
W/G
G/R
BR
1P
1N
1K
1I
1G
BR/R
(B)
1L
1E
1C
L/O
1J
1H
Y
1F
2Y
L/R
Y/B
R/B
1A
1D
B/Y
W/L
1B
2Z
2W
2U
2S
L/W
LG/R
L/Y
LG/B
2V
2T
2X
2Q
2O
2M
G/W
G/B
G/Y
2R
2P
2K
2I
2G
2E
2C
BR/W
B/O
R/W
BR/B
2N
2L
2F
2D
2B
2H
2A
2J
B322
B
B
G/B
( )... European
G/B
p40nUK
B-3c
Harness symbol
[ Black ]
(F)(INJ)
X09
X05
Wiring Diagram
[ Black ]
(F)(E)
B322
Z40
12
B301
B321
p41nUK
B-4a
Battery
X01
MAIN
X07
B(E)
B/W(E)
B/W(F)
X01
FUEL INJ
X01
BTN
L/W(E)
X08
30A
X02
30A
OFF
ST
ROOM
W/R(F)
W/R(E)
Fuse block
Ignition switch
L/R(F)
X03
10A
IG1 IG2
X03
ACC
X02
Fuse block
X03
X03
ENGINE
W(F)
W(F)
B/W(F)
15A
L/W
(F)
L/W
(F)
B401
1A
L/B(F)
B401
1G
2F
B402
Main
relay
W
(F)
1E
1D
1I
Powertrain control
module (PCM)
1K
2U
2V
2W
2E
2C
LG/R
(F)
LG/B
(F)
L/W
(F)
P
(F)
B/O
(F)
LG/R
(INJ)
LG/B
(INJ)
L/G
(INJ)
1B
B401
X05
W
(F)
B402
W
(F)
O
(F)
B404
L/B(F)
R/W
(F)
O
(F)
O
(F)
Y/B
(F)
Y
(F)
BR/R
(F)
B/Y
(F)
Ignition coil
Capacitor
Z41
Ignition
module
O(F)
B403
B405
B
(F)
O
(F)
10
11
12
B406
LG/B
(INJ)
B
(F)
B407
Fuel injector
1
LG/B
(INJ)
B411
Idle air
control
valve (IAC)
B409
B408
Fuel injector
3
Fuel injector
2
Fuel injector
4
Camshaft
position
sensor
B410
B406
B407
B/Y
(INJ)
B(F)
B/Y(F)
LG/R
(INJ)
B410
B403
B/Y
(F)
LG/R
(INJ)
B/Y
(INJ)
B/Y
(INJ)
B411
B409
B408
B/Y
(INJ)
B/O(F)
B/Y
(INJ)
B/Y
(F)
X05
50
B/Y(INJ)
B/Y(INJ)
Instrument cluster
(Section C2a)
B/O
(INJ)
X05
B/Y(F)
B/Y(F)
1
B401
B404
B410
1T
1R
L/G
B402
1M
W/G
BR
1P
1N
B405
1K
1I
BR/R
B/W
L/B
R/B
L/O
1J
1H
1L
B/Y
1G
1E
1C
Y/B
Y
1F
1A
2Y
2U
L/W
LG/R
B/Y
L/Y
LG/B
1D
1B
2Z
2X
2V
2S
R/W
B/Y
B/O
2Q
2O
2M
G/W
G/B
G/Y
2P
2N
2L
L
2T
B406
B411 Camshaft
2W
L/R
13
2R
2K
B/Y
2G
2E
P
B/O
G/O
R/W
BR/B
2H
2F
2D
2B
BR/W
LG/R
2I
2J
B407
2C
2A
B403 Capacitor
L/W
L/W
B/Y
L/B
LG/R
B/Y
B408
LG/B
B/Y
(F)
B409
LG/B
B/Y
Wiring Diagram
X08
80A
p42nUK
B-4a
Harness symbol
[ Black ]
(F)(E)
Wiring Diagram
X08
[ Black ]
Idle air control valve (IAC)
B410
Main fuse box
X01
13
B409
Fuel injector 4
[ Grey ]
B407
Fuel injector 3
[ Grey ]
B403
Capacitor
Z42
[ Black ]
B402
B404
Main relay
Ignition coil
X07
(F)(E)
[ Black ]
X05
(F)(INJ)
[ Black ]
B405
Ignition module
B406
Fuel injector 1
[ Grey ]
[ Grey ]
B408
Fuel injector 2
[ Grey ]
B411
Camshaft position sensor
B401
[ Grey ]
X02
Ignition switch
[ White ]
X03
X02
Fuse block
Ignition switch
[ Blue ]
p43nUK
B-4b
1N
1P
2N
2D
2L
2K
2Q
2M
2H
2O
2P
2T
2X
B401
V
(F)
W
(F)
BR
(F)
BR/B
(F)
G
(F)
G/W
(F)
BR/W
(F)
G/Y
(F)
BR/W
(INJ)
G/Y
(INJ)
X05
L/Y
(F)
L
(F)
X05
B419
G/W
(INJ)
G
(INJ)
G/W
(INJ)
B420
Canister
purge solenoid valve
B419
B412
B413
Door ajar
switch, tailgate
B417
B414
Z43
Heated
oxygen
sensor
(HO2S),
front
B415
B416
Engine Coolant
Temperature (ECT)
sensor
B414
B415
G/O
(F)
Throttle
Position
Sensor
(TPS)
B416
G/B
(F)
O
(F)
B420
B/Y
(F)
B/Y
(F)
B/Y(F)
X05
B417
BR/B
(F)
BR/B
(INJ)
BR/B
(INJ)
BR/B
(INJ)
B/O
(INJ)
B/O
(F)
B/Y
(F)
B/Y
(F)
BR/B(INJ)
B418
X05
BR/B(F)
Main relay
(Section B4a)
13
B401
1S
1Q
1O
R/G
W/G
G/B
1V
B414
1T
1R
BR/B
B412
1M
1K
1I
BR/R
BR
1P
1N
B415
1L
B/W
L/B
R/B
L/O
1J
1H
1E
1C
Y/B
Y
1F
BR/B
1G
1D
2Y
1A
2W
2U
2S
L/R
L/W
LG/R
B/Y
L/Y
LG/B
2V
2T
2Z
1B
B416
2X
B417
BR/W BR/B
B420
L/Y
B/Y
2O
2M
G/W
G/B
G/Y
2P
2N
2L
2R
2K
2G
2E
P
B/O
G/O
R/W
BR/B
2H
2F
2D
2B
2I
BR/W
2J
B/Y
2C
2A
BR/B
B413
B
G/W
B418
G/W
G/Y
B419
2Q
BR
B/O
G/B
G/O
B/Y
Wiring Diagram
Powertrain control
module (PCM)
p44nUK
B-4b
Harness symbol
[ Black ]
Engine Coolant Temperature (ECT)
sensor
B415
B419
B414
Wiring Diagram
[ Black ]
Canister purge solenoid
valve
B412
Throttle Position Sensor (TPS)
[ Blue ]
Fuel pressure solenoid valve
B416
B420
13
Z44
X05
(F)(INJ)
[ Black ]
B417
Heated oxygen sensor
(HO2S), front
[ Black ]
B418
B413
B401
Powertrain control
module (PCM)
[ Yellow ]
p45nUK
B-4c
Z
Wiring Diagram
1Q
1J
L/O
(F)
R/G
(F)
R/B
(F)
1O
2A
2B
1V
W/G
(F)
B
(F)
B
(F)
G/B
(F)
B401
B
(F)
G/B(F)
X09
X05
G/B
(E)
G/B
(F)
Z45
B421
6
14
A/C Relay 1
(Section G2)
B422
Clutch switch
16
Neutral position
switch
B421
B
(INJ)
B
(F)
B422
B
(E)
X09
B
(F)
12
B401
1S
1Q
1O
R/G
W/G
G/B
1V
1T
1R
B421
1M
1K
BR/R
BR
1P
1N
1L
1I
1G
B/W
L/B
R/B
L/O
1J
1H
1E
1C
Y/B
Y
1F
1D
1A
2Y
2W
2U
2S
L/R
L/W
LG/R
B/Y
L/Y
LG/B
2V
2T
1B
2Z
2X
2K
2Q
2O
2M
G/W
G/B
G/Y
2P
2N
2L
2R
2I
2A
2E
P
B/O
G/O
R/W
BR/B
2H
2F
2D
2B
BR/W
2J
2C
2G
B422
B
B
G/B
G/B
p46nUK
B-4c
Harness symbol
Z
Wiring Diagram
12
[ Black ]
(F)(E)
X09
B422
Z46
X05
(F)(INJ)
[ Black ]
B401
Powertrain control module
(PCM)
[ Yellow ]
B421
Clutch switch
p47nUK
B-5
Battery
MAIN
B(E)
B/W(E)
X01
B/W(F)
X01
X02
X07
OFF
ST
Fuse block
F2 CIS,G6
WL,WL Turbo
IG1 IG2
ENGINE
W(F)
B/W(F)
(PTC)
30A
Instrument cluster
(Section C1a)
X01
B502
B/W
(F)
A
B/W
(F)
C
X03
15A
X03
Instrument cluster
(Section C2a)
48
G/B
(E)
19
B502
Y
(F)
L/O
(F)
B503
Fuel heater
L/O(F)
X04
X18
18
B503
Y
(R2)
Z47
Data Link
Connector
(DLC)
(Section U)
B501
Fuel pump/fuel
gauge sender
14
B501
X09
Y
(F)
G/R
(R)
Y
(R)
G/R
(R2)
Y
(R2)
L/O
(F)
Y
(R)
B/R
(E)
G/R
(F)
X04
X18
B501
Fuel
gauge
Fuel pump/fuel
gauge sender
B/R
(R2)
B501
B/R
(F)
X18
B/R(R)
B
(R2)
B/R(F)
X04
X18
16
B501
WL,
WL Turbo
B502
10 11
B/R
C B/W
B/W
G/R
G/R
L/O
F2 CIS,G6
B/R
B/R(R)
B/R(R2)
B503
A
G/B
B/R
B/O(F)
X04
ACC
X02
B/O(INJ)
X05
13
Ignition switch
Wiring Diagram
80A
p48nUK
B-5
Harness symbol
10
(R)(R2)
X05
X18
(F)(R)
X04
11
X07
B501
(F)(E)
[ Black ]
F2 CIS,G6
Z48
13
Fuel heater
Main fuse box
B503
[ Black ]
(F)(E)
X09
X01
X04
(F)(R)
X02
Ignition switch
[ White ]
X02
16
B502
WL,WL Turbo
X03
Fuse block
Ignition switch
[ Blue ]
Wiring Diagram
X01
[ Black ]
(F)(INJ)
B-6a
B T N 30A
X 0 8
01
W/ R( E)
B( E)
B /L(F )
B/ W( F )
B/ W( E)
F IP 15A
A
X 0 2
07
L/W (F )
Ignition
switch
OF F
ST
B/ W( F)
X 0 3
B6 02
B/ W
(E )
X 0 3
IG 1
07
X
IG 2
ROOM
10A
AC C
02
15A
X 0 3
B /L(F )
LG
(F )
B/ L
(F )
B/ L
(F )
4C
4D
4X
B6 0 8
B/ W
(F)
B6 0 1
B6 0 7
G/O
(F )
Y/ G
(F )
4Z
4T
B6 0 8
L G/R
(F )
2K
4V
R/B
(E )
1C
1V
2D
4A
3O
4B
1D
Shield
BR
(F)
Fuel pump
(Section B-6c)
G/B
(F )
X
Z49
B6 0 4
P
(F )
B6 0 3
B/ R
(F )
L
(F )
G/W
(F)
B/ R
(F)
B6 1 1
B6 1 3
Clutch
switch
No .1
No .2
No .3
No .4
Glow plugs
B 6 0 8
L/W
B/ L
LG
1K
1I
1G
1Q
1C
20
1A
2K
B/ L
L/Y
BR/Y
R/L
GY /L
G/R
G Y /B
G/Y
P/ B
G/ B
1V
1T
1R
1P
1N
1L
1J
1H
1F
1D
B 6 03
L /R
B6 0 4
2G
BR /W
BR /B
L/W
W/ L
1B
2L
2J
3K
2C
R/Y
2H
2F
P/ L
BR /R
Y/ R
2D
B6 0 5
3I
3G
3E
3M
3A
3P
3N
3L
3J
3H
B6 06
3F
3D
4U
LG
3B
4Q
LG /B
L/B
GY
(G /O )
B/ L
BR
Y/ G
4Z
4X
4V
B6 07
09
B/ R
(F )
20
4O
4M
4K
4I
4S
4W
R/W
B/ L
2B
B
(F )
4Y
3C
G/W
B6 1 3
B/ R
(E )
B6 1 2
B
(F )
20
3O
2A
2E
2I
1E
B/ W
1M
1O
1S
B/ R
(F)
Fuel pump
3
1U
B6 1 1
B/ R
(F )
B
(F )
Neutral
position
switch
B6 1 2
Idle switch
B6 0 5
G/B (E )
G/B
(F )
B6 1 0
B6 0 3
09
G/B (F )
R
(F)
L/W
4I
4Q
B6 0 1
55
B 6 0 2
B6 09
W/ R
(F )
3B
Powertrain
control module (PCM)
(F)
Exhaust
Gas Recirculation
(EGR)
valve
B6 0 1
01
B/ L
(F)
B 6 01
B6 09
L/R
(F )
03
B /L( F)
B/ L
(F )
B/ L
(F )
B6 0 6
B/ L(F)
GL OW
60 A
B/ L
(F )
B6 0 7
Intake air
control
valve
E N GINE
B6 02
B/ L
(F )
B6 0 6
B/ L
(F )
X 0 3
W
(F )
B/ L
(F )
B/ L
(F )
03
4G
B/ Y
LG/ R
W/ R
G/B
R/B
4R
4T
4P
4N
4L
4J
4H
4C
4A
B/ L
B/ R
B/ L
B/ R
4D
4B
4E
4F
BR
R
R/B
G/O
Y/ G
B /L
B/ L
LG/R
B/ L
B6 0 9
B /L
B 6 10
B6 11
G/W
B6 12
G/B
B6 13
G/B
B /R
Wiring Diagram
B/ L (F)
A
B/ W( E)
)... W LT 3
WL T 3
W/ R( F )
MA IN 8 0 A
Battery
p50UK
B-6a
Harness symbol
[Black]
(F)(E)
X07
B604
[Brown]
Glow plug relay
(F)(E)
[Black]
X08
[Grey]
(F)(E)
Wiring Diagram
[Brown]
Glow plug
relay
B607
X09
[Black]
Exhaust gas recirculation (EGR) solenoid valve (vent)
B603
Main fuse box
B608
X01
B613
B606
Intake air control valve
[Black]
B609
Z50
B603
Glow plug relay
Idle switch
B611
Clutch switch
B612
B605
Glow plugs
B610
Fuel pump
[Grey]
20
B601
Powertrain control
module (PCM)
X02
Ignition switch
[White]
X03
B602
PCM module relay
Fuse
block
X02
Ignition switch
[Blue]
B-6b
12
58
Immobiliser module
(Section T-2)
10
11
59
B/ Y
(F )
Y/ R
(F )
W
(F)
4K
2B
Wiring Diagram
W/ L
(F )
W/ L (F )
BR/ R
(F )
W/ L
(F)
B6 0 1
2J
Reference
voltage
1G
1I
1K
1S
2L
2A
2I
1F
1J
1T
1A
1P
2C
1R
B6 01
BR /W
(F )
BR /B (F )
BR/ B (F )
56
Shield
BR /W (F )
BR/ W (F )
W
(F )
B
(F)
R
(F )
L/Y
(F )
L/ W
(F )
R/Y
(F )
Z51
BR /W
(F )
BR/ B
(F )
G/Y
(F )
BR/ B
(F )
BR /Y
(F )
V
(F )
BR/ W
(F )
V
(E )
BR/ W
(E )
09
BR/ B
(E )
B6 14
BR/ B (E )
10
B/ R
(F )
BR /B
(E )
B6 1 5
B6 1 5
Fuel pump
20
B6 0 1
1U
Powertrain
control module (PCM) (F)
B 6 14
1K
1I
1G
1Q
1C
L/Y
BR/Y
R/L
GY /L
G/R
G Y /B
G/Y
P/ B
G/ B
L /R
1V
1T
1R
1P
1N
1L
1J
1H
1F
1D
BR /B
L/W
W/ L
1B
2L
B 61 5
L/ Y
BR /W
/Y
2F
BR /R
Y/ R
2D
2B
BR/ B
P/ L
(F )
(F )
(F)
B6 1 8
3O
3K
3I
3G
3E
B6 1 9
G/W
3A
3N
4Y
3L
3J
3H
B 6 1 6
Engine Coolant
Temperature (ECT)
sensor (E)
3F
3D
4U
LG
3B
BR /Y
LG /B
L/B
GY
(G /O )
B/ L
BR
Y/ G
4Z
4X
4V
BR /B
BR /W
GY /L
BR /B
BR /B
BR /B
B 61 9
BR /B
P/ L
R/L
BR /W
4Q
4O
4M
4K
4I
4S
4W
R/W
B/ L
3P
3C
3M
P/ L
R/L
(F )
L /W
B 61 8
BR /W
2H
BR /B
EGR valve
position sensor
(E)
V
R/Y
BR/ W
(F )
B6 1 6
2C
BR /W
2J
2A
BR/ B
(F )
2E
2G
2I
B/ L
BR
2K
1A
1E
B/ W
B6 1 7
1M
1O
1S
B6 1 6
Engine Coolant
Temperature
(ECT) sensor
GY /L
(F )
BR/ B
(E )
G/Y
(E )
EPROM
BR /W
BR /B (E )
B6 1 7
BR/ Y
(E )
( )...W LT 3
Instrument
cluster
(Section C-3a)
G/Y
4T
4G
B/ Y
LG/ R
W/ R
G/B
R/B
4R
4P
4N
4L
4J
4H
4C
4A
B/ L
B/ R
B/ L
B/ R
4D
4B
4E
4F
p52UK
B-6b
Harness symbol
Z
Wiring Diagram
[Grey]
(F)(E)
X10
B615
Engine Coolant Temperature (ECT) sensor
Z52
B616
Intake Air Temperature (IAT) sensor 2
[Black]
B614
B617
EGR valve position sensor
Fuel pump
[Grey]
B618
Boost pressure sensor
[Grey]
20
B601
Powertrain
control
module
(PCM)
B619
Accelerator
pedal position sensor
B-6c
A/C Relay 1
(Section G3)
Instrument cluster
(Section C3a)
( )... W LT 3
Instrument cluster
(Section C3b)
60
B/ L
(F )
R/W
(F )
R/B
(F )
G/R
(F )
GY
(F )
1U
3C
4L
1N
4S
Wiring Diagram
Starter relay
(Section A3)
B6 0 1
4U
4W
1M
4E
3D
4Y
1O
1Q
1H
1B
B6 0 1
Shield
Fuel pump
(Section B6b)
56
55
BR /B (F )
B/ L(F)
BR /B (F )
B/ L(F)
B/ L (F)
B/ L (F)
B/ L
(F )
LG/B
(F )
BR/ B (F )
L/B
(F )
GY /B
(F )
R
(F )
BR/ B
(F )
B
(F )
W
(F )
B/ L
(F)
BR/ B
(F )
P
(F )
Z53
B/ R
(F )
Fuel temperature
sensor
20
1U
Powertrain
control module (PCM) (F)
B 6 2
1O
1S
1Q
1M
1K
1I
1G
1C
2K
1A
2G
B/ L
L/Y
L /R
BR /W
B/ W
BR/Y
R/L
GY /L
G/R
G Y /B
G/Y
P/ B
G/B
BR /B
L/W
W/ L
1V
1T
1R
1P
1N
1L
1J
1H
1F
1D
1B
2L
B6 2 1
LG /B
L/ B
BR /B
GY /B
B/ L
B/ L
2J
B/ L
D
G/B
B/ R
B/ L
A
3O
2A
3K
R/Y
2H
2F
P/ L
BR /R
Y/ R
2D
3I
3G
3E
3M
2C
Mass Air Flow (MAF) sensor / Intake Air Temperature (IAT) sensor
(F)
BR /B
2E
2I
1E
B6 2 2
3A
B/ L
3N
B/ L
P/ B
BR /B
3L
3J
3H
3F
3D
TDC sensor
20
4U
LG
3B
4Q
4O
4M
4K
4I
4S
4W
R/W
3P
4Y
3C
G/W
2B
Fuel pump
B6 0 1
BR/ B
(F )
B6 2 2
B/ R
(F )
P/ B
(F )
B/ L
(F )
G/ B
(F )
D A
B6 2 1
B6 2 0
B/ L
(F )
B/ L
(F )
LG /B
L/B
GY
(G /O )
B/ L
BR
Y/ G
4Z
4X
4V
4T
4G
B/ Y
LG/ R
W/ R
G/B
R/B
4R
4P
4N
4L
4J
4H
4C
4A
B/ L
B/ R
B/ L
B/ R
4D
4B
4E
4F
p54UK
B-6c
Harness symbol
Z
Wiring Diagram
Z54
B622
TDC sensor
[Grey]
B620
Fuel pump
[Grey]
B621
Mass Air Flow (MAF)
sensor / Intake Air Temperature (IAT) sensor
20
B601
Powertrain control
module (PCM)
B-7
Battery
+
PT C
X 0 1
30 A
Instrument cluster
(Section C3a)
01
48
G/ B
(E )
Y
(F )
B7 0 2
04
18
Y
(R )
Fuel heater
Y
(R 2)
B7 0 1
Fuel gauge
sensor
B7 0 2
B7 0 1
B
(E )
B/ R
(R 2)
Z55
18
04
10
B/ R
(R )
B
(F )
B/ R
(F )
B7 01
B7 0 2
G/B
B/ R
16
Wiring Diagram
B( E)
p56UK
B-7
Harness symbol
Z
Wiring Diagram
(R)(R2)
Fuel heater
B702
X18
[Grey]
(F)(E)
(F)(R)
X10
X04
X01
B701
Fuel gauge sensor
Z56
Regular cabin
Stretch cabin
(R)(R2)
X18
16
(F)(R)
X04
X04
(F)(R)
B701
Fuel gauge sensor
Double cabin
p57nUK
C-1a
MAIN
B(E)
B/W(E)
X01
B/W(F)
X02
X07
BTN
Ignition switch
OFF
ST
W/R(E)
30A
X08
X01
W/R
(F)
IG1 IG2
Fuse block
ACC
Fuse block
X02
METER
ROOM
W(F)
B/Y(F)
L/R(F)
10A
X03
...
...
...
...
...
...
15A
X03
B/Y
(F)
X03
X03
Instrument cluster
C101
1K
1J
22
Safety
1.4W
Fuel gauge
1I
2K
Tachometer
Microprocessor
1F
1L
1P
1N
1G
Charge
Speedometer
1M
Sedimentor
1.4W
1.4W
2C
2I
C101
L
(F)
BR/B
(F)
L/W
(F)
Y
(F)
B/R
(F)
X09
Y/B
(F)
R/Y
(F)
W/L
(F)
W/B
(F)
21
W
(F)
Z57
C104
L
(E)
51
L
(E)
L/W
(E)
48
L/W
(E)
C103
Door entry
switches
(Section I3)
C103
Fuel pump/fuel
gauge sender
(Section B5)
Immobiliser module
(Section T)
Powertrain control
module (PCM)
(Section B1b, 2b)
C102
Speedometer sensor
Speedometer sensor
except 4x4
4x4
5
L/W
1P
C103
L/Y
1O
R/Y
1N
W/L
1M
Speedometer sensor
(E)
except 4x4
L/W
C102
L
1L
C104
B
(F)
16
C101
Sedimentor
switch
Generator
(Section A1)
L/R
B/Y
B/R
1K
1J
1I
Y/B
1H
R/B
1F
1E
B
1D
C104
4x4
L/W
1G
R/G
G/B
G/W
1C
1B
1A
O
B/L
2N
<<R/L>>
2M
GY
2L
((BR/B))
(Y/G)
2K
2J
W
2I
<BR>
2H
[GY/R]
<LG/R>
BR
2G
2F
L/Y
2E
Y/R
2D
W/B
2C
2B
R/W
2A
Instrument cluster
(Section C1b)
Wiring Diagram
<>
[ ]
()
<< >>
(( ))
Battery
p58nUK
C-1a
Harness symbol
X08
Wiring Diagram
[ Black ]
(F)(E)
[ Black ]
(F)(E)
X09
X01
[ Grey ]
Speedometer sensor
C103
Z58
16
Instrument cluster
C101
C104
Sedimentor switch
[ Black ]
Instrument cluster
X07
(F)(E)
[ Black ]
C101
C102
Coolant temperature
sensor
X02
X03
Fuse block
X02
Ignition switch
Ignition switch
[ White ]
[ Blue ]
p59nUK
C-1b
Instrument cluster
Instrument cluster
(Section C1a)
22
26
Instrument cluster
(Section C1c)
Brake fluid
Air bag
4x4
4x4
1.4W
1.4W
2G
RFW
1.4W
2G
Rear fog
lamp
Oil pressure
1.4W
1.4W
1.4W
1.4W
2H
2D
2J
2M
2M
2E
C101
GY/R
(F)
LG/R
(F)
X09
BR
(F)
Y/R
(F)
Y/G
(F)
GY/R
(E)
Z59
4x4 Mode
switch
23
C109
B/R
(E)
C106
C105
C101
L/Y
R/Y
W/L
1P
1O
1N
1M
C107
C106
with air
bag
B
(F)
C105
L
1L
L/R
B/Y
B/R
1K
1J
1I
C108
Y/B
1H
1G
R/B
1F
1E
B
1D
C109
R/G
G/B
G/W
1C
1B
1A
L/Y
L/Y
B/R
GY/R
O
B/L
2N
<<R/L>>
2M
GY
2L
((BR/B))
2K
(Y/G)
2J
W
2I
Brake
fluid
sensor
Vacuum
warning
switch
B
(F)
L/W
C106
C108
C106
Park
brake
switch
52
Oil pressure
switch
L/Y
(F)
L/Y
(F)
C107
Brake
fluid
sensor
X09
B/R
(F)
L/Y
(F)
Y/R
(E)
25
24
O
(F)
R/L
(F)
X09
C109
except
European
specifications
(LHD)
European
specifications
(LHD)
<BR>
[GY/R]
<LG/R>
BR
L/Y
Y/R
W/B
2H
2G
2F
2E
2D
2C
R/W
2B
2A
Y/R
C106
Wiring Diagram
...
...
...
...
...
...
<>
[ ]
()
<< >>
(( ))
p60nUK
C-1b
Harness symbol
Wiring Diagram
C109
C108
Vacuum warning switch
[ Black ]
C106
Z60
Instrument cluster
C101
[ Black ]
Instrument cluster
X09
(F)(E)
[ Black ]
C101
C105
C107
Park brake switch
p61nUK
C-1c
27
28
29
30
45
R/B
(F)
R/W
(F)
G/B
(F)
G/W
(F)
B/L
(F)
GY
(F)
Illumination
3.4x4
1B
High
beam
1.4W
1A
RH
direction
indicator
1.4W
LH direction indicator
1.4W
2N
2L
Rear
window
heater
on
1.4W
Pre
glow indicator
1.4W
26
1D
1C
C101
B
(F)
R/G
(F)
Z61
38
Instrument illumination
potentiometer
(Section I1)
L/W
1P
L/Y
1O
R/Y
W/L
1N
1M
L
1L
L/R
B/Y
B/R
1K
1J
1I
[ ]
...
Instrument cluster
2A
1E
C01
...
()
...
<< >> ...
(( ))
...
...
C101
Instrument cluster
(Section C1b)
< >
Y/B
1H
1G
R/B
1F
1E
B
1D
R/G
G/B
G/W
1C
1B
1A
B/L
2N
O
<<R/L>>
2M
GY
2L
((BR/B))
(Y/G)
2K
2J
W
2I
<BR>
2H
[GY/R]
<LG/R>
2G
BR
2F
L/Y
2E
Y/R
W/B
2D
2C
R/W
2B
2A
Wiring Diagram
Direction indicator
switch
(Section F1)
Headlamp switch
(Section I1)
p62nUK
C-1c
Harness symbol
Z
Wiring Diagram
Instrument cluster
[ Black ]
Instrument cluster
C101
Z62
5
C101
p63nUK
C-2a
MAIN
B(E)
B/W(E)
B/W(F)
X02
Ignition switch
OFF
ST
W/R(E)
30A
X07
BTN
X08
X01
IG1 IG2
W/R
(F)
Fuse block
ACC
METER
ROOM
15
10A
X03
G/R(F)
Fuse block
X02
W(F)
B/Y(F)
L/R(F)
...
...
...
...
...
...
15A
X03
B/Y
(F)
X03
X03
C201
1H
1K
Instrument cluster
1J
22
Fuel gauge
Tachometer
Microprocessor
1I
1L
1F
1P
1N
1G
Charge
1.4W
Speedometer
1M
Sedimentor
1.4W
2C
C201
Y
(F)
L
(F)
L/W
(F)
B/O
(F)
X09
R/Y
(F)
Y/B
(F)
Z63
W/L
(F)
X05
L
(E)
19
B/O
(INJ)
L
(E)
L/W
(E)
Door entry
switches
(Section I3)
C203
Speedometer sensor
except 4x4
50
C202
Speedometer sensor
W/B
(F)
21
L/W
(E)
C203
O
(F)
4x4
Powertrain
control
module
(PCM)
(Section
B3c)
Ignition module,
Ignition coil
(Section B4a)
G6
F2 CIS
Generator
(Section A2)
13
C201 Instrument
L/W
1P
C203
cluster (F)
R/Y
1O
1N
O
((W/L))
1M
C202
L
1L
L/W
L/R
B/Y
B/O
1K
1J
1I
((G/R))
1H
4x4
L/W
Y/B
1G
R/B
1F
1E
B
1D
R/G
G/B
G/W
1C
1B
1A
B/L
2N
O
[GY/R]
<<R/L>>
2M
2L
2K
2J
<BR>
2I
2H
L/Y
[GY/R]
<LG/R>
2G
2F
2E
Y/R
W/B
2D
2C
R/W
2B
2A
Y/B
Instrument
cluster
(Section C2b)
Wiring Diagram
80A
X01
<>
[ ]
()
<< >>
(( ))
Battery
p64nUK
C-2a
Harness symbol
X09
13
Wiring Diagram
[ Black ]
(F)(E)
[ Grey ]
Speedometer sensor
C203
X01
[ Black ]
(F)(E)
X08
X07
(F)(E)
[ Black ]
X05
Instrument cluster
(F)(INJ)
[ Black ]
C201
C202
Crash sensor centre radiator
[ Black ]
F2 CIS
[ Black ]
Instrument cluster
C201
Z64
X01
[ Grey ]
Speedometer sensor
C203
X02
Ignition switch
[ Blue ]
X03
Fuse block
X07
X05
(F)(E)
[ Black ]
(F)(INJ)
[ Black ]
X08
(F)(E)
[ Black ]
G6
X09
(F)(E)
[ Black ]
C202
Crash sensor centre radiator
[ Black ]
X02
Ignition switch
[ White ]
p65nUK
C-2b
Instrument cluster
Instrument cluster
(Section C2a)
22
26
4x4
1.4W
4x4
1.4W
RFW
1.4W
2G
2G
Air bag
1.4W
2J
2H
Brake
fluid
1.4W
Rear
fog
lamp
1.4W
Oil
pressure
1.4W
2M
2D
Instrument
cluster
(Section C2c)
2E
2M
C201
GY/R
(F)
LG/R
(F)
X09
GY/R
(E)
Z65
European
specifications
(LHD)
Y/R
(F)
Y/G
(F)
BR
(F)
C207
C207
25
24
Remote freewheel
control system
(Section H)
B
(E)
Y/R
(E)
Brake
fluid sensor
52
C204
Oil pressure
switch
C205 Brake
R/Y
1N
O
((W/L))
1M
B
(F)
with air
bag
C204
L
1L
L/R
B/Y
B/O
1K
1J
1I
C206
C205
B
(F)
1O
Brake
fluid
sensor
B
(F)
1P
C205
Park
brake
switch (F)
C205
X09
L/W
L/Y
(F)
C206
C205
4x4 Mode
switch
23
C201
L/Y
(F)
O
(F)
R/L
(F)
X09
European
specifications
(LHD)
((G/R))
1H
Y/B
1G
R/B
1F
1E
B
1D
R/G
G/B
G/W
1C
1B
1A
C207 4x4
L/Y
B
GY/R
B/L
2N
O
(Y/G)
<<R/L>>
2M
2L
2K
2J
<BR>
2I
2H
L/Y
[GY/R]
<LG/R>
2G
2F
2E
Y/R
W/B
2D
2C
R/W
2B
2A
Oil pressure
switch (E)
Y/R
Wiring Diagram
< >...
[ ]...
( )...
(( ))...
<< >>...
p66nUK
C-2b
Harness symbol
[ Black ]
Wiring Diagram
(F)(E)
X09
C205
Brake fluid sensor
Instrument cluster
C201
F2 CIS
Z66
C204
C201
[ Black ]
Instrument cluster
C204
[ Black ]
4x4 Mode switch
C207
C206
Park brake switch
C205
Brake fluid sensor
G6
X09
(F)(E)
[ Black ]
p67nUK
C-2c
29
28
< >...
[ ]...
( )...
45
(( ))...
<< >>...
R/B
(F)
G/B
(F)
R/W
(F)
G/W
(F)
Instrument cluster
2A
1E
High
beam
1.4W
Illumination
3.4x4
1B
1A
2N
LH
direction
indicator
1.4W
RH
direction
indicator
1.4W
Rear
window
heater
on 1.4W
26
1D
1C
C201
B
(F)
R/G
(F)
Z67
38
Instrument illumination
potentiometer
(Section I1)
Instrument cluster
(F)
L/W
1P
R/Y
1O
1N
O
((W/L))
1M
1L
L/R
B/Y
B/O
1K
1J
1I
((G/R))
1H
Y/B
1G
R/B
1F
1E
B
1D
R/G
G/B
G/W
1C
1B
1A
B/L
2N
O
<R/L>
2M
2L
2K
(Y/G)
2J
<B/R>
2I
2H
C201
G6
European specifications (LHD)
B/L
(F)
C201
Instrument cluster
(Section C2b)
L/Y
[GY/R]
<LG/R>
2G
2F
2E
Y/R
W/B
2D
2C
R/W
2B
2A
Wiring Diagram
27
Direction indicator
switch
(Section F1)
Headlamp switch
(Section I1)
p68nUK
Harness symbol
C-2c
Z
Wiring Diagram
Instrument cluster
[ Black ]
Instrument cluster
C201
Z68
5
C201
C-3a
MA IN
B( E)
B/ W (E)
B /W (F )
A
80 A
01
BT N
X
01
Immobiliser module
(Section T2)
02
OF F
ST
10A
08
03
C3 1 0
C3 1 0
P( F)
61
ROO M
W/ R( F )
W/ R( E)
30 A
07
03
L/R
(F )
IG 2
IG 1
Ignition
switch
AC C
X 0 2
ME TE R
B/ Y (F )
W( F )
L/R (F)
15A
X 03
L/R
(F )
X 03
Instrument cluster
C3 0 1
1J
1K
Safety
1.4W
Coolant temp.
gauge
Fuel gauge
Tachometer
(Section C3c)
Speedometer
Charge
1.4W
Sedimentor
1.4W
Microprocessor
2K
1I
1F
1L
1P
1N
1G
1H
2C
1M
2I
C3 0 1
L
(F )
BR/ B
(F )
L/W
(F )
Y
(F )
B/ R
(F )
R/Y
(F )
Y/ B
(F )
X 0 9
W/ B
(F )
W/ L
(F )
G/ R
(F )
W
(F )
Z69
C3 0 4
L
(E )
51
L/W
(E )
48
Immobiliser
module
(Section T2)
21
L/W
(E )
L
(E )
C3 0 3
Door lock
switch
(Section I3)
C3 0 3
Fuel gauge
sensor
(Section B7)
except 4X4
4X4
3
16
1P
C3 0 3
C3 0 2
L/W
R/Y
1O
1N
W/ L
L/R
1M
1L
1K
B /Y
B /R
G/R
Y/ B
R/B
R/ G
G/B
G/W
1J
1I
1H
1G
1F
1E
1D
1C
1B
1A
L/W
C3 0 4
C3-02
Speedometer
sensor
C3 0 1
Sedimentor
switch
60
C3 0 4
4X 4
L/W
B/ L
R/ L
2N
2M
GY
BR/ B
(Y /G )
2L
2K
2J
C 31 0
W
2I
<B R >
<L G /R >
2H
2G
L/R
2F
L/ Y
Y/ R
W/ B
2E
2D
2C
R/W
2B
2A
Y/ B
(Section C3b)
Wiring Diagram
Battery
p70UK
C-3a
Harness symbol
(F)(E)
[Grey]
(F)(E)
X08
X07
X09
Wiring Diagram
[Black]
(F)(E)
[Grey]
Speedometer sensor
C303
X01
Z70
Instrument cluster
C301
[Black]
Instrument cluster
C304
C301
Sedimentor switch
Key warning switch
C310
16
C302
Coolant temperature
sensor
X02
Ignition switch
[White]
X02
X03
Fuse block
Ignition switch
[Blue]
C-3b
)...
AI R BAG
1.4W
2H
2G
GLOW
1. 4 W
OIL
1.4W
1. 4 W
RF W
LOC K
1.4W
4W D
2J
2D
B R AKE
1. 4 W
2L
2E
C3 01
Y/ G
(F )
LG/R
(F )
Z71
24
Y/ G
(F )
Y/ G
(F )
47
25
Remote freewheel
control module
(Section H2)
L/Y
(F )
Y/ R
(F)
BR
(F )
23
GY
(F )
X 0 9
C3 0 6
Y/ R
(E )
L/ Y
(F )
L/Y
(F )
C3 0 7
Brake fluid
sensor
Park brake
switch
C3 0 5
Oil pressure
switch
Powertrain control
module (PCM)
(Section B6c)
4X 4
C3 0 6
B
(F )
C3 0 1
1P
C3 0 6
C3 0 5
L/W
R/Y
1O
1N
W/ L
L/R
1M
1L
1K
B /Y
B /R
G/R
Y/ B
R/B
R/ G
G/B
G/W
1J
1I
1H
1G
1F
1E
1D
1C
1B
1A
C3 0 7
L/Y
B
Wiring Diagram
Instrument cluster
(Section C3a)
B/ L
R/ L
2N
2M
L/Y
GY
BR/ B
(Y /G )
2L
2K
2J
W
2I
<B R >
<L G /R >
2H
2G
2F
L/ Y
Y/ R
W/ B
2E
2D
2C
R/W
2B
2A
Y/ R
p72UK
C-3b
Harness symbol
Z
Wiring Diagram
[Grey]
(F)(E)
X09
C306
Brake fluid sensor
Z72
Instrument cluster
C301
[Black]
Instrument cluster
C301
C305
Oil pressure switch
C307
Park brake switch
C-3c
Rear window
heater relay
(Section I2)
27
28
29
30
45
52
R/B
(F )
R/W
(F )
G/B
(F )
G/W
(F)
B/ L
(F )
R/L
(F )
Instrument cluster
C3 0 1
1E
2A
1B
2N
1A
2M
(Section C3a)
ILLU M I
3.4X 4
T URN
RH
1. 4 W
T URN
LH
1.4W
B EAM
1. 4W
1C
R.DEF
1. 4 W
1D
C3 0 1
R/G
(F )
B
(F )
Z73
38
C3 01
Instrument
cluster (F)
L/W
1P
R/Y
1O
1N
W/ L
L/R
1M
1L
1K
B /Y
B /R
G/R
Y/ B
R/B
R/ G
G/B
G/W
1J
1I
1H
1G
1F
1E
1D
1C
1B
1A
B/ L
R/ L
2N
2M
GY
BR/ B
(Y /G )
2L
2K
2J
W
2I
<B R >
<L G /R >
2H
2G
2F
L/ Y
Y/ R
W/ B
2E
2D
2C
R/W
2B
2A
R. F O G
1.4 W
)...
Wiring Diagram
Headlamp
switch
(Section E4)
Headlamp
switch
(Section I1)
p74UK
C-3c
Harness symbol
Z
Wiring Diagram
Instrument cluster
[Black]
Instrument cluster
C301
Z74
C301
p75nUK
Windshield Wiper/Washer
()
MAIN
B/W(E)
B(E)
80A
B/W(F)
X07
X01
Fuse block
IG1 IG2
WIPER
B/R(F)
15A
X03
L
(F)
X02
OFF
ST
Wiring Diagram
X01
...
Ignition switch
ACC
X02
X03
Wiper/washer switch
L(F)
D02
Onetouch wipe
High speed
L
(F)
Intermittent
wipe
Low speed
Washer switch
Off
High speed
Off
Low speed
Intermittent wipe
Intermittent
wiper relay
D02
L(F)
L
(F)
L/O
(F)
L/B
(F)
L/Y
(F)
L/W
(F)
Z75
D03
D01
Windshield washer
pump motor
D01
Circuit
breaker
Windshield wiper
motor
D01
Windshield washer
pump motor (F)
B
L/O
D02
Wiper/washer switch
(F)
(G/R)
D03 Windshield
wiper motor
(F)
L/Y
L/W
L/B
B
(F)
Stop switch
B
(F)
L/O
L/W
L/Y
L/B
Battery
p76nUK
Harness symbol
D01
D03
D03
X01
X01
D01
X07
Z76
(F)(E)
[ Black ]
F2 CIS, G6
X07
3
[ White ]
Ignition switch
X02
D02
Wiper/washer switch
5
X02
Ignition switch
X03
Fuse block
[ Blue ]
(F)(E)
[ Black ]
WL,WL Turbo
Wiring Diagram
p77nUK
Headlamps (without daytime running lamps / without headlamp levelling, before model year 2002)
Fuse block
TAIL
BTN
W/R(E)
B(E)
W/R(F)
Y/R(F)
10A
X03
X03
HEAD
R(E)
30A
X01
R(F)
X08
E101
Light
switch
Off
TNS
Headlamp
switch
Headlamp
flasher
Headlamps
Dimmer switch
Low
beam
High beam
R/B(F)
E101
R/W
(F)
Z77
Instrument cluster
(Section C1c, 2c)
R/L
(F)
R/W(F)
28
R/W
(F)
R/L
(F)
R/W
(F)
R/L
(F)
E102
Headlamp, LH
side
E103
60/55W
60/55W
E102
E103
B(F)
1
E101
R/B
E102 Headlamp,
R/L
R/W
G/W
G/O
Y/R
LH side (F)
G/B
E103
R/L
B
R/L
R/W
R/B(F)
39
Instrument Illumination
(Section I1)
R/B(F)
40
R/B(F)
41
E101
R/W
Headlamp, RH
side
Wiring Diagram
30A
X01
Battery
E-1
p78nUK
E-1
Harness symbol
Z
Wiring Diagram
[ Black ]
(F)(E)
X08
X01
Z78
E103
Headlamp, RH side
[ Black ]
E102
Headlamp, LH side
[ Black ]
E101
Headlamp switch
X03
Fuse block
p79nUK
E-2
Headlamps (with daytime running lamps / with headlamp levelling, before model year 2002)
Battery
MAIN
A
B/W(E)
B(E)
B/W(F)
X01
Fuse block
X07
BTN
W/R(E)
Ignition switch
W/R(F)
Y/R(F)
10A
X03
R(E)
30A
X03
IG1 IG2
Headlamp switch
X08
B/R
(F)
E201
Light
switch
R.FOG
TNS
E201
R/Y(F)
R/G(F)
10A
E206
Headlamp
levelling
motor LH
Headlamp
levelling
motor RH
Headlamps
Fuse block
R
(F)
Dimmer
switch
Headlamp
flasher
X03
R/G(F)
E207
X03
Off
Fuse block
X03
ACC
X02
R(F)
X01
OFF
ST
HEAD
53
X02
TAIL
30A
High beam
WIPER
15A
X03
Low
beam
L
(F)
E201
R/B(F)
R/G(F)
E207
E206
B
(F)
B(F)
W
(F)
E205
E204
Z79
E208
Instrument cluster
(Section C1c, 2c)
W/L
(F)
28
R/W(F)
R/W
(F)
B
(F)
R/L
(F)
R/W
(F)
R/L
(F)
E202
E208
Headlamp, LH
side
B
(F)
B
(F)
W/L(F)
41
W/L(F)
40
E203
Headlamp, RH
side
60/55W
60/55W
B
(F)
E203
E202
B(F)
E201
R/B
E205
R/Y
E202
R/G
G/W
G/O
Y/R
R/W
Daytime Running
Lamps (DRL) relay (F)
W/L
R/W
R/B
G/B
E203
E208
Headlamp levelling
switch (F)
G
B
E204
R/L
R/W
Headlamp levelling
motor RH (F)
E207
B
W
R/L
E206
Instrument Illumination
(Section I1)
Daytime Running
Lamps (DRL) relay
E204
G(F)
39
E205
Headlamp
relay
R/W
(F)
Headlamp
levelling
switch
Wiring Diagram
80A
R/G
R
R/W
R/G
Headlamp levelling
motor LH (F)
R/G
R/L
W
B
p80nUK
E-2
Harness symbol
[ Black ]
(F)(E)
Wiring Diagram
X07
[ Black ]
(F)(E)
E204
X08
X01
Z80
E203
Headlamp, RH
side
[ Black ]
Headlamp levelling
switch
E208
E206
E207
[ Grey ]
E202
[ Grey ]
Headlamp, LH
side
[ Black ]
E201
Headlamp switch
X02
X03
Fuse block
X02
Ignition switch
Ignition switch
[ Blue ]
[ White ]
p81nUK
E-3
Licence plate lamps / Parking Lamps / Tail lamps / Rear fog lamps (before model year 2002)
...
<>
R/G(F)
X04
E308
R/G(F)
R/L(F)
R/L(F)
Wiring Diagram
Headlamp switch
(Section E2)
R/L(R)
B(F)
R/B
(F)
<W/L>
41
R/G
(F)
X04
R/W
(F)
R/B
(F)
<W/L>
40
R/L
(F)
E309
E309
R/B
(R)
R/G(F)
R/L(F)
R/L(F)
Instrument cluster
(Section C1b, 2b)
52
X18
R/B
<W/L>
(F)
R/B
<W/L>
(F)
E301
X18
R/B
(R2)
E302
LH parking lamp
E303
RH parking lamp
5W
5W
E301
E303
Z81
B
(F)
E305
RH Licence plate
lamp
5W
R/B
(R2)
R/B
(R2)
E304
LH Licence plate
lamp
5W
E302
B
(F)
R/B
(R2)
R/L
(R2)
E306
E304
B
(F)
5W
E305
E307
Tail lamp, RH
side
E306
B
(R2)
B
(R2)
B
(R2)
B
(R2)
11
10 11
11
10 11
Rear fog
lamp
21W
E307
B
(R2)
B
(F)
E301
E306
E302
R/B
<W/L>
R/B
<W/L>
R/W
G/W
R/B
W/G
E307
E303
R/L
B
E304
R/B
R/L
11
E309 Rear
R/G
E305 Tail
R/B
E308
B
R/L
R/W
R/W
G/B
R/B
W/G
p82nUK
E-3
Harness symbol
E306
E304
10
(R)(R2)
E307
X18
Wiring Diagram
(F)(R)
X04
E305
E303
LH Licence plate
lamp
E302
11
RH parking lamp
Z82
E301
LH parking lamp
X04
(F)(R)
E308
Rear fog lamp relay
E309
Rear fog lamp switch
E-4
Battery
+
MA IN
B/ W( E)
B( E)
B/ W( F )
X 0 1
X 0 7
TA IL
BT N
W/ R( E )
W/ R( F )
30A
10A
03
X 0 3
IG 1
HE AD
R( E)
30A
01
Headlamp switch
X 0 8
IG 2
Ignition switch
AC C
02
R( F )
02
OF F
ST
Y/ R( F)
Wiring Diagram
80A
B/ R
(F )
E4 0 1
Light switch
03
R.F O G
53
E4 0 1
Off
R/Y (F )
R/G(F )
R/G
(F )
10 A
03
TN S
X 0 3
R/G
(F )
E4 07
WI PE R
15A
R
(F )
Dimmer switch
Headlamp
flasher
R/ G (F )
Head
High
beam
03
Low
beam
L
(F )
E4 0 6
Headlamp
levelling
motor LH
E4 0 1
R/B( F )
R/ B (F )
R/G( F )
E4 0 6
E4 0 7
R/W
(F )
G
(F )
Daytime Running
Lamps (DRL)
relay
W
(F )
Headlamp relay
G(F )
Z83
B
(F)
Instrument cluster
(Section C3c)
28
R/ W( F )
R/W
(F )
Headlamp, LH
side
R/B
E4 0 5
E4 0 8
R/Y
19
E 4 0 2
R/G
G/W
G/O
Y/ R
R /W
R/W
R/B
G/B
G
B
E 4 03
B
(F )
18
19
E 4 0 6
B
(F )
4
E4 0 4
B
E 4 0 7
R/G
R/L
R/W
40
B
(F )
60 /55W
B
(F )
R/L
W/ L(F )
E4 0 3
Headlamp, RH
side
E 4 03
R/L
(F )
E 4 0 2
R/W
(F )
60/ 55W
B
(F )
18
R/L
(F)
E4 0 2
B
(F )
E4 0 8
E 4 01
E4 0 5
E4 04
E4 0 8
Headlamp
levelling
switch
Instrument illumination
(Section I1)
E4 0 5
E4 0 4
G
(F)
39
R/W( F )
R/W
R/G
R/G
R/L
W
B
p84UK
E-4
Harness symbol
[Black]
(F)(E)
X07
E404
Wiring Diagram
[Blue]
Headlamp relay
(F)(E)
Daytime Running
Lamps (DRL) relay
X08
E405
Main fuse box
X01
19
Z84
E403
Headlamp, RH side
[Black]
E408
E406
Headlamp levelling
motor RH
E407
[Grey]
Headlamp levelling
motor LH
[Grey]
18
E402
Headlamp, LH side
[Black]
E401
Headlamp switch
X02
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
E-5
Licence plate lamps / Parking Lamps / Tail lamps / Rear fog lamps (WL3, WLT3, as of model year 2002)
R/G( F )
R /L(F )
R/G( F )
04
R /L(F )
Wiring Diagram
Headlamp switch
(Section E4)
R /L(R )
B( F)
E5 0 8
E5 0 8
X 0 4
Daytime Running
Lamps (DRL)
relay
(Section E4)
40
R/G
(F )
W /L( F)
W/ L (F )
R/ W
(F )
R/B
(R )
W/ L
(F )
X
R/L
(F )
E5 0 9
E5 0 9
R/L (F )
18
R/B
(R 2 )
W/ L (F )
52
R/L (F )
Instrument
cluster
(Section C3c)
X 1 8
R/B( R2 )
R/B( R2 )
R/L
(R 2 )
B
(F )
W/ L
(F )
W/ L
(F )
R/B
(R 2)
R/B
(R 2)
R/B
(R 2)
R/B
(R 2)
E5 07
LH parking
lamp
Z85
5W
E5 0 2
5W
E5 01
E 501
E5 0 2
E5 04
E5 0 3
RH parking
lamp
E5 0 2
LH Licence
plate lamp
5W
B
(R 2 )
18
19
10 11
10 1 1
11
10 1 1
E5 0 3
E 5 0 4
11
E 5 05
E 5 08 Rear
E 5 09
R /W
R/L
R/W
G/ B
R/B
W/ G
R/B
B
G/W
W/ G
R/B
B
(R 2)
E5 0 6
B
(R 2)
R/B
5W
B
(R 2)
R/L
B
E5 0 5
Tail lamp,
RH side
B
(R 2)
W/ L
R/W
5W
E5 04
E5 0 6
Tail lamp,
LH side
B
(F)
E 507
E5 0 5
B
(F )
W/ L
5W
E5 0 3
E 506
RH Licence
plate lamp
B
R/ L
R /W
p86UK
E-5
Harness symbol
10
[Black]
RH Licence plate lamp
E504
(R)(R2)
X18
E507
19
E505
(F)(R)
X04
E503
LH Licence plate
lamp
[Black]
11
Z86
E502
RH parking lamp
18
E501
LH parking lamp
X04
(F)(R)
E508
Rear fog lamp
relay
E509
Rear fog lamp
switch
Wiring Diagram
E506
p87nUK
F-1
Fuse block
MAIN
B(E)
B/W(E)
B/W(F)
L/Y(F)
10A
X01
A
B/W(E)
B/W(F)
X07
X02
Ignition
switch
OFF
ST
IG1 IG2
ACC
METER
X02
W(F)
B/Y(F)
X03
15A
F103
X03
F104
Hazard flasher
switch
G/R(F)
F103
Electronic
flasher
module
F104
G/O
(F)
F103
G/B
(F)
G/O(F)
G/W
(F)
G/B(F)
G/B(F)
G/W(F)
G/W(F)
LH direction indicator
RH direction indicator
E101
<E201>
X18
X04
X04
G/B(R)
G/B(F)
G/B
(R2)
Z87
21W
21W
E305
F102
F103
R/W
G/B
R/B
W/G
G/W(R)
G/W
(F)
F106
5W
21W
F106
E306
R/G
E306
R/B
B/Y
G/W
G/B
L/Y
G/R
R/W
G/W
R/B
W/G
E306
B
(F)
F104 Electronic
G/O
21W
F102
B
(F)
Direction
indicator
switch
F102
Side direction
indicator lamp,
RH side
B
(R2)
B
(F)
10 11
E101 Direction
<E201>
flasher mod-
G/O
B
F105
E101
<E201>
G/W
(R2)
ule (F)
30
F105
G/W
29
B
(F)
G/B
G/W
(F)
Instrument cluster
(Section C1c, 2c)
Side direction
indicator lamp,
LH side
5W
B
(F)
11
E305
F105
F101
B
(R2)
G/B
(F)
X18
G/W(F)
G/W
(F)
F101
G/W(F)
G/B
(F)
G/B
(F)
E305
F101
G/B(F)
G/O
(F)
R/B
G/R
G/B
R/L
<R/Y> <R/G>
F106
G/W
G/O
Y/R
R/W
G/B
G/W
Wiring Diagram
80A
X01
...with
<>
HAZARD
Battery
p88nUK
F-1
Harness symbol
10
(R)(R2)
E306
Wiring Diagram
X01
X18
F106
[ Black ]
Side direction indicator
lamp, LH side
F105
(F)(R)
X04
E305
LH Rear direction indicator lamp
F102
Direction indicator lamp,
RH side front
11
X07
Z88
(F)(E)
[ Black ]
F101
Direction indicator lamp,
LH side front
3
Hazard flasher switch
F103
[ White ]
Ignition switch
X02
X04
(F)(R)
4
F104
Electronic
flasher module
X03
X02
Ignition switch
Fuse block
[ Blue ]
p89nUK
F-2
<>
MAIN
B(E)
B/W(E)
B/W(F)
BTN
STOP
X08
X01
X02
15A
X03
G/W
(F)
X03
Ignition switch
OFF
ST
W/R(F)
W/R(E)
30A
Fuse block
X07
IG1 IG2
Fuse block
ACC
METER
X02
X03
Stop lamp
switch
F201
X09
F201
F206
<L>
F205
16
Reversing
lamps
switch
F2 CIS,G6
F2 CIS,G6
R/W(F)
W/G(F)
R/W(E)
X09
W/G
(F)
G/R
(F)
Dual horn
B/Y(E)
X03
F205
Horn relay
Single
horn
15A
F206
G/W
(F)
A
B/Y(F)
W(F)
G/W(F)
G/W(F)
with remote
freewheel control system
R/W(E)
R/W(F)
X08
X04
R/W(F)
R/W(E)
R/W
(R)
W/G
(R)
WL,WL Turbo
X18
B/R
(F)
B/R
(F)
G/R
(F)
B/R
(F)
W/G
(R2)
R/W
(R2)
S102
Z89
F204
F203
F202
Horn
Horn
LH
Horn
RH
G/R
(F)
G/R
(F)
R/W
(R2)
F207
W/G
(R2)
Reversing
lamp,
left
21W
Clock
spring
D02
Horn
switch
Horn
switch
F202
D02
E305
21W
Stop
lamp
RH
21W
Reversing
lamp,
right
E306
B
(R2)
B
(R2)
11
10 11
RH (F)
F204
Horn (F)
F205
F206
F207 Horn
switch (F)
C
A
G/W
G/W
G/W
B/R
21W
E306
Stop
lamp
LH
F203 Horn
Horn LH (F)
R/W
(R2)
E305
G/R
F201
W/G
(R2)
B/R
B/R
E305 Reversing
L/W
L/Y
L/B
G/R
B
G/W
B/Y
W/G
R/W
B/R
G/R
R/W
G/B
R/B
W/G
E306
R/W
G/W
R/B
W/G
S102 Shorting
G/R
G/R
B/Y
B/W
Y/G
Y/G
R/G
R/G
G/R
B/W
B/Y
Wiring Diagram
80A
X01
...G6
Battery
p90nUK
F-2
Harness symbol
Reversing lamp, right
X01
X09
Stop lamp RH
10
Reversing lamps switch
E306
(R)(R2)
F206
X18
Stop lamp LH
E305
[ Black ]
(F)(E)
X07
(F)(R)
X04
F204
Horn
[ Black ]
F203
Horn RH
Z90
[ Black ]
11
X08
(F)(E)
[ Black ]
F2 CIS, G6
F202
Horn LH
[ Black ]
X01
S102
X09
Reversing lamps switch
F206
[ Black ]
[ White ]
Ignition switch
(F)(E)
X07
X02
F205
X04
F204
D02
Horn
[ Black ]
F203
Horn RH
[ Black ]
Horn switch
F201
X02
Horn relay
Ignition switch
X08
(F)(E)
[ Black ]
X03
F202
Horn LH
[ Black ]
WL, WL Turbo
Fuse block
[ Blue ]
(F)(R)
F207
Horn switch
Wiring Diagram
[ Black ]
(F)(E)
F-3
Turn Signal and Hazard Lamps (WL3, WLT3, as of model year 2002)
MA IN
B( E)
X
L/Y (F )
B/ W( F)
01
A
B/ W (E)
B /W (F )
X 0 7
10A
03
03
X 0 2
Ignition switch
OF F
ST
IG 1
IG 2
AC C
X 0 2
X 03
X 03
ME TE R
W( F )
B/ Y( F)
15 A
F3 0 3
Flasher unit
Hazard flasher
switch
F3 04
F3
F3
F3 04
G/R( F )
03
G/O
(F )
03
G/B
(F )
G/ W
(F )
G/O(F )
left
G/B (F )
G/W (F )
X
18
G/B
(F )
X 0 4
G/B (R)
G/B (F )
G/B (F )
G/B (F )
Z91
G/ B
(F )
G/W
(F)
29
21 W
21 W
E5 0 5
F 3 0 1 Direction
indicator lamp, LH
B
(F )
11
18
F 3 0 2
G/B
F 3 0 3
F3
G/W
B
E4 01
R/Y
21 W
B /Y
G/W
G/B
L/Y
G/R
R /G
G/W
G/O
Y /R
21 W
Direction
indicator
lamp, RH
rear
E5 0 6
B
(F )
B
(R 2)
19
10 11
F 3 0 5
G/O
B
B
E5 0 5
R /W
B
(F )
E5 0 6
F3 02
F3 04
R/B
Side direction
indicator lamp,
RH
5W
F3 06
R /B
G/W
(R 2)
F3 02
B
(F)
R/G
right
Direction indicator
switch
G/W (R)
G/W
(F )
F3 06
05
G/O
X 1 8
30
Instrument
cluster
(Section C3c)
B
(F )
G/W
B
F 3 06
05
Side direction
indicator lamp,
LH
5W
F3 01
B
(R 2 )
front (F)
F3
G/W (F )
G/W (F )
04
G/ W
(F )
G/B
(F )
F3 01
E5 0 5
G/W (F )
G/B
(F )
G/ B
(R 2 )
E4 0 1
E4 0 1
G/ W
(F )
G/B
G/R
G/B
R/W
B
R/B
E5 0 6
G/B
W/G
G/O
(F )
R/W
G/W
R/B
W/G
Wiring Diagram
X 0 1
HAZ A RD
B/ W (E)
80 A
Battery
p92UK
F-3
Harness symbol
F306
10
(R)(R2)
X01
X18
Direction indicator
lamp, LH rear
E505
19
(F)(R)
Side direction indicator lamp, LH
F305
X04
11
F302
Direction indicator lamp, RH front
Z92
[Black]
18
X07
(F)(E)
[Black]
F301
F303
[Black]
X04
(F)(R)
E401
F304
X02
Flasher unit
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
Wiring Diagram
E506
F-4
Reversing lamps / Stop Lamps / Horns (WL3, WLT3, as of model year 2002)
Battery
+
MA IN
B( E)
B/ W( E)
B/ W( F )
X 0 1
X 0 2
X 0 7
BT N
ST O P
W/ R( E)
30A
OF F
ST
Ignition switch
W/ R( F )
01
X 0 8
03
15 A
G/W
(F)
X 0 3
IG 1
IG 2
AC C
ME TE R
X 0 2
G/W (F )
B/ Y( F)
X
G/W (F )
G/W
(F )
A
W( F )
15A
03
03
X 0 9
F4 04
B/ Y
(E )
F4 0 1
Horn relay
F4 04
X
F4 0 1
W/ G
(F )
G/R
(F )
F4
05
18
G/R
(F )
B/ R
(F )
F4 05
R/W( E )
04
W/ G
(R )
B/ R
(F )
08
R/W( F )
W/ G
(R 2)
R/W
(R 2)
W/ G
(R 2)
R/W
(R 2)
S2 0 2
F4
02
F4
Z93
Horn LH
03
Horn
RH
G/R
(F )
G/R
(F )
F4 06
R/W
(R 2)
W/ G
(R 2 )
E5 0 5
G/R
Clock
spring
21W
Stop
lamp LH
21W
E5 0 6
Reversing
lamp, LH
21W
Reversing
lamp, RH
D2 0 2
Horn
switch
D2 0 2
F4 02
Horn LH (F)
F 40 3
Horn
switch
E5 0 5
E5 0 6
B
(R 2)
B
(R 2)
11
10 11
Horn RH (F)
F 4 0 5
G/ W
G/ W
G/ W
B/ R
G /R
B/ R
L/ W
L/ Y
L/ B
B/ Y
W/ G
R/W
B/ R
E 5 05
L/O
G/W
F 4 0 6
G/ R
B
R/W
G/B
R/B
W/ G
E5 0 6
R/W
G/W
R/B
W/G
S 20 2
G/R
G/R
B /Y
B /W
Y /G
Y/ G
B /W
B /Y
G/R
Stop lamp RH
21 W
Wiring Diagram
80A
p94UK
F-4
Harness symbol
[Grey]
(F)(E)
X07
E506
(R)(R2)
X18
X01
E505
Reversing lamps switch
(F)(R)
F405
X04
11
F403
Z94
Horn RH
[Black]
X08
(F)(E)
S202
F402
Horn LH
[Black]
X04
(F)(R)
F404
Stop lamp switch
F406
Horn switch
F401
D202
Horn relay
X02
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
Horn switch
Wiring Diagram
X09
[Black]
(F)(E)
p95nUK
G-1
X01
( )...
X07
X01
MAIN
B(E)
B/W(E)
B/W(F)
B/W(E)
X02
OFF
ST
(A/C)
LG/R(F)
IG1 IG2
10A
ACC
X02
WIPER
L(F)
Ignition switch
B/W(F)
Wiring Diagram
80A
L(F)
B/R(F)
15A
(HEATER)
B/R(F)
LG/R
(F)
40A
X03
L
(F)
X03
Fuse block
L(F)
L
(F)
G106
A/C Relay
1
G106
Resistor
Powertrain control
module (PCM)
(Section B1b, 2b)
7
R/B
(F)
LG/B
(F)
A/C switch
L
G105
M
G103
G110
G108
L/Y
L/Y
(F)
A/C pressure
switch
Z95
R/W
(F)
L
(F)
G108
G104
L/W
(F)
R/G
(F)
L/R
L/Y
(F)
L/B
L/B
G102
G109
Blower
motor
G105
L/B
L(F)
L
(F)
L/R
(F)
L/B
(F)
X09
(L)
G102
Blower assembly
G101
R/G
(E)
AMP
2
3
Off
G107
A/C Compressor
clutch
B
(F)
Fan switch
Thermo switch
G101 C
G102
L/R
B
G106
LG/B
R/B
L/Y
L/B
G107
(F)
L/R
L/Y
G108
L/B
G103
(Blower assembly)
L/R
L/B
L/Y
G109
R/G
LG/B
Resistor
(Short cord)
L
L/R
L/Y
L/B
R/W
Resistor
G105 Blower
motor
(Short cord)
(Short cord)
L/B
L/B
L/W
G104
G110
L/Y
L/W
Battery
p96nUK
G-1
Harness symbol
X01
[ Black ]
(F)(E)
Wiring Diagram
X07
[ Black ]
(F)(E)
X09
G102
Z96
A/C switch
G110
G106
G108
[ White ]
Ignition switch
A/C Relay 1
Resistor
G103
G107
X02
G104
Resistor
G105
Blower motor
G109
Thermo switch
G101
Heater control module
X02
Ignition switch
X03
Fuse block
[ Blue ]
p97nUK
G-2
Battery
X07
X01
MAIN
B(E)
B/W(E)
B/W(F)
B/W(E)
X02
Ignition switch
B/W(F)
OFF
ST
(A/C)
LG/R(F)
IG1 IG2
10A
ACC
X02
WIPER
L(F)
Wiring Diagram
80A
L(F)
B/R(F)
15A
(HEATER)
B/R(F)
LG/R
(F)
X03
L
(F)
G206
A/C Relay
1
Powertrain control
module (PCM)
(Section B3c, 4c)
7
40A
Fuse block
X03
Thermo switch
L(F)
L
(F)
Resistor
A/C switch
Blower assembly
G202
G206
R/B
(F)
LG/B
(F)
G205
M
R/G
(F)
G203
G210
G208
G204
L/B
L(F)
G208
L/Y
L/Y
(F)
Z97
L
(F)
R/W
(F)
L/W
(F)
L/R
L/Y
(F)
G209
G205
L/B
L/B
G202
G207
A/C Compressor
clutch
Blower
motor
L
(F)
L/R
(F)
L/B
(F)
G201
AMP
2
3
Off
Thermo switch
B
(F)
Fan
switch
G201 Heater
control module
G202 (F)
(F)
G206
LG/B
R/B
Blower assembly
E
(F)
L/R
L/Y
L/R
L/B
L/Y
L/B
G207
A/C Compressor
clutch (E)
LG/B
G208
G203
(Blower assembly)
L/R
L/B
L/Y
G209
R/W
R/G
Resistor
(Short cord)
L
L/R
L/Y
L/B
G204 Resistor
(Short cord)
R/W
Blower motor
(Short cord)
L/B
L/B
L/W
G205
G210
L/Y
L/W
p98nUK
G-2
Harness symbol
Wiring Diagram
X01
G206
A/C Relay 1
X07
G202
Z98
(F)(E)
[ Black ]
G208
A/C switch
G210
G207
A/C Compressor clutch
[ White ]
Ignition switch
G203
Resistor
X02
G204
Resistor
G205
Blower motor
G209
Thermo switch
G201
Heater control module
X02
Ignition switch
X03
Fuse block
[ Blue ]
G-3
01
MA IN
01
B( E)
B/ W( E)
Battery
07
B/ W (F )
B/ W( E)
B/ W (F )
02
Ignition switch
OF F
ST
Wiring Diagram
80A
A/ C
LG/R(F )
IG 1
IG 2
AC C
10A
X 0 2
WI PER
L(F)
L(F )
B/ R (F)
15A
L
(F )
LG/R
(F )
HEAT ER
B/ R (F)
40A
X 0 3
03
G3 0 6
A/C Relay
L(F )
G3 0 6
7
G30
G3 0 4
G3 03
05
Blower
motor
G3
G310
L/B
L( F)
L/Y
L/ Y
(F )
Z99
R/W
(F)
L
(F )
G
(F )
L/W
(F )
09
L/R
G3 02
L
(F )
L/Y
(F )
L/R
(F )
05
L/B
L /B
L/Y
(F )
G309
G
(E )
Blower assembly
L/B
(F )
G3 01
AM P
1
G30
G3
A/C pressure
switch
G30
G30
Resistor
A/C switch
Powertrain control
module (PCM)
(Section B6c)
R/B
(F )
LG/B
(F )
L
(F )
B
(F )
A/C Compressor
clutch
OF F
4
Thermo switch
Fan
switch
G301
G302
L/Y
L/B
G303
(F )
L/R
L/Y
L/B
L/R
L
G307
LG/R
LG/B
R/B
G3 0 8
L/B
(Short cord)
L/R
L/Y
L /B
G3 05
Resistor
(Short cord)
B
G306
G304
Resistor
G309
LG/ B
G 3 1 0
L/W
R/W
(Short cord)
L/B
L/B
L/Y
Blower motor
L/Y
L/W
p100UK
G-3
Harness symbol
[Grey]
(F)(E)
Wiring Diagram
X09
[Black]
(F)(E)
X07
Main fuse box
X01
Blower assembly
G302
A/C switch
Z100
G310
G303
Resistor
G306
A/C Relay
G308
A/C pressure switch
[Black]
G307
A/C Compressor
clutch
G304
Resistor
G305
Blower motor
G309
Thermo switch
G301
X02
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
p101nUK
< >...
MAIN
B(E)
B/W(E)
80A
X01
B/W(F)
X02
X07
Lock solenoid
Ignition switch
Free solenoid
OFF
ST
IG1 IG2
H04
ACC
X02
W
(F)
H02
B/W
(F)
Fuse block
B
(F)
H03
B/W
(F)
H04
ENGINE
B/W(F)
15A
X03
X03
B/W
(F)
R
(F)
LG
(F)
G/O
(F)
H01
R/G
(F)
GY/R
(F)
LG/B
(F)
E
H01
Z101
B
(F)
X09
R/G
(E)
H06
Remote freewheel
switch
H05
H07
H06
B/R
(E)
<B>
LG/R
(F)
24
23
LG/B
(E)
GY/R
(E)
H05
BR
(F)
Neutral position
switch
B/R
(E)
<B>
H07
Instrument cluster
(Section C1b, 2b)
B/R
(E)
<B>
B/R
(F)
<B>
X09
B/R
(F)
H01 Remote
6
WL,
WL Turbo
GY/R G/O
LG/B
R/G
H05 Remote
freewheel
switch (E)
R/G
B/R
<B>
H02
LG/R
LG
B/W
BR
B
D
H06 4x4
B/R
GY/R
<B>
H03
H07 Neutral
position
switch (E)
B/R
LG/B
<B>
B/W
B
(F)
G6
H04
LG
B/W
Remote freewheel
main switch (F)
G/O
Wiring Diagram
X01
G6
Battery
p102nUK
Harness symbol
[ Grey ]
Lock solenoid
H02
H02
[ Yellow ]
Free solenoid
X01
[ Yellow ]
Free solenoid
[ Black ]
Neutral position switch
H03
H07
[ Black ]
4x4 Mode switch
H06
H03
[ Black ]
Neutral position
switch
X01
H07
[ Black ]
Remote freewheel
switch
H05
H06
X07
Z102
(F)(E)
[ Black ]
X07
H05
(F)(E)
[ Black ]
WL, WL Turbo
G6
3
Ignition switch
[ White ]
X02
X02
Ignition switch
H01
Remote freewheel control
module
[ Blue ]
H04
Remote freewheel main
switch
[ Blue ]
X03
Fuse block
Wiring Diagram
[ Blue ]
Lock solenoid
H-2
Battery
+
MA IN
B( E)
B/ W (E )
X 0 1
B/ W( F)
X 0 2
X 0 7
IG 1
G2
Lock solenoid
Free solenoid
Ignition switch
OF F
ST
Wiring Diagram
X 0 1
80 A
AC C
X 0 2
H 2 02
W
(F )
H 2 03
B/ W
(F )
B/ W
(F )
E N GINE
B/ W( F)
X
03
15A
X 0 3
B/ W
(F )
R
(F )
LG
(F )
H2 0 1
H2 0 1
GY /R
(F )
R/G
(F)
L G/B
(F )
LG/ R
(F)
X 0 9
B
(F )
R/G
(E )
GY /R
(E )
Z103
H2 0 5
LG /B
(E )
H2 0 6
H2 0 4
H2 0 7
4x4 Mode
switch
H2 0 5
23
H2 0 6
B/ R (E)
B
(F )
B/ R (E)
B /R (E )
X
H2 0 5
20
GY /R
G/O
LG /B
R/G
B/ W
BR
H 2 02
LG/ R
H2 0 6
LG
H2 04
R
B
H 2 03
B/ W
H2 0 7
R/G
B/ R
B/ R
09
H2 0 4
B/ R
(E )
B/ R( E)
H2 0 1
24
Instrument cluster
(Section C3b)
H2 0 7
B/ R
(E )
G/O
(F )
BR
(F )
GY /R
B/ R
LG /B
LG
B/ W
G/O
p104UK
H-2
Harness symbol
[Grey]
(F)(E)
X07
[Blue]
Lock solenoid
H202
[Yellow]
Free solenoid
H203
X01
Wiring Diagram
X09
[Black]
(F)(E)
[Black]
Neutral position switch
H207
H206
4x4 Mode switch
[Black]
Z104
[Blue]
Remote freewheel main switch
H204
H205
Remote freewheel switch
[Black]
20
X02
H201
Remote freewheel control module
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
p105nUK
I-1
Instrument Illumination
39
R/B(F)
R/B(F)
R/B
(F)
Oscillator
R/B
(F)
R/B
(F)
27
Instrument cluster
(Section C1c, 2c, 3c)
R/B
(F)
44
Clock
(Section I2)
F103
G211(F2 CIS,G6)
G111(WL,WL Turbo)
J01
F103
Audio illumination
Hazard flasher
switch illumination
G211(F2 CIS,G6)
G111(WL,WL Turbo)
J01
1E
1F
R/G
(F)
R/G
(F)
I101
R/B(F)
B
(F)
R/G
(F)
Instrument cluster
(Section C1c, 2c, 3c)
R/G
(F)
Z105
38
R/G
(F)
R/G(F)
R/G(F)
R/G(F)
I101
F103
G111(WL,WL Turbo)
G211(F2 CIS,G6)
B
G/O
R/G
R/G
R/B
J01
1K
L/R
L/Y
L/W
1N
1L
1E
R/B
1C
L/R
1A
L/W
R/G
1J
1H
1F
1D
1B
R/B
B/Y
G/W
G/B
L/Y
G/R
R/G
R/B
Wiring Diagram
Headlamp switch
(Section E1, 2, 4)
p106nUK
I-1
Harness symbol
Z
Wiring Diagram
F103
Instrument illumination
potentiometer
I101
Z106
J01
Audio illumination
p107nUK
I-2
Battery
BTN
B(E)
W/R(E)
W/R(F)
X08
MAIN
X03
A
B/W(E)
80A
B/W(E)
B/W(F)
X01
X02
OFF
ROOM
10A
ACC
X03
Ignition switch
B
B/W(E)
ST
B/W(F)
IG1 IG2
X07
R.DEF
W(F)
W
(F)
B/W(F)
X03
Instrument cluster
(Section C1c, 2c, 3c)
20A
Fuse block
X02
Fuse block
L
(F)
X03
Fuse block
METER
X03
Instrument Illumination
(Section I1)
CIGAR
15A
44
B/Y(F)
15A
X03
I204
45
Wiring Diagram
30A
X01
X03
Rear window
heater relay
X03
I204
L/W
(F)
B/L
(F)
B/L
(F)
Z107
L/W
(F)
Rear window
heater switch
B/L
(F)
I203
I206
14
B
R/B
L/R
lighter (F)
I202
I201
I203 Outlet
(F)
B
(F)
I204
L/W
L/W
Clock
Cigar lighter
B
(F)
I202 Cigar
Clock (F)
I202
I203
B
(F)
I201
I201
I205
B/L(R)
I207
L/W
(F)
Outlet
X04
R/B
(F)
L/W(F)
I205
L/R
(F)
G
(F)
L/W
B
B
(F)
I205 Rear
window heater
switch (F)
B/Y
B/L
I206
I207
p108nUK
I-2
Harness symbol
I206
(F)(R)
X04
I207
Rear window heater
grid
14
X07
(F)(E)
[ Black ]
X08
(F)(E)
[ Black ]
Z108
WL, WL Turbo
Clock
Rear window heater
switch
I201
I205
X01
[ White ]
Ignition switch
X02
(F)(R)
X04
[ Black ]
Rear window heater
relay
I202
Cigar lighter
I204
[ Black ]
I203
Outlet
[ Black ]
X07
(F)(E)
[ Black ]
X02
Ignition switch
X08
(F)(E)
[ Black ]
X03
F2 CIS, G6
Fuse block
[ Blue ]
Wiring Diagram
X01
p109nUK
I-3
Interior lamps
Fuse block
BTN
ROOM
B(E)
W/R(E)
X01
W/R(F)
X08
X01
10A
X03
Wiring Diagram
30A
Battery
X03
L/R
(F)
X11
L/R
(IN)
I301
Interior lamp
Off
On
Door
Instrument cluster
(Section C1a, 2a)
I301
21
R/Y
(IN)
X11
R/Y
(F)
I306
R/Y
(F)
X19
Z109
R/Y(FR)
R/Y(FR)
R/Y(F)
R/Y(F)
X04
R/Y(R)
R/Y
(FR)
R/Y
I304
R/Y
(R)
I302
LH Rear
door
entry
switch
I305
LH Front
door
entry
switch
RH Rear
door entry
switch
Double cabin
I301
I302
R/Y
(Regular cabin)
R/Y
L/R
L/R
I306
(Short cord)
R/Y
I303
RH Front
door entry
switch
Double cabin
LH Front door entry switch
(FR)
I303
I304
I305
(Short cord)
(Stretch cabin)
(Double cabin)
R/Y
(R)
R/Y
R/Y
R/Y
R/Y
p110nUK
I-3
Harness symbol
Interior lamp
Main fuse box
X01
I301
Wiring Diagram
[ Black ]
RH Front door entry
switch
I303
(F)(R)
X04
I302
LH Front door entry
switch
[ Black ]
Z110
X08
X11
(F)(E)
[ Black ]
(F)(IN)
Regular cabin,
X19
Stretch cabin
(F)(FR)
[ Black ]
RH Rear door entry
switch
[ Black ]
RH Front door entry
switch
Interior lamp
I301
I305
I303
(F)(IN)
X11
(F)(R)
X04
X04
(F)(IN)
(F)(R)
X11
I304
I306
(FR) Short cord
X03
Fuse block
X19
(F)(FR)
I302
X19
(F)(FR)
Double cabin
p111nUK
Audio Systems
Battery
MAIN
B(E)
B/W(E)
B/W(F)
X01
X07
X02
BTN
W/R(E)
30A
Wiring Diagram
80A
OFF
ST
Ignition switch
X08
X01
IG1 IG2
W/R
(F)
Fuse block
ACC
X02
ROOM
L/R(F)
L
(F)
10A
CIGAR
L/W(F)
X03
L/R
(F)
L/W
(F)
1C
1A
15A
X03
J01
Audio unit
3A
1K
J04
1L
1M
1N
J01
Z111
L
(F)
L/W
(F)
X15
L/R
(DR1)
L/Y
(DR1)
L
(DR2)
J03
Speaker,
left
Speaker,
right
1E
L/R
R/B
L/Y
L/W
R/G
1C
L/R
L/W
(F)
L/R
(F)
L/Y
(F)
J06
Speaker,
right
1K
L
(F)
Speaker,
left
1N
J05
1M
L/W
(DR2)
J02
15
1L
L/Y
(F)
L/R
(F)
X12
B
1K
J01
left (DR1)
J03
1A
L/W
L/Y
1N
J04
Audio unit
1L
1J
1H
1F
1D
L/W
L/R
1B
J05
L
J06
3A
(Short cord)
L/W
L/Y
L/R
p112nUK
Harness symbol
Z
Wiring Diagram
Speaker, right
J03
(F)(DR2)
X15
X01
J02
Speaker, left
X12
(F)(DR1)
Z112
Audio unit
Audio unit
J01
J04
(F)(DR2)
X15
[ White ]
Ignition switch
X07
(F)(E)
[ Black ]
X02
J06
Speaker, right
X08
(F)(E)
[ Black ]
(F)(DR1)
X12
15
X02
Ignition switch
X03
J05
Speaker, left
Fuse block
[ Blue ]
p113nUK
K-1
Battery
MAIN
B(E)
B/W(E)
X01
B/W(F)
X01
X07
X02
Wiring Diagram
80A
Ignition switch
OFF
ST
IG1 IG2
ACC
X03
X02
Fuse block
(P.WIND)
X03
W(F)
30A
Open
Open
R/L
(F)
K101
G/W
(DR1)
Auto circuit
R/L
(DR1)
R/W
(DR1)
X13
R/L
(F)
X14
G/W
(F)
R/W
(F)
G/W
(DR2)
R/W
(DR2)
R/L
(F)
X17
X16
K101
R/L
(DR2)
Z113
K102
G/B
(DR1)
B
(DR1)
R/B
(DR1)
Close
Open
K102
X14
B
(F)
G/B
(DR2)
K103
M
Open
Close
LH Front
window
motor
R/B
(DR2)
K104
RH Front window
motor
Open
Close
K101
K102
G/W
R/W
R/L
G/B
R/B
R/B
G/W
G/B
K103 LH
K104
R/W
G/B
G/B
R/L
R/B
R/B
p114nUK
K-1
Harness symbol
Z
Wiring Diagram
X01
K102
RH Front window
motor
K104
(F)(DR2)
X16
(F)(DR2)
X07
X17
Z114
(F)(E)
[ Black ]
[ White ]
Ignition switch
K101
Power window main switch
X02
X16
K103
(F)(DR2)
X17
(F)(DR2)
(F)(DR1)
X03
X13
Fuse block
X14
(F)(DR1)
X02
Ignition switch
[ Blue ]
X13
X14
(F)(DR1)
(F)(DR1)
p115nUK
K-2
MAIN
B(E)
B/W(E)
X01
X01
Ignition switch
X07
Fuse block
IG1 IG2
(P.WIND)
ACC
X02
W(F)
30A
OFF
ST
R/L(F)
X03
X02
B/W(F)
Wiring Diagram
80A
Battery
X03
R/L(F)
Close
Close
Open
Close
Open
Close
Open
K201
Open
K201
G/W
(DR1)
R/W
(DR1)
R/L
(DR1)
G/W
(F)
R/W
(F)
R/L
(F)
X14
W
(DR1)
L/W
(DR1)
W/R
(DR1)
W
(F)
L/W
(F)
W/R
(F)
G/Y
(DR1)
X13
R/L(F)
X14
G/Y
(F)
R/L(F)
X06
X20
R/L(F)
W
(R)
L/W
(R)
R/L
(R)
W
(DR3)
L/W
(DR3)
R/L
(DR3)
R/L
(F)
X17
Z115
B
(DR1)
X16
R/W
(DR2)
G/W
(DR2)
R/B
(DR1)
Close
X14
Open
B
(F)
Close
Open
G/B
(DR3)
Close
Open
R/L
(DR4)
Open
K206
Close
Open
Close
Open
R/B
(DR4)
K208
RH Rear window
motor
Close
Open
Close
K201
K205
W/R
G/Y
G/B
R/B
W
B
K202
L/W
R/L
R/B
G/W
R/W
G/W
G/B
R/L
L/W
K206
R/B
G/B
K203
G/B
R/L
K204
R/W
G/B
G/B
R/L
R/B
R/B
L/W
K207
K206
G/B
(DR4)
K207
L/W
(DR4)
X22
R/B
(DR3)
K204
W
(DR4)
K205
R/B
(DR2)
K203
R/L
(FR)
K205
Power window
switch, RH side
front
K202
G/B
(DR2)
G/Y
(FR)
X21
R/L
(DR2)
K202
G/B
(DR1)
W/R
(FR)
K208
G/B
G/B
R/B
R/B
R/B
p116nUK
K-2
Harness symbol
Z
Wiring Diagram
X01
K202
[ Blue ]
RH Front window
motor
RH Rear window
motor
K207
K205
(R)(DR3)
X21
K204
(F)(DR2)
X16
Z116
X07
(F)(E)
[ Black ]
(F)(R)
K208
X06
LH Rear window
motor
K206
[ White ]
Ignition switch
X22
(FR)(DR4)
X02
X17
X16
(F)(DR2)
X17
(F)(DR2)
K201
(F)(DR2)
X20
(F)(FR)
X13
(F)(DR1)
X14
(F)(DR1)
K203
LH Front window
motor
[ Blue ]
X06
(F)(R)
X13
X03
(F)(DR1)
Fuse block
X20
(F)(FR)
X14
(F)(DR1)
X02
Ignition switch
[ Blue ]
p117nUK
K-3
Fuse block
MAIN
B(E)
(D/L)
B/W(E)
X01
Double cabin
B/W(F)
X07
30A
X03
X03
G(F)
G(F)
G
(F)
G
(F)
G
(F)
X04
X14
W/G
(F)
G/O(F)
G
(FR)
X17
G/R(F)
X21
K301
G
(DR2)
K303
G
(DR4)
K304
K305
Lock
Lock
Central door
locking
Lock
K302
G/Y
(DR1)
Lock
M
Unlock
Unlock
Unlock
RH Front
door lock
motor
Door lock
motor, LH
side rear
Door lock
motor, RH
side rear
K303
K304
R
(DR2)
Z117
K301
X22
G
(DR3)
K302
X14
X19
G
(R)
G
(F)
G/O
G/R
(DR1) (DR1)
Unlock
K305
R
(DR4)
R
(DR3)
X21
X17
G/Y
(F)
G/Y
(F)
B
(F)
R
(F)
X22
R
(R)
R
(F)
R
(FR)
X04
X19
R
(F)
G/Y(F)
K301
K302
G/O
G/R
W/G
G/O
R(F)
K303
K304
K305
G/Y
G
G/Y
R
(F)
R(F)
Wiring Diagram
80A
X01
Battery
G/R
p118nUK
K-3
Harness symbol
Wiring Diagram
X01
K305
(R)(DR3)
RH Front door lock
motor
X21
K303
X07
Z118
(F)(E)
[ Black ]
(F)(R)
X04
3
K304
Door lock motor, LH
side rear
X22
(FR)(DR4)
X17
K302
(F)(DR2)
X14
(F)(DR1)
X17
(F)(DR2)
X19
(F)(FR)
X04
(F)(R)
K301
Door lock timing
unit
X03
Fuse block
X19
(F)(FR)
X14
(F)(DR1)
p119nUK
Power mirrors
Battery
MAIN
B(E)
B/W(E)
X01
B/W(F)
X01
X07
Right
ST
IG1 IG2
Down
X02
OFF
ACC
Up
X02
Down
Up
Left
Select LH mirror
Right
Select RH mirror
Select LH mirror
Select RH mirror
L01
L
(F)
BR
(F)
BR/Y
(F)
L/B
(F)
Z119
BR
(F)
BR
(F)
LG/B
(F)
BR/B
(F)
L/W
(F)
X13
B
(F)
BR/B
(DR1)
LG/B
(DR1)
BR
(DR2)
L/B
(DR2)
X03
L03
Power mirror, RH
side
Power mirror, LH
side
M
CIGAR
BR/Y
(DR2)
L02
Left
Right
Fuse block
X16
BR
(DR1)
Up
Down
Up
Down
Left
Right
L01
L/W
L02
LG/B
L/B
BR/Y BR/B
L03
BR
Ignition
switch
BR
15A
X03
Wiring Diagram
80A
p120nUK
Harness symbol
Z
Wiring Diagram
X01
L03
(F)(DR2)
X16
Z120
X07
(F)(E)
[ Black ]
[ White ]
Ignition switch
X02
L02
L01
X16
(F)(DR2)
X13
(F)(DR1)
X02
X03
X13
(F)(DR1)
Fuse block
Ignition switch
[ Blue ]
p121nUK
Battery
MAIN
B(E)
B/W(E)
X01
X01
B/W(F)
A
X07
Wiring Diagram
80A
X02
Ignition switch
OFF
ST
IG1 IG2
ACC
X02
Fuse block
S.WARM
W(F)
BR/Y(F)
X03
15A
X03
BR/Y
(F)
P01
Heated seat
switch
P01
P01
BR/B
(F)
X19
B
(F)
Z121
BR/B
(FR)
P02
Heater
P02
B
(FR)
17
P01
P02
Heater (FR)
BR/B
BR/B
BR/Y
p122nUK
Harness symbol
Wiring Diagram
X01
X07
Z122
(F)(E)
[ Black ]
[ White ]
Ignition switch
P02
Heated Seats
X02
[ Blue ]
Heated seat switch
17
P01
X19
(F)(FR)
X02
Ignition switch
X03
Fuse block
X19
(F)(FR)
[ Blue ]
P-2
MA IN
B (E )
B/ W( E)
X 01
X 01
B/ W( F)
B
X 0 7
IG 1
02
OF F
ST
G2
Wiring Diagram
80 A
Battery
Ignition switch
AC C
02
S. WARM
W( F )
BR/ Y (F )
X
03
15 A
03
BR/ Y
(F )
P2 0 1
P2 0 1
BR/ B
(F )
BR /B (F )
BR/ B
(F )
X 1 9
04
B
(F )
BR
(R )
Z123
BR/ B
(F R )
P2 0 2
P2 0 3
P2 0 2
P2 0 3
B
(R )
B
(F R )
17
P2 0 1
P2 0 2
P2 0 3
BR /B
BR /B
BR
BR /Y
04
B
(F )
3
p124UK
P-2
Harness symbol
Z
Wiring Diagram
[Black]
(F)(E)
X07
Main fuse box
X01
P203
(F)(R)
X04
Z124
P202
17
X19
3
[Blue]
Heated seat switch
P201
X04
(F)(R)
X02
X02
(F)(FR)
X19
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
(F)(FR)
Z-S
Wiring Diagram
Air Bags
Service Warnings
Component Disassembly
D
Disassembling and reassembling the components of
the air bag system can render the system inoperative,
which may result in serious injury or death in the
event of an accident. Do not disassemble any air bag
system component.
RIGHT
Wiring Harness Repair
D
Incorrectly repairing an air bag system wiring harness
can accidentally deploy the air bag, which can cause
serious injury. If a problem is found in the system
wiring, replace the wiring harness. Do not try to repair
it.
D
A live (undeployed) air bag placed face down on a
surface is dangerous. If the air bag deploys, the
motion of the air bag can cause serious injury. Always
face the front surface up to reduce the motion of the
air bag in case it accidentally deploys.
RIGHT
WRONG
Z-125
WRONG
Wiring Diagram
Component Reusing
D
Even if an air bag does not deploy in a collision and
does not have any external signs of damage, it may
have been damaged internally, which may cause
improper operation. Improper operation may cause
serious injury. Always selfcheck the undamaged air
bag to determine whether it can be reused. (Refer to
ON-BOARD DIAGNOSTIC FUNCTION, AIR BAG
SYSTEM.)
Z-126
Z-S
p127nUK
S-1
MAIN
B(E)
B/W(E)
B/W(F)
A
X07
X01
Wiring Diagram
80A
X01
< >...
Battery
X02
Ignition switch
OFF
ST
IG1 IG2
ACC
Fuse block
X02
METER
W(F)
B/Y(F)
B/Y(F)
15A
X03
ENGINE
B/W(F)
15A
B/W(F)
S102
X03
S101
Z
R/G
(F)
Y/G
(F)
L
(F)
LG
(F)
R
(F)
Y/R
(F)
AB
B
(F)
B
(F)
S101
S102
R/G
(F)
S103
Shorting bar
B
(F)
Y/G
(F)
Z127
Shorting
bar
S104
LG
Shorting
bar
Clock spring
Y/G
(F)
Y/G
(F)
LG
S105
Inflator
46
47
Shorting bar
25
Instrument cluster
(Section C1b, 2b)
Inflator
Driver air bag unit
8
S101
S102 Shorting
S103 (F)
Clock spring
(Clock spring)
(F)
W
AA
G/R
R/G
Y/G
LG
Y/R
B/Y
AB
B/W
R/G
R/G
G/R
B/W
B/W
B/Y
R
S104
B/Y
Y/G
LG
C
Y/G
S105
B
Y/R
LG
LG
p128nUK
S-1
Harness symbol
Z
Wiring Diagram
X01
S104
[ White ]
Ignition switch
S102
X02
Z-128
S103
9
X07
(F)(E)
[ Black ]
S101
S105
X02
X03
Fuse block
Ignition switch
[ Blue ]
S-2
Battery
+
MA IN
B/ W (E)
B( E)
X 0 1
B/ W( F)
01
AB
X 0 7
IG 1
02
OF F
ST
G2
Wiring Diagram
80A
Ignition switch
AC C
X 0 2
ME TE R
B/ Y (F )
W( F )
X
B/ Y( F )
15A
03
E N GINE
B/ W (F )
15A
B/ W( F)
S2 0 2
03
S2 01
L
(F)
LG
(F)
R
(F )
Y/ R
(F )
AB
X
S2 0 1
Y/ G
(F )
S2 0 3
Shorting bar
B
(F )
S2 0 2
S2 0 4
LG
B
(F )
Shorting bar
Z129
Y/ G
(F )
Clock spring
L
Shorting bar
LG
S2 0 5
Inflator
25
Shorting bar
Instrument cluster
(Section C3b)
Inflator
S2 0 1
S2 02
S 2 03
WU
AA
G/R
BY
B/ W
AB
B /Y
B /W
Y /G
Y/ G
B /W
B /Y
LG
G/R
R
S 2 0 4
B/ Y
(Clock spring)
S2 0 5
Y/ R
R
LG
LG
p130UK
S-2
Harness symbol
Z
Wiring Diagram
X01
[Yellow]
Passenger air bag
unit
Shorting bar connector
S204
S202
Z130
Clock spring
S203
X07
(F)(E)
[Black]
S201
Air bag module
S205
Driver air bag unit
[Yellow]
X02
Ignition switch
X02
Ignition switch
X03
Fuse block
[Blue]
[White]
p131nUK
X01
X01
MAIN
Battery
B(E)
B/W(E)
B/W(F)
A
X07
X02
BTN
W/R(E)
Instrument cluster
(Section C1a)
Ignition switch
W/R(F)
30A
X08
Fuse block
IG1 IG2
ROOM
10A
ACC
X02
W/R(F)
X03
OFF
ST
L/R(F)
51
Wiring Diagram
80A
X03
Fuse block
ENGINE
W(F)
15A
X03
BR/B
(F)
L/R
(F)
X03
B/W
(F)
T01
L
Coil
Immobiliser module
C
T01
T02
B/R
(F)
V/W
(F)
B/W(F)
GY(F)
Z131
Y(F)
B209
Diesel pump
unit
DDS1
49
Powertrain control
module (PCM)
(Section B2a)
B209
B/R
(F)
T01
16
T02
I
BR/B
C
B/R
Coil (F)
B209
L/R
J
GY
C
R/L
V/W
GY
B/W
B/R
BR/W L/B
G/W
B/W
B/R
V/W
p132nUK
Harness symbol
Z
Wiring Diagram
X01
Z132
[ White ]
Ignition switch
16
X07
(F)(E)
[ Black ]
X02
X08
(F)(E)
[ Black ]
Immobiliser module
T01
B209
Diesel pump unit
[ Grey ]
T02
X02
X03
Fuse block
Ignition switch
[ Blue ]
Coil
T-2
01
MA IN
Battery
+
01
B( E)
A
B/ W( F)
B/ W( F )
X
07
X 0 2
BT N
W/ R( E)
W/ R( F )
30 A
Wiring Diagram
80 A
OF F
ST
Ignition switch
08
IG 1
IG 2
AC C
02
W
(F )
X 0 3
X 0 3
ROOM
10A
X 0 3
T2
E N GINE
15A
X 0 3
L/ R
(F )
B/ W
(F )
01
Immobiliser module
T2
B/ R
(F)
W
(F )
R
(F )
BR/ B
(F )
P
(F )
Y
(F )
GY
(F )
59
54
51
61
01
Z133
T2
02
Coil
Powertrain control
module (PCM)
(Section B6b)
Starter relay
(Section A3)
20
T 2 01
B/ R
L/R
J
Coil (F)
R
B/ W
T 2 02
I
W
GY
GY
D
Instrument cluster
(Section C3a)
p134UK
T-2
Harness symbol
(F)(E)
X08
Wiring Diagram
X07
[Black]
(F)(E)
X01
Z134
Immobiliser module
T201
20
T202
Coil
X02
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
p135nUK
< >...
MAIN
B(E)
B/W(E)
X01
B/W(F)
A
X07
Wiring Diagram
80A
X01
X02
Ignition switch
OFF
ST
IG1 IG2
ACC
Fuse block
X02
METER
W(F)
15A
X03
12
BR/R(F)
10
Y/B(F)
11
Y(F)
X03
B/Y(F)
Powertrain control
module (PCM)
(Section B3a, 4a)
B/O
(F)
Y/G(F)
47
R/G(F)
46
Z135
Data Link
Connector
(DLC)
X05
B
(F)
B/R
(F)
B/O
(INJ)
L/O(F)
18
O(F)
F2 CIS,G6
13
F2 CIS,G6
U01 Data
WL,WL Turbo
FEN
KLN
TEN
+B
GND
FAB
GND
F/P
TAB
<Y/G>
F2 CIS, G6
BR/R B/Y
Y/B
B/R
IG
Battery
Y/B
BR/R B/Y
B/O
<R/G>
<Y/G>
L/O
<R/G>
p136nUK
Harness symbol
X01
X01
2
2
13
U01
Data Link Connector
(DLC)
U01
Data Link Connector
(DLC)
X07
Z136
(F)(E)
[ Black ]
X07
(F)(E)
[ Black ]
X05
(F)(INJ)
[ Black ]
WL, WL Turbo
F2 CIS, G6
[ White ]
Ignition switch
X02
X02
Ignition switch
X03
Fuse block
[ Blue ]
Wiring Diagram
U-2
MA IN
B/ W (E )
X 0 1
80A
B/ W( F)
A
01
B
X
X 0 7
IG 1
02
OF F
ST
G2
Ignition switch
AC C
02
ME TE R
W( F )
X
12
B R /R (F )
11
Y /R (F )
10
B /Y (F )
03
15 A
03
B/ Y
(F)
U201
Instrument cluster
(Section C3b)
47
Y /G(F )
Z137
B/ R
(F )
58
B
(F )
W /L( F)
20
U2 0 1
FA B
TE N
+B
B/ Y
BR /R
Y/ R
B/ R
IG
GND
<Y /G >
W/ L
Wiring Diagram
B( E)
Battery
B/ Y
p138UK
U-2
Harness symbol
Z
Wiring Diagram
X01
U201
Z138
X07
(F)(E)
[Black]
20
X02
X02
X03
Fuse block
Ignition switch
[Blue]
Ignition switch
[White]
p139nUK
X02
X03
X01
(L/W)
with central
locking
(R)
30A
R
R
W/R
30A
30A
10A
R/B
80A
60A
<G/B>
B/W
B/W
10A
B/W
30A
LG/R
L/Y
W/G
HEAD
BTN
<PTC>
MAIN
B/Y
B/R
X04
B/R
10
11
20A
( )...
17
15A
L/W
18
12
19
13
20
15A
G/W
B/Y
15A
10A
Y/R
B/W
15A
18
S.WARM
(D/L)
14
METER
R.DEF
15
ENGINE
16
STOP
17
(HEATER)
TAIL
18
CIGAR
ROOM
19
WIPER
20
10
21
R.FOG
11
22
(P .WIND)
21
14
13
10A
L/R
15
W
16
30A
R/L
22
R/G
10A
21
40A
12
HAZARD
R/Y
B/R
(A/C)
W
W/R
15A
L/Y
15A
with heated
seats
BR/Y
10A
B/W
LG/R
B/W
<30A>
B/W
10A
F2 CIS, G6
(F) (R)
X05
Z139
WL, WL Turbo
(F) (INJ)
F2 CIS
G6
(F)
F2 CIS, G6
(F)
I
B/R
W/G
R/W
B/L
<G>
R/B
<<W/L>>
<R>
G/W
G/B
G/R
(BR/B)
R/Y
(F)
[R/L]
B/O
W/G
R/W
R/Y
(F)
R/B
<<W/L>>
B/L
(( B ))
G/W
G/B
[R/L]
(BR/B)
B/Y
L/W
G/Y
BR/B
(( B ))
B/Y
B/O
BR/W LG/R
LG/B
G/W
B/Y
L/W
G/Y
BR/B LG/B
J
(INJ)
BR
RY
R/W
W/G
BR
B/R
RY
R/W
W/G
B/R
G/R
R/B
<R>
<G>
B/L
(R)
(R)
B
[ R/L ]
G/B
G/W
R/B
<R>
<G>
B/L
[ R/L ]
G/B
G/W
(INJ)
LG/B BR/B
G/Y
L/G
B/Y
LG/B BR/B
LG/R BR/W
B/O
B/Y
G/Y
L/G
B/Y
G/W
G/W
X06
Heated Seats
... RH Front door entry switch
( ( ) )...
< >...
not used
<< >>...
Double cabin
(F) (R)
( )...
X07 (F)
]...
(E)
X08
(F)
R/L
L/W
R/L
(R)
W
(F) (E)
B/Y
(F)
L/W
B/W
B/W
(E)
B/W
B/W
W/R
(F)
W/R
B/Y
R/W
(F)
R/W
( L/W )
( L/W )
( )...
F2 CIS, G6
Wiring Diagram
(30A)
p140nUK
(F) (E)
(IN)
X12 (F)
(DR1)
X09
Y/R
W/B
R/G
L/W
B/Y
L
W
G/R
L/W
(F)
(F)
L/R
F2 CIS
(F)
(F)
I
Y/R
B/R
R/G
R/G
LG/B
(R/W)
<GY/R>
W
W/G B/Y
B/R
(G/B) (W/B) (B/Y) (B)
L/W
L
G/R
GY/R
(BR) (L/W) (L)
R/Y
Y/R
G/B
W/B
B/Y
G/B
W/B
B/Y
R/W
BR
L/W
GY/R
Y/R
L/W
R/W
L/Y
(IN)
(DR1)
L/R
L/R
L
X13 (F)
(E)
(E)
B/R
W
G/R
<GY/R>
B/Y
L
W/B
L/W
B/R
(B)
W
B/Y
W/B
R/G
(B/Y) (W/B) (G/B)
G/R
L/W
L
GY/R
LG/B
(L) (L/W) (BR)
Y/R
R/G
(E)
Y/R
R/G
(R/W)
B/Y
W/B
<GY/R>
L/W
(DR1)
X15
(E)
G/B
BR
Y/R
R/W
W/B
B/Y
R/W
G/B
L/W
R/L
BR/Y
L/B
BR
Y/R
BR/B
BR
Z140
( )...
(F) (DR1)
X16 (F)
C
<G/Y>
(F)
G/Y
G/W
(B)
<G/Y>
L/R
L/W
(R/L)
(DR2)
LG/B
BR/B
LG/B
<W>
R/W
BR
G/W
B/R
G/O
BR/Y
( )...
(R/L)
(DR2)
( )...
X20
(R2)
(DR2)
G
L/B
BR
(F) (FR)
R/Y
G/W
R/W
R/B
W/G
(R/L)
W/R
( )... European
< >...F2 CIS,G6
(DR3)
Double cabin
R/Y
R/L
X22 (FR)
L/W
(DR4)
Double cabin
L/W
R/L
(R)
<G>
G/Y
W/R
R/L
(FR)
G/Y
(FR)
R/L
W/R
(DR3)
B/R
(G/W) (R/W)
( )...
X21 (R)
<R>
BR/B
( )...
G/W
(F)
BR/B
(BR)
(FR)
not used
<G/R>
R/W
G/Y
R
(F)
( )...
W/G
<G/R> G/B
Y
Double cabin
G/B
R/B
(R/L)
(R)
(F)
< >...
X19
(DR2)
(F)
G/R
G/Y
<W> G/R
R/L
<L/W>
G/O
K
(DR1)
X17 (F)
(F)
K
B
<W/R> R/W
<L/W>
(DR2)
L/Y
(F)
(DR1)
X14
(F) (DR2)
R/L
L/W
(DR4)
R/L
specifications (LHD)
Wiring Diagram
R/Y
(F)
01
1
R
R
W/ R
30A
X 0 3
5
10A
LG/ R
10A
L/Y
10
W/ G
11
15A
B/ R
B/ R
R /B
30 A
80A
60A
<G /B >
B/ W
B/ W
B /W
30A
20A
15A
L/W
40A
15A
L/W
17
18
12
19
13
20
B/ W
B
B/ W
HEAD
GLOW
BTN
PT C
MA IN
B/ Y
B/ R
W/ R
15A
G/W
B/ Y
15A
10A
Y/ R
B/ W
15A
10A
L/R
(F) (R)
Z141
B/ R
B/ L
W/ G
R /W
W/ L
14
G/B
X 07
(F) (R)
10A
R/G
13
S. W A R M
D/L
14
ME TE R
R.DEF
15
E N GINE
FI P
16
ST O P
17
HE AT ER
TA IL
18
CIGA R
ROOM
19
WI PE R
20
10
21
R.F O G
11
22
P. W IN D
21
15
W
30A
R/L 22
X 08 F
(F) (E)
R/Y
(F )
L/W
R/L
R /W
W/G
B/ R
(G/R)
<G>
B /L
(F)
B/ W
B /W
(E )
B/ W
B/ W
(R )
W
not used
R/L
G/B
< >...Double
G/W
R/B
<R>
X 10
<R /G >
(F )
<L G /B >
L/W
B/ Y
W/ B
BR/ Y Y/ R
L
(F) (E)
X 14
BR /W
G/B
(F) (DR1)
G/Y
(F )
BR/ R G/Y
B/ R
BR /B
K
B
G/Y
L/W
G/O
G/R
(B )
<G /Y >
(F )
W/ R
R/W
G/W
K
<G Y /R >
(E )
L/W
B/ R
> ...4X 4
W/ B
B/ Y
Y/ R
BR/ Y
G/B
<R /G >
(DR1 )
G/Y
<L G /B >
(E )
BR /B
<
> ...
BR /W
<B>
<L/ W >
<W >
G/Y
G/R
G/O
W/ R
R
W/ R
B /L
R/W
(E )
<G Y /R >
L/W
B/ L
R/ W
(F )
cabin
(F) (E)
(F) (E)
R/L
BR/ B
R/Y
G/W
06
(R )
<
R/Y
16
R/L
BR
( )...
12
HAZ A RD
(F )
X 09
15A
A/ C
> ...
X 04
BR /Y
Wiring Diagram
02
(R) (R2)
G/B
(F) (FR)
(G/R)
R
(F )
B/ R
W/ G
R/B
R/W
R/W
R /B
G/B
G/W
R/Y
BR /B
R/L
(R2)
G/W
W /G B/ R
<R>
(F R )
(B R/ B )
)...
not used
( )...
R/Y
<G >
Wiring Diagram
R/L
(R )
X 1 8
Z142
Parts index
4x4 Mode switch . . . . . . . . . Z59, 65, 101, 103
A/C Compressor clutch . . . . . . . . Z95, 97, 99
A/C pressure switch . . . . . . . . . . . Z95, 97, 99
A/C Relay . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
A/C switch . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
Accelerator pedal position sensor . . . . . . Z51
Air bag module . . . . . . . . . . . . . . . . . . . . . . Z129
Audio illumination . . . . . . . . . . . . . . . . . . . Z105
Audio unit . . . . . . . . . . . . . . . . . . . . . . . . . . Z111
Blower assembly . . . . . . . . . . . . . . Z95, 97, 99
Blower motor . . . . . . . . . . . . . . . . . Z95, 97, 99
Boost pressure sensor . . . . . . . . . . . . . . . . Z51
Brake fluid sensor . . . . . . . . . . . . . Z59, 65, 71
Camshaft position sensor . . . . . . . . . . Z35, 41
Canister purge solenoid valve . . . . . . . Z37, 43
Capacitor . . . . . . . . . . . . . . . . . . . . . . . . Z35, 41
Central door locking . . . . . . . . . . . . . . . . . Z117
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . Z107
Clock spring . . . . . . . . . . . . . . . . . . . . . . . . Z129
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z107
Clutch switch . . . . . . . . . . . . . . . . . Z39, 45, 49
Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z131, 133
Coolant temperature sensor . . . . Z57, 63, 69
Data Link Connector (DLC) . . . . . . . Z135, 137
Daytime Running Lamps
(DRL) relay . . . . . . . . . . . . . . . . . . . . . . . Z79, 83
Diesel pump unit . . . . . . . . . . . . . Z27, 31, 131
Direction indicator lamp, LH front . . . . Z87, 91
Direction indicator lamp, LH rear . . . . . . . Z91
Direction indicator lamp, RH front . . . Z87, 91
Direction indicator lamp, RH rear . . . . . . . Z91
Direction indicator switch . . . . . . . . . . . Z87, 91
Door lock motor, LH side rear . . . . . . . . . Z117
Door lock motor, RH side rear . . . . . . . . . Z117
Door lock timing unit . . . . . . . . . . . . . . . . . Z117
Driver air bag unit . . . . . . . . . . . . . . . Z127, 129
EGR valve position sensor . . . . . . . . . . . . Z51
Electronic flasher module . . . . . . . . . . . . . . Z87
Engine Coolant Temperature
(ECT) sensor . . . . . . . . . . . Z27, 31, 37, 43, 51
Exhaust gas recirculation
(EGR) solenoid valve (vacuum) . . . . . . . . Z49
Exhaust gas recirculation
(EGR) solenoid valve (vent) . . . . . . . . . . . Z49
Exhaust Gas Recirculation
(EGR) valve . . . . . . . . . . . . . . . . . . . . . . . . . Z33
FICD solenoid valve 1 . . . . . . . . . . . . . Z27, 31
FICD solenoid valve 2 . . . . . . . . . . . . . Z27, 31
Flasher unit . . . . . . . . . . . . . . . . . . . . . . . . . . Z91
Free solenoid . . . . . . . . . . . . . . . . . . . Z101, 103
Fuel gauge sensor . . . . . . . . . . . . . . . . . . . Z55
Fuel heater . . . . . . . . . . . . . . . . . . . . . . . Z47, 55
Fuel injectors . . . . . . . . . . . . . . . . . . . . . Z35, 41
Fuel pressure solenoid valve . . . . . . . . Z37, 43
Fuel pump/fuel gauge sender . . . . . . . . . . Z47
Z143
Parts index
Neutral position switch . Z39, 45, 49, 101, 103
Oil pressure switch . . . . . . . . . . . . Z59, 65, 71
Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z107
Park brake switch . . . . . . . . . . . . . Z59, 65, 71
Passenger air bag unit . . . . . . . . . . . . . . . Z129
PCM module relay . . . . . . . . . . . . . . . . . . . . Z49
Power mirror, LH side . . . . . . . . . . . . . . . . Z119
Power mirror, RH side . . . . . . . . . . . . . . . Z119
Power mirror switch . . . . . . . . . . . . . . . . . Z119
Power steering pressure switch . . . . . Z37, 43
Powertrain control module (PCM) Z27 Z53
Power window main switch . . . . . . . Z113, 115
Power window switch, LH side rear . . . . Z115
Power window switch, RH side
front . . . . . . . . . . . . . . . . . . . . . . . . . . . Z113, 115
Power window switch, RH side rear . . . . Z115
Rear fog lamp relay . . . . . . . . . . . . . . . . Z81, 85
Rear fog lamp switch . . . . . . . . . . . . . . Z81, 85
Rear fog lamp . . . . . . . . . . . . . . . . . . . . Z81, 85
Rear window heater grid . . . . . . . . . . . . . Z107
Rear window heater relay . . . . . . . . . . . . Z107
Rear window heater switch . . . . . . . . . . . Z107
Remote freewheel control module . Z101, 103
Remote freewheel main switch . . . . Z101, 103
Remote freewheel switch . . . . . . . . . Z101, 103
Resistor . . . . . . . . . . . . . . . . . . . . . . Z95, 97, 99
Reversing lamp, left / Stop lamp LH . Z89, 93
Reversing lamp, right /
Stop lamp RH . . . . . . . . . . . . . . . . . . . . . Z89, 93
Reversing lamps switch . . . . . . . . . . . . Z89, 93
RH Front door entry switch . . . . . . . . . . . Z109
RH Front door lock motor . . . . . . . . . . . . . Z117
RH Front window motor . . . . . . . . . . Z113, 115
RH Licence plate lamp . . . . . . . . . . . . . Z81, 83
RH parking lamp . . . . . . . . . . . . . . . . . . Z81, 83
RH Rear direction indicator lamp . . . . . . . Z87
RH Rear door entry switch . . . . . . . . . . . . Z109
RH Rear window motor . . . . . . . . . . . . . . Z115
Sedimentor switch . . . . . . . . . . . . . . . . . Z57, 69
Short cord . . . . . . . . . . . . . . . . . . . . . . . . . . Z109
Shorting bar connector . . . . . . . . Z89, 93, 129
Side direction indicator lamp, LH side . . . Z87
Side direction indicator lamp, LH . . . . . . . Z91
Side direction indicator lamp, RH side . . . Z87
Side direction indicator lamp, RH . . . . . . . Z91
Speaker, left . . . . . . . . . . . . . . . . . . . . . . . . Z111
Speaker, right . . . . . . . . . . . . . . . . . . . . . . . Z111
Speedometer sensor . . . . . . . . . . Z57, 63, 69
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . Z25
Starter . . . . . . . . . . . . . . . . . . . . . . . Z21, 23, 25
Stop lamp switch . . . . . . . . . . . . . . . . . . . . . Z93
Tail lamp, LH side . . . . . . . . . . . . . . . . . Z81, 85
Tail lamp, RH side . . . . . . . . . . . . . . . . . Z81, 85
TDC sensor . . . . . . . . . . . . . . . . . . . . . . . . . Z53
Z144
SECTION TITLE
RANGER
2003
lefthanddrive
(LHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.
SECTION
General Information
GI
Ground points
Schematic
A~U
Connectors
Parts index
PI
Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment and with a timer control valve (TCV) on the fuel injection pump
(FIP).
Euro 2 regulation models (WL, WL Turbo engines) are not equipped with an EGR cooler
in the engine compartment, but with a timer control valve (TCV) on the fuel injection
pump (FIP).
Euro 1 regulation models (WL, WL Turbo engines) are neither equipped with an EGR
cooler in the engine compartment nor with a timer control valve (TCV) on the fuel injection pump (FIP).
EGR cooler
TCV
FIP
Wire colours
Colour
Code
Colour
Code
Black
Orange
Blue
Pink
Brown
BR
Purple
Dark blue
DL
Red
Dark green
DG
Sky blue
Green
PU
R
SB
Tan
Grey
GY
Violet
Light blue
LB
White
Light green
LG
Yellow
Natural
TOCB3UK
TOCB3UK
Table of Contents
General Information . . . . . . . . . . . . . . . . . . . . . . 2
Ground points . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine
Charging System . . . . . . . . . . . . . . . . . . . . . . .
Starting System . . . . . . . . . . . . . . . . . . . . . . . .
Engine control
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preglow system
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Euro 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel heater . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
20
24
28
20
24
28
34
Chassis
Remote freewheel control system . . . . . . . . 60
AntiLock Control 4Wheel . . . . . . . . . . . . 82
Instrument cluster
Instrument cluster . . . . . . . . . . . . . . . . . . . . . . 36
Body
Front wiper/washer . . . . . . . . . . . . . . . . . . . . .
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear defrost . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote keyless entry . . . . . . . . . . . . . . . . . . .
Power windows . . . . . . . . . . . . . . . . . . . . . . . .
Central door locking . . . . . . . . . . . . . . . . . . . .
Power mirrors . . . . . . . . . . . . . . . . . . . . . . . . .
Heated seats . . . . . . . . . . . . . . . . . . . . . . . . . .
Air bags Service warnings . . . . . . . . . . . . .
Air bags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Immobiliser system . . . . . . . . . . . . . . . . . . . . .
42
56
62
68
74
76
80
84
86
88
90
Interior Lighting
Instrument illumination . . . . . . . . . . . . . . . . . . 64
Interior lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Exterior Lighting
Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daytime Running Lamps . . . . . . . . . . . . . . . .
Licence plate lamps . . . . . . . . . . . . . . . . . . . .
Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . .
Tail lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp levelling . . . . . . . . . . . . . . . . . . . . .
Rear fog lamps . . . . . . . . . . . . . . . . . . . . . . . .
Turn Signal and Hazard Lamps . . . . . . . . . .
Reversing lamps . . . . . . . . . . . . . . . . . . . . . . .
Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
44
46
46
46
48
50
52
54
56
Air conditioning
Heating / Air conditioning . . . . . . . . . . . . . . . . 58
Accessory
Cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Audio Systems
with audio harness . . . . . . . . . . . . . . . . . . .
without audio harness . . . . . . . . . . . . . . . .
62
64
70
72
Other
Data Link Connector (DLC)
Euro 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Euro 2, 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Parts index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
GI
Wiring Diagrams
GI
General Information
Ground points
Schematic
A~U
Connectors
PI
Parts index
GI
8
B
10
12
B /O
B
6
B /W
D
C
E
B
A
WITH AIRBAG SYSTEM
WITH ABS
B (E M )
B (D )
B (E M )
B (E M )
B (F )
B (E M )
B (F )
TO EACH
UNIT
B (E M )
TO EACH
UNIT
B (D )
EMISSION
HARNESS
(EM)
J C 02
11
B (D )
B (D )
B (D )
B /W ( E M )
DASH
HARNESS
(D)
B (D )
WITH AIRBAG SYSTEM
TO EACH
UNIT
FRONT
HARNESS
(F)
B
(F )
10
B (D )
B (F )
B (F )
B (D )
J C 03
B (D )
B (E M )
J C 01
B (F )
B (D )
B / O (D )
3
WITHOUT AIRBAG SYSTEM
B (F )
B (F )
B (F )
B ( I)
B ( I)
B (F )
INSTRUMENT
PANEL
HARNESS
(I)
B (F )
B ( I)
B (F )
B (IN )
INTERIOR
LIGHT
HARNESS
(IN)
12
SHORT
CORD
B (F )
Ground indication
On vehicle
Indication
IG
MAIN
100 A
F B 0 9
K E Y
X 01
F B 07
60 A
B (E )
B /W (D )
B /W ( F )
B
F B 0 5
A
B T N
40 A
IN J OR
FIP
30 A
B (F )
B (D )
J B 0 5
G
W /R ( F )
J B 0 3
W /R ( D )
R OO
1 B
10 A
X 03
8
F B 0 3
F B 0 3
Y /L (F )
X 0 6
F B 0 4
F B 0 3
L G /R
(E M )
X 09
Y
L /R ( E )
J B 0 4
L /R (E M )
SPV RELAY
(SECTION B_1b)
W /Y
(E M )
I G1I G2
A C C
X 0 3
L (D )
A A
X 0 6
O F F
S T
E N G IN E
10 A
14 J B 01
B / L (D )
MAIN
RELAY
F B 0 4
ENGINE SWITCH
L /R
(D )
F B 0 4
W /G (E M )
B /L
(E M )
L /R
(E M )
B 1 0 1
B /W
(F )
1 E
3 W
B 1 0 3
1 B
1 A
B 1 0 2
1 F
P C M
2 M
GLOW
PLUG
RELAY
3 R
3 P
L G
B R /B
( E M )
1 S
1 N
1 Q
B 1 0 1
L
B 1 02
(E M )
L
(E )
F B 0 1
F B 0 3
(E M )
L (E )
I
L
L /B
( E M )
G /B
(E M )
G /W
(E M )
B
(E )
(E )
J
B 1 0 5
X 0 9
1 1
23
22
14
A/C RELAY
(SECTION G2)
B
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)
B
(E M )
B 1 0 4
(SECTION U)
31
AD FAN RELAY
(SECTION G2)
GLOW
PLUG
G
G
B 1 01
P C M (E M )
1 U
1 S
Y
W /G
1 V
B 1 0 3
G L O W
P L U G
B /W
1 O
1 M
1 K
P /L
L /W
L /R
1 I
1 G
1 Q
W /R L /B
W /L
V /W
1 T
1 R
R E L A Y
1 C
1 A
2 O
R /Y
L /R
G /R
B /L
W /Y
1 F
1 D
1 B
2 P
1 E
L G /R
G /W
1 P
1 N
1L
1 J
1 0 4 G L O W P L U G
(S H O R T C O RD )
1 H
2 K
2 I
2 G
2 E
2 A
2 M
B 1 05
L /W
2 N
2L
E N G I N E ( E ) S H O R T
(E )
3 Y
2 C
L G / BB R / W R / L
2 J
R /Y
B R /Y L / Y
2 H
2 F
C O R D )
B /W
3 Q
3 Z
3 X
3 O
3 M
3 K
3 G
R /B
L G
3 V
3 T
3 A
3 I
3 S
L /R
R /L
O
2 B
2 D
C O RD
(S H O R T
3 U
3 W
G Y /RP /B
3 R
V
B R / BY / B
3 P
3 N
3 E
3 C
G /Y
G /R
3L
3 J
3 H
3 F
B /O
3 D
3 B
B 1 0 2
(E)
G L O W
P L U G
R E L A Y
L /R
L
B
GI
B (E )
A
System name
M A IN
100A
IG KE Y
60A
X 0 1
F B 0 7 D
B /W ( F )
F B 0 5
B (F )
IN J O R
F IP
30A
F B 0 3
GLOW
40A
F B 0 3
W /G ( E M )
F B 0 4
Y /L (F )
S
F B 0 4
M A IN R E L A Y
F B 0 3
G
D
F B 0 4
L /R ( E )
L /R ( E M )
B 1 0 1
1E
3W
B 1 0 3
B 1 0 2
2M
GLOW
PLUG
RELA Y
3R
B 1 0 1
L
(E M )
B 1 0 2
F B 0 1 F B 0 3
B
(E )
LG
(E M )
L (E )
I
L
(E )
B 1 0 5
X 0 9
L G /R
(E M )
X 0 9
B /W
(F )
23
B
B
(E M )
D A T A L IN K
( S E C T IO N U
B 1 0 4
GLOW
PL UG
B 1 0 1 P C M ( E M ) 1 U
Connector code
1O
1S
1V
B103
Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air conditioning system connectors
H : Transmission control system connectors
I : Interior light system connectors
J : Audio/radio system connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
N : Power steering/4-wheel steering system
connectors
O : Anti-lock brake system connectors
P : Power seat/seat heater system connectors
Q : Auto cruise control system connectors
R : Auto adjusting suspension system
connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB: Joint box connections
1K
1T
1I
1C
1G
1A
W /Y
1P
1N
B /L
1L
1J
1H
B 1 0 4 G L O W P L U G
( S H O R T C O RD )
B
B /W
1F
2I
G / Y W /Y
1D
1B
G /R
L G /BB R /WR /L
L /W
R
2P
2N
2L
2J
Harness
9
Unit
Sensor
B
2H
B 1 0 5 E N G IN E ( E )S H O R T C O RD
(E )
(S
Ground numbers
Types of grounds
2G
2M
L G /R R / Y R /W
G /W
1R
2K
2O
1E
W /G W /L V / W
1M
1Q
W /R L /B P /L L /W L /R
GI
System code
B-1A
Current symbol
DATA LINK
CONNECTOR (DLC)
(SECTION U)
B /W (D )
B (D )
1B
ENGINE SWITCH
17
18
G /Y
(E M )
W /Y
(E M )
R /W
(E M )
O FF
ST
A CC
IG 1 IG 2
E N G IN E
J B 0 4 1 0 A 1 4 J B 0 1
X 0 6
16
X 0 3
X 0 3
L (D )
B /L (D )
AA
B /L
(E M )
B 1 0 1
1F
1D
1I
1A
* Shielded wire:
Prevents signal disturbances from
electrical interference. Wire is
covered by a metal meshing for
grounding.
PCM
2C
2A
1S
2B
2E
R /Y
(E M )
SHIELD WIRE
B 1 0 7
W /R
(E M )
P /B G Y /R O
(E M ) (E M ) (E M )
INTAKE AIR
TEMPERATURE
SENSOR NO.1
1
B 1 0 7
O
(E M )
B
(E M )
14
REFRIGERANT
PRESSURE SWITCH
(SECTION G1)
B 1 0 6
Connector symbols
BOOST SENSOR
3Y
3Q
3U
3W
3K
3I
L G B R /BY / B G /R
3V
3T
3A
3G
R /B
R /L
3X
3M
3S
B / W L /R
3Z
3O
3R
3P
3N
3L
3E
3C
G /Y
3J
3H
3F
Circuit
diagram symbol
L /R
L
B /O
3D
Connector
diagram symbol
3B
P / B G Y /R O
R /Y
Male
Male
Female
Female
L
R
(Example)
Connector on harness side
Symbol
(Example)
Solid colour wire
B
(F)
Black
Striped wire
W/R
(F)
White
(base
colour)
View from
harness side
Red
(stripe)
D Colours for connectors except milk-white are given in
locations.
D The harness symbol is in ( ) following the harness
symbols (refer to P-7).
GI
Routing diagram
D The routing diagram shows where electrical components are on the system circuit diagram by call out line and connector
symbols.
Connector symbol
Component name
Ground symbol
(Example)
Connector
Symbol
Common connectors
X-9
System connectors
I-03
HARNESS SYMBOL
(F)
(E)
(R)
INSTRUMENT
CLUSTER
VACUUM
SWITCH
C-01
C-05
(F)-(I)
X-02
(F)-(I)
X-02
C-06
PARKING BRAKE SWITCH
GI
SYMBOL
DESCRIPTION OF HARNESS
SYMBOL
FRONT HARNESS
(F)
(DR1)
(F2)
(DR2)
ENGINE HARNESS
(E)
(DR3)
DASH HARNESS
(D)
(DR4)
REAR HARNESS
(R)
FLOOR HARNESS
(FR)
(R2)
(IN)
(R3)
A/C HARNESS
(AC)
INJECTION HARNESS
(INJ)
(I)
EMISSION HARNESS
(EM)
(EM2)
(EM3)
GI
Symbols
Symbol
Meaning
Symbol
Battery
Light
Ground (1)
Meaning
3.4 W
Resistance
Motor
Pump
Remarks
D Current will not flow through a circuit if
ground is faulty.
Fuse (1)
Precautions
Cigarette lighter
(Box)
Fuse (2)
<Blade type>
<Tube type>
D Generates sound when current flows.
Horn
(Cartridge)
Main fuse/
Fusible link
<Cartridge type>
<Fusible link>
Speaker
Transistor (1)
Collector (C)
Base (B)
NPN
Emitter (E)
C
B
Transistor (2)
Collector (C)
EC B
C
PNP
Emitter (E)
Speed sensor
Ignition switch
E
B
D Reading code.
2 S C 828 A
Base (B)
Heater
Semiconductor
Number of
terminals
Revision mark
A: High-frequency PNP
B: Low-frequency PNP
C: High-frequency NPN
D: Low-frequency NPN
B 1
B 2
S T
IG 2
O FF
IG 1
O FF
A C C
GI
Meaning
Symbol
Meaning
Harness
Connection
D
B
Selection
WITH ABS
Switch (2)
A
Diversion point D
for the different
circuits according to
the vehicles
specification is
indicated by a white
dot.
Relay (1)
D
B
WITHOUT ABS
C
D Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil
Current to coil
No Flow
Flow
D Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil
Current to coil
Flow
No Flow
Diode
Sensor (thermistor)
Capacitor
Light-emitting diode
(LED)
Cathode (K)
Anode (A)
Flow of direct current
A K
A
Anode (A)
Cathode (K)
Anode (A)
Flow of current
Solenoid
Reference diode
(Zener diode)
GI
Meaning
D The wiring position can be exchanged freely within the
connector.
Abbreviations
3GR
Third Gear
CCT
Circuit
4GR
Fourth Gear
CIGAR
Cigarette
Ampere
CIS
A/C
Air Conditioning
CKP
A/F
Air Fuel
CLS
A/R
Auto Reverse
CMP
AAS
COMBI
Combination
ABS
CON
Conditioner
ACC
Accessories
CONT
Control
ACV
CPU
ADD
Additional
CSD
AIR
CTP
AIS
DEF
Defroster
ALL
DI
Distributor Ignition
AM
Amplitude Modulation
DLC
AMP
Amplifier
DLI
Distributorless Ignition
ANT
Antenna
DOHC
Double-Overhead Camshaft
AP
Accelerator Pedal
DTC
AS
Autostop
DTM
ASV
ECM
AT
Automatic Transmission
ECPS
ATX
Automatic Transaxle
ECT
B+
EGR
BAC
EI
Electronic Ignition
BARO
Barometric Pressure
ELEC
Electric
CAC
ELR
CARB
Carburetor
ETR
Electronic Tuner
10
Front
OBD
On-board Diagnostic
F/I
Fuel Injector
OFF
Switch Off
FC
Fan Control
ON
Switch On
FICB
Power
FM
Frequency Modulation
P/S
Power Steering
FP
Fuel Pump
P/W CU
FPR
PAIR
GEN
Generator
PCM
GND
Ground
PNP
Park/Neutral Position
H/D
Heater/Defroster
PRCV
HEAT
Heater
PRG
HEI
High-Energy Ignition
PSP
HI
High
PTC
HO2S
QSS
Quicik-Start System
IAC
Rear
IAT
REC
Recirculation
ICM
RF
Right Front
IG
Ignition
RFW
Remote Freewheel
ILLUMI
Illumination
RH
Right Hand
INT
Intermittent
RPM
Engine Speed
JB
Joint Box
RR
Rear Right
KS
Knock Sensor
SAPV
LCD
SFI
LF
Left Front
SOL
Solenoid
LH
Left Hand
ST
Start
LO
Low
SW
Switch
LR
Left Rear
TC
Turbocharger
Motor
TCM
MAF
TCV
MAP
TEMP
Temperature
MFI
TICS
MID
Middle
TP
MIL
TR
Transmission Range
MIN
Minute
TWS
MIX
Mixture
Volt
MPX
Multiplex
VAF
MT
Manual Transmission
VENT
Ventilation
MTR
VOL
Volume
MTX
Manual Transaxle
VR
Voltage regulator
NC
Normally Closed
VRIS
NO
Normally Open
VSS
O2S
Oxygen Sensor
Watt(s)
WOT
11
GI
Y-a
Ground points
except
Euro 1
without
central
locking
B( F )
B/ R
B
B
6
6
B
3
B/ R
B/ R
B
B
B
B
Euro 1
B/ R
B (F )
12
B( F )
B( F )
4
B( F )
B( F )
12
B( F )
to each
unit
Front harness
5
B( F )
Front harness
B( F )
B( F )
B( F )
to each unit
B( F )
B( F )
B( F )
B( F )
B( F )
B( F )
B/ R (F )
B( F )
3
B/ R (F )
06
B( F R )
10
Ground
(Section Yb)
B/ R (F )
except Euro 1
11
(F )
(E)
(R)
Y-a
Harness symbol
3
6
5
[Euro 1, Euro 2]
X06
(F)-(FR)
13
2
[Euro 3]
3
X06
2
(F)-(FR)
Y-b
Ground points
B
7
B
B
10
11
12
13
B( F R )
10
B (D R 3)
11
Door harness 3
12
Door harness 4
13
Heated rear
screen ground
14
audio
ground
14
B( R 2 )
B( R 2 )
B( R 2 )
Ground
(Section Ya)
Rear harness 2
B( F R )
B( F R )
Floor harness
B( R 2 )
14
to each unit
B( F R )
to each
unit
B( F 2 )
9
27
Front harness 2
Ground
(Section
Ya)
B( F 2 )
04
B( F )
26
B( R )
B (D R 4 )
AntiLock Control
4Wheel
Freestyle cabin / Stretch
cabin (with rear access)
B( F R )
10
Floor harness
audio ground
(F )
(E)
(R)
Y-b
Harness symbol
7
[Double cabin]
14
13
10
15
(R)-(DR4)
X2 6
12
04
(F)-(R)
8
X04
X27
(F)-(R)
13
(FR)-(DR3)
11
10
Schematic
current from battery
Battery
B
W/ R
L/ R
B T N 60A
M A IN 8 0 A
IG
KEY
1 40A
IG
KEY
2 40A
R O OM 10A
System
F IP / IN J 20A
Ignition
switch
B/ L
A /C 10A
B/ W
LG/R
OF F
ST
GLOW
HE A T E R 40 A
60A
System
IG 1
IG 2
AC C
B/ W
B/ R
HE A D 20A
W
R. DE F O G 20A
B/ Y
B/ W
TA IL 1 0A
Headlamp
switch
L/ R
R/ B
CIG A R 15A
Euro 3
Off
Euro 3
Headlamp
TNS
flasher
L/ R
B
2,
L/ W
R/ B
L/ R
Head
16
High beam
B4
Fuel heater
G /B
B/ Y
L/ R
Low
beam
Interior lamps
I 3
I 4
Audio Systems
J1
J2
P/ W 1 5 A
G
P .W IND 30A
Power windows
K
R/ L
R/ W
M E T E R 15A
B/ Y
Front wiper/washer
I 2
L/ W
P T C 30A
Clock
Instrument illumination
L/ R
L/ R
Instrument cluster
I 1
S T OP 15A
Dimmer
switch
B/ W
Cigar lighter
Rear defrost
L/ W
Light switch
B/ Y
Engine control
Preglow system
B/Y
Y/ R
except
Euro 3
1,
L/ W
W
B/ W
A / C2 10A
Charging System
Starting System
R/ W
HE A D 3 0 A
OF F
B/ Y
Section
Section
WI P E R 15A
W/ G
D/ L 30A
R/ G
L/ W
Power mirrors
R
E
L/ R
R/ W
AntiLock Control
4Wheel
A BS 6 0 A
Y
B/ W
R/ B
E N GI NE 15A
R/ Y
Headlamp levelling
BR /Y
R/ G
Heated seats
S .WA R M 15A
R .F OG 10A
R /G
B/ Y
B/ W
B/ Y
Reversing lamps
Air bags
L/ Y
HA Z A RD 10A
L/ R
Immobiliser system
B/ Y
T
B/ W
Stop Lamps
Horn
G/ W
B/ Y
U1,
U2
17
01
01
03
03
R/ W
(E )
09
& .
(F )
Cold area
@ Euro 3
Euro 1, Euro 2, not cold area
(F )
HE A D 30A
HE A D 20A
M A IN 8 0 A
Cold area
B/ L
(F )
IG KE
Y1
4 0A
IG KE
Y2
4 0A
B /W (E)
R (E)
B/ W
A
(F )
B( E)
Euro 1
Powertrain control
module (PCM)
(Section B1b)
B( E )
B/ Y
B/ Y
B/ Y
B/Y
(F )
(F )
(F )
(F )
02
OF F
ST
IG 2
(F )
B/ Y
03
03
W
B/ W
(F )
(F )
(F )
(F )
E N GI NE 15A
03
except Euro 3
01
02
B/ Y
B/ Y
Starter
Ignition
switch
AC C
Euro 1
Powertrain control
module (PCM)
(Section B2b)
02
OF F
IG 1
Starter
relay
Regulator
Generator
A
18
(F )
W/ B (E )
Immobiliser module
(Section T)
(F )
01
B/ L
&B /Y
08
B/ Y
@B /L
B/ L
(F )
B/ L
(F )
(F )
(E )
02
03
B/ L
A
02
09
W/ B
(F )
Euro 3
M
5
Instrument cluster
(Section Cb)
01
A 02
Starter (E)
B
B
B
A 03
Generator (E)
B/L
&B /Y
R
B/ W
W/ B
B /W
B/ Y
B/ L
(F )
(E)
(R)
Harness symbol
[Grey]
(F)(E)
X08
[Grey]
(F)(E)
X09
19
A02
Generator
[Grey]
A01
Starter
A02
Generator
X03
Fuse block
X02
Ignition
switch
A03
Starter
relay
B-1a
01
01
B/ L
(F )
(E )
MA IN 80 A
IG KE
Y1
4 0A
IG KE
Y2
40A
B/W
B/ W
(F )
(F )
GLOW
60A
B/ W
(F )
OF F
OF F
ST
02
01
IG 2
IG 1
(F )
B1 0 6
B1 0 5
AC C
02
03
B1 0 9
FICD solenoid
valve 2
FICD solenoid
valve 1
03
B/ W
(F )
B/ W
B/ W (F )
Ignition
switch
Fuel shutoff
valve
B/ W
(F )
(F )
B1 0 6
B1 0 5
E N GI N E 15A
B/ W
(F )
(F )
(F )
B1 0 1
Powertrain control
module (PCM)
I
B
B1 0 1
R/ B
BR
BR /Y
(F )
(F )
(F )
(F )
W
(F )
B/ R (F )
B1 0 2
B/ R (F )
20
Glow plug
relay
B1 0 2
08
BR /Y
(E )
(E )
(F )
(E )
Engine Coolant
Temperature
(ECT) sensor
R( F )
B1 0 4
B
No. 4
No. 3
No. 2
No. 1
(F )
B/ R
B1 08
B1 0 7
(F )
B/ R (E )
B/ R
Glow plugs
B1 0 7
GY
W /L
R /B
R /W
B/ W
BR /Y
R/ B
B/ Y
B /R
BR
R
B
BR
B/ R
BR /Y
B/ R
B/ W
B /W
B /W
B-1a
Harness symbol
Glow plug relay
B102
WL T u rbo
[Brown]
Glow plug relay
B102
[Grey]
(F)(E)
[Black]
Fuel shutoff valve
B109
X08
X01
B107
Engine Coolant
Temperature
(ECT) sensor
[Grey]
21
B108
B105
FICD solenoid
valve 1
[Grey]
[Black]
B104
WL
B109
Glow plugs
Fuel shutoff
valve
[Black]
4
X03
Fuse block
X03
Ignition switch
B101
Powertrain control module
(PCM)
B-1b
A/C Amplifier
(Section G)
A/C Relay
(Section G)
B/ Y
R/ W
R/B
(F )
(F )
(F )
B1 0 1
Powertrain control
module (PCM)
K
B1 0 1
GY
W/ L
(F )
(F )
22
7
Instrument cluster
(Section Cb)
BR
GY
W /L
R /B
B /W
R/ W
BR /Y
B/ Y
B /R
Instrument cluster
(Section Ca)
B-1b
Harness symbol
23
B101
Powertrain control module
(PCM)
B-2a
01
01
B/ L
B
(E )
(F )
M A IN 8 0 A
IG
K EY
1 40A
IG
K EY
2 40A
B/ W
(F )
B/ W
(F )
GLOW
60A
B/ W
(F )
Ignition switch
OF F
OF F
ST
X
02
B/ W
(F )
B/W (F )
01
B2 0 6
B2 0 5
IG 2
IG 1
AC C
02
03
FICD solenoid
valve 1
03
FICD solenoid
valve 2
B/ W
(F )
(F )
B2 0 5
B2 0 6
E N GI NE 15A
B/ W
(F )
(F )
(F )
B2 0 1
BR /Y
(F )
(F )
(F )
BR /W
R/L
G/ W
L/ B
B/ W
(F )
(F )
(F )
(F )
(F )
B2 0 1
R/ B
BR
(F )
(F )
B/ R (F )
B2 0 2
B2 0 9
Glow plug
relay
B/ R (F )
X
08
24
B/ R
(E )
(E )
B2 0 8
B2 0 7
R( F )
B2 0 4
Fuel pump
Fuel
shutoff
valve
B2 0 9
Engine Coolant
Temperature
(ECT) sensor
Glow plugs
B
No.4
No.3
No.2
No.1
(F )
Position sensor
(E )
R
(F )
TCV
Idle
switch
B/ R (E )
BR /Y
B2 0 2
B/ R
(F )
B/ R
(F )
B2 0 7
B/ R
(F )
B/R
(E )
4
Q
BR /R
L /B
BR
B /Y
M
GY
W /L
R/ B
B /W
R /W
BR /Y
R/ L
G /W
B /Y
B /R
C
G
BR
R
R /B
B /W
B
B R /W
C
B/ R
BR /Y
B/ R
R/L
B /R
G /W
B /W
BR /W
L/ B
B /R
W
F
F
B /W
B-2a
Harness symbol
Glow plug relay
B202
[Grey]
(F)(E)
[Grey]
Fuel pump
B202
X08
[Brown]
Glow plug relay
B202
X01
B206
FICD solenoid valve 2
25
B208
Pump speed sensor
[Grey]
B207
Engine Coolant Temperature (ECT) sensor
[Grey]
B204
Glow plugs
B205
FICD solenoid valve 1
[Black]
X03
Fuse block
X02
Ignition switch
B201
Powertrain control
module (PCM)
B2-b
A/C Amplifier
(Section G)
A/C Relay
(Section G)
10
11
B/ Y
BR /R
B/ Y
R/W
R/ B
(F )
(F )
(F )
(F )
(F )
B2 0 1
B2 0 1
W/ L
(F )
GY
(F )
(F )
26
W/ L
(F )
W/ L
(F )
12
B2 1 0
7
Instrument cluster
(Section Cb)
Instrument cluster
(Section Ca)
B/ R
(F )
Q
BR /R
L /B
BR
GY
G
W /L
B/ Y
R/ B
B /W
R /W
R /L
G /W
E
BR /Y
B/ R
C
G
B R /W
B /Y
B /R
B2-b
Harness symbol
[Green]
3
27
B210
Powertrain control module
(PCM)
B-3a
01
01
W/ R
(E )
(F )
M A IN 8 0 A
03
03
B/ L
(F )
L/ R
(F )
BT N 60 A
X
B/ L
(F )
R OOM 10A
01
L/ W
B/ L
(F )
(F )
FI P / IN J 2 0A
IG
L/ W
L/ W
(F )
(F )
K EY
1 40A
B/ L
B/ L
B/ L
B/ L
B/ L
(F )
(F )
(F )
(F )
(F )
B/ W
(F )
IG
K EY
2 40A
02
B3 0 6
B3 0 2
PCM module
relay
OFF
OF F
ST
IG 2
IG 1
Exhaust gas
recirculation
(EGR) solenoid valve
(vacuum)
AC C
B3 0 6
X
B3 0 2
B3 0 8
B3 0 7
Ignition
switch
B3 0 7
B3 0 9
Exhaust gas
recirculation
(EGR) solenoid valve
(vent)
B3 0 8
Exhaust Gas
Recirculation
(EGR) valve
B3 0 9
02
X
03
03
W
B/ L (F )
B/ L(F )
(F )
B/ L
B/ L
B/ L
(F )
(F )
(F )
LG(F )
G/ O
Y/ G
LG/ R
W/ R
(F )
(F )
(F )
(F )
4Z
4T
4Q
4I
E N GI N E 15A
B/ L (F )
B/ L (F )
B/ L (F )
4C
4D
4X
B/ W (F )
B3 0 1
3B
41
4V
2K
Powertrain
control module (PCM)
2D
1C
1V
4A
4B
3O
1D
Fuel pump
(Section B-3c)
B3 0 1
G/ B
BR (F )
R/ B
(F )
(F )
GLOW
60A
B3 0 3
B/ R
B/ R
G/ W
(F )
(F )
(F )
28
P( F )
(E )
B3 1 3
Neutral
position
switch
(F )
L(F )
Shield
B3 1 1
B3 1 2
Clutch
switch
Idle switch
B3 0 3
G/ B
(F )
G/ B
B/ R (F )
Glow plug
relay
09
G/ B
28
B3 1 3
B/ R (E )
B( F )
R( F )
B3 1 1
B3 1 0
B3 1 2
B/ R (F )
No.1
No.2
No.3
No.4
Glow plugs
(F )
(F )
1U
B301
Powertrain control module
(PCM) (F)
1O
1S
B/L
L/Y
B/ W
BR /Y
1V
1T
1K
1I
1G
1A
1E
R/ L
GY /L
G/ R
GY /B
1R
1P
1N
1L
1M
1Q
2K
2G
2E
BR /W
L/ W
2L
G /Y
P /B
G /B
BR /B
1J
1H
1F
1D
1B
R/Y
L/R
3O
2A
W /L
2J
2H
2F
P/L
3K
3I
3G
3E
3M
2C
BR /R
Y /R
2D
2B
3L
3J
3H
3F
C
L /W
B/ L
LG
4U
LG/ B
L/ B
GY
B/ L
LG
G /O
B /L
BR
Y/ G
3D
3B
4Z
4X
4V
4T
4O
28
4M
4K
4A
4I
4S
L/ W
4Q
4W
R /W
3N
4Y
3A
3C
G/ W
3P
2I
1C
08
B/ R (F )
Fuel pump
4
B/ R (F )
B3 0 5
4G
LG/ R
B/ Y
W /R
4E
4C
G /B
B /L
B/ R
B/ L
B /R
4D
4B
R /B
4R
4P
4N
4L
4J
B308
4H
4F
BR
R
R/B
G/ O
B /L
B
Y/ G
B/ L
G/W
G/B
G/ B
B /R
B /L
LG/ R
B/ L
B-3a
Harness symbol
[Grey]
(F)(E)
X08
[Grey]
(F)(E)
X09
Main fuse box
X01
[Brown]
Glow plug relay
[Black]
Exhaust gas recirculation
(EGR) solenoid valve (vent)
B308
Neutral position switch
B313
B303
B307
Exhaust gas recirculation (EGR) solenoid
valve (vacuum)
[Black]
29
Clutch switch
B312
B305
Glow plugs
B309
Exhaust Gas
Recirculation
(EGR) valve
B306
Intake air control
valve
Joint connector
X28
X03
4
Fuse block
X02
Ignition switch
B302
PCM module
relay
B311
Idle switch
B301
Powertrain control module
(PCM)
B-3b
Instrument cluster
(Section Ca)
12
W/ L
W/ L
(F )
(F )
Immobiliser module
(Section T)
10
11
13
14
BR /R
(F )
B/ Y
(F )
Y/ R
(F )
(F )
2A
4K
2B
2I
W/ L
(F )
B3 0 1
2J
1G
1K
1I
1S
2L
2E
1T
1A
1J
1P
1F
1R
2C
B3 0 1
BR /W
BR /B
BR /B
BR /B
(F )
(F )
(F )
(F )
Shield
L/ Y
L/ W
R/ Y
(F )
(F )
(F )
(F )
(F )
(F )
BR /W
30
BR /W
BR /B
BR /Y
(F )
(F )
(F )
B3 1 4
BR /W
(F )
BR /B (F )
(F )
G/ Y (F)
V( F )
BR /W (F )
V( E )
BR /W (E )
X
X
BR /B (E )
08
B/R
BR /B
BR /B
(F )
(E )
(E )
BR /Y
BR /B
G/ Y
BR /B
(E )
(E )
(E )
(E )
09
BR /W
GY /L
BR /B
BR /W
R/ L
BR /B
P/ L
(F )
(F )
(F )
(F )
(F )
(F )
(F )
B3 1 7
B3 1 8
28
EPROM
B 3 1 5
B3 16
B 315
Engine Coolant
Temperature
(ECT) sensor
B/R
(F )
B3 1 9
B3 1 6
Boost pressure
sensor
Fuel pump
3
B301
1U
1O
B/L
L/Y
B/ W
BR /Y
1V
1M
1K
1I
1G
1Q
1S
1T
1A
1E
R/ L
GY /L
G/ R
GY /B
1R
1P
1N
1L
G /Y
P /B
1J
1H
1F
B314
Fuel pump (F)
2G
L/R
BR /W
G /B
BR /B
L/ W
W /L
1D
2E
2I
1B
2L
2J
2A
BR /W
B R /B
R
BR /W
L/Y
R/Y
4Y
R /Y
2H
2F
4Q
4W
2C
4U
BR /R
LG/ B
L/ B
GY
Y /R
G /O
B /L
BR
Y/ G
2B
4Z
4X
4V
4T
2D
4O
4M
4K
4I
4S
P /L
2K
1C
4A
4G
LG/ R
B/ Y
W /R
4E
4C
G /B
B /L
B /R
B/ L
B /R
R /B
4R
4P
4N
4L
4J
4H
4F
L/W
BR /Y
BR /B
BR /W
G Y /L
BR /B
BR /B
B R /B
BR /B
P/ L
R /L
BR /W
42
G/ Y
4D
4B
Powertrain control
module (PCM)
(Section B3c)
B-3b
Harness symbol
[Grey]
Fuel pump
[Grey]
[Grey]
(F)(E)
X09
[Grey]
B314
(F)(E)
X08
3
[Black]
Intake air temperature
sensor 2
B316
31
Joint connector
X28
B317
EGR valve
position sensor
B318
Boost pressure
sensor
[Grey]
[Black]
B319
Accelerator pedal position sensor
[Black]
B301
Powertrain control module
(PCM)
B-3c
A/C Amplifier
(Section G)
A/C Relay
(Section G)
Instrument cluster
(Section Ca)
Instrument cluster
(Section Cb)
15
B/ L
R/ W
R/ B
G/ R
GY
(F )
(F )
(F )
(F )
(F )
1U
3C
4L
1N
4S
B3 0 1
4W
4U
1L
1M
1Q
1O
4Y
3D
4E
1H
1B
B3 0 1
BR /B
(F )
Shield
Fuel pump
(Section B3b)
32
BR /B
BR /B
(F )
42
41
BR /B
(F )
(F )
B/ L
B/ L
(F )
(F )
LG/ B
B/ L
L/ B
(F )
(F )
(F )
B/ L
(F )
GY /B
(F )
BR /B
(F )
(F )
(F )
(F )
B/ L
(F )
BR /B
B/ L
B/ L
G/ B
B/ L
P/ B
BR /B
(F )
(F )
(F )
(F )
(F )
(F )
(F )
(F )
B3 2 0
B/ R
B3 2 1
B/ R
(F )
Fuel temperature
sensor
28
B/ R
Fuel pump
(F )
1U
1O
1M
1K
1I
1G
1Q
1S
BR /Y
R/ L
GY /L
G/ R
GY /B
G /Y
P /B
1V
1T
1R
1P
1N
1L
1J
1H
1F
L/ Y
L/R
BR /W
G /B
BR /B
3I
3G
3E
3A
1D
1B
3P
(F )
3L
3J
3H
3F
B/ L
L/ B
B/ L
BR /B
W
LG/ B
GY /B
B /L
BR /B
B/ L
G /B
B/ R
B /L
LG/ B
L/ B
GY
LG
G /O
B /L
BR
Y /G
3D
3B
4Z
4X
4V
4T
P /B
BR /B
4O
4M
4K
4I
4S
B/ L
4Q
4U
4W
R /W
3N
4Y
3C
G/ W
3K
3M
1C
B/ W
B/ L
3O
1A
1E
28
B/ R
B301
Powertrain control module
(PCM) (F)
B3 2 2
(F )
E
4A
4E
4C
G /B
B /L
B /R
B /L
B/ R
4D
4B
4G
LG/ R
B/ Y
W /R
R/ B
4R
4P
4N
4L
4J
4H
4F
TDC sensor
Harness symbol
B-3c
[Grey]
Fuel pump
B320
[Black]
Mass Air Flow (MAF)
sensor / Intake air
temperature sensor
B321
33
B322
TDC sensor
[Grey]
Joint connector
X28
B301
Powertrain control module
(PCM)
B-4
Fuel heater
Battery
01
01
B
(E )
M A IN 80A
PTC 30A
G/ B (F )
B4 0 1
Fuel
heater
B4 0 1
34
B( F )
B401
Fuel
heater (F)
G/ B
(F )
(E)
(R)
B-4
Harness symbol
B401
Fuel heater
[Grey]
35
4
C-a
Instrument cluster
Battery
01
# .. with
01
B/ L
B
(E )
MA IN 8 0 A
01
03
IG
03
KEY
(F )
1 40A
B/ W
L/ R
W/ R
(F )
(F )
IG
R OOM 10A
B T N 60A
KEY
(F )
2 40A
ST
E URO 3
Powertrain control
module (PCM)
(Section B3c)
IG 2
G/ R
15
02
Ignition switch
OF F
OF F
IG 1
AC C
(F )
X
02
03
03
B/ Y
W
(F )
(F )
M E T E R 15A
Instrument cluster
C01
1H
1J
1K
Low fuel
indicator
1.4W
Water temperature
gauge
Speedometer
Tachometer
Microprocessor
Safety
1.4W
Fuel indicator
gauge
(Section I2)
b
1F
1I
1L
1P
1N
1G
1M
2K
C
Y( F )
X
(Section Cb)
(Section Cc)
L/ W
(F )
(F )
04
08
R/ Y
W/ L
Y/ B
(F )
(F )
(F )
01
Y( R )
36
19
Y( R 2 )
B/ R
L/ W
(E )
(E )
C04
(F )
L
(E )
C0
L/ W
(E )
BR /B
(F )
C03
Fuel pump/fuel
gauge sender
29
04
19
B/ R
B/ R
B/ R
(F )
(R)
(R 2)
Speedometer
sensor
Speedometer
sensor
4x2
except 4x2
Door entry
switches
(Section I3)
Powertrain control
module (PCM)
(Section B1b,
B2b, B3b)
B/ R (F )
16
C02
C04
X
Immobiliser
module
(Section T)
01
L /W
1P
02
C 03
1O
R /Y
W /L
L /R
B /Y
1N
1M
1L
1K
1J
1I
&G /R
1H
Y /B
R /B
1G
1F
1E
1D
Y/ B
B /R
L/W
except 4x2
L/ W
R/ G
G /B
G /W
B/ L
R/ L
GY
1C
1B
1A
2N
2M
2L
C 04
L
B/ R
(B R/ B ) @Y /G
2K
2J
W
2I
#B R
#LG/ R
2H
2G
2F
L /Y
Y /R
W /B
B
%L G
R /W
2E
2D
2C
2B
2A
with immobiliser
unit
(F )
(E)
(R)
C-a
Harness symbol
[Euro 1, Euro 2]
[Grey]
Speedometer sensor
C03
4x2
[Grey]
(F)-(E)
(R)-(R2)
X08
X19
[Double cabin]
[Grey]
Speedometer sensor
X01
C03
except 4x2
(F)-(R)
X04
Instrument cluster
C01
[Black]
Instrument cluster
C01
C02
Coolant temperature sensor
37
[Grey]
(F)-(E)
Fuse block
(R)-(R2)
X19
X02
[Euro 3]
X01
X03
X08
03
[Grey]
Speedometer sensor
C03 4x2
Ignition switch
[Grey]
Speedometer sensor
C03
except 4x2
X04
(F)-(R)
C02
Coolant temperature sensor
X04
(F)-(R)
C-b
Instrument cluster
remote freewheel control system
with air bag
with ABS
( ) ...
with immobiliser unit
#
. with
Instrument cluster
(Section
Ca)
Park
brake
1.4W
RF W
4WD
LOCK
1. 4W
Air bag
1.4W
Preglow
indicator
1.4W
ABS
1.4W
1. 4W
d
2E
2G
2H
L/ Y
Y/ G (F )
(F )
38
L/ Y
LG/ R
BR
(F )
(F )
L/ Y
Charge
1.4W
2D
2C
2L
2I
Y/ G
Y/ G
(F )
(F )
%L G
GY
Y/ R
W/ B
(F )
(F )
(F )
(F )
(F )
C0
Brake
fluid sensor
BR /W
C0
36
Park brake
switch
C0
B( F )
01
09
R/ L
GY
2M
2L
(B R /B ) @Y /G
2K
2J
W
2I
#B R
#LG/ R
2H
2G
L/ Y
(Short cord)
B R/ W
without
ABS
Data Link
Connector
(DLC)
(Section
U1, U2)
B
(F )
2F
L /Y
Y /R
W /B
B
%L G
R/ W
2E
2D
2C
2B
2A
17
ABS control
module
(Section O)
C 05
B/ L
(F )
35
34
Powertrain
control module (PCM)
(Section
B1b, B2b,
B3c)
Y/ R
05
(E )
Generator
(Section A)
Sedimentor
switch
C
05
C06
B
(F )
with ABS
4
2N
(F )
37
01
09
LG
C0
(F )
(F )
Sedimentor
1.4W
(Section Cc)
2B
2J
Low oil
pressure
1.4W
C 06
C 07
C 08
L/ Y
B
BR /W
Y/ R
B
(F )
(E)
[Grey]
(F)-(E)
(R)
C-b
Harness symbol
[Grey]
Sedimentor switch
C05
Brake fluid sensor
C07
X09
C06
Oil pressure switch
39
Instrument cluster
C01
[Black]
Instrument cluster
C01
(F) Short cord
C09
C08
Park brake switch
C-c
Instrument cluster
Headlamp
switch
(Section E1)
Flasher unit
(Section F1)
Rear window
heater relay
(Section I1)
. .with
( ).
19
20
18
21
22
G/ B
G/ W
R/ W
B/ L
R/ L
(F )
(F )
(F )
(F )
(F )
Instrument cluster
C01
1B
1A
LH
direction
indicator
1.4W
(Section Cb)
(Section Ca)
2A
RH direction indicator
1.4W
2N
High
beam
1.4W
2M
Rear fog
lamp
1.4W
1D
C01
40
B
(F )
01
L/ W
1P
1O
R/ Y
W /L
L /R
B /Y
B/ R
1N
1M
1L
1K
1J
1I
&G /R
1H
Y /B
R /B
R/ G
G /B
G /W
B/ L
R/ L
GY
1G
1F
1E
1D
1C
1B
1A
2N
2M
2L
(B R/ B ) @Y /G
2K
2J
#B R
#LG/R
2I
2H
2G
% ..with ABS
& ..Euro 3
2F
L/ Y
Y /R
W/ B
2E
2D
2C
B
%L G
R/ W
2B
2A
(F )
(E)
(R)
C-c
Harness symbol
Instrument cluster
C01
[Black]
Instrument cluster
C01
41
Front wiper/washer
Battery
01
01
# .. without
B/ L
(F )
B
(E )
M A IN 8 0 A
IG KE
Y1
40A
IG KE
Y2
40A
B/ W
(F )
X
02
Ignition switch
ST
OF F
OF F
IG 1
AC C
IG 2
X
(F )
(F )
03
03
W
(F )
WI P E R 15A
L( F )
Wiper/washer switch
D02
Wiper
switch (2)
HI G H
IN T
02
Onetouch
OF F
HI GH
OF F
IN T
LO W
Washer
switch
LO W
L/ Y (F )
02
L/ W(F )
01
L/ B
B
(F )
42
L/ O (F )
D0
(F )
Windshield wiper
motor
Stop
switch
D03
Windshield
washer pump
motor
M
LO
HI
M
Circuit
breaker
D 01
02
#G/ R
L/B
D 03
L/ W
L/ Y
L
L/ O
L /O
B( F )
L/ W
L /Y
L/B
01
air bag
(F )
(E)
(R)
Harness symbol
Windshield wiper motor
D03
43
D01
Windshield washer
pump motor
D02
Wiper/washer
switch
X02
X03
Fuse block
Ignition switch
E-1
01
01
B/ L
(F )
(E )
IG
M A IN 8 0 A
K EY
1 40A
B/ W
(F )
IG
K EY
2 40A
03
03
W/ R
Y/ R
(F )
R/ W
(F )
HE A D 20A
(F )
R( F )
(F )
Light
switch
Headlamp
flasher
R/G
R/ G
(F )
(F )
03
03
02
03
B/R
(F )
(F )
A/C 2 1 0A
E1 0 1
Head
Off
03
TNS
Dimmer switch
High beam
R/ Y
(F )
R .FOG 10A
AC C
E1 0 1
R/ G
27
IG 1
IG 2
Headlamp switch
26
OF F
(F )
Headlamp levelling
switch
(Section E3)
OF F
ST
HE A D 30A
02
Ignition switch
(F )
T A IL 10A
B T N 60A
E1 0 1
R/ B
R/ B
(F )
(F )
25
Instrument illumination
(Section I2)
Low beam
R/ B
(F )
E1 01
R/ G
R/ W (F )
(F )
R/ W
(F )
E1 0 4
Headlamp relay
E1 0 5
R/W
(F )
Daytime Running
Lamps (DRL) relay
E1 04
W
R/ L(F )
44
Instrument cluster
(Section Cc)
(F )
R/W
18
(F )
R/ W
R/ L
R/ W
R/L
(F )
(F )
(F )
(F )
E1 0 2
E1 0 5
E1 0 3
Headlamp,
LH side
60/ 55 W
Headlamp,
RH side
B( F )
60/ 55W
W/ L( F )
W/ L
(F )
E 103
E 1 02
B( F )
W/ L( F )
R/ B
(R)
(F )
(F )
B( F )
B( F )
1
E 1 01
E 1 02
W/ R
B /Y
Y /R
W/ B
E 103
E 1 04
E 105
R/ L
R/ L
W/ L
R/ B
R /Y
R /G
R /W
R/W
R/W
R /B
R/ W
W
R/ G
R
R/ L
24
Parking Lamps
(Section E2)
23
Tail lamps
(Section E2)
04
(F )
(E)
E-1
Harness symbol
(R)
[Double cabin]
(F)-(R)
X04
E103
Headlamp,
RH side
E104
Headlamp relay
45
E102
Headlamp, LH side
2
6
X03
Fuse block
X02
Ignition switch
E101
Headlamp switch
X04
(F)-(R)
X04
(F)-(R)
E-2
23
R/ B
(R )
W/ L
X
(F )
19
R/ B
(R2)
R/ B
R/ B
(R 2 )
(R 2)
W/ L
W/ L
R/ B
R/ B
(F )
(F )
(R2)
(R2)
E2 0 1
E2 0 5
E2 0 2
LH parking lamp
RH parking lamp
5W
5W
E2 0 1
E2 0 2
R/ B
(R 2 )
E2 0 6
Tail lamp, LH
side
5W
R/ B
(R2)
E2 0 4
Tail lamp, RH
side
5W
5W
E2 0 6
E2 0 5
E2 0 7
RH Licence
plate lamp
LH Licence plate
lamp
5W
E2 0 4
E2 0 7
46
(F )
(F )
(R2)
(R2)
(R2 )
(R2)
B
(R2)
E 2 01
E 2 02
W/ L
W/ L
E 2 04
E 2 05
R/W
E 2 06
G /B
R/W
E 2 07
G /W
R/B
R/B
W/G
R/B
W/G
R/B
(F )
(E)
(R)
E-2
Harness symbol
(R)-(R2)
X19
[Double cabin]
[Grey]
LH Licence plate lamp
E207
E205
Tail lamp, LH
side
8
1
Tail lamp, RH
side
E206
[Grey]
RH Licence plate lamp
E204
47
(R)-(R2)
E202
RH parking
lamp
X19
[Grey]
LH Licence plate lamp
E207
E201
LH parking
lamp
2
E205
Tail lamp, LH side
8
E-3
Headlamp levelling
Headlamp switch
(Section E1)
26
R/G
R/ G
(F )
(F )
R/ G (F )
E3 0 1
0
1
G
(F )
E3 0 1
2
3
R/ G
R/ G
(F )
(F )
(F )
(F )
E3 0 2
48
Headlamp levelling
switch
E 303
E3 0 1
C
C
E3 0 3
E3 0 2
B
(F )
E 3 01
E 3 02
E3 0 3
(F )
(F )
R/ G
R/ G
R/ G
(F )
(E)
(R)
E-3
Harness symbol
E303
Headlamp levelling motor RH
49
E302
Headlamp levelling motor LH
E301
Headlamp levelling switch
E-4
27
R/ G
(F )
R/ G
(F )
R/ G
R/ W
(F )
(F )
E4 0 1
E4 0 2
E 402
E 4 01
R/ L
R/L
(F )
(F )
R/ L
(F )
R/ L
(F )
R/L
(F )
C
04
19
R/ L
22
(R )
50
Instrument
cluster
(Section Cc)
R/ L
(R2 )
E4 0 3
E4 0 3
B( F )
E 4 01
E 4 02
E 4 03
B( R 2 )
R/ G
R/ L
R/ L
R /W
R /W
R/G
R/L
(F )
(E)
(R)
E-4
Harness symbol
(R)-(R2)
X19
[Double cabin]
E403
Rear fog lamp
X04
E401
Rear fog lamp
switch
(F)-(R)
51
(R)-(R2)
E402
Rear fog lamp relay
X19
E403
Rear fog lamp
X04
(F)-(R)
X04
(F)-(R)
F-1
01
01
W/ R
(E )
(F )
03
B T N 60A
M A IN 8 0 A
03
HA Z A RD 10A
IG
K EY
1 40A
IG
K EY
2 40A
B/ W
LH
(F )
X
OF F
ST
IG 2
Ignition
switch
OF F
IG 1
E1 0 1
AC C
RH
02
B/ Y( F )
W/ B (F )
W/ R( F )
L/ Y (F )
02
W
(F )
M E T E R 15A
F1 0 1
A
Flasher unit
G
G/ W( F )
G/ B (F)
F1 01
G/ R (F)
G/ W
(F )
G/ W
(F )
G/ R
G/ B
(F )
G/ W( F)
G/ B (F)
G/ W( F)
G/ B (F )
52
F1 0 5
Side direction
indicator lamp,
RH
21W
F1 0 5
F1 0 3
F1 0 6
21W
Side direction
indicator lamp,
LH
5W
F1 0 4
B( F )
F1 0 6
B( F )
G/ W (R 2 )
Flasher unit
(F)
W/ R
G /W
W /B
G /R
F 1 02
G/ B
19
F1 02
21W
G/ W( F)
G/ B (F)
20
19
Hazard flasher
switch
B( F )
F1 02
B( F )
E2 0 5
21W
Instrument cluster
(Section Cc)
B( F )
E2 0 5
B( R 2 )
F1 0 6
Remote keyless
entry
(Section I4)
G/ B (R 2 )
E2 0 6
E2 0 6
04
G/ B (F)
F1 0 4
F1 0 3
B( F )
F1 0 1
G/ R (F)
X
G/ B (R )
G/ W( R )
32
G/ W (F )
G/ B (F)
5W
(F )
B( R 2 )
8
F 1 03
F 1 04
F1 0 5
L/ Y
B
F
G /B
D
E 1 01
R/ G
R/ B
G/ R
G/ W
G/ B
R/ B
R/ Y
R/ L
E 2 05
R/ W
W/ R
B/ Y
Y/ R
W/ B
R/W
B
R/B
E 2 06
G /B
W/G
R/W
B
R/B
G /W
W/G
G/W
(F )
(E)
F-1
Harness symbol
(R)
[Double cabin]
X19
7
X01
E205
Direction indicator
lamp, LH rear
F103
Direction indicator
lamp, RH front
[Black]
F106
Side direction indicator lamp, LH
Direction indicator lamp, RH rear
E206
X04
53
F104
Direction indicator lamp, LH front
[Black]
(F)-(R)
Flasher unit
F101
2
(R)-(R2)
X19
E205
Direction indicator
lamp, LH rear
X03
Fuse block
X02
Ignition switch
E101
Direction indicator
switch
X04
(F)-(R)
X04
(F)-(R)
F-2
Reversing lamps
Battery
01
01
B/ L
(E )
(F )
IG
M A IN 8 0 A
KEY
1 40A
B/ W
(F )
IG
KEY
2 40A
02
Ignition switch
OF F
ST
IG 2
OF F
IG 1
AC C
08
R/ W
(F )
R/ W
(E )
F2 0 1
04
19
F2 0 1
R/W
(R )
R/W
(R 2)
54
R/ W
R/W
(R 2)
(R2)
E2 0 6
E2 0 5
21W
<18W>
21W
<18W>
E2 0 5
B
(R2)
F 2 01
E 2 05
R/ W
B/ Y
R/ W
R/B
E 2 06
G /B
R/ W
W/G
R/B
G /W
W/G
08
E2 0 6
B
(R 2)
03
03
W
(F )
B/ Y
(F )
B/ Y
(E )
M E T E R 15A
02
S e ries
(F )
(E)
(R)
F-2
Harness symbol
(R)-(R2)
[Grey]
(F)-(E)
X01
X19
F201
[Double cabin]
X01
E205
Reversing lamp,
left
8
X04
(F)-(R)
55
X03
Fuse block
X02
Ignition switch
X04
(F)-(R)
X04
(F)-(R)
F-3
01
01
03
# ..
03
G/ W
W/ R
(F )
(F )
(E )
M A IN 80A
(F )
S T OP 15A
B T N 60A
G/ W
G/ W
G/ W
G/ W
(F )
(F )
C
(F )
A
F3 0 1
Horn relay
F3 0 3
F3 0 1
F3 0 3
W/ G
(F )
G/ R (F)
W/ G
28
(F )
W/ G
(F )
04
19
W/ G
B/ R
(R )
G/ R (F)
(F )
S1 0 2
W/ G
(R 2 )
G/ R (F)
56
F3 0 4
W/ G
W/ G
B/ R
B/ R
(R2)
(R 2 )
(F )
(F )
E2 0 5
E2 0 6
Stop lamp LH
F 3 02
Horn LH (F)
Horn switch
(R2)
(R 2 )
F 3 03
F 3 04
F 3 05
Horn RH (F)
E 2 06
S 102
B/ R
R/ W
G /B
R/ B
W /G
R/ W
G /W
R/B
W/G
G /R
B
Horn switch
L/ W
B/ R
G/ R
W/ G
E 2 05
02
#G/ R
B/ R
G /W
G/ W
02
G/ W
A
G/ R
Horn RH
E2 0 6
(F )
F3 0 5
Horn LH
21W
E2 0 5
F301 H
F3 0 2
Stop lamp RH
21 W
G/ R
Clock
spring
B /Y
B/ W
Y /G
Y/ G
B /W
B/ Y
G /R
L/ B
L /O
(F )
(E)
(R)
F-3
Harness symbol
(R)-(R2)
X19
Stop lamp RH
E206
X01
[Double cabin]
E205
Stop lamp LH
F305
Horn RH
[Black]
X04
(F)-(R)
57
F302
Horn LH
[Black]
Stop lamp RH
Horn relay
F301
(R)-(R2)
E206
7
X19
S102
D02
Horn switch
X03
E205
Stop lamp LH
Fuse block
F304
Horn switch
F303
Stop lamp
switch
X04
(F)-(R)
X04
(F)-(R)
01
01
B/ L
(E )
(F )
X
03
M A IN 8 0 A
IG
KEY
1 40A
B T N 60A
IG
KEY
2 40A
03
W/ R
B/ W
(F )
(F )
A/C 1 0 A
03
Ignition switch
03
B/ R
(F )
IG 2
IG 1
AC C
(F )
A/C 2 10 A
/
LG R
(F )
02
OFF
OF F
ST
02
(F )
B/ R (F )
G
07
B/ R
(F )
(F )
A/C Relay
HE A T E R 40A
Y( F )
03
06
LG/ B
R/ B
(F )
(F )
07
06
Powertrain control
module (PCM)
(Section B1b,
B2b, B3c)
L/ B
Blower motor
Blower assembly
04
Resistor
Y
09
(F )
A/C pressure
switch
04
09
58
R/ W
(F )
(F )
G
(F )
G
X
09
L/ W
L/ Y
(F )
(F )
10
G
05
03
L/B
E
L/ Y
L/R
L/ Y
(F )
11
L/ R
L/ B
(F )
(F )
(F )
G
01
A/C Amplifier
(E )
G
08
L/ Y
L/ B
(F )
Fan switch
4
L/ R
B
3
Off
A/C switch
(F )
L/ R
L/ Y
L /B
L/ B
L/ B
E
L
G 08
L/ R
L/ R
L/ B
L/ B
R/ B
L
LG/ R
L/ Y
LG/ B
L/Y
L/W
LG/ B
L/ W
R /W
Harness symbol
[Grey]
(F)(E)
X09
X01
G07
A/C Relay
59
G09
A/C pressure
switch
[Black]
Resistor
G04
G08
A/C Compressor clutch
X03
Fuse block
X02
Ignition switch
G11
A/C switch
G01
Heater control
module
G05
Resistor
G10
A/C Amplifier
G06
Blower
motor
G03
(F) Blower assembly
01
01
B/ L
(E )
(F )
M A IN 8 0 A
IG
KEY
1 40A
IG
KEY
2 40A
B/ W
(F )
X
ST
IG 1
IG 2
02
Lock solenoid
Ignition switch
OF F
OF F
Free solenoid
AC C
H0
X
H03
02
03
B/ W
B/ W
(F )
(F )
03
B/ W
(F )
(F )
E N GI NE 15A
B/ W
LG
(F )
(F )
(F )
H01
R/ G
GY /R
(F )
(F )
F
H
LG
(F )
X
R/ G
(E )
60
05
(F )
05
B/ R
(E )
06
B/ R (E )
G/ O
(F )
H07
4x4 Mode
switch
Remote
freewheel
switch
09
/
LG B
(E )
GY /R
(E )
01
/B
/R
(F )
BR
(F )
36
37
H04
Remote
freewheel
main switch
Transfer
neutral
switch
06
H07
B/ R
LG
Instrument cluster
(Section Cb)
H04
B/ R (E )
(E )
B
(F )
B/ R (E )
X
08
B/ R (F )
GY /R
G/ O
LG/ B
R/ G
B /W
LG/ R
BR
B/ R
LG/ B
LG
R
B
R/ G
B/W
LG
B/W
G/ O
B/ R
B/ R
GY /R
Harness symbol
Free solenoid
H03
[Grey]
(F)(E)
[Grey]
(F)(E)
X09
X08
[Blue]
Lock solenoid
H02
[Black]
Transfer neutral switch
H07
[Black]
4x4 Mode switch
H06
X01
61
H05
Remote freewheel switch
[Black]
H04
Remote freewheel main
switch
[Blue]
X03
Fuse block
X02
Ignition switch
H01
Remote freewheel control
module
I-1
01
01
B/ L
(E )
(F )
M A IN 8 0 A
IG KE
Y1
40A
B/ W
(F )
IG KE
Y2
40A
03
03
02
W/ R
(F )
R .D E FOG 20A
B T N 60A
OFF
ST
IG 2
B/ Y
(F )
(F )
03
Ignition switch
OF F
IG 1
AC C
02
03
03
W
(F )
(F )
M E T E R 15A
I1 0 4
CI G A R
15A
03
I1 0 4
L/ W
B/ L
(F )
(F )
(F )
B/ L
L/ W
I1 0 5
(F )
62
B/ L
(F )
04
B/ L
L/ W
(F )
(F )
I1 0 1
I1 0 2
Outlet
Cigar
lighter
I1 0 5
(R )
I1 0 1
I1 0 3
I1 0 2
21
(F )
(F )
B
(F )
B
Instrument
cluster
(Section Cc)
I1 0 3
(F )
B
(F )
13
(R )
L/ W
B
L/ W
B
(Short cord)
B/ L
B /Y
B
W
G
B/ L
I-1
Harness symbol
Main fuse box
[Double cabin]
[Black]
Rear window
heater grid
I103
X01
I103
Rear window
heater grid
[Black]
X04
13
(F)(R)
63
Rear window
heater switch
I105
[Black]
Rear window
heater grid
I103
X03
Fuse block
I103
Rear window
heater grid
[Black]
X02
Ignition switch
X04
I104
Rear window
heater relay
(F)(R)
I102
Outlet
[Black]
I101
Cigar lighter
[Black]
X04
(F)(R)
13
I-2
01
01
03
# ..without
& ..Euro 3
03
W/ R
B
(E )
(F )
B T N 60A
M A IN 8 0 A
R OOM 10 A
B/ L
(F )
IG
KEY
1 40A
IG
KEY
2 40A
B/ W
(F )
Headlamp switch
(Section E1)
25
OF F
ST
IG 2
02
Ignition
switch
OF F
IG 1
AC C
R/ B
(F )
02
L/ R
(F )
L
R/ B
R/ B
(F )
R/ B
(F )
R/ B
(F )
(F )
R/ B
(F )
(F )
R/ B
X
(F )
C
(Section
Ca)
R/ B
(F )
01
1E
b
R/B
(F )
Cluster illumination
R/B
(F )
R/ B
(F )
J1 0 1
Hazard flasher
switch illumination
I2 0 3
Audio illumination
F1 0 2
1C
C
15A
# J 201
F1 0 2
J1 0 1
03
L/ W
(F )
I2 0 3
# J 201
I2 0 1
01
R/G
R/G
R/ G
(F )
(F )
(F )
R/ G
03
CI G A R
Clock
(F )
64
R/ G
R/ G
(F )
(F )
R/ G (F )
I2 0 1
I2 0 2
Illumination dimmer
B
OS C
(F )
I2 0 2
B
(F )
I2 01
Clock (F)
01
L/ W
B
R/ B
L/R
1P
1O
F 1 02
R/ Y
W/ L
L/ R
B /Y
B /R
1N
1M
1L
1K
1J
1I
&G /R
1H
Y/B
R /B
R/ G
G /B
G /W
1G
1F
1E
1D
1C
1B
1A
R/ G
L/W
I2 02
D
I2
03
J101
# J201
1K
1E
1C
1A
L/ R
R /B
L /R
L/W
L/ Y
L/ W
1N
1L
1D
1B
B
B
R /G
R/ G
R/ B
R /B
R/ G
1J
1H
1F
R/ B
G/ R
audio harness
(F )
(E)
(R)
I-2
Harness symbol
Cluster illumination
C01
[Black]
Cluster illumination
C01
65
[Black]
Audio illumination
J101
J201
Clock
I201
Audio illumination
J101
J201
X03
Fuse block
X02
Ignition switch
I202
I203
Illumination
dimmer
I-3
Interior lamps
Battery
01
01
W/ R
(E )
(F )
M A IN 80 A
03
03
10
L/ R
(F )
B T N 60 A
R OOM 10A
L/ R
(I N)
with power
windows
I3 0 1
with keyless
entry
Power window
main switch
(Section K1)
Remote keyless
entry module
(Section I4)
31
Interior lamp
Instrument cluster
(Section Ca)
30
29
ON
OF F
D OOR
R/ Y
B/ L
R/ Y
(F )
(F )
(F )
I3 0 1
R/Y ( IN )
R/ Y
Freestyle cabin /
Stretch cabin
(with rear access)
(F )
X
10
04
R/ Y
X
R/ Y (F )
(F )
06
R/Y
R/ Y
R/ Y
(F R )
(F )
(F )
R/ Y (F )
R/ Y
(F R)
R/ Y (R )
DO UB LE CA B
R/ Y
(F R)
R/ Y
66
(F R)
X
R/ Y (R )
27
I3 0 6
X
26
R/ Y
R/Y
R/ Y
(DR3)
R/ Y (R)
R/ Y (F R )
(R)
R/Y (DR 4)
I3 0 5
I3 0 3
Door
entry
switch, LH
front
Door
entry
switch,
LH rear
I3 0 3
Door entry
switch, LH
front
Door
entry
switch,
RH rear
except Freestyle
cabin / Stretch
cabin (with rear access)
R/ Y (R )
I3 0 2
I3 0 4
Door entry
switch, RH
front
I3 0 2
Door entry
switch, RH
front
Freestyle cabin /
Stretch cabin
(with rear access)
except Freestyle
cabin / Stretch
cabin (with rear
access)
Double cabin
I3 01
except
Regular cabin
I302
Door entry
switch, RH
front
I3 06
R/ Y
R/ Y
I3 0 3
L /R
L/ R
(F R)
R/ Y
I3 04
I3 05
R/ Y
R /Y
R/ Y
(Short cord)
R /Y
(F )
(E)
(R)
I-3
Harness symbol
[Black]
Door entry switch, RH rear
I304
Interior lamp
I301
[Double cabin]
Main fuse box
[Black]
Door entry switch, RH front
I302
X01
(F)-(IN)
X10
X04
(F)-(R)
I305
Door entry switch, LH rear
[Black]
I306
(FR) Short cord
(F)-(IN)
67
I303
Door entry switch, LH front
[Black]
X06
X10
(F)-(FR)
*
**
(R)-(DR4)
X26
[Black]
Door entry switch, RH front
* I302
[Black]
Door entry switch, RH front
I302
**
(FR)-(DR3)
X27
X03
Fuse block
X06
(F)-(FR)
I301
Interior lamp
X10
(F)-(IN)
I303
*
Door entry switch, LH front
[Black]
X04
X04
(F)-(R)
(F)-(R)
X06
(F)-(FR)
I303 **
Door entry switch, LH front
[Black]
I-4
01
01
B/L
(E )
(F )
M A IN 8 0 A
IG
KEY
1 40A
IG
KEY
2 40A
B/ W
(F )
X
02
Ignition switch
ST
03
IG 2
03
OF F
OF F
IG 1
AC C
W/ R
X
(F )
B T N 60A
ROOM
03
03
W
10A
(F )
M E T E R 15A
L/ R
B/ Y
(F )
(F )
I4 0 1
I4 0 1
68
B/ L
G/ R
LG/ R
(F )
(F )
(F )
(F )
30
Door entry
switches
(Section I3)
32
Flasher unit
(Section F1)
33
I4
01
O
LG
/R
B/ L
B
L/ R
G/ R
J
B/ Y
02
(F )
(E)
(R)
I-4
Harness symbol
69
4
X03
Fuse block
X02
Ignition switch
I401
Remote keyless
entry module
J-1
Battery
X
01
01
B
(E )
@ ..
B/ L
(F )
M A IN 8 0 A
IG
KEY
1 40A
IG
KEY
2 40A
B/ W
(F )
02
Ignition switch
ST
IG 2
03
OFF
OF F
IG 1
03
AC C
02
W/ R
X
(F )
03
03
R OOM 10 A
B T N 60A
L/ W
(F )
L/ R (F )
(F )
C IGA
R 15A
J1 0 1
1C
Audio unit
2A
2B
2F
2H
P/ L (F )
GY /L (F )
GY /R (F )
GY (F )
P /L(F R )
G Y /L( F R )
GY /R (R )
GY (R )
P/ L (F R )
GY /L (F R )
GY /R (R )
GY (R )
GY /R
GY
(DR4)
(DR 4 )
3A
1A
1L
1N
1K
1M
J1 0 1
06
04
L/ W
L/ Y
(F )
(F )
(F )
70
GY /L
P/ L
(F R )
(F R)
GY
GY /R
GY /R
GY
(DR3)
(DR 3 )
(DR 3 )
(D R3)
24
J1 0 5
27
J1 0 5
Door
speaker, LH
side, rear
Double cabin
GY (R )
GY /R (R )
GY
GY /R
(DR4)
(DR 4 )
26
J1 0 4
Door speaker, RH
side, rear
22
L/ R
(F )
13
L/Y
#L/W
L/ R
L/ Y
#L
@L /W
@L
(DR 1 )
(D R1)
(D R2)
(D R2)
L/ R
J1 0 2
J1 0 4
J1 0 3
Door
speaker, LH
side, front
Door speaker,
RH side, rear
Double cabin
16
Door
speaker,
RH side,
front
14
Audio unit
J102
(F )
1M
1K
L/ R
(F )
1E
1C
1A
R/ B
L /R
L/ W
L/ Y
L /W
R/ G
1N
1L
2I
(Short cord)
2C
2A
P/ L
3A
B
1J
1H
1F
1D
1B
2J
GY
GY /R
2H
2F
GY /L
2D
2B
J103
J104
J105
L/ Y
#L/ W
L/ Y
@L/ W
GY
GY
L/ R
#L
L/ R
@L
GY /R
GY /R
J-1
Harness symbol
(R)(DR4)
X22
Door speaker, RH
side, rear
J104
Door speaker, LH
side, rear
J105
Door speaker, RH
side, front
J103
X01
[Double cabin]
(F)(DR2)
X16
X04
X24
(F)(R)
(FR)(DR3)
J102
Door speaker,
LH side, front
X13
71
(F)(DR1)
(F)(DR1)
X13
(R)(DR4)
X06
[Black]
Audio unit
J101
14
Audio unit
J101
X26
(F)(FR)
Door speaker, RH
side, rear
J104
Door speaker, RH
side, front
J103
(F)(DR2)
(FR)(DR3)
X16
X27
(F)(DR2)
X16
X03
Fuse block
X02
Ignition switch
J105
Door speaker,
LH side, rear
X04
X06
(F)(R)
(F)(FR)
X04
(F)(R)
J102
Door speaker,
LH side, front
X13
(F)(DR1)
X06
(F)(FR)
J-2
01
01
B/ L
(E )
(F )
M A IN 8 0 A
IG
K EY
1 40A
IG
K EY
2 40A
B/ W
(F )
ST
IG 2
03
IG 1
03
02
Ignition switch
OFF
OF F
AC C
02
W/ R
X
(F )
B T N 60A
03
03
R OOM 10A
L/ W
(F )
L/ R (F )
(F )
CI G A R 15A
J2 0 1
1C
1A
Audio unit
3A
2A
2B
2F
2H
P/L (F )
GY /L (F )
GY /R (F )
GY (F )
P/ L (F R )
G Y/ L (F R )
GY /R (R )
GY (R )
P/ L (F R )
GY /L (F R )
GY /R (R )
GY (R )
1L
1K
1N
1M
J2 0 1
72
GY /L
P/ L
(F R)
(F R )
X
24
GY
GY /R
GY /R
GY
(DR 3 )
(DR3)
(D R3)
(DR 3 )
J2 0 5
06
27
J2 0 5
GY
(DR 4 )
(DR4)
GY (R )
GY /R (R )
GY
GY /R
(DR4)
(DR 4 )
26
J2 0 4
Door speaker,
LH side, rear
Door speaker, LH
side, rear
Double cabin
GY /R
04
Door speaker, RH
side, rear
Freestyle cabin / Stretch cabin
(with rear access)
L/ W
L/ Y
L/ R
(F )
(F )
(F )
(F )
22
J2 0 4
Door speaker,
RH side, rear
J2 0 2
J2 0 3
Door speaker, LH
side, front
Door speaker, RH
side, front
Double cabin
14
1M
(Short cord)
(F )
1K
1E
1C
1A
L/ R
R/B
L/R
L/W
L/ Y
L/W
R/G
1N
1L
2I
2C
2A
P/ L
3A
B
1J
1H
1F
1D
1B
2J
GY
GY /R
2H
2F
GY /L
2D
2B
L/ W
L/ Y
GY
GY
L/ R
GY /R
GY /R
J-2
Harness symbol
(FR)(DR3)
Door speaker, RH
side, rear
J204
X01
X24
(R)(DR4)
[Double cabin]
X22
X04
(F)(R)
J205
Door speaker,
LH side, rear
73
14
[Black]
Audio unit
J201
X06
(FR)(DR3)
(R)(DR4)
(F)(FR)
X27
X26
Door speaker, RH
side, rear
J204
Audio unit
J201
X03
Fuse block
J202
Door speaker,
LH side, front
X02
Ignition switch
X06
(F)(FR)
X04
J205
Door speaker,
LH side, rear
X04
(F)(R)
(F)(R)
X06
J203
Door speaker,
RH side, front
(F)(FR)
K-1
Power windows
# .. with
Battery
X
01
01
03
03
W/ R
(E )
(F )
M A IN 8 0 A
B T N 60A
B/ W
(F )
IG KE
Y2
40A
IG KE
Y1
40A
P / W 15A
31
G( F )
B/ L
X
OF F
ST
(F )
02
01
R/ Y (F )
X
Ignition switch
OF F
13
15
R/ L
IG 2
IG 1
(F )
AC C
X
Close
02
Open
03
03
13
G( D R 1)
R/ L
R/ L
R/ L
(F )
(F )
(F )
(D R1)
P .WI ND 30A
Close
Open
K1 0 1
Close
Power
cutoff
switch
Open
Close
G /Y (DR1)
L/ W(DR 1)
W( DR1)
G /W (DR1)
G/ Y (F)
W(F )
X
07
06
X
05
23
R/ L(F R )
G Y (FR )
X
W(D R 3)
25
W(R)
X
L/W( DR3)
24
R /L (DR 3 )
Vc c
R/ L
R/ L
R/L
(R )
(F )
(F )
04
R /W( F )
W (DR4)
L/ W(D R 4)
22
G /W (DR2)
R/ L(DR4 )
18
R /W (DR 2 )
74
Close
K1 0 1
K1 0 2
Open
16
Close
K1 0 9
R /L( DR2)
K1 0 3
Open
G/ B
R/ B
(DR1 )
(DR 1 )
K1 0 5
B
K1 0 4
G /B (D R 3)
K1 0 3
G /B (DR4 )
R/ B (DR3)
G /B (DR2 )
Close
Open
15
Close
Open
IC 1
X
K1 0 6
Power window
motor, RH side
rear
(DR 1 )
R/ B (D R 2)
K1 0 7
Power window
motor, LH side rear
Open
K1 0 2
R/B (DR 4)
K1 0 8
IC 2
Close
Open
B
(F )
Close
6
#W/ R
#G/ Y
G /B
#L/ W
#W
G /W
R/W
R/ L
R /B
R /L
R/ Y
R/ L
L/ W
R/ B
G/ B
R /B
G /B
R/ L
G /W
L/ W
R/ B
G/ B
G/ B
G/ B
G/ B
G/ B
R/ B
R/ B
R/B
R/ B
K109 Power window main switch Power window motor, left front
R /W
R/ L(F )
L/ W( R)
Open
R/ L
(F )
K1 0 4
Close
15
L/ W( F )
G/ W(F )
W /R (FR )
Auto
circuit
R/ W(DR 1)
X
W /R (F)
Open
K1 0 1
W/R( DR1)
R/ Y (DR1)
K-1
Harness symbol
(R)(DR4)
X22
(F)(DR4)
[Blue]
Power window
motor, right front
K106
X01
X23
(F)(DR2)
X16
(F)(DR2)
[Double cabin]
X18
K107
Power window
motor, RH side
rear
X04
K108
Power window motor, LH side
rear
K104
Power window switch, LH
side rear
(F)(R)
K101
Power winX25
dow main
switch
(FR)(DR3)
K109
X24
Power window main
(FR)(DR3)
switch Power window
motor, left front
X05
(F)(R)
X13
(F)(DR1)
X15
(F)(DR1)
75
(F)(DR1)
(F)(DR1)
X13
X06
X07
(F)(FR)
(F)(FR)
K105
Power window motor,
left front
[Blue]
[Blue]
Power window
motor, right front
K106
X15
(F)(DR2)
X16
(F)(DR2)
X03
X18
Fuse block
(F)(DR2)
X02
X16
Ignition switch
X04
X07
(F)(R)
(F)(FR)
X06
X18
(F)(FR)
(F)(DR2)
X04
(F)(R)
X05
(F)(R)
K101
Power window
main switch
K109
Power window main switch
Power window motor, left front
K105
Power window
motor, left front
[Blue]
X13
(F)(DR1)
X15
(F)(DR1)
X06
(F)(FR)
K102
Power window
switch, RH side
front
K-2a
01
01
W/ R
(F )
M A IN 80A
03
B
(E )
03
W/ G
(F )
B T N 60A
D/ L 30A
K2 0 1
A
G/ R
G/ O
(F )
(F )
F
K2 0 1
15
with keyless
entry
(F )
LG/ R (F )
G/ R
G/ O
(DR1)
(D R1)
K2 0 2
Lock
Unlock
Door lock
switch
K2 0 2
76
B
(DR 1 )
B
(F )
G/ R
without keyless
entry
MK
B
G/ O
G/O
L
W/G
LG/ R
R
G/ R
G/ R
G/ O
15
33
K-2a
Harness symbol
[Double cabin]
Main fuse box
X01
K202
Door lock switch
77
(F)(DR1)
X15
X03
X15
(F)(DR1)
Fuse block
K202
Door lock switch
X15
(F)(DR1)
K-2b
(F )
(F )
(F )
G
(F )
K2 0 1
(F )
(F )
G
(F )
X
07
G
X
(F R)
15
X
K2 0 1
G
(DR 2 )
K2 0 2
23
(R )
G
(D R4)
K2 0 4
Door lock
motor, RH
front
Unlock
25
(DR3)
K2 0 3
Door lock
motor, LH
front
05
18
X
(D R1)
K2 0 5
Door lock
motor, LH
rear
Unlock
Door lock
motor, RH
rear
Unlock
Unlock
R
(F )
Lock
Lock
K2 0 2
78
(D R1)
(DR2 )
R
(D R4)
(F )
I
M
05
(F )
(F )
G/O
L
(F )
K
G/ R
(F )
23
(R )
07
25
(F R)
(F )
18
15
Lock
K2 0 5
(DR3)
X
X
X
Lock
K2 0 4
K2 0 3
LG/ R
J
W/G
G
D
B
G
G/ R
G /O
K-2b
Harness symbol
Door lock motor,
RH rear
K205
Door lock timing
unit
K201
(F)(DR1)
(R)(DR4)
X23
X15
[Double cabin]
(F)(DR2)
X18
(F)(R)
X05
X07
K204
Door lock motor, LH rear
(F)(FR)
X25
X18
(FR)(DR3)
K202
Door lock motor,
LH front
(F)(DR2)
79
X15
X05
(F)(DR1)
X07
(F)(R)
(F)(FR)
(F)(DR2)
X18
K202
Door lock motor,
LH front
X15
(F)(DR1)
Power mirrors
Battery
X
01
# ..
01
B/ L
(E )
(F )
IG KE
M A IN 8 0 A
Y1
40A
B/ W
(F )
IG KE
Y2
40A
ST
IG 2
X
03
L/ W
Up
Down
Up
Right
Down
L01
Right
Left
Select RH mirror
Select RH
mirror
Select LH mirror
Select LH mirror
L01
BR
LG/ B
BR /B
L/ B
(F )
(F )
(F )
(F )
BR /Y
(F )
BR
BR
(F )
(F )
17
80
L/ B
BR /Y
BR
(D R2)
(DR2)
(D R2)
L03
LG/ B
BR /B
#L /B
#B R/ Y
(DR1)
(DR1)
14
BR
(DR 1 )
(F )
L02
Power mirror,
RH
M2
M1
Power mirror, LH
M2
Left/right
M1
Up/down
Left/right
Up/down
Right
Left
Right
Left
Up
Down
Up
Down
5
L/ W
L/ B
BR /Y
BR /B
LG/ B
#L/ B
BR/B
#B R/ Y
BR
L/ B
BR /Y
B
R
(F )
CI G A R 15 A
02
OF F
IG 1
AC C
03
L
(F )
Left
OFF
02
Ignition switch
Harness symbol
Power mirror,
RH
L03
X01
[Double cabin]
(F)(DR2)
X17
81
X14
L02
Power mirror,
LH
(F)(DR1)
(F)(DR1)
X14
Power mirror,
RH
L03
(F)(DR2)
X17
L01
Power mirror
switch
[Grey]
X03
Fuse block
X02
Ignition switch
X17
(F)(DR2)
X14
(F)(DR1)
L02
Power mirror,
LH
01
01
B/ L
B
MA IN 80 A
IG
KE Y
(F )
(E )
1 40A
C
B/ W
(F )
IG
KE Y
06
2 40A
X
OFF
ST
02
Ignition switch
OF F
(R)
L/ R
(F 2)
IG 2
ABS 6 0 A
IG 1
38
39
40
G/ B
Y/ R
V/ Y
(F )
(F )
(F )
B/ W
04
G/ W
W/ L
(R )
(R )
AC C
B/ W (F )
X
02
X
03
03
B/ W
(F )
(F )
E N GI NE 15A
L/ R
L/ R
(F 2)
(F 2)
21
11
12
B/ W (F )
X
11
G/ W
(F 2)
W/ L
(F 2 )
G/ B
(F 2 )
Y/ R
(F 2)
V/ Y
(F 2)
B/ W (F 2 )
O
AB
AC
AA
AD
ABS control
module
BR /W
BR /R
BR /Y
BR
(F 2)
(F 2 )
(F 2)
(F 2)
W
O
(F 2)
(F 2 )
(F 2 )
(F 2)
X
82
(F 2)
(F 2)
12
BR /W
BR /R
BR /Y
BR
(R)
(R)
(R )
(R )
(F )
(F )
(F )
BR /W
BR /R
BR /Y
BR
(R2)
(R 2)
(R 2)
(R 2)
02
03
04
W/ G
LG
(F 2)
(F 2)
12
20
LG
(F )
(F )
05
28
11
W/ G
Stop lamp
switch
(Section F3)
01
21
X
G
(F )
01
17
Instrument
cluster
(Section Cb)
AC
AA
L/ R
L/ R
W/ G
G/ B
W/ L
BR /Y
LG
Y/ R
AD
AB
AC
AA
AD
AB
G/ W
V/ Y
L
H
BR /R
BR
BR
B/ W
BR /R
BR /W
BR /Y
B/ W
G /W
W /L
B R /W
Harness symbol
(R)(R2)
X20
[Grey]
ABS control module
O01
Main fuse box
[Grey]
Wheel speed sensor, RH side rear
O05
X01
[Double cabin]
(R)(F2)
X21
O04
Wheel speed
sensor, LH side
rear
[Grey]
X04
83
O03
Wheel speed
sensor, RH side
front
[Grey]
(F)(R)
O06
Yaw rate acceleration sensor
[Black]
O02
Wheel speed
sensor, LH side
front
[Grey]
(R)(R2)
X20
[Grey]
Wheel speed sensor, RH side rear
O05
X03
Fuse block
O04
Wheel speed
sensor, LH side
rear
[Grey]
X21
X02
9
Ignition switch
(F2)(R)
(R)(F2)
X21
X12
X04
(F)(F2)
(F)(R)
X11
(F)(F2)
X04
(F)(R)
O06
Yaw rate acceleration sensor
[Black]
Heated seats
Battery
X
01
# ..
01
B/ L
(E )
(F )
M A IN 8 0 A
IG KE
Y1
40A
B/ W
(F )
IG KE
Y2
40A
OF F
ST
IG 1
AC C
IG 2
X
P
01
01
BR /B
BR /Y
(F )
(F )
03
W
(F )
S .WA RM 15A
BR /B (F )
BR /B (F )
06
Heated seat
switch
04
BR /W
BR /B
#B R/ B
(F R)
(R)
03
02
Seat cushion
heater, RH
front
Seat cushion
heater, LH
front
84
03
B
(F )
02
B( R )
B( F R )
04
B( F )
10
BR /W
#B R /B
BR /B
BR /Y
03
02
OF F
02
Ignition
switch
Regular cabin
Harness symbol
X01
[Double cabin]
P03
Seat cushion
heater, LH front
X04
(F)(R)
10
P02
Seat cushion
heater, RH front
85
[Blue]
Heated seat switch
P01
X06
X03
(F)(FR)
Fuse block
X02
Ignition switch
P03
Seat cushion
heater, LH front
X06
X04
(F)(FR)
10
(F)(R)
P02
Seat cushion
heater, RH front
X04
(F)(R)
X06
(F)(FR)
Wiring Diagram
Air Bags
Service Warnings
Component Disassembly
D Disassembling and reassembling the components of
the air bag system can render the system inoperative,
which may result in serious injury or death in the
event of an accident. Do not disassemble any air bag
system component.
RIGHT
Wiring Harness Repair
D Incorrectly repairing an air bag system wiring harness
can accidentally deploy the air bag, which can cause
serious injury. If a problem is found in the system
wiring, replace the wiring harness. Do not try to repair
it.
RIGHT
WRONG
86
WRONG
Wiring Diagram
Component Reusing
D Even if an air bag does not deploy in a collision and
does not have any external signs of damage, it may
have been damaged internally, which may cause
improper operation. Improper operation may cause
serious injury. Always selfcheck the undamaged air
bag to determine whether it can be reused. (Refer to
ON-BOARD DIAGNOSTIC FUNCTION, AIR BAG
SYSTEM.)
87
S-1
Air bags
Battery
X
01
01
B/ L
(F )
(E )
M A IN 80A
IG
KEY
1 40A
B/ W
(F )
IG
KEY
2 40A
OF F
ST
Passenger air
bag unit
Inflator
IG 2
02
OF F
Ignition
switch
ACC
IG 1
Inflator
Shorting bar
Y/ R
Y/ R
(F )
03
S1 0 5
S1 0 4
02
W( F )
Shorting bar
(F )
Clock spring
EN G IN E
15A
ME T E R
15A
Y/ B
S1 0 3
B/ Y( F )
B/ W (F )
B/ Y( F )
B/ W (F )
AB
03
S1 0 2
L( F )
LG(F )
S1 0 1
S
S1 0 1
88
Y/ G (F )
Shorting bar
S1 0 2
Y/ G (F )
B
(F )
(F )
34
Instrument
cluster
(Section Cb)
5
(F )
W
AA
Y/G
LG
Y/R
B/ Y
B /W
AB
G /R
B /Y
B/ W
Y /G
Y/ G
B /W
B/ Y
G /R
LG
Y /R
Y/ B
Y/ R
Y /R
Y /B
S-1
Harness symbol
X01
89
[Yellow]
Passenger air
bag unit
S104
S103
(F) Clock
spring
[Yellow]
X03
S105
Driver air bag
unit
Shorting bar
connector
S102
Fuse block
X02
Ignition switch
S101
Air bag module
Immobiliser system
Battery
X
01
# ..
01
B/ L
(E )
(F )
M A IN 8 0 A
IG
KEY
1 40A
IG
KEY
2 40A
Euro 3
B/ W
(F )
X
03
03
02
L/ R
W/ R
(F )
(F )
B T N 60A
OF F
ST
OF F
Ignition switch
R OOM 10A
L/ R
IG 2
IG 1
AC C
(F )
T
03
X
X
Keyless
switch
Euro 3
T
03
W
E N GI NE 15A
03
B/ W (F )
T
Immobiliser module
F
(F )
L/ R (F )
P( F )
03
02
01
C
T
W(F )
B/ R
B/ R
(F )
(F )
90
R
(F )
Y
(F )
BR /B
B2 0 9
GY
(F )
X
(F )
T
Starter relay
(Section A)
28
Fuel pump
Euro 3
(F )
B2 0 9
14
B/ R
(F )
Coil
B/ R (F )
B/ R
L/R
C
BR /B
B/ W
L /R
#P
GY
GY
R/ L
B /R
G /W
B /W
BR /W
L/ B
B /R
W
F
Euro 2
DD S 1
02
16
Instrument
cluster
(Section Ca)
01
B
F
Harness symbol
[Grey]
Fuel pump
B209
[Euro 1, Euro 2]
3
X01
Coil
T02
Joint connector
X28
X03
Fuse block
91
X02
Ignition switch
T03
Keyless switch
[Euro 3]
3
X01
T01
Immobiliser
module
U-1
01
# ..
01
B/ L
% ..
(F )
(E )
M A IN 8 0 A
IG KE
Y1
40A
IG KE
Y2
40A
B/ W
(F )
X
OF F
ST
IG 2
IG 1
AC C
X
X
03
03
B/ Y
(F )
W
(F )
M E T E R 15A
39
Y/ R
(F )
ABS control
module
(Section O)
38
G/ B
(F )
AntiLock Control
4Wheel
B/ R
(F )
Instrument
cluster
(Section Cb)
35
Y/ G
(F )
92
U101
Data Link
Connector
(DLC)
B
(F )
KL N
+B
GN D
TB S
FA B
B/ Y
%Y/ R
B/R
%G /B
GN D
#Y /G
BU SB
%V /Y
40
ABS control
module
(Section O)
AntiLock Control
4Wheel
02
OF F
02
Ignition
switch
U-1
Harness symbol
X01
[Grey]
Data Link Connector (DLC)
U101
93
2
X03
Fuse block
X02
Ignition switch
U-2
01
# ..
01
B/ L
(F )
(E )
IG
M A IN 8 0 A
KE Y
1 40A
B/W
(F )
IG
Euro 3
Powertrain control
module (PCM)
(Section B3b)
KE Y
2 40A
ST
IG 2
13
11
12
IG 1
03
03
W
(F )
M E T E R 15A
W/ L(F )
Y/ R
(F )
B/ Y
BR /R
(F )
(F )
ABS control
module
(Section O)
38
G/ B
(F )
B/ R
(F )
Instrument cluster
(Section Cb)
35
Y/ G
(F )
94
U201
Data Link Connector (DLC)
B
(F )
FE N
KLN
TE N
+B
GN D
B/ Y
B/ Y
B/ R
TB S
FA B
BR /R
Y/ R
IG
G/ B
GN D
#Y /G
BU SB
W/ L
B
V/ Y
AC C
X
X
Y/ R (F )
OF F
10
B/Y
(F )
39
02
Ignition switch
Powertrain control module (PCM)
(Section B2b, B3b)
OF F
40
ABS control
module
(Section O)
02
U-2
Harness symbol
[Euro 2]
X01
1
X03
95
Fuse block
X02
[Euro 3]
Ignition switch
X01
[Grey]
Data Link Connector (DLC)
U201
X-1
Connectors
X01 Main fuse box
#... Euro 3
... with fuel heater
(E )
(E )
<3 0A
60A
40A
40A
B/ W
A
60A
80A
7
30A
60A
B /L
W /R
G/ B
L/ R
J
A
B/ W
#2 0A
(F 2)
(F )
#L /W
G
R/ W
R /B
B/ L
B/ Y
B/ W
B/R
( )... if equipped
1
MAIN
IG KE
IG KE
BT N
(F IP /I N J)
Y2
(P T C )
H EAD
Y1
(A B S )
(G LO W)
96
W/ R
R/ Y
10A
LG/ R
W/ G
#
30A
10A
L/ Y
G
#
15A
20A
10A
R/ G
W/R
#
B/ R
40A
17
10
11
20A
15A
L /W
(A /C )
12
HA Z A R D
13
(S .W A R M )
18
(R .D E F OG)
14
ME T E R
19
(R .F OG)
15
E N GI N E
20
HE A D
16
W IPER
12
R/ W
20A
15A
W/ R
G/ W
5
BR /Y
15A
B/ Y
15A
13
B/ R
10A
Y/ R
10A
L/ R
B/ W
15A
15A
10A
21
ST O P
17
(HE A T E R)
TA IL
18
CI G A R
R OOM
19
(D /L )
20
10
(P /W )
21
(A /C 2 )
(A B S )
22
(P .WI ND)
14
15
16
W
#
30A
R/L
#
22
11
( )... if equipped
X-2
Connectors
X04 (F) (R)
(R )
C
%/R/L
B/W
R/L
W/G
R/W
B/L
BR /B
W/L
G/W
R/Y
GY/R
B/R
B/R
GY
G/B
(F )
@GY/R
R/W
R/Y
&GY/R
@G Y
G/B
G/W
R/B
W/G
BR / W
#BR / B
R/L
B/L
A
%R /L
B/ W
(R)
(F )
L/ W
%W
&G
%L /W
&R
97
@R /L
BR /B
(F R )
GY/L
R/Y
%B
P/L
@R/L
#P/L
R/Y
#GY/L
#... Euro 3
@... Euro 1, Euro 2, not cold
area
(F )
(F )
B/Y
G/Y
@G Y
%G
W
#
L/ W
B/Y
#B /L
L/W
(E )
(I N)
(F )
#GY/R
%G/B
%BR/B
W/B
Y/R
%G/Y
B/R
W
#
B/L
@B/Y
%R
%... Euro 3
#... with remote freewheel control system
(F )
B/R
BR/Y
@W/R
R/W
(E )
(F R )
W/R
R
G
%BR/W
#R/G
#LG/B
%V
#R/G
#LG/B
%V
BR /B
W/B
Y/R
%BR/W
%G /Y
#GY/R
%/G/B
%BR/B
L/R
R /Y
R/Y
L /R
R/W
BR/Y
B/Y
X-3
Connectors
X11 (F) (F2)
(F )
(F )
(F 2)
LG
B /W
B/ W
#B
G/ B
G/ B
LG
Y/ R
Y /R
G
(F )
(F 2)
W/G
V/Y
V/ Y
W /G
(DR1)
R/ L
L/ W
L/ R
#L
#R/ L
#G
L/ Y
#L/ W
(DR1)
(F )
L/B
BR/Y
BR
BR
BR/B
#BR/Y
LG/B
#L/B
G/ Y
G
R/ Y
W/ R
98
(DR 1 )
G/ W
B
R/W
G/ O
L/ W
G/ R
@L/ W
@W
& G /W
G/ R
R/ L
L/ R
@L
(F )
(F )
@W/ R &R /Y
%R
#R/ L
LG/ B
B R /B
BR
BR
BR /Y
L/ B
R/ W
(DR 2 )
(DR2)
L/ Y
@L/ W
L/Y
(D R2)
L/ R
%G
@G /Y
&R /W
(F )
G/ O
G /W
@G/W
@R/W
(R2)
(R)
@G/R
G/ B
G /W
(R)
R/L
R /W
R /B
W /G
G /B
R/ L
B /R
B/R
W /G
(R )
(R 2 )
R /B
R /W
G /W
BR /Y
Y
BR/Y
BR
BR/W B R /R
BR /R
BR /W
BR
BR /Y
BR
B R /W
BR /R
(F 2 )
G/ W
G/ W
W/ L
W/ L
BR/Y
BR /R
BR/W
BR
X-4
Connectors
X22 (R) (DR4)
(R)
(DR4 )
(R)
GY
GY/R
R /L
R /L
#G Y
#GY/R
L/W
#L/ W
#W
(F R)
(DR3)
(F R)
P/ L
GY /L
R/L
R /L
#G Y
GY
W/R
#L/ W
#GY/R
99
#W
(R )
(F R)
(DR4)
R/Y
GY
GY
GY/R
R /Y
R/ Y
P/ L
GY/R
(D R3)
GY/L
GY
B/ R
B/ R
B/ R
B /R
B/ R
B /R
B/ R
R /Y
GY/R
Parts index
Heater panel illumination lamp . . . . . . . . . . . 64
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Horn relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Horn switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Idle switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Illumination dimmer . . . . . . . . . . . . . . . . . . . . . 64
Immobiliser module . . . . . . . . . . . . . . . . . . . . . 90
Instrument cluster . . . . . . . . . . . . . . . . 36, 38, 40
Intake air control valve . . . . . . . . . . . . . . . . . . 28
Intake air temperature sensor . . . . . . . . . 30, 32
Interior lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Keyless switch . . . . . . . . . . . . . . . . . . . . . . . . . 90
Licence plate lamps . . . . . . . . . . . . . . . . . . . . 46
Lock solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Mass Air Flow (MAF) sensor . . . . . . . . . . . . . 32
Neutral position switch . . . . . . . . . . . . . . . . . . 28
Oil pressure switch . . . . . . . . . . . . . . . . . . . . . 38
Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Park brake switch . . . . . . . . . . . . . . . . . . . . . . 38
Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . . 46
Passenger air bag unit . . . . . . . . . . . . . . . . . . 88
PCM module relay . . . . . . . . . . . . . . . . . . . . . . 28
Power mirrors . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Power mirror switch . . . . . . . . . . . . . . . . . . . . 80
Powertrain control module
(PCM) . . . . . . . . . . . . 20, 22, 24, 26, 28, 30, 32
Power window main switch . . . . . . . . . . . . . . 74
Power window motors . . . . . . . . . . . . . . . . . . 74
Power window switches . . . . . . . . . . . . . . . . . 74
Pump speed sensor . . . . . . . . . . . . . . . . . 20, 24
Rear fog lamp . . . . . . . . . . . . . . . . . . . . . . . . . 50
Rear fog lamp relay . . . . . . . . . . . . . . . . . . . . . 50
Rear fog lamp switch . . . . . . . . . . . . . . . . . . . 50
Rear window heater grid . . . . . . . . . . . . . . . . 62
Rear window heater relay . . . . . . . . . . . . . . . 62
Rear window heater switch . . . . . . . . . . . . . . 62
Remote freewheel control module . . . . . . . . 60
Remote freewheel main switch . . . . . . . . . . . 60
Remote freewheel switch . . . . . . . . . . . . . . . . 60
Remote keyless entry module . . . . . . . . . . . . 68
Resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Reversing lamps . . . . . . . . . . . . . . . . . . . . . . . 54
Reversing lamps switch . . . . . . . . . . . . . . . . . 54
Sedimentor switch . . . . . . . . . . . . . . . . . . . . . . 38
Speakers . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 72
Speedometer sensor . . . . . . . . . . . . . . . . . . . 36
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Stop Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Stop lamp switch . . . . . . . . . . . . . . . . . . . . . . . 56
Tail lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TDC sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transfer neutral switch . . . . . . . . . . . . . . . . . . 60
Wheel speed sensors . . . . . . . . . . . . . . . . . . . 82
100
42
42
42
82
101
Z
SECTION TITLE
RANGER
2000 2002
Right-hand-drive
(RHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.
SECTION
General Information
GI
Ground points
Schematic
A~U
Connectors
Parts index
PI
APPLICATION:
This manual is applicable to vehicles beginning
with the Vehicle Identification Numbers (VIN) and
related materials shown on the following page.
Z
Vehicle identification numbers (VIN)
(Chassis numbers)
WF0
WF0
WF0
WF0
WF0
Note:
Euro 3 regulation models (WL3, WLT3 engines) are equipped with an EGR cooler in
the engine compartment.
Non Euro 3 regulation models are not equipped with an EGR cooler in the engine compartment.
EGR cooler
Wire colours
Colour
Code
Colour
Code
Black
Orange
Blue
Pink
Brown
BR
Purple
Dark blue
DL
Red
Dark green
DG
Sky blue
Green
PU
R
SB
Tan
Grey
GY
Violet
Light blue
LB
White
Light green
LG
Yellow
Natural
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . Z2
GROUND POINTS (WL, WL TURBO,
BEFORE MODEL YEAR 2002) . . . . . . . . . . . . . . Z12
GROUND POINTS (F2 CARB) . . . . . . . . . . . . . . . Z14
GROUND POINTS (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z16
SCHEMATIC ( WL, WL TURBO, BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z18
SCHEMATIC (F2 CARB) . . . . . . . . . . . . . . . . . . . . Z19
SCHEMATIC (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . Z20
ENGINE-RELATED SYSTEMS
STARTING SYSTEM / CHARGING
SYSTEM (WL, WL TURBO, BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM / CHARGING
SYSTEM (F2 CARB) . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM / CHARGING
SYSTEM (WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWERTRAIN (WL: GENERAL SPECS) /
QUICKSTART SYSTEM (WL) . . . . . . . . . . .
POWERTRAIN (WL: U.K. SPECS, WL
TURBO) / GLOW SYSTEM (WL, WL
TURBO, BEFORE MODEL YEAR 2002) . . .
IGNITION SYSTEM (F2 CARB) . . . . . . . . . . .
POWERTRAIN / IGNITION (F2 CARB) . . . .
FUEL CONTROL SYSTEM . . . . . . . . . . . . . . .
POWERTRAIN CONTROL SYSTEM /
GLOW SYSTEM (WL3, WLT3, AS OF
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . .
Z21
Z23
Z25
Z27
Z31
Z35
Z37
Z39
Z41
CHASSIS-RELATED SYSTEMS
REMOTE FREEWHEEL CONTROL
SYSTEM (BEFORE MODEL YEAR 2002) . . Z91
REMOTE FREEWHEEL CONTROL
SYSTEM (WL3, WLT3, AS OF MODEL
YEAR 2002) . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z93
INSTRUMENT CLUSTER-RELATED SYSTEMS
INSTRUMENT CLUSTER (WL, WL
TURBO, BEFORE MODEL YEAR 2002) . . . Z47
INSTRUMENT CLUSTER (F2 CARB) . . . . . . Z53
INSTRUMENT CLUSTER (WL3, WLT3,
AS OF MODEL YEAR 2002) . . . . . . . . . . . . . . Z57
BODY-RELATED SYSTEMS
WINDSCREEN WIPER / WASHER
(BEFORE MODEL YEAR 2002) . . . . . . . . . . . Z63
Z67
Z69
Z71
Z73
Z75
Z77
Z79
ACCESSORIES
CIGAR LIGHTER / CLOCK / OUTLET . . . . . Z97
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . Z101
OTHER
DATA LINK CONNECTOR (BEFORE
MODEL YEAR 2002) . . . . . . . . . . . . . . . . . . . Z125
DATA LINK CONNECTOR (WL3, WLT3,
AS OF MODEL YEAR 2002) . . . . . . . . . . . . . Z127
COMMON CONNECTORS LIST
(BEFORE MY 2002) . . . . . . . . . . . . . . . . . . . . . . . Z129
COMMON CONNECTORS LIST
(WL-3, WLT-3, AS OF MY 2002) . . . . . . . . . . . . Z131
PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . Z133
Z-GI
Wiring Diagrams
GI
General information
Ground points
Schematic
A~U
Connectors
PI
Parts index
Z-2
Y-1
GROUND POINTS (WL, WL Turbo, before model year 2002)
10
14
3
7
8
15
B/R
B/R
16
B/R
17
11
B/R
WI T H F UE L
I NJ E CT I O N
P UM P
B( F )
B( F )
B( F )
WI T H
IMMOBILIZER
UNI T
B (F )
B (F )
B (F )
9
F RO NT
HA RNE S S
WI T H A I R B A G
Z-12
TO
EACH
UNIT
B( F )
B( F )
B / R(F )
FRONT
HARNESS
B / R(F )
B( F )
TO
EACH
UNIT
B( F )
16
WI T H I M M O B I L Z E R UNI T
5
B (R2 )
10
B (R2 )
11
RE A R
NO . 2
HA RNE S S
14
F I L A M E NT
15
S HO RT CO RD
B (F R)
17
FLOOR
HA RNE S S
B( F )
B/ R ( F )
B/ R ( F )
B (R2 )
W I H T F U EL I N J EC T I ON PU MP
WIRING DIAGRAM
HARNESS SYMBOL :
(F)
(E)
(R)
10
6
1
11
14
17
Z-13
DOUBLE CAB
2
16
10
3
5
7
4
11
WIRING DIAGRAM
8
15
14
Z
Y-1
Y-2
GROUND POINTS (F2 CARB)
Z
WIRING DIAGRAM
1
2
10
14
B/O
11
15
Z-14
B( F )
B (R2 )
10
B( F )
B (R2 )
11
RE A R
NO . 2
HA RNE S S
14
F I L A M E NT
15
S HO RT CO RD
TO
EACH
UNIT
B( F )
TO
EACH
UNIT
B( F )
B( F )
B( F )
B( F )
B/ O( F )
FRONT
HARNESS
B (R2 )
HARNESS SYMBOL :
(F)
(E)
(R)
10
Z-15
11
2
3
5
14
WIRING DIAGRAM
15
Z
Y-2
Y-3
4
B
15
11
B/R
16
B/R
B/R
B/R
B/R
18
19
A
E
B(F)
B(F)
B/R(F)
B(F)
B/R(F)
B(F)
B(F)
B/R(F)
B/R(F)
B(F)
B/R(F)
Z-16
B(F)
TO
EACH
UNIT
FRONT
HARNESS
B/R(F)
B(F)
20
B/R(F)
B(F)
B(F)
B(F)
FRONT
HARNESS
TO
EACH
UNIT
B/R(F)
B/R(F)
B/R(F)
16
B(F)
18
B(F)
B(F)
B(F)
19
B/R
B/R
B/R
B/R
17
B/R
JC-01
B(R2)
10
B(R2)
11
REAR
NO.2
HARNESS
14
FILAMENT
15
SHORT CORD
17
FLOOR
HARNESS
B(R2)
B(FR)
DOUBLE CAB
WIRING DIAGRAM
10
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
10
16
18
11
14
STRETCH CAB
REGULAR CAB
19
Z-17
JC-01
20
10
7
5
11
WIRING DIAGRAM
14
8
15
9
DOUBLE CAB
17
Z
Y-3
From No.
F175-30-01I
W-1
ELECTRICAL WIRING SCHEMATIC (WL, WL Turbo, before model year 2002)
T -1
REAR W IN D O W
DEFR O STER
SYST EM CIRCUIT
SECT ION
B/Y
6 0 A GL OW
3 0 A H EAD
8 0 A M AI N
3 0 A BT N
B/ W
B/W
W/R
W /R
W/R
2 0 A R . D EF
Z-18
1 0 A R OOM
1 5 A ST OP
OFF
10A HAZARD
L/Y
LG/R
F -2
F -1
BRAKE LIGHT S
F -2
HORN
F -2
ILLUMINAT ION
LIGHT S
I-1
LICENCE PLAT E
LIGHT S/
PARKING LIGHT S/
T AILLIGHT S
E-3
HEADLIGHT S
(WIT HOUT HEADLIGHT
LEVELING SYST EM)
E-1
W /G
W
B/W
IG2
BACK-UP LIGHT S
1 0 A ( A/ C )
30A (D/L)
ST
R/B
B /Y
IG1
AUDIO SYST EM
L/Y
L/R
G/W
Y/R
10A TAIL
EN GI N E
SW I T C H
R/ B
ACC
B/ R
1 5 A C I GAR
4 0 A ( H EAT ER )
1 5 A W I PER
HE A DL I G HT
S WI T CH
L/W
R/ Y
R/ L
R/ W
1 0 A R. F O G
R/ G
C-1a
INST RUMENT CLUST ER C-1b
C-1c
R/ L
R/ W
15A
W
15A
EN GI N E
M ET ER
3 0 A ( P. W I N D )
B/W
HEADLIGHT S
(WIT H HEADLIGHT
LEVELING SYST EM)
E-2
REAR F OG LIGHT
E-3
B/Y
R/ G
R/L
WINDSHIELD WIPER
AND WASHER
POWER WINDOWS
D
K-1
K-2
WIRING DIAGRAM
I-2
CL O C K
I-2
O U TL ET
I-2
IN TER IO R L IG H T
DATA L IN K
CO N N EC TO R
I-3
I-2
S-1
PO W ER TR AIN C O N TR O L
SYSTEM/
Q U IC K-STAR T
SYSTEM
HEATER AN D AIR
CO N D ITIO N ER
B-1a
B-1b
PO W ER TR AIN C O N TR O L
SYSTEM/
G L O W SYSTEM
G -1
B-2a
B-2b
A-1
T H EFT-D ETER R EN T
SYSTEM
T -2
PO W ER D O O R L O C KS
K-3
BATTERY
+
B-3
B-4
B-5
G -2
I-3
I-2
I-2
I-2
IG N ITIO N SYSTEM/
PO W ER TR AIN C O N TR O L
SYSTEM
FU EL C O N TR O L
SYSTEM
H EATER AN D
AIR C O N D ITIO N ER
IN TER IO R L IG H T
C IG AR ETTE L IG H TER
R EAR W IN D O W
D EFR O STER
O U TL ET
BAT T ERY
+
SYST EM CI RCUI T
SECTI ON
F- 2
C LOCK
I- 2
B/Y
AU DIO SY STEM
3 0 A HEAD
8 0 A M AIN
10A
B/W
B/W
3 0 A BT N
Z-19
10A
(A/C)
20A
R.DEF
30A
B/W
IG1
OFF
IG2
HAZ ARD
L/Y
F- 1
L ICEN CE PLA TE
L IGHT S/
PAR KING L IGHT S/
T AILL IGHT S
E -3
I- 1
H EADLI GH TS
( WITH OUT HEADL IGHT
LEVELI NG SYST EM)
E -1
W/R
W/R
ST
10A
RO O M
15A
ST O P
(D/L )
L G /R
W
10A
Y/R
W/G
TAIL
R/B
L /R
G /W
IG NIT IO N
SWIT CH
HE A DLI GHT
S WI T CH
R/L
A CC
R/W
15A
L
CIG AR
L /W
I NST RUMEN T
C LUST ER
C-2 a
C-2 b
(HEAT ER)
15A
(WIPER)
15A
ENG INE
W
15A
M ET ER
30A
(P.WIND)
F- 2
BR AKE L IGHTS
F- 2
L
L
B/W
B/Y
POWER WINDOWS
K-1
K- 3
R/L
POWER OU TSI DE
MI RRORS
WIRING DIAGRAM
40A
B/R
H ORN
Z
W-2
W-3
OTHERS
SYSTEM CIRCUIT
B/Y
80A MAIN
30A BTN
R/B
B/W
B/W
W/R
W/R
10A A/C
30A D/L
W/R
Z-20
B/W
20A R.DEF
15A FIP
10A ROOM
15A STOP
OFF
IG1
IG2
BACK-UP LIGHTS
F-4
F-3
BRAKE LIGHTS
F-4
HORNS
F-4
ILLUMINATION
LIGHTS
I-1
LICENCE PLATE
LIGHTS /
PARKING LIGHTS /
TAILLIGHTS
E-5
B/Y
ST
AUDIO SYSTEM
SECTION
10A HAZARD
L/Y
LG/R
W/G
L/Y
W
L/W
Y/R
L/R
10A TAIL
G/W
ENGINE
SWITCH
R/B
ACC
HEADLIGHT
SWITCH
L
15A CIGAR
L/W
R/Y
R/W
B/R
40A HEATER
15A WIPER
10A R.FOG
R/G
INSTRUMENT
CLUSTER
POWER OUTSIDE
MIRRORS
C-3a
C-3b
C-3c
R/L
15A ENGINE
B/W
15A METER
B/Y
30A P.WIND
R/L
R/W
HEADLIGHTS
E-4
R/G
E-5
WINDSHIELD WIPER
AND WASHER
D-2
POWER WINDOWS
K-1
K-2
WIRING DIAGRAM
IMMOBILIZER SYSTEM
REAR WINDOW
DEFROSTER
OUTLET
DATA LINK
CONNECTOR
CLOCK
CIGARETTE LIGHTER
INTERIOR LIGHT
REMOTE FREEWHEEL
CONTROL SYSTEM
STARTING SYSTEM/
CHARGING SYSTEM
60A GLOW
30A HEAD
T-3
I-2
U-2
I-2
I-2
I-2
I-3
S-2
G-3
H-2
B-6a POWERTRAIN
B-6b CONTROL SYSTEM /
B-6c GLOW SYSTEM
A-3
THEFT-DETERRENT
SYSTEM
T-4
K-3
BATTERY
+
From No.
F175-30-01I
A-1
STARTING SYSTEM / CHARGING SYSTEM (WL, WL Turbo, before model year 2002)
BATTERY
+
-
WIRING DIAGRAM
R(E)
B(E)
30A
MAIN
B/W(E)
B(E)
80A
X-01
B/W
(E)
A
B/W(F)
X-07
OFF
ST
X-02
IG1
IG2
INSTRUMENT
CLUSTER
(SECTION C-1a)
X-02
ENGINE
SWITCH
ACC
W/B
(F)
B/Y
(F)
B
(E)
X-09
B/W
(E)
A1-01
R
(E)
W/B
(E)
A1-02
B/Y(F)
Z-21
B/Y(E)
A1-01
PCM
(SECTION B-1b,2b)
X-08
VOLTAGE
REGULATOR
STARTER
A1-02
1B
W/R
(E)
A1-01 STARTER(E)
A1-02 GENERATOR(E)
1B
W/R
B
B/Y
W/B
W/R
2A
B/W
2A
W/R
(E)
GENERATOR
(F)
HARNESS SYMBOL :
(E)
[BLACK]
(F)-(E)
(R)
[BLACK]
(F)-(E)
X-09
X-08
[BLACK]
(F)-(E)
X-07
MAIN FUSE BLOCK
X-01
Z-22
A1-02
A1-01
STARTER
GENERATOR
X-02
ENGINE SWITCH
[WHITE]
X-02
WIRING DIAGRAM
ENGINE SWITCH
[BLUE]
Z
A-1
A-2
STARTING SYSTEM (F2 CARB) / CHARGING SYSTEM (F2 CARB)
BATTERY
+
WIRING DIAGRAM
R(E)
X-01
30A
MAIN
B(E)
B/W(E)
80A
X-01
B/W
(E)
A
B/W(F)
X-07
OFF
ST
B/Y(F)
X-02
IG1
IG2
INSTRUMENT
CLUSTER
(SECTION C-2a)
X-02
IGNITION
SWITCH
ACC
B/Y
(F)
W/B
(F)
B
(E)
X-09
X-08
B/W
(E)
A2-01
R
(E)
W/B
(E)
B/Y
(E)
A2-02
Z-23
B/Y(E)
A2-01
VOLTAGE
REGULATOR
STARTER
A2-01 STARTER(E)
A2-02 GENERATOR(E)
B/Y
B/W
W/B
GENERATOR
HARNESS SYMBOL :
(F)
(E)
(R)
[BLACK]
(F)-(E)
X-09
MAIN FUSE BLOCK
X-01
Z-24
X-07
(F)-(E)
[BLACK]
X-08
(F)-(E)
[BLACK]
A2-02
A2-02
GENERATOR
[GRAY]
GENERATOR
X-02
A2-01
STARTER
IGNITION SWITCH
[WHITE]
WIRING DIAGRAM
X-02
IGNITION SWITCH
[BLUE]
Z
A-2
A-3
BATTERY
+
R(E)
X-01
30A
MAIN
B(E)
B/W(E)
80A
X-01
B/W
(E)
A
B/W(F)
X-07
X-02
INSTRUMENT
CLUSTER
(SECTION C-3a)
2
X-02
OFF
ST
IG1 IG2
ENGINE
SWITCH
ACC
X-02
W
(F)
B
(E)
W/B
(F)
X-03
B/Y
(F)
15A
ENGINE
X-09
X-03
B/W
(F)
B/W
(E)
R
(E)
W/B
(E)
A3-03
STARTER
RELAY
A3-01
A3-02
A3-03
Z-25
R(F)
B/L
(F)
B/L(E)
A3-01
B/L(F)
B/L(F)
X-08
66 IMMOBILIZER UNIT
(SECTION T-3)
IC REGULATOR
1 PCM
(SECTION B-6c)
STARTER
A3-01 STARTER(E)
A3-02 GENERATOR(E)
B/L
B/W
W/B
R
B/W
B/Y
B/L
GENERATOR
WIRING DIAGRAM
HEAD
B(E)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(F)-(E)
[BLACK]
(F)-(E)
X-08
(R)
[GRAY]
(F)-(E)
X-09
X-07
MAIN FUSE
BLOCK
X-01
Z-26
A3-01
STARTER
A3-03
STARTER RELAY
A3-02
GENERATOR
X-02
ENGINE SWITCH
[WHITE]
X-03
FUSE BLOCK
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BULE]
Z
A-3
From No.
F175-30-01I
B-1a
POWERTRAIN CONTROL SYSTEM (WL: GENERAL SPECS.) / QUICK-START SYSTEM (WL)
BATTERY
+
-
A
B/W(E)
80A
X-01
X-01
B/W(F)
X-01
X-07
X-02
OFF
ST
GLOW
IG1
IG2
60A
WIRING DIAGRAM
B(E)
B/W
(F)
ENGINE
SWITCH
B/W
(F)
B/W
(F)
ACC
X-02
W
(F)
B1-05
FICD
SOLENOID VALVE
No.1
B1-05
FUSE BLOCK
ENGINE
B/W(F)
15A
X-03
B1-06
FICD
SOLENOID VALVE
No.2
B1-06
X-03
B/W
(F)
G
(F)
P
(F)
B1-01
PCM
O
BR
(F)
R
(F)
G/R
(F)
W
(F)
B/R
(F)
B1-01
R/B
(E)
B/W
(F)
B/R(F)
B1-09
X-09
Z-27
B1-03
B1-02
G/R
(E)
GLOW PLUG
RELAY
W
(E)
GLOW PLUG
ENGINE COOLANT
TEMPERATURE
SENSOR
B1-07
R(F)
R(F)
No.4
No.3
No.2
No.1
B1-04
B
(F)
FUEL
CUT
VALVE
B/R
(F)
FUEL
INJECTION
PUMP
B/R(E)
B1-07
B1-02
B/R
(E)
B1-08
NE SENSOR
B/R(E)
6
B1-01 PCM(F)
I
O
BR
GY
P
P
B/W
W/L
R/B
B/W
R/W
G/R
B/Y
BR
B/R
R/B
B/R
G/R
B1-08 NE SENSOR(E)
B/R
B/W
B/W
(F)
HARNESS SYMBOL :
(E)
[BROWN]
GLOW PLUG RELAY
B1-02
GLOW PLUG
RELAY
(R)
[BLACK]
(F)-(E)
X-07
[BROWN]
GLOW PLUG RELAY
B1-03
B1-02
[BLACK]
(F)-(E)
X-09
6
FICD SOLENOID
VALVE No.2
[BLACK]
FICD SOLENOID
VALVE No.1
B1-06
B1-05
X-01
ENGINE COOLANT
TEMPERATURE SENSOR
B1-07
Z-28
B1-09
FUEL INJECTION PUMP
[BLACK]
B1-08
NE SENSOR
[GRAY]
B1-04
GLOW PLUG
X-02
ENGINE SWITCH
[WHITE]
ENGINE SWITCH
[BLUE]
B1-01
PCM
WIRING DIAGRAM
X-02
X-03
FUSE BLOCK
Z
B-1a
B-1b
POWERTRAIN CONTROL SYSTEM (WL: GENERAL SPECS.) / QUICK-START SYSTEM (WL)
THERMOSWITCH
(SECTION G-1)
B/Y
(F)
R/W
(F)
R/B
(F)
B1-01
D
PCM
M
GY
(F)
W/L
(F)
B1-01
Z-29
B1-01 PCM(F)
W/L
R/W
R/B
B/W
BR
GY
P
P
G/R
B/Y
B/R
B
INSTRUMENT CLUSTER
(SECTION C-1c)
INSTRUMENT CLUSTER
(SECTION C-1a)
WIRING DIAGRAM
ENGINE SWITCH
(SECTION A-1)
HARNESS SYMBOL :
(F)
(E)
(R)
Z-30
B1-01
PCM
WIRING DIAGRAM
Z
B-1b
B-2a
POWERTRAIN CONTROL SYSTEM (WL: U.K. SPECS., WL Turbo) / GLOW SYSTEM (WL, WL Turbo, before model year 2002)
< >...WL-T
80A
B/W(F)
X-01
X-07
X-02
OFF
ST
X-01
GLOW
IG1
IG2
60A
B/W
(F)
ENGINE
SWITCH
B/W
(F)
B/W
(F)
B/W
(F)
ACC
X-02
W
(F)
B2-05
FICD
SOLENOID VALVE
No.1
B2-05
FUSE BLOCK
ENGINE
B/W(F)
X-03
15A
B2-06
FICD
SOLENOID VALVE
No.2
B2-06
49
X-03
B/W
(F)
G
(F)
P
(F)
IMMOBILIZER
UNIT
(SECTION T-1)
B2-01
PCM
O
BR
(F)
R
(F)
G/R
(F)
W
(F)
B/R
(F)
BR/W
(F)
R/L
(F)
G/W
(F)
L/B
(F)
B2-01
R/B
(E)
B/R(F)
B2-09
X-09
Z-31
B2-03
B2-02
G/R
(E)
GLOW PLUG
RELAY
W
(E)
ENGINE COOLANT
TEMPERATURE
SENSOR
B2-07
R(F)
TIMER
CONTROL
VALVE
IDLE
SWITCH
CONTROL LEVER
POSITION SENSOR
B2-09
FUEL
INJECTION
PUMP
C
B/R
(F)
No.4
No.1
B
(F)
No.3
GLOW PLUG
No.2
B2-04
B/R
(F)
B/R(E)
B2-08
B2-07
B2-02
B/R
(E)
NE SENSOR
B/R(F)
B/R(E)
6
B2-01 PCM(F)
K
S
BR/R
Y/B
T
B/W
L/B
<Y>
R
BR
GY
P
P
W/L
B/W
R/L
I
E
BR/W
G/R
G/W
B/Y
B/R
G/R
BR
R/B
B/R
B2-08 NE SENSOR(E)
B/R
R/L
B/R
G/W B/W
BR/W
L/B
B/R
F
V/W
B/W
WIRING DIAGRAM
B/W(E)
B(E)
X-01
BATTERY
+
HARNESS SYMBOL :
(F)
(E)
[BROWN]
GLOW PLUG RELAY
B2-02
GLOW PLUG
RELAY
(R)
[BLACK]
(F)-(E)
X-07
[BROWN]
GLOW PLUG RELAY
B2-03
B2-02
[BLACK]
(F)-(E)
X-09
6
FICD SOLENOID
VALVE No.2
[BLACK]
FICD SOLENOID
VALVE No.1
B2-06
B2-05
X-01
ENGINE COOLANT
TEMPERATURE SENSOR
B2-07
Z-32
B2-09
FUEL INJECTION
PUMP
[GRAY]
B2-08
NE SENSOR
[GRAY]
B2-04
GLOW PLUG
X-02
X-02
X-03
ENGINE SWITCH
[BLUE]
FUSE BLOCK
B2-01
PCM
[BLACK]
WIRING DIAGRAM
ENGINE SWITCH
[WHITE]
Z
B-2a
B-2b
POWERTRAIN CONTROL SYSTEM (WL: U.K. SPECS., WL Turbo) / GLOW SYSTEM (WL, WL Turbo)
WIRING DIAGRAM
ENGINE SWITCH
(SECTION A-1)
12
10
B/Y
(F)
BR/R
(F)
Y/B
(F)
GY
(F)
W/L
(F)
B2-01
PCM
R
B2-01
Y
(F)
B2-10
Z-33
B/R
(F)
EGR SOLENOID
VALVE
WL Turbo
4
INSTRUMENT CLUSTER
(SECTION C-1c)
INSTRUMENT CLUSTER
(SECTION C-1a)
B2-01 PCM(F)
K
S
BR/R
Y/B
T
L/B
<Y>
R
BR
GY
P
P
I
G
W/L
B/W
R/L
BR/W
G/R
G/W
B/Y
B/R
B
B/R
HARNESS SYMBOL :
(F)
(E)
(R)
[GRAY]
EGR SOLENOID VALVE
B2-10
Z-34
WIRING DIAGRAM
B2-01
PCM
[BLACK]
Z
B-2b
B-3
IGNITION SYSTEM (F2 CARB)
BATTERY
+
MAIN
B/W(E)
X-01
80A
B/W(F)
X-01
X-07
IG1
X-02
OFF
ST
IG2
WIRING DIAGRAM
B(E)
IGNITION
SWITCH
ACC
X-02
W(F)
W
(F)
Y/G
W(F)
W(F)
54
B3-04
PCM
(SECTION B-4)
NOISE
FILTER
B3-01
B3-02
+
W(F)
B3-03
IGNITION
COIL
B
Z-35
CONDENSER
(SHORT CORD)
W
(NOISE FILTER)
Y/G
CHECK
CONNECTOR
(TACHOMETER)
(F)
HARNESS SYMBOL :
(E)
(R)
IGNITION COIL
B3-01
X-01
Z-36
B3-02
IGNITION COIL
X-07
(F)-(E)
[BLACK]
B3-04
(F)-NOISE FILTER
B3-03
X-02
CHECK CONNECTOR
(TACHOMETER)
IGNITION SWITCH
[WHITE]
WIRING DIAGRAM
X-02
IGNITION SWITCH
[BLUE]
Z
B-3
B-4
POWERTRAIN CONTROL SYSTEM (F2 CARB)
BATTERY
+
MAIN
A
B/W(E)
80A
X-01
B/W(F)
X-01
X-07
OFF
ST
X-03
FUSE BLOCK
ENGINE
IG1
X-03
IG2
IGNITION
SWITCH
ACC
X-02
W(F)
B/W(F)
X-02
15A
B/W(F)
B/W
(F)
C
B/W(F)
B/W(F)
B/W
(F)
A
B4-05
POSITIVE
TEMPERATURE
COEFFICIENT
HEATER RELAY
B4-05
B/W
(F)
Y/R
(F)
B/Y
(F)
W
(F)
B/W
(F)
R/L
(F)
IGNITION
COIL
(SECTION B-3)
B4-02
B/W
(E)
B/W
(E)
X-09
54
FAST IDLE
CAM BREAKER
SOLENOID VALVE
B4-02
Y/R(F)
B4-01
J
PCM
X-08
H
B4-01
R/L
(E)
Y/R
(F)
Y/R
(F)
SLOW
FUEL
CUT
SOLENOID
VALVE
B/L
(F)
B/L(E)
Z-37
B4-04
X-09
FUEL PUMP
RELAY
(SECTION B-5)
B
(F)
X-09
B
(F)
4
B4-01 PCM(F)
B/L
B4-03 CARBURETOR(E)
B/Y
B/W
B/Y
Y/R
B/W
CARBURETOR
B4-04
B/O
(E)
55
Y/R
AIR
VENT
SOLENOID
VALVE
WATER
THERMOSWITCH
B4-06
POSITIVE
TEMPERATURE
COEFFICIENT
HEATER
B4-03
B/W
B/W
R/L
Y/R
B/W
F
R/L
B/L
B/W
B/O
WIRING DIAGRAM
B(E)
HARNESS SYMBOL :
(F)
(E)
(R)
[GREEN]
FAST IDLE CAM BREAKER
SOLENOID VALVE
[BLACK]
B4-02
(F)-(E)
POSITIVE TEMPERATURE
X-09
COEFFICIENT
HEATER RELAY
CARBURETOR
B4-03
B4-05
MAIN FUSE BLOCK
X-01
[BLACK]
(F)-(E)
X-07
5
Z-38
X-08
[WHITE]
IGNITION SWITCH
(F)-(E)
[BLACK]
X-02
B4-06
POSITIVE TEMPERATURE
COEFFICIENT
HEATER
X-02
IGNITION SWITCH
[BLUE]
B4-04
WIRING DIAGRAM
WATER THERMOSWITCH
X-03
FUSE BLOCK
B4-01
PCM
Z
B-4
B-5
FUEL CONTROL SYSTEM
BATTERY
+
A
B/W(E)
80A
X-01
B/W(F)
X-01
X-02
X-07
OFF
ST
FUSE BLOCK
F2 CARB
IG1
ENGINE
W(F)
B/W(F)
B/W
(F)
A
B5-02
B/W
(F)
D
X-03
15A
IG2
IGNITION
SWITCH
ACC
X-02
WL Turbo
X-03
INSTRUMENT
CLUSTER
(SECTION C-1a)
INSTRUMENT
CLUSTER
(SECTION C-2a)
FUEL
PUMP
RELAY
WIRING DIAGRAM
B(E)
48
19
B5-02
Y
(F)
Y/R
(F)
G/R
(F)
Y
(F)
X-04
G/R
(R)
X-04
Y
(R)
X-18
Y
(R2)
Y
(R)
X-18
55
PCM
(SECTION
B-4)
G/R
(R2)
Y
(R2)
B5-01
FUEL GAUGE
SENDER
UNIT
B5-01
Z-39
B5-01
FUEL
PUMP
FUEL
GAUGE
SENDER
UNIT
FUEL
GAUGE
B/R
(R2)
B5-01
X-18
B
(R2)
B/R(R)
B/R(R2)
X-18
WL,
WL Turbo
B/R
G/R
F2 CARB
B/R
B/R(R)
X-04
G/R
B/W
B/W
Y/R
B/R(F)
X-04
10 11
B/O(F)
16
(F)
HARNESS SYMBOL :
(E)
(R)
10
(R)-(R2)
X-18
(F)-(R)
X-04
11
16
B5-01
Z-40
FUEL GAUGE
SENDER UNIT
WL,WL Turbo
X-01
X-02
IGNITION SWITCH
[WHITE]
WIRING DIAGRAM
X-02
IGNITION SWITCH
[BLUE]
X-04
X-07
X-03
(F)-(E)
[BLACK]
(F)-(R)
FUSE BLOCK
F2 CARB
B5-02
B-5
B-6a
POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
BTN 30A
W/R(E)
WLT-3
W/R(F)
B/L(F)
MAIN 80A
B/L(F)
B/W(E)
X-07
B/W
(E)
B
L/W(F)
X-02
X-03
IG1
X-07
IG2
ENGINE
B/L
(F)
15A
X-03
B/L(F)
B/L(F)
LG
(F)
L/R
(F)
X-03
B/L(F)
B/L
(F)
B/L
(F)
B/L
(F)
4C
4D
4X
B/L
(F)
B/W
(F)
B6-01
Y/G
(F)
LG/R
(F)
W/R
(F)
4Z
4T
4Q
4I
2K
4V
2D
4A
4B
3O
1D
B6-01
SHIELD
WIRE
BR
(F)
B6-04
Z-41
P
(F)
B6-03
GLOW PLUG
RELAY
G/B
(F)
B/R
(F)
L
(F)
B6-11
1O
1S
1Q
L/Y
1V
1T
1I
1R
1G
1E
1P
1N
1L
1J
B
P/B
1H
1F
B6-13
B/R
(E)
B6-12
B
(F)
B
(F)
X-09
B/R
(F)
1C
1A
20
2K
2G
L/R BR/W
G/B BR/B
L/W
W/L
2L
2J
1D
1B
2E
2I
2A
20
3O
3K
R/Y
2H
2F
3I
3G
3E
3M
2C
P/L
BR/R
Y/R
2D
2B
G/W
3P
3A
3L
3J
3H
3F
4U
B/L
LG
3D
3B
(G/O)
4Z
4O
4Q
4M
4K
4I
4S
4W
R/W
3N
4Y
3C
20
LG/B
L/B
GY
B/L
BR
Y/G
4X
4V
4T
4G
B/Y W/R
LG/R
4E
G/B
R/B
4R
4P
4N
4L
4J
4H
4F
4C
4A
B/L
B/R
B/L
B/R
4D
4B
BR
L/W L/W
B/L
1K
1M
B/R
(F)
NEUTRAL
SWITCH
CLUTCH
SWITCH
B6-11
B/R
(F)
B6-13
INJECTION PUMP
3
1U
PUMP SPEED
SENSOR
B
(F)
G/B(E)
B6-12
IDLE
SWITCH
No.1
No.2
No.3
No.4
GLOW PLUG
G/B(F)
G/B
(F)
R
(F)
B6-05
X-09
G/W
(F)
B/R
(F)
B6-10
B6-03
BR/Y
B6-09
EGR
CONTROL
SOLENOID
VALVE
B6-09
PCM
67
B/L
B6-08
EGR
SOLENOID
VALVE
(VENT)
B6-08
G/O
(F)
1C
1V
3B
INJECTION PUMP
(SECTION B-6c)
B/W
B/L
(F)
B6-01
B/L
(F)
R/B
(E)
B6-01 PCM(F)
B/L
(F)
B6-07
EGR
SOLENOID
VALVE
(VACUUM)
B6-07
B6-06
INTAKE
SHUTER
SOLENOID
VALVE
B6-06
B/L
(F)
X-03
W
(F)
B6-02
GLOW
60A
ROOM
10A
ACC
X-02
B/L
(F)
X-03
ENGINE
SWITCH
OFF
ST
B/W(F)
X-03
B6-02
B/W(F)
B/W(E)
FIP 15A
X-01
)...WLT-3
}...CAUTION LABEL TITLE
R/B
G/O
Y/G B/L
B/L
LG
LG/R B/L
B/L
G/W
G/B
G/B
B/R
WIRING DIAGRAM
(
{
X-08
X-01
B(E)
BATTERY
+
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
[BROWN]
GLOW PLUG
RELAY
[BLACK]
(F)-(E)
B6-04
X-07
[BROWN]
GLOW PLUG
RELAY
(R)
(F)-(E)
X-08
[GRAY]
(F)-(E)
[BLACK]
EGR SOLENOID
VALVE (VACUUM)
B6-07
X-09
B6-03
[BLACK]
EGR SOLENOID
VALVE (VENT)
MAIN FUSE
BLOCK
NEUTRAL SWITCH
B6-08
X-01
B6-13
B6-06
INTAKE SHUTER
SOLENOID VALVE
[BLACK]
B6-09
EGR CONTROL
SOLENOID VALVE
B6-03
Z-42
CLUTCH SWITCH
20
B6-12
5
4
B6-05
GLOW PLUG
B6-10
X-02
INJECTION PUMP
[GRAY]
ENGINE SWITCH
[WHITE]
B6-01
PCM
X-03
FUSE BLOCK
B6-11
IDLE SWITCH
B6-02
PCM CONTROL RELAY
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BULE]
Z
B-6a
From No.
F175-30-01I
B-6b
POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
DATA LINK CONNECTOR
(SECTION U-2)
WIRING DIAGRAM
INSTRUMENT CLUSTER
(SECTION C-3a)
5
68
)...WLT-3
IMMOBILIZER UNIT
(SECTION T-3)
12
10
69
70
BR/R
(F)
B/Y
(F)
Y/R
(F)
W
(F)
2A
4K
2B
W/L
(F)
W/L(F)
W/L
(F)
B6-01
2J
REFERENCE
VOLTAGE(Vref)
1G
1K
1I
1S
2L
2I
PCM
2E
1F
1J
1T
1A
1P
2C
1R
B6-01
BR/W
(F)
PCM
71 (SENSOR GROUND)
(SECTION B-6c)
BR/B(F)
BR/B(F)
SHIELD WIRE
BR/W(F)
BR/W(F)
W
(F)
B
(F)
L/Y
(F)
R
(F)
L/W
(F)
R/Y
(F)
Z-43
BR/W
(F)
BR/B
(F)
G/Y
(F)
BR/B
(F)
BR/Y
(F)
BR/B(E)
V
(E)
BR/W
(E)
BR/B
(E)
B6-16
BR/W
(F)
BR/B
(F)
R/L
(F)
BR/B
(F)
P/L
(F)
B6-18
B6-19
BR/B
(E)
G/Y
(E)
B6-15
ENGINE COOLANT
TEMPERATURE
SENSOR
BR/W GY/L
(F)
(F)
BR/B(E)
B6-17
BR/Y
(E)
TIMER POSITION
SENSOR
BR/W
(F)
X-10
BR/B
(E)
B/R
(F)
V
(F)
X-09
B6-14
ACCELERATOR
POSITION SENSOR
B6-16
INTAKE AIR
TEMPERATURE
SENSOR No.2
EGR VALVE
POSITION SENSOR
BOOST SENSOR
20
B6-01 PCM(F)
1O
1U
1S
1Q
B/L
L/Y
B/W
BR/Y
1V
1T
1M
1K
1I
1G
1E
1R
1N
1L
1J
B
P/B
1H
1F
1C
1A
2K
2G
L/R BR/W
G/B BR/B
L/W
W/L
2L
2J
1D
1B
2E
2I
2A
3O
R/Y
2H
2F
3K
3I
BR/W
L/Y
P/L
BR/R
Y/R
2D
2B
G/W
3P
3A
3L
3J
3H
3F
4U
B/L
LG
3D
3B
(G/O)
4Z
LG/B
L/B
GY
B/L
BR
Y/G
4X
4V
4T
BR/W BR/B
BR/B
BR/Y BR/B
4Q
BR/B
P/L
R/L BR/W
4O
4M
4K
4I
4S
4W
R/W
3N
4Y
L/W
R/Y BR/B
3E
3C
3G
3M
2C
G/Y
4G
B/Y W/R
LG/R
4E
G/B
R/B
4R
4P
4N
4L
4J
4H
4F
4C
4A
B/L
B/R
B/L
B/R
4D
4B
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
[GRAY]
(F)-(E)
X-10
B6-15
ENGINE COOLANT
TEMPERATURE SENSOR
Z-44
20
B6-16
INTAKE AIR
TEMPERATURE SENSOR NO.2
[BLACK]
B6-14
B6-17
INJECTION PUMP
[GRAY]
B6-18
BOOST SENSOR
EGR VALVE
POSITION SENSOR
[GRAY]
WIRING DIAGRAM
B6-01
PCM
B6-19
ACCELERATOR
POSITION SENSOR
Z
B-6b
From No.
F175-30-01I
B-6c
POWERTRAIN CONTROL SYSTEM / GLOW SYSTEM (WL-3, WLT-3, as of model year 2002)
THERMOSWITCH
(SECTION G-3)
INSTRUMENT
CLUSTER
(SECTION C-3a)
( )...WLT-3
{ }...CAUTION LABEL TITLE
INSTRUMENT
CLUSTER
(SECTION C-3b)
72
B/L
(F)
R/W
(F)
R/B
(F)
G/R
(F)
GY
(F)
1U
3C
4L
1N
4S
B6-01
SENSOR GROUND
PCM
1L
4U
4W
1M
4E
3D
4Y
1O
1Q
1H
1B
P/B
(F)
BR/B
(F)
B6-01
SHIELD
WIRE
INJECTION PUMP 71
(SECTION B-6b)
PCM CONTROL RELAY
67
{MAIN RELAY}
(SECTION B-6a)
BR/B(F)
B/L(F)
BR/B(F)
B/L(F)
B/L(F)
B/L(F)
B/L
(F)
LG/B
(F)
BR/B(F)
L/B
(F)
R
(F)
GY/B BR/B
(F)
(F)
W
(F)
B
(F)
B/L
(F)
BR/B
(F)
P
(F)
Z-45
FUEL
SHUT
OFF
SOLENOID
FUEL
TEMP
SENSOR
CONTROL
SLEEVE
POSITION
SENSOR
1O
1Q
B/L
L/Y
B/W
BR/Y
1V
1T
1M
1K
1I
1G
1C
1E
1P
1N
1L
1J
B
P/B
1H
1F
2K
1A
2G
ELECTRONIC
GOVERNOR
L/R BR/W
G/B BR/B
L/W
W/L
2L
2J
1D
BR/B
LG/B
L/B
BR/B
GY/B
B/L
B/L
B/L
1B
G/B B/R
2E
2I
B6-22
INTAKE AIR
TEMPERATURE
SENSOR No.1
B/L
A
2A
3O
R/Y
2H
2F
P/L
BR/R
Y/R
2D
2B
3K
3I
3G
3E
3N
P/B BR/B
4Y
3L
3J
3H
3F
B/L
LG
3D
3B
(G/O)
4Z
TDC SENSOR
20
4U
4Q
4O
4M
4K
4I
4S
4W
R/W
B/L
3A
3C
G/W
3P
MASS AIR
FLOW SENSOR
3M
2C
B/R
(F)
20
1S
B/L
(F)
G/B
(F)
B/R
(F)
TIMER
CONTROL
VALVE
INJECTION PUMP
1U
B/L
(F)
B6-21
B6-20
B6-01 PCM(F)
B/L
(F)
LG/B
L/B
GY
B/L
BR
Y/G
4X
4V
4T
4G
B/Y W/R
LG/R
4E
G/B
R/B
4R
4P
4N
4L
4J
4H
4F
4C
4A
B/L
B/R
B/L
B/R
4D
4B
WIRING DIAGRAM
A/C RELAY
No.1
(SECTION G-3)
STARTER
RELAY
(SECTION A-3)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
20
Z-46
B6-22
TDC SENSOR
[GRAY]
B6-20
INJECTION PUMP
[GRAY]
B6-21
MASS AIR FLOW /
INTAKE AIR TEMPERATURE SENSOR
WIRING DIAGRAM
B6-01
PCM
Z
B-6c
From No.
F175-30-01I
C-1a
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)
B/W(E)
B/W(F)
80A
BTN
W/R(E)
30A
FUSE BLOCK
ROOM
10A
X-03
X-03
ENGINE
SWITCH
ACC
FUSE BLOCK
METER
W(F)
L/R(F)
C1-10
C1-10
IG2
X-02
KEY REMINDER
SWITCH
L/Y(F)
OFF
IG1
X-02
ST
W/R(F)
X-08
X-01
B/Y(F)
L/R(F)
15A
X-03
B/Y
(F)
X-03
C1-01
INSTRUMENT CLUSTER
1J
1K
22
WATER
TEMPERATURE
GAUGE
SECURITY
1.4W
2K
FUEL
GAUGE
1I
1F
1L
B/R
(F)
BR/B
(F)
1G
1P
L
(F)
BR/B
(F)
TACHO
METER
MICROCOMPUTER
L/W
(F)
Y
(F)
X-09
SPEEDOMETER
1M
1N
Y/B
(F)
CHARGE
1.4W
SEDIMENTOR
1.4W
2C
R/Y
(F)
W/L
(F)
W/B
(F)
21
INSTRUMENT
CLUSTER
(SECTION C-1b)
2I
C1-01
W
(F)
C1-04
Z-47
56
L
(E)
THEFTDETERRENT
CONTROL
MODULE
(SECTION
T-2)
51
IMMOBILIZER
UNIT
(SECTION T-1)
L/W
(E)
48
L
(E)
L/W
(E)
C1-03
C1-03
FUEL GAUGE
SENDER UNIT
(SECTION B-5)
WITH
THEFTDETERRENT
SYSTEM
VEHICLE
SPEEDOMETER
SENSOR
EXCEPT 4X4
PCM
(SECTION
B-1b,2b)
DOOR
SWITCHES
(SECTION
I-3)
C1-02
WATER
TEMPERATURE
SENDER UNIT
VEHICLE
SPEEDOMETER
SENSOR
4X4
1P
1O
R/Y
W/L
L/R
1N
1M
1L
1K
B/Y
B/R
1J
1I
1H
L/W
C1-04
B
(F)
16
L/W
SEDIMENTOR
SWITCH
GENERATOR
(SECTION A-1)
Y/B
R/B
R/G
G/B
G/W
1G
1F
1E
1D
1C
1B
1A
B/L
2N
O
<<R /L>>
2M
GY BR/B
2L
2K
(Y/G)
2J
W
2I
[GY/R]
<LG/R>
2G
4X4
L/W
<BR>
2H
L/Y
L/R
BR
2F
L/Y
Y/R
W/B
2E
2D
2C
R/W
2B
2A
Y/B
WIRING DIAGRAM
B(E)
X-01
<
[
(
<<
X-07
BATTERY
+
(F)
HARNESS SYMBOL :
[BLACK]
(F)-(E)
X-07
(E)
[BLACK]
(F)-(E)
X-08
(R)
[BLACK]
(F)-(E)
X-09
[GRAY]
VEHICLE SPEEDOMETER SENSOR
C1-03
X-01
INSTRUMENT CLUSTER
Z-48
C1-01
C1-04
[BLACK]
INSTRUMENT CLUSTER
SEDIMENTOR SWITCH
C1-01
WL,WL Turbo
C1-02
WATER TEMPERATURE
SENDER UNIT
16
C1-10
X-02
ENGINE SWITCH
[WHITE]
X-03
FUSE BLOCK
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BLUE]
Z
C-1a
C-1b
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)
INSTRUMENT CLUSTER
INSTRUMENT
22
CLUSTER
(SECTION C-1a)
26
4WD
1.4W
RFW
LOCK
1.4W
4WD
1.4W
2G
2G
BRAKE
1.4W
R.FOG
1.4W
OIL
1.4W
INSTRUMENT
CLUSTER
(SECTION C-1c)
AIR BAG
1.4W
2J
2H
2M
2D
2M
2E
C1-01
GY/R
(F)
U.K. SPECS.
LG/R
(F)
X-09
Y/R
(F)
Y/G
(F)
BR
(F)
GY/R
(E)
Z-49
4X4
WITHOUT
REMOTE
FREEWHEEL
CONTROL
SYSTEM
R/L
(F)
X-09
C1-09
4X4
INDICATOR
SWITCH
C1-09
SAS UNIT
(SECTION
S-1)
RFW
CONTROL MODULE
(SECTION H)
B/R
(E)
X-09
C1-05
52
OIL
PRESSURE
SWITCH
REAR FOG
LIGHT
SWITCH
(SECTION
E-3)
B/R
(F)
6
WITH
AIR BAG
1P
1O
5
EXCEPT
U.K. SPECS.
U.K. SPECS.
W/L
L/R
1N
1M
1L
1K
B/Y
B/R
1J
1I
1H
Y/B
R/B
R/G
G/B
G/W
B/L
1G
1F
1E
1D
1C
1B
1A
2N
L/Y
L/Y
B/R
GY/R
O
<<R/L>>
2M
GY BR/B
2L
2K
(Y/G)
2J
W
2I
<BR>
2H
[GY/R]
<LG/R>
2G
BR
2F
L/Y
Y/R
W/B
2E
2D
2C
R/W
2B
2A
L/Y
(F)
C1-06
BRAKE
FLUID
LEVEL
SENSOR
C1-06
C1-08
VACUUM
SWITCH
B
(F)
R/Y
C1-07
PARKING
BRAKE
SWITCH
B
(F)
L/W
L/Y
(F)
L/Y
(F)
C1-06
BRAKE
FLUID
LEVEL
SENSOR
C1-06
Y/R
(E)
25
24
23
O
(F)
Y/R
WIRING DIAGRAM
<
[
(
<<
(F)
HARNESS SYMBOL :
BRAKE FLUID
LEVEL SENSOR
C1-06
(E)
(R)
[BLACK]
VACUUM SWITCH
C1-08
4X4 INDICATOR
SWITCH
C1-09
INSTRUMENT CLUSTER
C1-01
Z-50
[BLACK]
INSTRUMENT CLUSTER
C1-01
X-09
(F)-(E)
[BLACK]
C1-05
OIL PRESSURE SWITCH
WIRING DIAGRAM
C1-07
PARKING BRAKE SWITCH
Z
C-1b
C-1c
INSTRUMENT CLUSTER (WL, WL Turbo, before model year 2002)
TURN SWITCH
(SECTION F-1)
PCM
(SECTION B-1b,2b)
27
28
29
30
45
R/B
(F)
R/W
(F)
G/B
(F)
G/W
(F)
B/L
(F)
GY
(F)
C1-01
INSTRUMENT CLUSTER
1E
2A
ILLUMI
3.4X4
BEAM
1.4W
INSTRUMENT
CLUSTER
26
(SECTION C-1b)
1B
TURN
LH
1.4W
1C
2N
1A
TURN
RH
1.4W
2L
R.DEF
1.4W
GLOW
1.4W
1D
C1-01
R/G
(F)
B
(F)
Z-51
38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)
L/W
1P
1O
R/Y
W/L
L/R
1N
1M
1L
1K
B/Y
B/R
1J
1I
1H
Y/B
R/B
R/G
G/B
G/W
1G
1F
1E
1D
1C
1B
1A
B/L
2N
O
<<R/L>>
2M
GY BR/B
2L
2K
(Y/G)
2J
W
2I
<BR>
2H
[GY/R]
<LG/R>
2G
BR
2F
L/Y
Y/R
W/B
2E
2D
2C
R/W
2B
2A
WIRING DIAGRAM
HEADLIGHT
SWITCH
(SECTION E-1,2)
HEADLIGHT
SWITCH
(SECTION I-1)
REAR WINDOW
DEFROSRTER
RELAY
(SECTION I-2)
HARNESS SYMBOL :
(F)
(E)
(R)
INSTRUMENT CLUSTER
C1-01
[BLACK]
INSTRUMENT CLUSTER
C1-01
Z-52
WIRING DIAGRAM
Z
C-1c
C-2a
INSTRUMENT CLUSTER (F2 CARB)
BATTERY
+
A
B/W(E)
B/W(F)
80A
BTN
X-01
X-02
OFF
ST
W/R(E)
30A
X-07
X-08
X-01
IG1
W/R
(F)
IG2
IGNITION
SWITCH
ACC
FUSE BLOCK
X-02
FUSE BLOCK
ROOM
METER
W(F)
B/Y(F)
L/R(F)
10A
X-03
15A
X-03
B/Y
(F)
X-03
X-03
C2-01
1K
INSTRUMENT CLUSTER
1J
22
WATER
TEMPERATURE
GAUGE
FUEL
GAUGE
1I
TACHO
METER
MICROCOMPUTER
1L
1F
Y
(F)
1P
L
(F)
X-09
Z-53
L
(E)
R/Y
(F)
Y/B
(F)
W/B
(F)
21
L/W
(E)
19
SEDIMENTOR
1.4W
2C
C2-01
X-09
B/O
(F)
CHARGE
1.4W
1N
1G
L/W
(F)
SPEEDOMETER
Y/B
(E)
DOOR SWITCHES
(SECTION I-3)
C2-03
FUEL GAUGE
SENDER UNIT
(SECTION B-5)
2
GENERATOR
(SECTION A-2)
C2-02
WATER
TEMPERATURE
SENDER UNIT
VEHICLE
SPEEDOMETER
SENSOR
5
L/W
1P
R/Y
1O
1N
1M
L/R
1L
1K
B/Y
B/O
1J
1I
L/W
1H
Y/B
R/B
R/G
G/B
G/W
1G
1F
1E
1D
1C
1B
1A
B/L
2N
2M
2L
2K
2J
2I
2H
2G
2F
L/Y
Y/R
W/B
2E
2D
2C
R/W
2B
2A
Y/B
INSTRUMENT
CLUSTER
(SECTION C-2b)
WIRING DIAGRAM
B(E)
(F)
HARNESS SYMBOL :
(E)
(R)
[BLACK]
(F)-(E)
MAIN FUSE BLOCK
X-09
X-01
[GRAY]
VEHICLE SPEEDOMETER SENSOR
C2-03
INSTRUMENT CLUSTER
C2-01
[BLACK]
INSTRUMENT CLUSTER
C2-01
Z-54
X-07
(F)-(E)
[BLACK]
X-08
(F)-(E)
[BLACK]
C2-02
X-02
WATER TEMPERATURE
SENDER UNIT
IGNITION SWITCH
[WHITE]
X-03
FUSE BLOCK
WIRING DIAGRAM
X-02
IGNITION SWITCH
[BLUE]
Z
C-2a
C-2b
INSTRUMENT CLUSTER (F2 CARB)
REAR WINDOW
DEFROSRTER
RELAY
(SECTION I-2)
TURN SWITCH
(SECTION F-1)
27
28
29
30
45
R/B
(F)
R/W
(F)
G/B
(F)
G/W
(F)
B/L
(F)
C2-01
1E
2A
1B
1A
2N
ILLUMI
3.4X4
BEAM
1.4W
TURN
LH
1.4W
TURN
RH
1.4W
R.DEF
1.4W
INSTRUMENT
22
CLUSTER
(SECTION C-2a)
OIL
1.4W
BRAKE
1.4W
2D
2M
2E
1D
1C
C2-01
Y/R
(F)
X-08
Z-55
C2-06
C2-05
BRAKE
FLUID
LEVEL
SENSOR
C2-05
Y/R
(E)
C2-04
OIL
PRESSURE
SWITCH
B
(F)
R/G
(F)
L/Y
(F)
O
(F)
PARKING
BRAKE
SWITCH
38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)
B
(F)
L/W
1P
R/Y
1O
1N
1M
L/R
1L
1K
B/Y
B/O
1J
1I
1H
Y/B
R/B
R/G
G/B
G/W
1G
1F
1E
1D
1C
1B
1A
B/L
2N
2M
2L
2K
2J
2I
2H
2G
2F
L/Y
Y/R
W/B
2E
2D
2C
R/W
2B
2A
Y/R
WIRING DIAGRAM
INSTRUMENT CLUSTER
HEADLIGHT
SWITCH
(SECTION E-1)
HEADLIGHT
SWITCH
(SECTION I-1)
(F)
HARNESS SYMBOL :
(E)
(R)
BRAKE FLUID
LEVEL SENSOR
C2-05
INSTRUMENT CLUSTER
C2-01
[BLACK]
INSTRUMENT CLUSTER
C2-01
Z-56
X-08
(F)-(E)
[BLACK]
C2-04
OIL PRESSURE SWITCH
WIRING DIAGRAM
C2-06
PARKING BRAKE
SWITCH
Z
C-2b
C-3a
< >...4X4
X-07
MAIN
B/W(E)
B/W(F)
A
80A
BTN
X-01
IMMOBILIZER UNIT
73
(SECTION T-3)
X-01
W/R(F)
X-03
C3-10
IG2
ENGINE
SWITCH
ACC
X-02
METER
W(F)
L/R(F)
P(F)
P(F)
IG1
L/R
(F)
C3-10
X-02
OFF
ST
10A
X-03
X-08
P(F)
THEFT-DETERRENT
CONTROL MODULE 58
(SECTION T-4)
ROOM
W/R(E)
30A
KEY REMINDER
SWITCH
B/Y(F)
15A
X-03
L/R
(F)
X-03
C3-01
1K
INSTRUMENT CLUSTER
1J
b (SECTION C-3b)
WATER
TEMPERATURE
GAUGE
SECURITY
1.4W
TACHO
METER
a (SECTION C-3c)
FUEL
GAUGE
SPEEDOMETER
CHARGE
1.4W
SEDIMENTOR
1.4W
MICROCOMPUTER
2K
1I
BR/B
(F)
Z-57
X-18
Y(R2)
C3-11
FUEL GAUGE
SENDER
UNIT
C3-11
B/R
(F)
BR/B
(F)
56
51
X-04
1G
1P
L
(F)
Y(F)
Y(R)
L/W
(F)
X-09
Y/B
(F)
L/W
(E)
L
(E)
L/W
(E)
C3-03
X-18
C3-03
R/Y
(F)
G/R
(F)
W/L
(F)
W/B
(F)
21
72
VEHICLE
SPEEDOMETER
SENSOR
EXCEPT 4X4
B/R
(F)
PCM
(SECTION B-6c)
PCM
(SECTION
B-6b)
1P
R/Y W/L
1O
1N
1M
L
1L
L/W
W
(F)
VEHICLE
SPEEDOMETER
SENSOR
4X4
SEDIMENTOR
SWITCH
GENERATOR
(SECTION A-3)
C3-04
16
L/R
B/Y
B/R
1K
1J
1I
2I
C3-01
B
(F)
L/W
2C
C3-02
WATER
TEMPERATURE
SENDER UNIT
X-04
16
1M
1H
DOOR
SWITCHES
(SECTION I-3)
B/R
(R)
WITH
THEFTDETERRENT
SYSTEM
1N
C3-04
L
(E)
B/R
(R2)
THEFTDETERRENT
CONTROL
MODULE
(SECTION
T-4)
IMMOBILIZER
UNIT
(SECTION T-3)
1L
1F
G/R Y/B
1H
Y
1F
R/B
1E
B
1D
1B
1A
B/L
R/L
2N
2M
4X4
L/W
1G
GY BR/B Y/G
2L
2K
2J
W
2I
<BR> <LG/R>
2H
2G
L/Y
2F
2E
R/W
Y/R W/B
2D
2C
2B
Y/B
2A
L/R
B/R
WIRING DIAGRAM
B(E)
BATTERY
+
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
[BLACK]
(F)-(E)
(E)
(F)-(E)
X-08
X-07
(R)
(R)-(R2)
[GRAY]
(F)-(E)
X-09
X-18
[GRAY]
VEHICLE SPEEDOMETER SENSOR
C3-03
X-01
(F)-(R)
X-04
C3-11
FUEL GAUGE SENDER UNIT
Z-58
C3-04
SEDIMENTOR
SWITCH
INSTRUMENT CLUSTER
C3-01
[BLACK]
INSTRUMENT CLUSTER
C3-01
16
C3-02
WATER TEMPERATURE
SENDER UNIT
KEY REMINDER
SWITCH
C3-10
WIRING DIAGRAM
X-02
ENGINE SWITCH
[WHITE]
X-04
(F)-(R)
X-02
X-03
ENGINE SWITCH
[BLUE]
FUSE BLOCK
Z
C-3a
From No.
F175-30-01I
C-3b
WIRING DIAGRAM
INSTRUMENT CLUSTER
(SECTION C-3a)
2G
OIL
1.4W
AIR BAG
1.4W
RFW
LOCK
1.4W
4WD
1.4W
2H
2J
GLOW
1.4W
BRAKE
1.4W
2L
2E
2D
C3-01
Y/G
(F)
L/Y
(F)
Y/R
(F)
BR
(F)
LG/R
(F)
GY
(F)
X-09
Z-59
Y/G
(F)
Y/G
(F)
23
25
47
DATA LINK
CONNECTOR
(SECTION U-2)
L/Y
(F)
SAS UNIT
(SECTION S-2)
C3-05
OIL
PRESSURE
SWITCH
L/Y
(F)
C3-06
BRAKE
FLUID
LEVEL
SENSOR
Y/R
(E)
24
RFW
CONTROL MODULE
(SECTION H-2)
PCM
(SECTION B-6c)
C3-07
PARKING
BRAKE
SWITCH
C3-06
B
(F)
4X4
5
C3-01 INSTRUMENT CLUSTER(F)
L/W
1P
R/Y W/L
1O
1N
1M
L
1L
L/R
B/Y
B/R
1K
1J
1I
L/Y
B
G/R Y/B
1H
< >...4X4
1G
Y
1F
R/B
1E
B
1D
1B
1A
B/L
R/L
2N
2M
GY BR/B Y/G
2L
L/Y
2K
2J
W
2I
<BR> <LG/R>
2H
2G
L/Y
2F
2E
R/W
Y/R W/B
2D
2C
2B
2A
Y/R
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
BRAKE FLUID
LEVEL SENSOR
C3-06
(R)
[GRAY]
(F)-(E)
X-09
INSTRUMENT CLUSTER
C3-01
[BLACK]
INSTRUMENT CLUSTER
Z-60
C3-01
5
C3-05
OIL PRESSURE SWITCH
WIRING DIAGRAM
C3-07
PARKING BRAKE SWITCH
Z
C-3b
From No.
F175-30-01I
C-3c
TURN SWITCH
(SECTION F-3)
REAR FOG
LIGHT SWITCH
(SECTION E-5)
27
28
29
30
45
52
R/B
(F)
R/W
(F)
G/B
(F)
G/W
(F)
B/L
(F)
R/L
(F)
C3-01
INSTRUMENT CLUSTER
1E
2A
1B
1A
2N
2M
ILLUMI
3.4X4
BEAM
1.4W
TURN
LH
1.4W
TURN
RH
1.4W
R.DEF
1.4W
R.FOG
1.4W
(SECTION C-3a) a
1D
1C
C3-01
B
(F)
R/G
(F)
Z-61
38
PANEL LIGHT
CONTROL SWITCH
(SECTION I-1)
L/W
1P
R/Y W/L
1O
1N
1M
L
1L
L/R
B/Y
B/R
1K
1J
1I
G/R Y/B
1H
1G
Y
1F
R/B
1E
B
1D
1B
1A
B/L
R/L
2N
2M
GY BR/B Y/G
2L
2K
2J
W
2I
<BR> <LG/R>
2H
2G
L/Y
2F
2E
R/W
Y/R W/B
2D
2C
2B
2A
WIRING DIAGRAM
HEADLIGHT
SWITCH
(SECTION E-4)
< >...4X4
HEADLIGHT
SWITCH
(SECTION I-1)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
INSTRUMENT CLUSTER
C3-01
[BLACK]
INSTRUMENT CLUSTER
C3-01
Z-62
WIRING DIAGRAM
C-3c
From No.
F175-30-01I
D
WINDSHIELD WIPER AND WASHER (before model year 2002)
B/W(E)
X-01
80A
B/W(F)
X-07
X-01
FUSE BLOCK
WIPER
IG1
B/R(F)
15A
X-03
L
(F)
X-02
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
OFF
ST
IG2
WIRING DIAGRAM
B(E)
ACC
X-02
X-03
WINDSHIELD WIPER AND WASHER SWITCH
L(F)
D-02
ONE-TOUCH
SWITCH
HIGH
WASHER
SWITCH
L
(F)
HIGH
OFF
LOW INT
OFF
LOW
INT
INT
RELAY
D-02
L(F)
L
(F)
L/O
(F)
L/B
(F)
L/Y
(F)
L/W
(F)
D-03
Z-63
D-01
WINDSHIELD
WASHER
MOTOR
D-01
AUTOSTOP
SWITCH
B
(F)
B
(F)
CIRCUIT
BREAKER
L/W
<
>
L/O
<
L/B
>
<
<L/W>
L/O
<L/Y>
<L/B>
<L>
(G/R)
L/W
L/Y
L/B
B
>
<B>
<
>
BATTERY
+
-
HARNESS SYMBOL :
(F)
(E)
WINDSHIELD
WASHER MOTOR
D-01
(R)
[BLACK]
(F)-(E)
X-07
MAIN FUSE BLOCK
X-01
X-01
D-03
1
D-03
WINDSHILD
WIPER MOTOR
D-01
WINDSHILD
WASHER MOTOR
Z-64
X-07
(F)-(E)
[BLACK]
F2 CARB
WL,WL Turbo
WIRING DIAGRAM
D-02
WINDSHIELD WIPER AND
WASHER SWITCH
X-02
X-02
X-03
FUSE BLOCK
Z
D
D-2
BATTERY
+
MAIN
X-01
80A
B/W(F)
A
X-07
X-01
IG1
WIPER
B/R(F)
15A
X-03
L
(F)
X-02
OFF
ST
IG2
ENGINE
SWITCH
ACC
X-02
X-03
L(F)
D2-02
ONE-TOUCH
SWITCH
HIGH
LOW INT
WASHER
SWITCH
L
(F)
HIGH
OFF
OFF
LOW
INT
INT
RELAY
D2-02
L(F)
L
(F)
L/O
(F)
L/B
(F)
L/Y
(F)
L/W
(F)
Z-65
D2-03
D2-01
M
WINDSHIELD
WASHER
MOTOR
B
(F)
D2-01
AUTOSTOP
SWITCH
B
(F)
WINDSHIELD WIPER MOTOR
4
5
D2-01 WINDSHIELD WASHER
MOTOR(F)
L/Y
L/O
L/W
L/B
L/O
L/Y
L/B
CIRCUIT
BREAKER
WIRING DIAGRAM
B/W(E)
B(E)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
WINDSHIELD
WASHER MOTOR
[BLACK]
(F)-(E)
D2-01
X-07
WINDSHIELD
WIPER MOTOR
MAIN FUSE BLOCK
D2-03
X-01
Z-66
5
4
D2-02
WINDSHIELD WIPER AND
WASHER SWITCH
X-02
ENGINE SWITCH
[WHITE]
X-03
FUSE BLOCK
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BLUE]
Z
D-2
From No.
F175-30-01I
E-1
HEADLIGHTS (WITHOUT HEADLIGHT LEVELING SYSTEM)
FUSE BLOCK
TAIL
W/R(F)
W/R(E)
30A
Y/R(F)
10A
X-03
WIRING DIAGRAM
B(E)
X-01
BATTERY
+
X-03
HEAD
R(E)
30A
X-01
R(F)
X-08
E1-01
LIGHT
SWITCH
OFF
TNS HEAD
LIGHT
HEADLIGHT
SWITCH
DIMMER
SWITCH
FLASHTO-PASS
HI
LO
R/B(F)
R/W
(F)
Z-67
INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)
28
R/L
(F)
R/W(F)
R/W
(F)
R/L
(F)
R/W
(F)
R/L
(F)
E1-02
LH
E1-03
60/55W
HEADLIGHTS
60/55W
E1-02
E1-03
B(F)
1
G/O
G/B
Y/R
R/W
R/L
R
R/L
R/B
R/L
R/W
R/B(F)
39
R/B(F)
40
R/B(F)
41
E1-01
E1-01
R/W
RH
ILLUMINATION LIGHTS
(SECTION I-1)
(F)
HARNESS SYMBOL :
(E)
(R)
[BLACK]
(F)-(E)
X-01
X-08
MAIN FUSE BLOCK
X-01
E1-03
Z-68
HEADLIGHT RH
[BLACK]
E1-03
HEADLIGHT RH
[BLACK]
X-08
(F)-(E)
[BLACK]
HEADLIGHT LH
[BLACK]
E1-02
HEADLIGHT LH
[BLACK]
E1-02
F2 CARB
WL,WL Turbo
WIRING DIAGRAM
E1-01
HEADLIGHT SWITCH
X-03
FUSE BLOCK
Z
E-1
E-2
HEADLIGHTS (WITH HEADLIGHT LEVELING SYSTEM, before model year 2002)
FUSE BLOCK
TAIL
W/R(F)
Y/R(F)
30A
10A
X-03
WIRING DIAGRAM
W/R(E)
B(E)
X-01
BATTERY
+
-
X-03
HEAD
R(E)
30A
R(F)
X-01
X-08
HEADLIGHT SWITCH
E2-01
LIGHT
SWITCH
OFF
TNS HEAD
LIGHT
FUSE BLOCK
REAR FOG LIGHT
SWITCH
(SECTION E-3)
R.FOG
53
E2-01
R/G(F)
R/Y(F)
10A
X-03
R/G(F)
E2-05
DIMMER
SWITCH
FLASHTO-PASS
X-03
HI
E2-04
LO
E2-01
HEADLIGHT
LH LEVELING
ACTUATOR
R/B(F)
HEADLIGHT
LEVELING
ACTUATOR
E2-05
39
R/B(F)
41
R/B(F)
40
ILLUMINATION
LIGHTS
(SECTION I-1)
R/L(F)
E2-04
B
(F)
R/B(F)
RH
R/L
(F)
R/W
(F)
G(F)
LICENSE PLATE
LIGHTS,
PARKING LIGHTS,
TAILLIGHTS
(SECTION E-3)
B(F)
Z-69
E2-06
B
(F)
HEADLIGHT
LEVELING
SWITCH
INSTRUMENT
CLUSTER
(SECTION
C-1c)
28
R/W(F)
R/W
(F)
R/L
(F)
R/W
(F)
R/L
(F)
E2-02
E2-06
E2-03
60/55W
LH
B
(F)
60/55W
HEADLIGHTS
E2-02
RH
E2-03
B(F)
R/B
R/Y
R/L
G/W
G/O
Y/R
R/W
G/B
R/L
R/L
B
R/W
G
B
R/G
B
R/W
R/G
(F)
HARNESS SYMBOL :
(E)
(R)
[BLACK]
(F)-(E)
X-01
X-08
Z-70
E2-03
HEADLIGHT RH
[BLACK]
E2-04
HEADLIGHT
LEVELING ACTUATOR RH
[GRAY]
E2-05
HEADLIGHT
LEVELING ACTUATOR LH
[GRAY]
E2-02
HEADLIGHT LH
[BLACK]
E2-06
HEADLIGHT LEVELING
SWITCH
HEADLIGHT SWITCH
X-03
FUSE BLOCK
WIRING DIAGRAM
E2-01
Z
E-2
E-3
LICENSE PLATE LIGHTS / PARKING LIGHTS / TAILLIGHTS / REAR FOG LIGHT (before model year 2002)
U.K. SPECS.
HEADLIGHT SWITCH
(SECTION E-2)
53
R/G(F)
WIRING DIAGRAM
REAR FOG
LIGHT RELAY
X-04
R/G(F)
R/L(F)
R/L(F)
R/L(R)
B(F)
E3-08
E3-08
X-04
41
R/B(F)
40
R/B(F)
R/G
(F)
HEADLIGHT
SWITCH
(SECTION E-1,2)
R/W
(F)
R/L
(F)
E3-09
R/B
(F)
PARKING
LIGHT
LH
E3-01
5W
Z-71
B
(F)
PARKING
LIGHT
RH
E3-02
B
(F)
R/L(F)
52
REAR FOG
LIGHT SWITCH
R/B
(R2)
R/B
(R2)
LICENSE
PLATE LIGHT
LH
E3-03
5W
X-18
R/B
(R2)
E3-04
E3-03
E3-02
E3-01
5W
R/L(F)
R/G(F)
X-18
R/B
(F)
INSTRUMENT
CLUSTER
(SECTION
C-1b)
E3-09
R/B
(R)
LICENSE
PLATE LIGHT
RH
E3-04
5W
E3-05
E3-07
E3-06
TAILLIGHT
LH
5W
R/L
(R2)
B
(F)
R/B
(R2)
TAILLIGHT
RH
5W
E3-05
21W
E3-07
E3-06
B
(R2)
B
(R2)
B
(R2)
B
(R2)
11
10 11
11
10 11
REAR FOG
LIGHT
B
(R2)
B
(F)
R/B
R/B
R/B
R/W
G/W
R/B
W/G
R/L
11
R/B
B
E3-09 REAR FOG LIGHT SWITCH(F)
R/G
R/W
R/L
R/G
B
R/L
R/W
R/W
G/B
R/B
W/G
HARNESS SYMBOL :
(F)
(E)
(R)
TAILLIGHT RH
E3-06
10
[BLACK]
LICENSE PLATE LIGHT RH
E3-04
(R)-(R2)
[BLACK]
LICENSE PLATE LIGHT LH
X-18
E3-03
(F)-(R)
TAILLIGHT LH
X-04
E3-05
11
E3-02
E3-07
PARKING LIGHT RH
Z-72
E3-01
DOUBLE CAB
PARKING LIGHT LH
TAILLIGHT RH
10
E3-06
[BLACK]
LICENSE PLATE LIGHT RH
E3-04
[BLACK]
LICENSE PLATE LIGHT LH
(R)-(R2)
X-18
E3-03
TAILLIGHT LH
E3-05
E3-09
REAR FOG
LIGHT RELAY
REAR FOG
LIGHT SWITCH
WIRING DIAGRAM
E3-08
11
X-04
(F)-(R)
E3-07
REAR FOG LIGHT LH
REGULAR CAB,
STRETCH CAB
Z
E-3
E-4
BATTERY
+
BTN
TAIL
W/R(F)
Y/R(F)
30A
X-01
10A
X-03
WIRING DIAGRAM
W/R(E)
B(E)
X-03
HEAD
R(F)
R(E)
30A
X-08
X-01
HEADLIGHT SWITCH
R/G(F)
R/Y(F)
R/G(F)
X-03
R/G
(F)
10A
OFF
TNS HEAD
LIGHT
X-03
R/G(F)
DIMMER
SWITCH
FLASHTO-PASS
R/G
(F)
E4-05
E4-01
LIGHT
SWITCH
E4-01
R.FOG
HI
LO
E4-04
E4-01
HEADLIGHT
LH LEVELING
ACTUATOR
E4-05
G(F)
R/W
(F)
Z-73
INSTRUMENT
28
CLUSTER
(SECTION C-3c)
E4-06
0
R/W
(F)
3
1
2
LH
18
E4-02 HEADLIGHT LH(F)
Y/R
HEADLIGHTS
LICENSE PLATE
LIGHTS,
40 PARKING LIGHTS,
TAILLIGHTS
(SECTION E-5)
R/L
(F)
60/55W
B
(F)
B
(F)
19
18
E4-04 HEADLIGHT LEVELING ACTUATOR RH(F)
R/L
R/L
B
RH
E4-03
B
B
R/W
R/B(F)
E4-03
60/55W
E4-02
19
R/L
R/W
(F)
R/L
(F)
E4-02
B
(F)
B
(F)
R/Y
R/L
(F)
R/W(F)
E4-06
R/B
ILLUMINATION
39 LIGHTS
(SECTION I-1)
G(F)
G
(F)
HEADLIGHT
LEVELING
SWITCH
R/B(F)
R/L(F)
E4-04
B
(F)
R/B(F)
HEADLIGHT
RH
LEVELING
ACTUATOR
R/G
B
R/W
R/G
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
(F)-(E)
X-08
MAIN FUSE BLOCK
X-01
18
E4-06
Z-74
E4-03
HEADLIGHT RH
[BLACK]
E4-04
HEADLIGHT LEVELING
ACTUATOR RH
[GRAY]
19
E4-05
HEADLIGHT LEVELING
ACTUATOR LH
[GRAY]
E4-02
HEADLIGHT LH
[BLACK]
HEADLIGHT SWITCH
X-03
FUSE BLOCK
WIRING DIAGRAM
E4-01
Z
E-4
From No.
F175-30-01I
E-5
R/G(F)
X-04
R/L(F)
R/G(F)
WIRING DIAGRAM
REAR FOG
LIGHT RELAY
HEADLIGHT SWITCH
53
(SECTION E-4)
R/L(F)
R/L(R)
B(F)
E5-08
HEADLIGHT
SWITCH
40
(SECTION E-4)
E5-08
X-04
R/G
(F)
R/B(F)
R/B(F)
R/B
(R)
R/B
(F)
R/W
(F)
R/L
(F)
E5-09
E5-09
X-18
R/L(F)
REAR FOG
LIGHT SWITCH
R/B
(R2)
R/B(F)
R/L(F)
R/B(R2)
INSTRUMENT
52 CLUSTER
(SECTION C-3c)
X-18
R/B(R2)
B
(F)
R/B
(F)
R/B
(F)
R/B
(R2)
R/B
(R2)
R/B
(R2)
R/L
(R2)
R/B
(R2)
E5-07
21W REAR FOG
LIGHT
E5-07
Z-75
E5-01 PARKING LIGHT LH(F)
E5-01
PARKING
5W LIGHT
LH
E5-01
E5-02
PARKING
5W LIGHT
RH
E5-02
B
(F)
B
(F)
B
(R2)
B
(R2)
B
(R2)
B
(R2)
18
19
10 11
10 11
11
10 11
R/B
R/B
E5-03
LICENSE
5W PLATE LIGHT
LH
E5-03
W/G
TAILLIGHT
LH
E5-05
5W
TAILLIGHT
RH
B
(R2)
E5-06
11
E5-05 TAILLIGHT LH(R2)
R/W G/B
R/B
R/B
R/G R/W
R/L
R/B
5W
E5-06
R/W G/W
B
E5-05
E5-04
LICENSE
5W PLATE LIGHT
RH
E5-04
R/L
R/L
R/W
R/B
W/G
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
TAILLIGHT RH
E5-06
10
[BLACK]
LICENSE PLATE
LIGHT RH
E5-04
[BLACK]
LICENSE PLATE
LIGHT LH
E5-03
(R)-(R2)
X-18
TAILLIGHT LH
E5-05
18
(F)-(R)
X-04
11
Z-76
E5-07
E5-02
PARKING LIGHT RH
19
3
E5-01
PARKING LIGHT LH
E5-09
REAR FOG LIGHT
SWITCH
WIRING DIAGRAM
X-04
(F)-(R)
E5-08
REAR FOG LIGHT
RELAY
Z
E-5
From No.
F175-30-01I
F-1
TURN AND HAZARD WARNING LIGHTS (before model year 2002)
MAIN FUSE BLOCK
MAIN
80A
X-01
B/W(F)
L/Y(F)
10A
X-01
A
B/W(E)
B/W(F)
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
OFF
ST
IG1
THEFT-DETERRENT
RELAY
(SECTION T-2)
X-02
X-07
IG2
ACC
METER
X-02
W(F)
B/Y(F)
WITH
THEFT-DETERRENT
SYSTEM
X-03
15A
59
THEFT-DETERRENT
CONTROL MODULE
(SECTION T-2)
61
62
G/R
(F)
G/Y
(F)
63
G/O(F)
F1-03
X-03
F1-04
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
(SECTION T-2)
F1-03
60
G/B
(F)
F1-04
FLASHER
UNIT
G/R(F)
WITHOUT
THEFT-DETERRENT
SYSTEM
F1-03
G/O
(F)
G/O(F)
G/W
(F)
G/O
(F)
LH
G/B(F)
G/W(F)
X-18
G/B(F)
G/B
(R2)
G/B
(F)
G/B
(F)
E3-05
REAR
21W TURN LIGHT
LH
F1-01
FRONT
21W TURN LIGHT
LH
F1-05
FRONT SIDE
5W TURN LIGHT
LH
Z-77
F1-01
E3-05
B
(R2)
11
G/W
B
R/W
G/B
R/B
W/G
F1-06
FRONT SIDE
5W
TURN LIGHT
RH
F1-02
FRONT
21W TURN LIGHT
RH
E3-06
REAR
21W TURN LIGHT
RH
E3-06
F1-02
B
(F)
B/Y
L/Y
G/O
B
R/W
G/W
R/B
W/G
>
G/R
<R/B>
(G/Y)
10 11
G/W
G/B
G/R
B
(F)
B
(R2)
R/B
TURN SWITCH
30
B
(F)
R/G
X-18
G/W
(R2)
F1-06
G/O
E1-01
<E2-01>
RH
G/W(R)
G/W
(F)
B
(F)
E1-01
<E2-01>
G/W
(F)
INSTRUMENT
CLUSTER
(SECTION
C-1c,2b, 3c)
G/W(F)
G/W
(F)
F1-05
B
(F)
G/W(F)
G/W(F)
G/W(F)
29
G/B
G/B(F)
X-04
G/B(F)
G/B
(F)
G/B(F)
X-04
G/B(R)
WIRING DIAGRAM
B/W(E)
B(E)
FUSE BLOCK
HAZARD
G/B
G/O
<
>
G/B
<
>
Y/R
R/W
<R/Y>
<R/L>
<G/W>
R
<
<G/O> <G/B>
R/L
> <R/W>
R/B
<R>
<Y/R>
G/W
<
>
BATTERY
+
(F)
HARNESS SYMBOL :
(E)
(R)
FRONT SIDE
TURN LIGHT RH
F1-06
MAIN FUSE BLOCK
(R)-(R2)
X-07
X-18
E3-06
10
X-01
E3-05
1
FRONT SIDE
TURN LIGHT LH
F1-05
(F)-(R)
X-04
11
F1-02
FRONT TURN LIGHT RH
[BLACK]
WL,WL Turbo
Z-78
F1-01
FRONT TURN LIGHT LH
[BLACK]
FRONT SIDE
TURN LIGHT RH
X-01
HAZARD WARNING
SWITCH
F1-06
FLASHER UNIT
F1-04
F1-03
1
TURN SWITCH
E2-01(WITH HEADLIGHT
LEVELING SYSTEM)
FRONT SIDE
TURN LIGHT LH
E1-01(WITHOUT HEADLIGHT
LEVELING SYSTEM)
F1-05
F1-02
FRONT TURN LIGHT RH
[BLACK]
F1-01
FUSE BLOCK
X-04
(F)-(R)
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
X-07
(F)-(E)
[BLACK]
X-03
F2 CARB
WIRING DIAGRAM
X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]
Z
F-1
F-2
BACK-UP LIGHTS / BRAKE LIGHTS / HORN (before model year 2002)
BATTERY
+
MAIN
A
B/W(F)
B/W(E)
80A
X-01
BTN
X-08
X-01
X-03
15A
X-02
OFF
ST
W/R(F)
W/R(E)
30A
FUSE BLOCK
STOP
X-07
G/W
(F)
X-03
IG1
IG2
ACC
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
X-02
B/Y(F)
15A
X-03
G/W(F)
G/W(F)
FUSE BLOCK
METER
W(F)
B/Y(E)
X-09
X-03
F2-06
G/W
(F)
A
F2-05
BACK-UP
LIGHT
SWITCH
F2-06
BRAKE
SWITCH
F2-01
HORN
RELAY
F2-05
F2-01
F2 CARB
W/G
(F)
G/R
(F)
WL,WL Turbo
R/W(F)
R/W(F)
R/W(E)
R/W(E)
X-08
X-04
W/G
(R)
R/W
(R)
W/G
(R2)
R/W
(R2)
X-18
B/R
(F)
G/R
(F)
B/R
(F)
B/R
(F)
S1-02
F2-04
HORN
Z-79
F2-03
HORN
RH
F2-02
HORN
LH
G/R
(F)
G/R
(F)
R/W
(R2)
F2-07
HORNS
W/G
(R2)
E3-05
G/R
E3-06
BACK-UP
LIGHT
LH
21W
CLOCK
SPRING
R/W
(R2)
W/G
(R2)
21W
BRAKE
LIGHT
LH
21W
BRAKE
LIGHT
RH
21W
BACK-UP
LIGHT
RH
D-02
G/W
G/W
G/W
B/R
G/R
B/R
L/W
L/Y
L/B
11
10 11
G/R
R/W
B
R/B
G/W
B/Y
W/G
R/W
B/R
B
(R2)
F2-04 HORN(F)
E3-06
B
(R2)
B/R
L/O
E3-05
HORN
SWITCH
HORN
SWITCH
G/B
W/G
R/W
B
R/B
G/W
W/G
G/R
G/R
B/Y
B/W
Y/G
Y/G
R/G
R/G
G/R
B/W
B/Y
WIRING DIAGRAM
B(E)
(F)
HARNESS SYMBOL :
(E)
[BLACK]
(F)-(E)
(R)
[BLACK]
(F)-(E)
[BLACK]
(F)-(E)
X-08
X-09
BACK-UP LIGHT RH /
BRAKE LIGHT RH
E3-06
(R)-(R2)
10
X-18
X-07
MAIN FUSE BLOCK
BACK-UP LIGHT LH /
BRAKE LIGHT LH
E3-05
X-01
F2-06
(F)-(R)
X-04
11
F2-03
HORN RH
Z-80
WL,WL Turbo
F2-02
HORN LH
MAIN FUSE BLOCK
X-01
F2-06
HORN RELAY
F2-01
SHORT CONNECTOR
S1-02
F2-07
HORN SWITCH
D-02
HORN SWITCH
F2-04
HORN
X-03
X-07
F2-05
(F)-(E)
[BLACK]
X-08
(F)-(E)
[BLACK]
BRAKE SWITVCH
[BLACK]
X-09
X-04
(F)-(R)
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
F2 CARB
(F)-(E)
[BLACK]
FUSE BLOCK
WIRING DIAGRAM
X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]
F-2
F-3
TURN AND HAZARD WARNING LIGHTS (WL-3, WLT-3, as of model year 2002)
MAIN
X-01
L/Y(F)
B/W(F)
X-03
X-01
A
B/W(E)
B/W(F)
X-07
IG1
IG2
X-03
THEFT-DETERRENT
RELAY
(SECTION T-4)
X-02
OFF
ST
10A
ENGINE
SWITCH
F3-03
FLASHER
UNIT
F3-03
F3-03
60
G/B
(F)
G/W
(F)
G/W(F)
G/W(F)
X-04
G/W
(F)
G/B
(F)
G/W
(F)
G/B(F)
G/B(F)
Z-81
G/B
(R2)
G/B
(F)
G/B
(F)
E5-05
REAR
21W TURN LIGHT
LH
E5-05
F3-01
FRONT
21W TURN LIGHT
LH
F3-01
F3-05
FRONT SIDE
5W TURN LIGHT
LH
F3-05
B
(R2)
B
(F)
B
(F)
11
19
B
F3-06 FRONT SIDE TURN LIGHT RH (F)
G/W
(F)
G/W
(R2)
F3-06
FRONT SIDE
5W TURN LIGHT
RH
F3-06
F3-02
FRONT
21W TURN LIGHT
RH
F3-02
E5-06
REAR
21W TURN
LIGHT
RH
E5-06
B
(F)
B
(F)
B
(R2)
18
10 11
B/Y
L/Y G/R
G/W
R/B
R/Y
R/W
Y/R
G/B
G/Y
R/G
G/O
B
B
(F)
R/G R/B
G/W
(F)
G/O
G/W(R)
30
G/W
G/B
G/W(F)
G/W(F)
INSTRUMENT
CLUSTER
(SECTION C-3c)
G/O
(F)
R/W G/B
B
R/B W/G
G/O
(F)
E4-01
E4-01 RH
TURN SWITCH
X-18
X-04
G/W(F)
29
LH
G/B(F)
G/B
(F)
F3-04
G/O(F)
G/B(F)
G/Y
(F)
F3-04
HAZARD
WARNING
SWITCH
THEFT-DETERRENT
CONTROL MODULE
(SECTION T-4)
G/B(F)
G/R
(F)
63
G/O(F)
B/Y(F)
15A
G/B(R)
62
METER X-03
X-03
W(F)
X-18
61
THEFT-DETERRENT
CONTROL MODULE
(SECTION T-4)
ACC
X-02
59
WIRING DIAGRAM
80A
HAZARD
B/W(E)
B(E)
BATTERY
+
R/W G/W
B
R/B W/G
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
E5-06
F3-06
10
(R)-(R2)
X-18
X-01
E5-05
18
1
(F)-(R)
X-04
F3-05
11
F3-02
Z-82
19
X-07
(F)-(E)
[BLACK]
HAZARD WARNING
SWITCH
F3-01
F3-03
F3-04
FLASHER UNIT
E4-01
TURN SWITCH
WIRING DIAGRAM
X-02
ENGINE SWITCH
[WHITE]
X-02
ENGINE SWITCH
[BLUE]
X-04
X-03
(F)-(R)
FUSE BLOCK
Z
F-3
From No.
F175-30-01I
F-4
BACK-UP LIGHTS / BRAKE LIGHTS / HORNS (WL-3, WLT-3, as of model year 2002)
BATTERY
+
MAIN
A
B/W(F)
B/W(E)
80A
X-01
BTN
STOP
W/R(E)
30A
X-07
X-01
W/R(F)
X-08
X-03
15A
G/W
(F)
X-03
X-02
OFF
ST
IG1
IG2
ENGINE
SWITCH
ACC
METER
X-02
W(F)
G/W(F)
G/W
(F)
F4-01
G/W
(F)
A
B/R
(F)
Z-83
F4-03
HORN
RH
S2-02
F4-06
W/G
(R2)
R/W
(R2)
W/G
(R2)
R/W
(R2)
R/B W/G
BACK-UP
21W LIGHT
RH
BRAKE
21W LIGHT
RH
E5-06
B
(R2)
B
(R2)
11
10 11
G/W
B/Y
W/G
R/W
B/R
R/W G/B
B
21W
BACK-UP
LIGHT
LH
E5-05
W/G
(R2)
E5-06
BRAKE
21W LIGHT
LH
B/R G/R
E5-05 BACK-UP LIGHT LH / BRAKE LIGHT LH(R2)
R/W
(R2)
E5-05
HORN
SWITCH
B/R
R/W
(R)
BACK-UP
LIGHT
SWITCH
G/R
(F)
CLOCK
SPRING
G/W
X-08
W/G
(R)
F4-05
R/W(E)
X-18
G/R
R/W(F)
X-04
B/R
(F)
F4-02
HORN
LH
F4-05
W/G
(F)
G/R
(F)
G/W
G/W
B/Y
(E)
F4-04
B/R
(F)
X-09
BRAKE
SWITCH
F4-01
X-03
F4-04
HORN
RELAY
B/Y(F)
15A
X-03
G/R
R/W G/W
B
R/B W/G
WIRING DIAGRAM
B(E)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
BACK-UP LIGHT RH /
BRAKE LIGHT RH
[GRAY]
(F)-(E)
[BLACK]
(F)-(E)
10
E5-06
X-09
X-07
MAIN FUSE BLOCK
BACK-UP LIGHT LH /
BRAKE LIGHT LH
(R)-(R2)
X-01
E5-05
X-18
BACK-UP LIGHT SWITCH
F4-05
(F)-(R)
X-04
11
F4-03
Z-84
HORN RH
[BLACK]
X-08
(F)-(E)
HORN RELAY
F4-02
F4-01
HORN LH
[BLACK]
SHORT CONNECTOR
S2-02
HORN SWITCH
F4-06
WIRING DIAGRAM
X-02
ENGINE SWITCH
[WHITE]
X-04
(F)-(R)
X-02
X-03
F4-04
ENGINE SWITCH
[BLUE]
FUSE BLOCK
BRAKE SWITCH
Z
F-4
From No.
F175-30-01I
G-1
HEATER AND AIR CONDITIONER (WL, WL Turbo, before model year 2002)
BATTERY
+
X-01
X-07
X-01
MAIN
B/W(E)
B/W(F)
80A
B/W(E)
X-02
IG2
ACC
B/W(F)
OFF
ST
(A/C)
IG1
LG/R(F)
10A
ENGINE
SWITCH
X-02
WIPER
L(F)
WIRING DIAGRAM
B(E)
B/R(F)
L(F)
15A
(HEATER)
B/R(F)
LG/R
(F)
L
(F)
40A
X-03
X-03
FUSE BLOCK
L(F)
L
(F)
G1-06
G1-06
L
PCM
(SECTION B-1b)
7
R/B
(F)
LG/B
(F)
G1-02
BLOWER UNIT
RESISTOR
A/C
RELAY No.1
A/C
SWITCH
G1-05
M
G1-03
G1-10
G1-08
L/Y
L/Y
(F)
REFRIGERANT
PRESSURE
SWITCH
L
(F)
G1-08
G1-04
G1-05
L/B
L(F)
R/W
(F)
L/W
(F)
Z-85
R/G
(F)
L/R
L/Y
(F)
L/B
L/B
G1-02
G1-09
BLOWER
MOTOR
L
(F)
L/R
(F)
L/B
(F)
X-09
G1-01
R/G
(E)
AMP
2
3
G1-07
OFF
4
MAGNETIC
CLUTCH
THERMOSWITCH
B
(F)
FAN
SWITCH
LG/R
LG/B
R/B
(F)
L/R
L/Y
L/R
L/B
L/Y
L/B
R/G
G1-04 RESISTOR
G1-03 RESISTOR
(BLOWER UNIT)
R/G
LG/B
L/R
L/B
L/Y
(SHORT CORD)
(SHORT CORD)
(SHORT CORD)
L/R
L/Y
L/B
G1-09 THERMOSWITCH(F)
L/W
R/W
L/B
L/B
L/Y
L/W
HARNESS SYMBOL :
(F)
(E)
(R)
[BLACK]
(F)-(E)
X-07
[BLACK]
(F)-(E)
X-09
MAIN FUSE BLOCK
X-01
A/C RELAY No.1
G1-06
Z-86
(F)-BLOWER UNIT
G1-02
X-02
ENGINE SWITCH
[WHITE]
X-02
G1-08
REFRIGERANT
PRESSURE SWITCH
[BLACK]
ENGINE SWITCH
[BLUE]
G1-07
X-03
MAGNETIC CLUTCH
WIRING DIAGRAM
FUSE BLOCK
G1-09
G1-01
THERMOSWITCH
G1-05
G1-03
RESISTOR
BLOWER MOTOR
G1-10
A/C SWITCH
G1-04
RESISTOR
Z
G-1
G-2
HEATER AND AIR CONDITIONER (F2 CARB)
BATTERY
+
X-01
X-07
X-01
MAIN
B/W(E)
B/W(F)
80A
B/W(E)
WIRING DIAGRAM
B(E)
X-02
B/W(F)
OFF
ST
(A/C)
LG/R(F)
IG1
10A
IG2
IGNITION
SWITCH
ACC
X-02
ENGINE
B/W(F)
W(F)
15A
WIPER
L(F)
LG/R
(F)
L(F)
B/R(F)
15A
L
(F)
(HEATER)
B/R(F)
A/C
RELAY No.1
X-03
FUSE BLOCK
L(F)
R/W
(F)
L
A/C
SWITCH
G2-05
M
LG
(F)
REFRIGERANT
PRESSURE
SWITCH
G2-08
G2-03
G2-10
L(F)
L/Y
R/W(F)
LG
(F)
Z-87
R/G(F)
L
(F)
R/W
(F)
L/R
L/Y
(F)
L/R
(F)
L/B
(F)
G2-01
G2-11
AMP
2
3
B
(F)
4
THERMOSWITCH
LG/R
LG/B
R/W
L/Y
L/R
L/B
L/Y
L/B
LG
B/W
G2-04 RESISTOR
G2-03 RESISTOR
(BLOWER UNIT)
(F)
L/R
L/R
L/B
L/Y
(SHORT CORD)
(SHORT CORD)
(SHORT CORD)
L/R
L/Y
L/B
L/B
L/B
G2-09 THERMOSWITCH(F)
R/G
B
(F)
FAN
SWITCH
OFF
G2-05
L/B
G2-02
L
(F)
B(F)
G2-04
L/B
L/B
G2-09
A/C
No.2
MAGNETIC
CLUTCH
BLOWER
MOTOR
L/Y
(F)
L/W
(F)
G2-11
G2-07
G2-02
BLOWER UNIT
RESISTOR
G2-12
G2-08
L
(F)
G2-12
FICD
SOLENOID
VALVE
G2-06
LG/B
(F)
40A
X-03
B/W
(F)
G2-06
R/G
LG/B
L/W
R/W
L/Y
LG
L/W
D
R/G
(F)
HARNESS SYMBOL :
(E)
(R)
G2-12
MAIN FUSE BLOCK
X-01
G2-11
1
Z-88
G2-06
A/C RELAY No.1
X-07
(F)-BLOWER UNIT
(F)-(E)
[BLACK]
G2-02
X-02
IGNITION SWITCH
[WHITE]
G2-08
PEFRIGERANT
PRESSURE SWITCH
[BLACK]
X-02
G2-07
IGNITION SWITCH
[BLUE]
MAGNETIC CLUTCH
X-03
FUSE BLOCK
WIRING DIAGRAM
G2-01
CLIMATE CONTROL UNIT
G2-09
THERMOSWITCH
G2-10
A/C SWITCH
G2-03
G2-04
G2-05
RESISTOR
RESISTOR
BLOWER MOTOR
Z
G-2
G-3
HEATER AND AIR CONDITIONER (WL-3, WLT-3, as of model year 2002)
X-01
X-07
X-01
MAIN
BATTERY
+
B/W(E)
B/W(F)
80A
B/W(E)
B/W(F)
B
A/C
LG/R(F)
X-02
OFF
ST
IG1
IG2
10A
L(F)
ENGINE
SWITCH
ACC
X-02
WIPER
L(F)
WIRING DIAGRAM
B(E)
B/R(F)
15A
HEATER
LG/R
(F)
L
(F)
B/R(F)
40A
X-03
X-03
L(F)
B
L
(F)
G3-06
RESISTOR
A/C
RELAY
G3-06
R/B
(F)
LG/B
(F)
PCM
(SECTION B-6c)
G3-02
L
A/C
SWITCH
G3-05
BLOWER
MOTOR
M
G3-03
G3-10
Z-89
G3-08
REFRIGERANT
PRESSURE
SWITCH
G3-08
L/Y
L/Y
(F)
L
(F)
G3-04
G3-05
L/B
L(F)
R/W
(F)
L/W
(F)
G
(F)
L/R
L/Y
(F)
L/B
G3-02
G3-09
L/B
L
(F)
L/R
(F)
BLOWER UNIT
L/B
(F)
X-09
G3-01
G
(F)
AMP
2
3
G3-07
OFF
4
MAGNETIC
CLUTCH
B
(F)
FAN
SWITCH
THERMOSWITCH
4
WITH AIR CONDITIONER
G3-01 CLIMATE CONTROL UNIT(F)
B
G3-06 A/C RELAY (F)
LG/R
L/Y
L/R
L/B
L/Y
L/B
G3-03 RESISTOR
(BLOWER UNIT)
L/R
L/B
L/Y
G3-04 RESISTOR
(SHORT CORD)
E
L/R
L/Y
L/B
(SHORT CORD)
L/B
L/B
G3-09 THERMOSWITCH(F)
LG/B R/B
LG/B
L/W R/W
(SHORT CORD)
L/Y
L/W
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
[GRAY]
(F)-(E)
X-09
[BLACK]
(F)-(E)
X-07
MAIN FUSE BLOCK
X-01
G3-06
A/C RELAY
Z-90
4
(F)-BLOWER UNIT
G3-02
G3-08
REFRIGERANT
PRESSURE SWITCH
[BLACK]
G3-07
MAGNETIC CLUTCH
X-02
ENGINE SWITCH
[WHITE]
G3-09
THERMOSWITCH
G3-10
A/C SWITCH
X-02
ENGINE SWITCH
[BLUE]
G3-01
CLIMATE
CONTROL UNIT
G3-05
G3-03
RESISTOR
WIRING DIAGRAM
X-03
FUSE BLOCK
BLOWER MOTOR
G3-04
RESISTOR
G-3
From No.
F175-30-01I
H
REMOTE FREEWHEEL CONTROL SYSTEM (before model year 2002)
BATTERY
+
-
A
B/W(E)
X-01
80A
X-01
B/W(F)
X-02
X-07
OFF
ST
IG1
IG2
LOCK
SOLENOID
ENGINE
SWITCH
FREE
SOLENOID
H-04
RFW
MAIN
SWITCH
H-04
ACC
X-02
W
(F)
H-02
H-03
B/W
(F)
B/W
(F)
FUSE BLOCK
ENGINE
B
(F)
B/W(F)
X-03
15A
X-03
B/W
(F)
R
(F)
LG
(F)
G/O
(F)
H-01
E
H-01
R/G
(F)
LG/B
(F)
GY/R
(F)
X-09
B
(F)
R/G
(E)
Z-91
H-06
H-07
4X4
INDICATOR
SWITCH
H-06
RFW
SWITCH
H-05
LG/R
(F)
24
23
LG/B
(E)
GY/R
(E)
H-05
BR
(F)
B/R(E)
NEUTRAL
SWITCH
INSTRUMENT
CLUSTER
(SECTION C-1b)
H-07
B/R(E)
B/R(E)
B/R(E)
X-09
B/R
(F)
GY/R
G/O
LG/B
R/G
B/W
BR
LG/R
LG
R
B
R/G
B/R
B/R
GY/R
B/R
LG/B
B/W
LG
B/W
G/O
WIRING DIAGRAM
B(E)
(F)
HARNESS SYMBOL :
(E)
[BLACK]
(F)-(E)
[BLACK]
X-07
X-09
X-01
(F)-(E)
(R)
[BLUE]
LOCK SOLENOID
H-02
[YELLOW]
FREE SOLENOID
H-03
6
[BLACK]
NEUTRAL SWITCH
H-07
H-06
5
3
RFW MAIN SWITCH
Z-92
H-04
4
H-05
RFW SWITCH
[BLACK]
X-02
ENGINE SWITCH
[WHITE]
X-03
X-02
ENGINE SWITCH
[BLUE]
WIRING DIAGRAM
FUSE BLOCK
H-01
RFW CONTROL MODULE
Z
H
H-2
REMOTE FREEWHEEL CONTROL SYSTEM (WL-3, WLT-3, as of model year 2002)
BATTERY
+
MAIN
B/W(E)
X-01
80A
X-01
B/W(F)
X-02
X-07
OFF
ST
IG1
IG2
LOCK
SOLENOID
ENGINE
SWITCH
WIRING DIAGRAM
B(E)
FREE
SOLENOID
ACC
X-02
H2-02
W
(F)
H2-03
B/W
(F)
B/W
(F)
ENGINE
B/W(F)
15A
X-03
X-03
B/W
(F)
R
(F)
LG
(F)
H2-01
I
H2-01
R/G
(F)
GY/R
(F)
LG/B
(F)
LG/R
(F)
X-09
B
(F)
R/G
(E)
GY/R
(E)
Z-93
RFW
SWITCH
H2-05
G/O
(F)
LG/B
(E)
H2-06
4X4
INDICATOR
SWITCH
H2-06
H2-05
BR
(F)
H2-07
23
NEUTRAL
SWITCH
24
INSTRUMENT
CLUSTER
(SECTION C-3b)
H2-07
B/R
(E)
B
(F)
B/R
(E)
B/R(E)
B/R(E)
H2-04
RFW
MAIN
SWITCH
H2-04
B/R(E)
B/R(E)
X-09
20
GY/R
G/O
LG/R
LG
LG/B
R/G B/W
BR
F
B
D
B/W
R/G
B/R
B/R GY/R
B/R LG/B
LG
4
H2-04 RFW MAIN SWITCH(F)
B/W
G/O
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
[GRAY]
(F)-(E)
X-09
[BLACK]
(F)-(E)
X-07
MAIN FUSE BLOCK
X-01
[BLUE]
LOCK SOLENOID
H2-02
[YELLOW]
FREE SOLENOID
H2-03
[BLACK]
NEUTRAL SWITCH
H2-07
H2-06
4X4 INDICATOR
SWITCH
[BLACK]
[BLUE]
RFW MAIN SWITCH
H2-04
20
Z-94
H2-05
RFW SWITCH
[BLACK]
X-02
ENGINE SWITCH
[WHITE]
X-02
WIRING DIAGRAM
ENGINE SWITCH
[BLUE]
X-03
FUSE BLOCK
H2-01
RFW CONTROL MODULE
Z
H-2
From No.
F175-30-01I
I-1
ILLUMINATION LIGHTS
R/B(F)
R/B(F)
R/B
(F)
OSC
R/B
(F)
R/B
(F)
27
INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)
R/B
(F)
44
CLOCK
(SECTION I-2)
G2-13(F2 CARB)
G1-11(WL,WL Turbo)
1E
J-01
F1-03
1F
J-01
F1-03
AUDIO
ILLUMINATION
HAZARD
WARNING
SWITCH
ILLUMINATION
R/G
(F)
R/G
(F)
I1-01
G2-13(F2 CARB)
G1-11(WL,WL Turbo)
CLIMATE
CONTROL UNIT
ILLUMINATION
R/B(F)
B
(F)
R/G
(F)
R/G
(F)
INSTRUMENT
CLUSTER
(SECTION C-1c,2b, 3c)
38
Z-95
R/G
(F)
R/G(F)
R/G(F)
R/G(F)
G/O
R/G
R/G
R/B
J-01 AUDIO ILLUMINATION(F)
1M
1K
1E
1C
1A
L/R
R/B
L/R
L/W
L/Y
L/W
1D
1B
1N
1L
R/G
1J
1H
1F
R/B
B/Y
G/W
G/B
L/Y
G/R
R/G
R/B
WIRING DIAGRAM
HEADLIGHT
SWITCH
39
(SECTION E-1,2, 4)
HARNESS SYMBOL :
(F)
(E)
(R)
HAZARD WARNING
SWITCH ILLUMINATION
F1-03
AUDIO
ILLUMINATION
J-01
Z-96
I1-01
PANEL LIGHT CONTROL SWITCH
G1-11(WL,WL Turbo)
G2-13(F2 CARB)
CLIMATE CONTROL UNIT
ILLUMINATION
WIRING DIAGRAM
Z
I-1
I-2
CIGARETTE LIGHTER / CLOCK / OUTLET / REAR WINDOW DEFROSTER
BATTERY
+
-
W/R(F)
W/R(E)
30A
X-01
X-08
MAIN
X-03
A
B/W(E)
80A
B/W(F)
B/W(E)
X-01
B
B/W(E)
B/W(F)
IG2
ACC
W
(F)
B/W(F)
FUSE
BLOCK
X-03
L
(F)
X-03
FUSE BLOCK
METER
INSTRUMENT CLUSTER
(SECTION C-1c,2b,3c)
ROOM
10A
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
X-02
W(F)
20A
OFF
IG1
FUSE BLOCK
R.DEF
X-03
X-02
ST
X-07
ILLUMINATION
LIGHTS
(SECTION I-1)
X-03
B/Y(F)
15A
X-03
I2-04
45
WIRING DIAGRAM
B(E)
CIGAR
15A
X-03
REAR WINDOW
DEFROSTER
RELAY
44
X-03
I2-04
B/L
(F)
G
(F)
L/W
(F)
L/W
(F)
Z-97
I2-03
I2-05
I2-01 CLOCK(F)
I2-02
I2-01
B
(F)
14
CLOCK
CIGARETTE
LIGHTER
I2-03
B/L(R)
I2-01
I2-02
OUTLET
FILAMENT
I2-06
R/B
(F)
L/W(F)
I2-05
REAR WINDOW
DEFROSTER
SWITCH
X-04
I2-07
L/R
(F)
L/W
(F)
WITH OUTLET
B/L
(F)
I2-03 OUTLET(F)
B
(F)
B
(F)
B
(F)
I2-06 FILAMENT(R)
I2-07 FILAMENT
(SHORT CORD)
B
R/B
L/R
L/W
L/W
B
L/W
B
B/Y
B/L
B/L
B/L
(F)
HARNESS SYMBOL :
(E)
(R)
[BLACK]
(F)-(E)
X-07
[BLACK]
FILAMENT
I2-07
FILAMENT
(F)-(E)
I2-06
X-08
MAIN FUSE BLOCK
X-01
(F)-(R)
X-04
14
Z-98
WL,WL Turbo
REAR WINDOW
DEFROSTER SWITCH
X-01
I2-05
[BLACK]
REAR WINDOW
DEFROSTER RELAY
CLOCK
I2-01
I2-04
4
[WHITE]
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
X-02
X-03
FUSE BLOCK
X-07
I2-03
(F)-(E)
[BLACK]
OUTLET
X-08
(F)-(E)
[BLACK]
X-04
(F)-(R)
I2-02
F2 CARB
CIGARETTE LIGHTER
WIRING DIAGRAM
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
Z
I-2
I-3
INTERIOR LIGHT
FUSE BLOCK
ROOM
W/R(E)
30A
W/R(F)
X-08
X-01
X-03
10A
WIRING DIAGRAM
B(E)
X-01
BATTERY
+
-
X-03
L/R
(F)
X-11
L/R
(IN)
I3-01
65
R/Y(F)
ON
INTERIOR
LIGHT
DOOR
I3-01
INSTRUMENT
CLUSTER
21
(SECTION C-1a,2a,3a)
R/Y
(IN)
R/Y
(F)
X-11
R/Y
(F)
I3-06
R/Y
(F)
X-19
R/Y(FR)
R/Y(FR)
R/Y(F)
R/Y(F)
R/Y(F)
Z-99
X-04
R/Y(R)
I3-05
DOOR
SWITCH
LR
I3-04
DOOR
SWITCH
RR
I3-03
DOOR
SWITCH
LF
R/Y
(R)
R/Y
(R)
R/Y
(FR)
R/Y
I3-02
DOOR
SWITCH
RF
R/Y
(REGULAR CAB)
R/Y
L/R
L/R
(STRETCH CAB)
(DOUBLE CAB)
(SHORT CORD)
R/Y
R/Y
R/Y
R/Y
R/Y
(F)
HARNESS SYMBOL :
(E)
(R)
[BLACK]
(F)-(E)
INTERIOR LIGHT
I3-01
X-08
[BLACK]
DOOR SWITCH RF
X-01
(F)-(IN)
I3-02
X-11
(F)-(R)
X-04
(F)-(FR)
X-19
I3-03
DOOR SWITCH LF
[BLACK]
Z-100
(F)-(IN)
X-11
INTERIOR LIGHT
[BLACK]
DOOR SWITCH RR
I3-01
I3-04
[BLACK]
DOOR SWITCH RF
I3-02
(F)-(IN)
X-11
(F)-(R)
X-04
I3-05
X-19
X-03
FUSE BLOCK
DOOR SWITCH LR
[BLACK]
X-04
(F)-(R)
I3-06
(FR)-SHORT CORD
I3-03
X-19
(F)-(FR)
DOOR SWITCH LF
[BLACK]
WIRING DIAGRAM
(F)-(FR)
Z
I-3
J
AUDIO SYSTEM
BATTERY
+
-
A
B/W(E)
B/W(F)
80A
BTN
X-01
X-07
W/R(E)
30A
X-02
OFF
ST
X-08
X-01
FUSE BLOCK
ROOM
W/R
(F)
L/R(F)
IG1
IG2
WIRING DIAGRAM
B(E)
ACC
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
X-02
L
(F)
10A
CIGAR
L/W(F)
X-03
L/R
(F)
L/W
(F)
1C
1A
15A
X-03
J-01
AUDIO UNIT
3A
Z-101
1K
1L
1M
1N
L
(F)
L/W
(F)
L/R
(F)
L/Y
(F)
J-01
J-04
X-15
B
X-12
L
(DR2)
L/W
(DR2)
L/R
(DR1)
L/Y
(DR1)
J-02
J-03
LH
RH
SPEAKERS
15
1K
1E
1C
1A
L/R
R/B
L/R
L/W
L/Y
L/W
R/G
1N
1L
1J
1H
1F
1D
1B
L/W
L/Y
L/R
(F)
HARNESS SYMBOL :
(E)
[BLACK]
(F)-(E)
(R)
[BLACK]
(F)-(E)
SPEAKER RH
J-03
X-08
X-07
MAIN FUSE BLOCK
X-01
[GREEN]
(F)-(DR1)
X-12
J-02
X-15
SPEAKER LH
Z-102
(F)-(DR2)
[GREEN]
[GREEN]
(F)-(DR1)
AUDIO UNIT
X-12
15
J-04
AUDIO UNIT
J-01
[GREEN]
(F)-(DR2)
X-02
X-03
FUSE BLOCK
WIRING DIAGRAM
X-15
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
Z
J
K-1
POWER WINDOWS (REGULAR CAB, STRETCH CAB)
BATTERY
+
-
A
B/W(F)
B/W(E)
80A
X-01
X-01
X-07
IG1
X-02
OFF
ST
IG2
ACC
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
X-02
X-03
FUSE BLOCK
(P.WIND)
X-03
W(F)
POWER WINDOW MAIN SWITCH
30A
POWER-CUT SWITCH
CLOSE
CLOSE
OPEN
OPEN
K1-01
G/W
(DR1)
AUTO
CIRCUIT
R/L
(F)
R/L
(DR1)
R/W
(DR1)
X-13
R/L
(F)
X-14
G/W
(F)
R/W
(F)
G/W
(DR2)
R/W
(DR2)
R/L
(F)
X-17
X-16
K1-01
R/L
(DR2)
K1-02
Z-103
G/B
(DR1)
B
(DR1)
R/B
(DR1)
CLOSE
OPEN
POWER
WINDOW
SUBSWITCH
K1-02
X-14
B
(F)
G/B
(DR2)
K1-03
M
OPEN
CLOSE
R/B
(DR2)
K1-04
POWER WINDOW
REGULATOR
RH
M
OPEN
CLOSE
POWER WINDOW
REGULATOR
LH
G/B
R/B
R/L
G/W
R/B
R/W
G/B
G/B
R/W
G/W G/B
R/L
R/B
R/B
WIRING DIAGRAM
B(E)
(F)
HARNESS SYMBOL :
(E)
(R)
POWER WINDOW
MAIN SWITCH
[BLACK]
(F)-(E)
[BLUE]
POWER WINDOW
REGULATOR RH
X-07
K1-01
K1-03
X-01
(F)-(DR1)
X-13
K1-02
X-16
(F)-(DR2)
Z-104
X-17
X-14
(F)-(DR2)
(F)-(DR1)
POWER WINDOW
SUBSWITCH LH
K1-04
POWER WINDOW
REGULATOR LH
[BLUE]
(F)-(DR1)
X-13
X-14
(F)-(DR1)
WIRING DIAGRAM
X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
IGNITION SWITCH (F2 CARB)
[WHITE]
(F)-(DR2)
X-16
X-03
FUSE BLOCK
X-17
(F)-(DR2)
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
Z
K-1
K-2
POWER WINDOWS (DOUBLE CAB)
MAIN FUSE BLOCK
MAIN
A
B/W(E)
X-01
80A
X-01
OFF
ST
X-07
FUSE BLOCK
(P.WIND)
IG1
R/L(F)
IG2
30A
ENGINE
SWITCH
ACC
X-02
W(F)
X-03
X-02
B/W(F)
WIRING DIAGRAM
B(E)
BATTERY
+
-
X-03
R/L(F)
POWER WINDOW MAIN SWITCH
POWER-CUT
SWITCH
CLOSE
OPEN
CLOSE
F
OPEN
CLOSE
OPEN
A
K2-01
AUTO
CIRCUIT
CLOSE
OPEN
K2-01
G/W
(DR1)
R/W
(DR1)
R/L
(DR1)
G/W
(F)
R/W
(F)
R/L
(F)
X-14
R/L
(DR1)
W
(DR1)
L/W
(DR1)
W/R
(DR1)
G/Y
(DR1)
W
(F)
L/W
(F)
W/R
(F)
C
G/Y
(F)
W/R
(FR)
G/Y
(FR)
R/L
(FR)
W
(DR4)
L/W
(DR4)
R/L
(DR4)
X-13
R/L(F)
X-14
R/L(F)
X-06
X-20
R/L(F)
R/L
(F)
X-17
B
(DR1)
L/W
(R)
R/L
(R)
W
(DR3)
L/W
(DR3)
R/L
(DR3)
X-16
G/W
(DR2)
Z-105
G/B
(DR1)
W
(R)
R/W
(DR2)
R/L
(DR2)
K2-02
R/B
(DR1)
X-14
CLOSE
OPEN
CLOSE
OPEN
B
(F)
K2-03
M
OPEN
CLOSE
M
OPEN
CLOSE
POWER WINDOW
REGULATOR
LF
CLOSE
OPEN
G/B
(DR4)
R/B
(DR4)
K2-07
M
OPEN
CLOSE
POWER
WINDOW
SUBSWITCH
LR
K2-06
R/B
(DR3)
K2-04
POWER WINDOW
REGULATOR
RF
POWER
WINDOW
SUBSWITCH
RR
K2-05
G/B
(DR3)
R/B
(DR2)
K2-06
K2-05
POWER
WINDOW
SUBSWITCH
LF
K2-02
G/B
(DR2)
X-22
X-21
K2-08
POWER WINDOW
REGULATOR
RR
M
OPEN
CLOSE
POWER WINDOW
REGULATOR
LR
W/R
G/Y
G/W R/W
L/W
R/L
R/B
R/W
G/B
G/B
R/L
G/B
R/B
G/W G/B
R/L
R/B
R/B
G/B
R/L
L/W
R/B
G/B
R/L
L/W
G/B
G/B
R/B
R/B
R/B
HARNESS SYMBOL :
(F)
(E)
(R)
[BLACK]
(F)-(E)
X-07
POWER WINDOW
SUBSWITCH RR
X-01
POWER WINDOW
MAIN SWITCH
K2-05
POWER WINDOW
REGULATOR RR
K2-07
K2-01
(R)-(DR3)
X-21
[BLUE]
POWER WINDOW
REGULATOR RF
K2-03
(F)-(DR1)
X-13
(F)-(R)
K2-08
X-06
POWER WINDOW
REGULATOR LR
Z-106
K2-06
(F)-(DR1)
X-22
X-14
POWER WINDOW
SUBSWITCH LR
(FR)-(DR4)
X-16
(F)-(DR2)
(F)-(DR1)
X-20
K2-02
POWER WINDOW
SUBSWITCH LF
(F)-(FR)
X-13
X-17
X-14
(F)-(DR1)
(F)-(DR2)
K2-04
POWER WINDOW
REGULATOR LF
[BLUE]
WIRING DIAGRAM
X-02
ENGINE SWITCH (WL,WL Turbo)
[WHITE]
(F)-(DR2)
X-16
X-03
FUSE BLOCK
X-17
X-06
(F)-(R)
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
(F)-(DR2)
X-20
(F)-(FR)
K-2
K-3
POWER DOOR LOCKS
MAIN FUSE BLOCK
FUSE BLOCK
(D/L)
MAIN
B/W(E)
80A
X-01
B/W(F)
X-07
X-01
DOUBLE CAB
30A
X-03
X-03
G(F)
WITH THEFT-DETERRENT
SYSTEM
THEFT-DETERRENT
CONTROL MODULE 64
(SECTION T-2,4)
G(F)
G
(F)
G
(F)
G
(F)
G/O
(F)
W/G
(F)
G/O(F)
X-04
G
(FR)
X-17
X-21
K3-01
X-14
G
(DR2)
K3-03
LOCK
G
(DR4)
K3-04
K3-05
LOCK
LOCK
DOOR
LOCK-LINK
SWITCH
X-22
G
(DR3)
K3-02
UNLOCK
X-19
G
(R)
G
(F)
G/R(F)
G/O G/R
(DR1) (DR1)
WIRING DIAGRAM
B(E)
BATTERY
+
M
DOOR LOCK
TIMER UNIT
LOCK
M
UNLOCK
UNLOCK
UNLOCK
K3-02
G/Y
(DR1)
R
(DR3)
R
(DR2)
K3-01
X-14
DOOR LOCK
ACTUATOR
RR
K3-04
DOOR LOCK
ACTUATOR
LF
K3-03
R
(DR4)
X-21
Z-107
X-17
B
(F)
G/Y
(F)
G/Y
(F)
R
(F)
X-22
R
(R)
R
(FR)
R
(F)
X-04
X-19
R
(F)
G/Y(F)
G/O
G/R
W/G
G/O
R(F)
G/Y
G
G/Y
R
(F)
R(F)
G/R
B
G
LG/R
(WITHOUT
THEFT-DETERRENT
SYSTEM)
B
R
LG/R
(WITHOUT
THEFT-DETERRENT
SYSTEM)
(WITH
THEFT-DETERRENT
SYSTEM)
DOOR LOCK
ACTUATOR
LR
K3-05
(WITH
THEFT-DETERRENT
SYSTEM)
HARNESS SYMBOL :
(F)
(E)
(R)
DOOR LOCK
ACTUATOR RR
K3-04
[BLACK]
(F)-(E)
DOOR LOCK-LINK
SWITCH
X-07
K3-02
(R)-(DR3)
X-21
X-01
(F)-(R)
X-04
K3-05
DOOR LOCK
ACTUATOR LR
X-22
(FR)-(DR4)
K3-03
X-17
Z-108
X-14
DOOR LOCK
ACTUATOR LF
(F)-(DR2)
(F)-(DR1)
X-19
(F)-(FR)
DOOR LOCK TIMER UNIT
K3-01
3
X-14
(F)-(DR1)
X-17
WIRING DIAGRAM
X-03
FUSE BLOCK
X-04
(F)-(R)
(F)-(DR2)
X-19
(F)-(FR)
Z
K-3
L
POWER OUTSIDE MIRRORS
BATTERY
+
-
A
B/W(E)
80A
X-01
B/W(F)
X-01
X-07
RIGHT
X-02
OFF
ST
LEFT
IG1
IG2
ACC
UP
DOWN
X-02
DOWN
UP
LEFT
LH
POWER
OUTSIDE
MIRROR
SWITCH
RIGHT
LH
RH
RH
L-01
L
(F)
BR
(F)
L/B
(F)
BR/Y
(F)
BR
(F)
BR
(F)
LG/B
(F)
BR/B
(F)
Z-109
X-16
B
(F)
BR/Y
(DR2)
BR
(DR1)
LEFT
UP
RIGHT
DOWN
FUSE BLOCK
CIGAR
BR/B
(DR1)
LG/B
(DR1)
X-03
L-02
L-03
L/W
(F)
X-13
BR
(DR2)
L/B
(DR2)
POWER
OUTSIDE
MIRROR
LH
UP
LEFT
DOWN
RIGHT
POWER
OUTSIDE
MIRROR
RH
BR
B
L/W
LG/B
L/B
LG/B
BR/Y
BR/B
BR/B
BR
IGNITION SWITCH
(F2 CARB)
ENGINE SWITCH
(WL,WL Turbo)
L/B
BR/Y
BR
15A
X-03
WIRING DIAGRAM
B(E)
HARNESS SYMBOL :
(F)
(E)
(R)
POWER OUTSIDE
MIRROR RH
[BLACK]
(F)-(E)
L-02
X-07
MAIN FUSE BLOCK
X-01
(F)-(DR1)
X-13
L-03
Z-110
POWER OUTSIDE
MIRROR LH
X-16
(F)-(DR2)
(F)-(DR1)
X-13
L-01
POWER OUTSIDE
MIRROR SWITCH
X-02
(F)-(DR2)
X-16
WIRING DIAGRAM
X-02
X-03
FUSE BLOCK
Z
L
WIRING DIAGRAM
RIGHT
RIGHT
*The references in this section can be found in Repair Manual [F161-10-99A (1999-1)]
Z-111
WRONG
WRONG
WIRING DIAGRAM
Component Handling
Component Reusing
*The references in this section can be found in Repair Manual [F160-10-99A (1999-1)]
Z-112
S-1
80A
B/W(F)
A
X-07
X-01
IG1
X-02
OFF
ST
IG2
WIRING DIAGRAM
B/W(E)
B(E)
X-01
ENGINE
SWITCH
ACC
FUSE BLOCK
METER
X-02
W(F)
B/Y(F)
B/Y(F)
15A
X-03
ENGINE
B/W(F)
15A
B/W(F)
S1-02
X-03
S1-01
Z
AB
SAS UNIT
S
AA
R/G
(F)
Y/G
(F)
L
(F)
LG
(F)
R
(F)
Y/R
(F)
B
(F)
B
(F)
S1-01
S1-03
SHORT BAR
S1-02
R/G
(F)
B
(F)
Y/G
(F)
SHORT
BAR
S1-04
LG
Z-113
CLOCK
SPRING
Y/G
(F)
Y/G
(F)
47
25
SHORT
BAR
LG
S1-05
INFLATOR
46
PASSENGER-SIDE
AIR BAG MODULE
SHORT BAR
INSTRUMENT CLUSTER
(SECTION C-1b)
WITH
PASSENGER-SIDE
AIR BAG MODULE
INFLATOR
DRIVER-SIDE
AIR BAG MODULE
8
W
AA
G/R
Y/G
LG
Y/R
Y/G
Y/G
B/Y
B/W
R/G
R/G
AB
B/W
B/W
B/Y
(CLOCK SPRING)
G/R
LG
R/G
BATTERY
+
-
Y/R
LG
LG
HARNESS SYMBOL :
(F)
(E)
(R)
[BLACK]
(F)-(E)
X-07
X-01
Z-114
7
(F)-(CLOCK SPRING)
S1-03
SHORT CONNECTOR
S1-02
PASSENGER-SIDE
AIR BAG MODULE
S1-05
S1-04
DRIVER-SIDE
AIR BAG MODULE
X-02
X-02
ENGINE SWITCH (WL,WL Turbo)
[BLUE]
IGNITION SWITCH (F2 CARB)
[BLUE]
8
9
S1-01
SAS UNIT
WIRING DIAGRAM
X-03
FUSE BLOCK
Z
S-1
S-2
AIR BAG SYSTEM (WL-3, WLT-3, as of model year 2002)
BATTERY
+
MAIN
B/W(E)
80A
X-01
X-01
B/W(F)
X-07
IG1
X-02
OFF
ST
IG2
WIRING DIAGRAM
B(E)
ENGINE
SWITCH
ACC
X-02
METER
W(F)
B/Y(F)
X-03
B/Y(F)
15A
ENGINE
B/W(F)
15A
B/W(F)
S2-02
X-03
S2-01
Z
AB
SAS UNIT
Q
L
(F)
LG
(F)
R
(F)
Y/R
(F)
S2-01
Y/G
(F)
S2-03
SHORT BAR
B
(F)
S2-02
Z-115
Y/G
(F)
SHORT
BAR
S2-04
LG
CLOCK
SPRING
B
(F)
SHORT
BAR
LG
S2-05
INFLATOR
25
PASSENGER-SIDE
AIR BAG MODULE
SHORT BAR
INSTRUMENT
CLUSTER
(SECTION C-3b)
WITH
PASSENGER-SIDE
AIR BAG MODULE
INFLATOR
8
S2-01 SAS UNIT(F)
DRIVER-SIDE
AIR BAG MODULE
W
AA
G/R B/Y
C
Y/G
LG
Y/R
B/W Y/G
AB
LG
R
S2-04 PASSENGER-SIDE AIR BAG MODULE(F)
B/Y B/W
G/R
(CLOCK SPRING)
Y/R
LG
LG
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
X-01
(F)-CLOCK SPRING
S2-03
Z-116
7
SHORT CONNECTOR
[YELLOW]
PASSENGER-SIDE
AIR BAG MODULE
[YELLOW]
DRIVER-SIDE
AIR BAG MODULE
S2-02
S2-05
S2-04
X-07
(F)-(E)
[BLACK]
X-02
ENGINE SWITCH
[WHITE]
WIRING DIAGRAM
X-02
X-03
ENGINE SWITCH
[BLUE]
FUSE BLOCK
S2-01
SAS UNIT
Z
S-2
From No.
F175-30-01I
T-1
BATTERY
+
-
X-01
X-01
MAIN
A
B/W(F)
B/W(F)
80A
X-07
WIRING DIAGRAM
B(E)
X-02
BTN
W/R(E)
W/R(F)
30A
INSTRUMENT
CLUSTER
(SECTION C-1a)
X-08
FUSE BLOCK
ROOM
IG1
L/R(F)
10A
FUSE BLOCK
ENGINE
X-03
IG2
ENGINE
SWITCH
ACC
X-02
W/R(F)
51
OFF
ST
X-03
W(F)
15A
X-03
BR/B
(F)
L/R
(F)
B/W
(F)
X-03
T1-01
IMMOBILIZER UNIT
C
COIL
D
T1-02
T1-01
B/R
(F)
V/W
(F)
B/W(F)
GY(F)
Y(F)
B2-09
Z-117
FUEL
INJECTION
PUMP
DDS1
49
PCM
(SECTION B-2a)
B2-09
B/R
(F)
16
T1-02 COIL(F)
I
B/R
BR/B
V/W
GY
B/W
N
L/R
J
GY
R/L
B/R
G/W B/W
BR/W
L/B
B/R
F
V/W
(F)
HARNESS SYMBOL :
(E)
(R)
6
MAIN FUSE BLOCK
X-01
Z-118
X-07
(F)-(E)
[BLACK]
X-08
(F)-(E)
[BLACK]
COIL
T1-02
B2-09
FUEL INJECTION PUMP
[GRAY]
16
X-02
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
[BLUE]
T1-01
IMMOBILIZER UNIT
WIRING DIAGRAM
ENGINE SWITCH
[WHITE]
Z
T-1
T-2
X-01
B/W
(E)
BTN
B/W(F)
X-01
X-07
X-08
B/W
(F)
FUSE BLOCK
61
G/R(F)
T2-02
THEFTDETERRENT
RELAY
15A
X-03
G/W
(F)
A
T2-03
THEFTDETERRENT
HORN RELAY
X-03
HAZARD
WARNING
SWITCH
(SECTION
F-1)
IG1
IG2
X-02
ENGINE
SWITCH
FUSE BLOCK
ENGINE
ACC
15A
ROOM
10A
X-03
KEY LEMINDER
SWITCH
(SECTION
C-1a)
TURN SWITCH
(SECTION F-1)
W(F)
X-03
G/W(F)
15A
X-03
X-02
OFF
X-03
STOP
L/Y(F)
L/Y
(F)
W/R
(F)
W/R
(F)
FUSE BLOCK
HAZARD
L/Y
(F)
ST
W/R(F)
W/R(E)
30A
X-07
DOOR LOCK
TIMER UNIT
(SECTION
K-3)
INTSRUMENT
CLUSTER
(SECTION
C-1a)
60
59
58
64
56
G/B
(F)
G/W
(F)
L/Y
(F)
G/O
(F)
BR/B
(F)
2K
2Q
X-03
FUSE
BLOCK
B/W
(F)
X-03
L/R
(F)
T2-01
T2-03
T2-02
P/L(F)
Y/R(F)
2D
1A
1D
1E
THEFT-DETERRENT CONTROL MODULE
2O
1B
2C
2S
1F
2N
2M
1C
2R
T2-01
T2-01
G/Y
(F)
LG/R(F)
GY/B
(F)
BR/W
(F)
B
(F)
LG/R
(FR)
LG/R
(R)
Z-119
FLASHER UNIT
(SECTION F-1)
T2-04
T2-05
THEFT-DETERRENT
HORN
BONNET
SWITCH
T2-04
B
(F)
X-23
K3-04
DOOR
LOCK-LINK
SWITCH LR
K3-05
DOOR
LOCK-LINK
SWITCH RR
K3-04
X-24
X-14
B
(F)
B
(F)
B(F)
65
DOOR SWITCHS
(SECTION I-3)
B
(DR1)
X-17
B(R)
63
FLASHER UNIT
(SECTION F-1)
T2-06
T2-07
B
(DR2)
X-23
B
(FR)
DOOR KEY
CCYLINDER
SWITCH
RF
DOOR KEY
CCYLINDER
SWITCH
LF
B
(DR3)
B
(DR4)
T2-06
T2-07
K3-05
R/Y
(F)
G/O
(F)
BR/R
(DR1)
BR/R
(DR2)
LG/R
(DR3)
LG/R
(DR4)
X-14
X-17
X-24
62
BR/R(F)
X-04
X-19
X-04
3
17
DOUBLE CAB
T2-01 THEFT-DETERRENT CONTROL MODULE(F)
1F
1E
G/W
1D
1C
G/B
G/O
1B
1A
L/R
B/W
2M
2S
2Q
2O
Y/R
BR/B
BR/R
2T
BR/R
2R
(LG/R)
2G
G/O
2P
BR/R
2N
2C
2A
P/L
2L
2J
2H
2F
2D
T2-02 THEFT-DETERRENT
RELAY(F)
L/Y
G/W
G/W
G/W
Y/R
GY/B
G/Y
G/R
T2-03 THEFT-DETERRENT
HORN RELAY(F)
C
L/Y
L/Y
BR/W
2I
2E
R/Y
2K
2B
LG/R
LG/R
P/L
BR/W
T2-05 THEFT-DETERRENT
HORN(F)
GY/B
WIRING DIAGRAM
B(E)
( )...DOUBLE CAB
BATTERY
+
-
(F)
HARNESS SYMBOL :
(E)
(R)
(R)-(DR3)
[BLACK]
BONNET
SWITCH
X-23
THEFT-DETERRENT
HORN RELAY
DOOR LOCK-LINK
SWITCH RR
K3-04
T2-03
T2-06
T2-04
MAIN FUSE BLOCK
(F)-(R)
X-01
X-04
K3-05
DOOR LOCK-LINK
SWITCH LR
X-24
(FR)-(DR4)
17
X-14
T2-07
(F)-(DR1)
X-17
Z-120
X-19
(F)-(DR2)
(F)-(FR)
T2-05
[BLACK]
THEFT-DETERRENT
CONTROL MODULE
THEFT-DETERRENT HORN
T2-01
X-07
(F)-(E)
[BLACK]
X-08
(F)-(DR1)
(F)-(E)
[BLACK]
X-14
T2-01
THEFT-DETERRENT
CONTROL MODULE
WIRING DIAGRAM
X-02
ENGINE SWITCH
[WHITE]
THEFT-DETERRENT
RELAY
T2-02
X-02
X-03
FUSE BLOCK
X-04
ENGINE SWITCH
[BLUE]
(F)-(R)
X-17
(F)-(DR2)
X-19
(F)-(FR)
T-2
T-3
IMMOBILIZER SYSTEM (WL-3, WLT-3, as of model year 2002)
X-01
X-01
A
B/W(F)
B(E)
80A
WIRING DIAGRAM
MAIN
BATTERY
+
B/W(F)
A
X-07
X-02
BTN
W/R(E)
30A
W/R(F)
OFF
ST
X-08
IG1
IG2
ENGINE
SWITCH
ACC
X-02
W
(F)
X-03
X-03
ROOM
10A
X-03
ENGINE
15A
X-03
L/R
(F)
B/W
(F)
T3-01
IMMOBILIZER UNIT
C
B/R
(F)
W
(F)
R
(F)
BR/B
(F)
P
(F)
Y
(F)
GY
(F)
70
66
51
73
PCM
(SECTION B-6b)
STARTER
RELAY
(SECTION A-3)
INSTRUMENT
CLUSTER
(SECTION C-3a)
KEY REMINDER
SWITCH
(SECTION C-3a)
T3-01
Z-121
T3-02
20
T3-01 IMMOBILIZER UNIT(F)
M
BR/B
T3-02 COIL(F)
I
B/W
L/R
GY
B/R
W
GY
COIL
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
[BLACK]
(F)-(E)
(R)
(F)-(E)
X-08
X-07
MAIN FUSE BLOCK
X-01
20
Z-122
COIL
T3-02
X-02
ENGINE SWITCH
[WHITE]
WIRING DIAGRAM
X-02
X-03
ENGINE SWITCH
[BLUE]
FUSE BLOCK
T3-01
IMMOBILIZER UNIT
Z
T-3
From No.
F175-30-01I
T-4
THEFT-DETERRENT SYSTEM (WL-3, WLT-3, as of model year 2002)
BATTERY
+
MAIN
B/W(E)
80A
X-01
BTN
B/W(F)
W/R(E)
30A
X-01
X-03
HAZARD
61 WARNING
G/R(F)
SWITCH
T4-02
(SECTION
THEFTF-3)
DETERRENT
RELAY
T4-02
Y/R(F)
ENGINE
SWITCH
ENGINE
X-02
2S
KEY LEMINDER
SWITCH
(SECTION
C-3a)
TURN SWITCH
(SECTION F-3)
ACC
W(F)
15A
X-03
DOOR LOCK
TIMER UNIT
(SECTION
K-3)
INTSRUMENT
CLUSTER
(SECTION C-3a)
60
59
58
64
56
G/B
(F)
G/W
(F)
P
(F)
G/O
(F)
BR/B
(F)
2K
2Q
X-03
ROOM
10A
15A
X-03
X-03
G/W
(F)
A
T4-03
THEFTDETERRENT
HORN RELAY
T4-03
P/L(F)
2C
15A
IG2
X-03
G/W(F)
X-03
X-02
OFF
IG1
W/R
(F)
W/R
(F)
STOP
L/Y(F)
L/Y L/Y
(F)
(F)
A
E
X-08
B/W
(F)
HAZARD
ST
W/R(F)
X-07
X-07
B/W
(E)
B/W
(F)
X-03
L/R
(F)
T4-01
1A
2D
1D
1E
THEFT-DETERRENT CONTROL MODULE
2O
1B
1F
2N
2M
2R
1C
T4-01
T4-01
G/Y
(F)
LG/R(F)
X-19
GY/B
(F)
B
(F)
BR/W
(F)
LG/R
(FR)
62
Z-123
T4-04
T4-05
THEFT-DETERRENT
HORN
B
(F)
B
(DR4)
X-24
BR/R
(DR1)
T4-07
K3-04
DOOR
LOCK-LINK
SWITCH RR
K3-04
T4-06
DOOR KEY
CCYLINDER
SWITCH
LF
T4-07
B
(DR2)
B
(DR3)
X-23
B
(FR)
X-14
BR/R
(DR2)
LG/R
(DR3)
K3-05
DOOR
LOCK-LINK
SWITCH LR
K3-05
T4-04
X-17
X-23
LG/R
(DR4)
BONNET
SWITCH
BR/R(F)
LG/R
(R)
X-24
FLASHER UNIT
(SECTION F-3)
BR/R
(F)
X-04
DOOR KEY
CCYLINDER
SWITCH
RF
T4-06
B
(DR1)
X-17
B(R)
B(F)
R/Y
(F)
G/O
(F)
65
63
FLASHER UNIT
(SECTION F-3)
DOOR SWITCHS
(SECTION I-3)
X-14
B
(F)
B
(F)
X-04
3
17
DOUBLE CAB
T4-01 THEFT-DETERRENT CONTROL MODULE(F)
1F
1E
G/W
1D
1C
2S
1B
2Q
2O
BR/R
2I
2G
2E
2R
2N
BR/R
2A
2L
2J
2H
2F
2D
T4-02 THEFT-DETERRENT
RELAY(F)
E
L/Y
BR/W
2P
2C
P/L
2T
2K
1A
B/W
R/Y
T4-06 DOOR KEY CYLINDER
SWITCH RF(DR1)
2M
G/Y
G/R
L/Y
G/W
G/W
G/W
Y/R
2B
LG/R
LG/R
T4-03 THEFT-DETERRENT
HORN RELAY(F)
GY/B P/L
BR/W
GY/B
WIRING DIAGRAM
B(E)
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
THEFT-DETERRENT
HORN RELAY
THEFT-DETERRENT
RELAY
T4-02
[BLACK]
BONNET
SWITCH
T4-03
DOOR LOCK-LINK
SWITCH RR
T4-04
K3-04
(R)-(DR3)
DOOR KEY CYLINDER
SWITCH RF
X-23
T4-06
X-01
(F)-(R)
X-04
K3-05
DOOR LOCK-LINK
SWITCH LR
X-24
(FR)-(DR4)
Z-124
X-14
17
(F)-(DR1)
X-07
T4-07
(F)-(E)
[BLACK]
T4-05
X-08
X-17
[BLACK]
THEFT-DETERRENT
CONTROL MODULE
THEFT-DETERRENT HORN
T4-01
(F)-(E)
X-19
3
(F)-(DR2)
(F)-(FR)
5
4
(F)-(DR1)
X-14
T4-01
THEFT-DETERRENT
CONTROL MODULE
WIRING DIAGRAM
X-02
ENGINE SWITCH
[WHITE]
X-02
ENGINE SWITCH
[BLUE]
X-03
X-04
(F)-(R)
FUSE BLOCK
X-19
X-17
(F)-(DR2)
(F)-(FR)
T-4
From No.
F175-30-01I
BATTERY
+
X-01
80A
B/W(F)
A
X-07
X-01
X-02
OFF
ST
IG1
WIRING DIAGRAM
B/W(E)
B(E)
IG2
ENGINE
SWITCH
ACC
FUSE BLOCK
METER
X-02
W(F)
15A
X-03
12
BR/R(F)
10
Y/B(F)
X-03
PCM
(SECTION B-2b)
B/Y(F)
Y/G(F)
47
R/G(F)
46
SAS UNIT
(SECTION S-1)
U-01
DATA LINK
CONNECTOR
Z-125
B
(F)
B/R
(F)
WL,WL Turbo
FEN
TEN
+B
GND
FAB
Y/B
BR/R
B/Y
B/R
GND
TAB
Y/G
R/G
HARNESS SYMBOL :
(F)
(E)
(R)
[BLACK]
(F)-(E)
X-07
X-01
U-01
Z-126
2
X-02
ENGINE SWITCH
[WHITE]
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BLUE]
X-03
FUSE BLOCK
Z
U
U-2
MAIN
B(E)
B/W(E)
X-01
80A
X-01
B/W(F)
X-07
X-02
OFF
ST
IG1
WIRING DIAGRAM
BATTERY
+
IG2
ENGINE
SWITCH
ACC
X-02
METER
W(F)
X-03
PCM
(SECTION B-6b)
12
BR/R(F)
69
Y/R(F)
10
B/Y(F)
15A
X-03
B/Y
(F)
INSTRUMENT
47
CLUSTER
(SECTION C-3b)
Z-127
B/R
(F)
PCM
68
(SECTION B-6b)
Y/G(F)
U2-01
DATA LINK
CONNECTOR
B
(F)
W/L(F)
20
TEN
+B
B/Y
D
BR/R
Y/R
B/R
Y/G W/L
B/Y
From No.
F175-30-01I
HARNESS SYMBOL :
(F)
(E)
(R)
X-01
U2-01
DATA LINK CONNECTOR
20
Z-128
X-07
(F)-(E)
[BLACK]
X-02
2
ENGINE SWITCH
[WHITE]
X-03
FUSE BLOCK
WIRING DIAGRAM
X-02
ENGINE SWITCH
[BLUE]
Z
U-2
From No.
F175-30-01I
X-1
WITH
AIR CONDITIONER
(R)
30A
1
R
R
30A
W/R
30A
B/W
R/B
80A
10A
B/W
B
60A
15A
B/R
LG/R
10A
L/Y
10
W/G
11
B/R
40A
17
A
30A
B/W B/W
15A
L/W
18
(A/C)
12
HAZARD
13
(D/L)
14
METER
R.DEF
-
15
ENGINE
16
STOP
17
(HEATER)
TAIL
ROOM
18
WIPER
-
20
B/W
20A
12
19
13
20
9
10
11
B/W
B/Y
15A
G/W
B/Y
14
15A
L
HEAD
BTN
MAIN
B/R
W/R
GLOW
10A
Y/R
10A
L/R
B/W
16
30A
R/L
R.FOG
22
(P.WIND)
22
R/Y
21
WITH
REAR FOG LIGHT
15
15A
CIGAR
-
21
W
1
19
10A
R/G
21
X-04 FRONT(F)-REAR(R)
WL,WL Turbo
W/G R/W
R/Y
(F)
B/L
<G>
BR
(R)
B
<R>
(LG/R)
R/L]
R/B
G/W G/B
G/R
( L G / R ) ((B R))
[R/L]
B/L
(B)
R/Y
R/L
G/B
G/W R/B
<R>
<G>
B/L
(F)
(R)
L/W
R/L
(F)
W
L/W
W/G R/W
R/B
R/Y
BR
R/Y
G/W G/B
G/R
(R)
Y
G/B
G/W R/B
B/L
X-07 FRONT(F)-ENGINE(E)
X-06 FRONT(F)-REAR(R)
B/O
(F)
B/W B/W
(E)
Z-129
B/R
F2 CARB
]...U.K. SPECS.
B/W B/W
(F)
B/Y
W/R
R/W
(R/L)
W/R
B/Y
(E)
(Y/R)
(R/W)
(R/W) (Y/R)
R/W
(R/L)
( )...F2 CARB
WIRING DIAGRAM
R/Y
L/Y
(F)
WL,WL-T.WITHOUT RFW
(F)
(F)
R/L
BR/B
LG/B
BR
(F)
(F)
L/R
F2 CARB
WL,WL-T,WITH RFW
L/R
(F)
I
Y/R
(R/G)
W/B
B/Y
L/W
W
G/R
B/R
Y/R
<GY/R>
R/G
W/B
B/Y
LG/B
L/W
W
G/R
B/R
B/W
B/L
W/B
B/Y
GY/R
B/W
Y/B
L/W
R/Y
BR/B
L/Y
(IN)
(DR1)
(DR1)
L/R
BR
L/R
(R/L)
LG/B
(E)
(E)
I
B/R
<GY/R>
B/Y
G/R
Y/R
W/B
L/W
(R/G)
B/R
GY/R
B/Y
G/R
W/B
L/W
R/G
Y/R
B/O
B/Y
L
LG/B
W/B
L/W
B/L
Y/B
B/W
[BR/R] <G/Y>
(F)
<W/R>
B/W
<W>
BR/Y
(F)
L/B
BR/Y
(R/L)
(DR2)
BR
(DR2)
G/W
[BR/R]
G/B
(R/L)
(R)
B/R
G/R
W/G
L/W
(F)
<W>
G/Y
G/R
<L/W>
G/O
<G/Y>
L/W
[BR/R]
(DR2)
L
R/B
R/W
G/W
<G/R>
<R>
(F)
(R2)
<G/R>
G/B
G/W
R/B
W/G B/R
<R>
(FR)
[LG/R]
DOUBLE CAB
[LG/R]
(R/L)
R/W
(G/W) (R/W)
((R/Y))
<G>
R/Y
<G>
DOUBLE CAB
G/Y
(F)
W/R
R/L
L/W
L/W
R/L
(R)
G/Y
W/R
L/W
(R)
LG/R
(FR)
(DR4)
LG/R
R/L
(FR)
G/Y
(FR)
R/L
W/R
(DR3)
R/L
(DR4)
(DR3)
LG/R
LG/R
R/L
WIRING DIAGRAM
X-20 FRONT(F)-FLOOR(FR)
[B]
[B]
L/B
BR/R]
R/W
BR
Z-130
R/L
(F)
G/W G/O
R/W
G/Y
K
<L/W>
(DR1)
Z
X-2
X-3
3
10A LG/R
R
R
W/R
30A
30A
R/B
80A
60A
B/W B/W
15A
B/R
B/R 40A
17
4
5
10
30A
W/G
11
20A
12
19
15A
L/W
13
20
14
15A
L/W
18
7
8
B/W
9
10
11
B/W
L
1
HEAD
BTN
MAIN
B/Y
15A
B/R
Z-131
(R)
B
<LG/R>
R/Y
R/L
16
30A
R/L
R/L
X-07 FRONT(F)-ENGINE(E)
(F)
W
L/W
L/W
(E)
B/W B/W
(F)
<LG/B>
W/B
G/B
<GY/R>
L/W
(F)
B/R
(F)
BR/B
BR/R G/Y
G/Y L/W
K
<GY/R>
(E)
L/W
Y/R BR/Y
B/R
G/B
21
22
22
(DR1)
<R/G>
(E)
<LG/B>
< >...4X4
G/Y
<G/Y>
BR/R
G/Y BR/W
BR/B
<L/W>
( )...NOT USED
B/L
W/R
R/W
W/R
B/L
R/W
(E)
<W/R>
W/B B/Y
19
20
X-10 FRONT(F)-ENGINE(E)
B/Y
18
(F)
BR/Y Y/R
16
17
21
B/W B/W
(R)
X-09 FRONT(F)-ENGINE(E)
<R/G>
15
X-08 FRONT(F)-ENGINE(E)
(F)
R/L
(BR)
14
METER
ENGINE
HEATER
CIGAR
R.FOG
P.WIND
15
B/W 15A
R/L
R/Y LG/R
W/G R/W
13
X-06 FRONT(F)-REAR(R)
L/R
10A
(F)
G
GLOW
X-04 FRONT(F)-REAR(R)
B/R
B/Y 15A
12
B/L
G/W
A/C
HAZARD
D/L
R.DEF
FIP
STOP
TAIL
ROOM
WIPER
-
WIRING DIAGRAM
From No.
F175-30-01I
BR/R
(F)
R/W G/W
BR/R
B
R
R/L
G/W R/W
G/B (G/R)
(R)
B/R W/G R/B R/W G/W
(DR2)
G
X-19 FRONT(F)-FLOOR(FR)
G/B
Z-132
(R)
(DR3)
R/Y
(LG/R)
R/L
(R2)
Y
B/R
(R)
(FR)
(LG/R)
(
X-23 REAR(R)-DOOR No.3(DR3)
R
(F)
)...NOT USED
R/Y
(G)
( )...DOUBLE CAB
LG/R
LG/R
(FR)
(DR4) LG/R
LG/R
WIRING DIAGRAM
Z
X-4
From No.
F175-30-01I
PARTS INDEX
4
H
4X4 INDICATOR SWITCH...............................Z-49,91,93
A
A/C RELAY .......................................................Z-85,87
A/C SWITCH.....................................................Z-85,87
AUDIO ILLUMINATION .........................................Z-95
AUDIO UNIT..........................................................Z-101
B
BACK-UP LIGHTS.................................................Z-79,83
BACK-UP LIGHT SWITCH....................................Z-79,83
BLOWER MOTOR............................................Z-85,87
BONNET SWITCH.................................................Z-119
BRAKE FLUID LEVEL SENSOR......................Z-49,55
BRAKE LIGHTS.....................................................Z-79,83
BRACK SWITCH...................................................Z-79,83
I
IGNITION COIL .....................................................Z-35
IMMOBILIZER UNIT..............................................Z-117
INSTRUMENT CLUSTER.................Z-47,49,51,53,55
INTERIOR LIGHT ..................................................Z-99
K
CARBURETOR......................................................Z-37
CHECK CONNECTOR ..........................................Z-35
CIGARETTE LIGHTER..........................................Z-97
CLIMATE CONTROL UNIT ..............................Z-85,87
CLIMATE CONTORL UNIT ILLUMINATION .........Z-95
CLOCK ..................................................................Z-97
CLOCK SPRING....................................................Z-113
COIL......................................................................Z-117
L
LICENSE PLATE LIGHTS.....................................Z-71,75
LOCK SOLENOID .................................................Z-91
M
MAGNETIC CLUTCH .......................................Z-85,87
N
DATA LINK CONNECTOR....................................Z-125
DOOR KEY CYLINDER SWITCH..........................Z-119
DOOR LOCK ACTUATORS..................................Z-107
DOOR LOCK TIMER UNIT....................................Z-107
DOOR LOCK-LINK SWITCH............................Z-107,119
DOOR SWITCHES ................................................Z-99
DRIVER-SIDE AIR BAG MODULE........................Z-113
NE SENSOR.....................................................Z-27,31
NEUTRAL SWITCH...............................................Z-91
NOISE FILTER ......................................................Z-35
O
OIL PRESSURE SWITCH................................Z-47
OUTLET.................................................................Z-97
P
EGR SOLENOID VALVE.......................................Z-33
ENGINE COOLANT TEMPERATURE SENSOR..........
..........................................................................Z-27,31
F
FAST IDLE CAM BREAKER SOLENOID VALVE
...............................................................................Z-37
FICD SOLENOID VALVES..........................Z-27,31,87
FILAMENT .............................................................Z-97
FLASHER UNIT.....................................................Z-77,81
FREE SOLENOID..................................................Z-91
FRONT SIDE TURN LIGHTS................................Z-77,81
FRONT TURN LIGHTS.........................................Z-77,81
FUEL GAUGE SENDER UNIT ..............................Z-39
FUEL INJECTION PUMP............................Z-27,31,117
FUEL PUMP RELAY .............................................Z-39
G
GENERATOR ...................................................Z-21,23
GLOW PLUG ....................................................Z-27,31
GLOW PLUG RELAY .......................................Z-27,31
R
REAR FOG LIGHT................................................Z-71,75
REAR FOG LIGHT RELAY....................................Z-71,75
REAR FOG LIGHT SWITCH.................................Z-71,75
REAR TURN LIGHT..............................................Z-77,81
Z-133
PARTS INDEX
REAR WINDOW DEFROSTER RELAY ................Z-97
REAR WINDOW DEFROSTER SWITCH..............Z-97
REFRIGERANT PRESSURE SWITCH ............Z-85,87
RESISTOR........................................................Z-85,87
RFW CONTROL MODULE....................................Z-91
RFW MAIN SWITCH .............................................Z-91
RFW SWITCH .......................................................Z-91
S
SAS UNIT..............................................................Z-113
SEDIMENTOR SWITCH........................................Z-47
SHORT CONNECTOR ....................................Z-79,113
SPEAKERS...........................................................Z-101
STARTER .........................................................Z-21,23
T
TAILLIGHTS..........................................................Z-71,75
THEFT-DETERRENT CONTROL MODULE.........Z-119
THEFT-DETERRENT HORN................................Z-119
THEFT-DETERRENT HORN RELAY....................Z-119
THEFT-DETERRENT RELAY...............................Z-119
THEFT-DETERRENT UNIT...................................Z-119
THERMOSWITCH ............................................Z-85,87
TURN SWITCH......................................................Z-77,81
V
VACUUM SWITCH ................................................Z-49
VEHICLE SPEEDOMETER SENSOR..............Z-47,53
W
WATER TEMPERATURE SENDER UNIT .......Z-47,53
WATER THERMOSWITCH ...................................Z-37
WINDSHIELD WASHER MOTOR .........................Z-63
WINDSHIELD WIPER AND WASHER SWITCH ..........
...............................................................................Z-63
WINDSHIELD WIPER MOTOR .............................Z-63
Z-134
SECTION TITLE
RANGER
2003
Righthanddrive
(RHD)
Wiring Diagrams
FOREWORD
This manual has been prepared to provide
information covering normal service repairs and
maintenance for the RANGER series.
SECTION
General Information
GI
Ground points
Schematic
A~U
Connectors
Parts index
PI
Wire colours
Colour
Code
Colour
Code
Black
Orange
Blue
Pink
Brown
BR
Purple
Dark blue
DL
Red
Dark green
DG
Sky blue
Green
PU
R
SB
Tan
Grey
GY
Violet
Light blue
LB
White
Light green
LG
Yellow
Natural
TABLE OF CONTENTS
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
GROUND POINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ELECTRICAL WIRING SCHEMATIC . . . . . . . . . . . 16
ENGINE-RELATED SYSTEMS
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . .
STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
ENGINE CONTROL SYSTEM . . . . . . . . . . . . . .
GLOW SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
20
20
CHASSIS-RELATED SYSTEMS
REMOTE FREEWHEEL CONTROL
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4 WHEEL ANTILOCK BRAKE
SYSTEM (4WABS) . . . . . . . . . . . . . . . . . . . . . . . . 70
INSTRUMENT CLUSTER-RELATED SYSTEMS
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . 26
BODY-RELATED SYSTEMS
WINDSHIELD WIPER AND WASHER . . . . . . .
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WINDOW DEFROSTER . . . . . . . . . . . . .
KEYLESS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER WINDOW SYSTEM . . . . . . . . . . . . . . .
POWER DOOR LOCK SYSTEM . . . . . . . . . . . .
POWER OUTSIDE MIRROR . . . . . . . . . . . . . . .
AIR BAG SYSTEM SERVICE CAUTIONS /
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . .
AIR BAG SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
IMMOBILIZER SYSTEM . . . . . . . . . . . . . . . . . . .
THEFT-DETERRENT SYSTEM . . . . . . . . . . . . .
32
46
52
58
62
64
68
72
74
76
78
34
36
36
36
38
40
42
44
46
Z-GI
Contents of wiring diagrams
D This wiring diagram comprises the sections shown below.
GI
General information
Ground points
Schematic
A~U
Connectors
PI
Parts index
GI
Ground points
This shows ground points of the harness.
GROUND POINTS(4SD)
3
10
12
B/W
B
B
E
B
B
B
B
C
B
B
B
B
E
D
C
B
A
(WITHOUT AIR BAG SYSTEM)
D
B
C
A
E
B
B
B
B
B
B
B
E
D
C
B
A
(WITH AIR BAG SYSTEM)
WITH ABS
B(EM)
B(F)
B(F)
B(F)
B(F)
TO
EACH
UNIT
B
(F)
B(EM)
B(EM)
B(EM)
B(D)
B(D)
EMISSION
HARNESS
(EM)
B(D)
11
B(D)
B(D)
DASH
HARNESS
(D)
B(D)
B/W(EM)
B(D)
WITH AIR BAG SYSTEM
TO
EACH
UNIT
FRONT
HARNESS
(F)
JC-02
10
JC-03
B(D)
B(EM)
B(F)
TO
EACH
UNIT
B(D)
B(EM)
JC-01
B(F)
B(D)
B/O(D)
B(F)
B(F)
B(I)
B(I)
B(I)
B(F)
B(F)
B(F)
INSTRUMENT
PANEL
HARNESS
(I)
B(IN)
B(F)
12
INTERIOR
LIGHT
HARNESS
(IN)
SHORT
CORD
Ground indication
On vehide
Indication
MAIN
100A
FB-09
IG KEY
60A
X-01
FB-07
B(E)
B/W(F)
A
INJ OR
FIP
30A
B/W(D)
FB-05
BTN
40A
B(F)
JB-05
G
W/R(F)
W/R(D)
1B
L/R
(D)
X-06
FB-04
FB-03
2
D
X-09
L/R(E)
L/R(EM)
LG/R
(EM)
W/Y
(EM)
1E
1B
SPV RELAY
(SECTION B-1b)
L/R
(EM)
B/L
(EM)
1A
1F
ACC
X-03
L(D)
AA
X-06
IG1 IG2
ENGINE
10A
14 JB-01
JB-04
B/L(D)
MAIN RELAY
X-03
OFF
ENGINE SWITCH ST
Y/L(F)
S
B(D)
FB-04
W/G(EM)
I
FB-04
ROOM
10A
8
FB-03
FB-03
JB-03
B1-01
B/W
(F)
3W
B1-03
B1-02
PCM
2M
GLOW
PLUG
RELAY
3R
3P
1S
LG
(EM)
BR/B
(EM)
G/B
(EM)
1N
1Q
B1-01
L
(EM)
B1-02
L
(E)
FB-01
FB-03
L(E)
L
(E)
B
(E)
J
B1-05
X-09
11
22
23
B
B1-04
L/B
(EM)
G/W
(EM)
14
B
(EM)
A/C RELAY
(SECTION G-2)
REFRIGERANT
PRESSURE SWITCH
(SECTION G-1)
31
AD FAN RELAY
(SECTION G-2)
GLOW
PLUG
B1-01 PCM(EM)
1U
1O
1S
W/L
V/W
1V
1T
1R
B/W
1M
1K
L/W
L/R
1I
1G
1Q
W/R L/B
W/G
1A
2O
LG/R
R/Y
L/R
G/R
B/L
1C
W/Y
1F
1D
1B
2P
1E
P/L
G/W
1P
1N
1L
1J
1H
2K
2I
2G
2E
2A
3Y
R/Y
GY/R P/B
B/W
2M
L
L/W
2N
2L
2J
BR/Y L/Y
2H
2F
2D
3
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
2B
3Q
3Z
3X
3M
3K
V
LG BR/B Y/B
3O
G/R
3I
3L
3J
3H
3F
3S
3V
3T
3A
3G
R/B
L/R
R/L
(SHORT CORD)
B
3U
3W
2C
LG/B BR/W R/L
3R
3P
3N
3E
3C
G/Y
B/O
3D
3B
L/R
L
B
GI
System name
BATTERY
-
MAIN
100A
FB-09
IG KEY
60A
X-01
FB-07
B(E)
B/W(F)
A
FB-05
B(F)
INJ OR
FIP
30A
FB-03
FB-03
FB-04
Y/L(F)
W/G(EM)
GLOW
40A
FB-04
MAIN RELAY
FB-03
U
D
FB-04
X-09
Y
L/R(E)
L/R(EM)
LG/R
(EM)
W/Y
(EM)
1E
1B
B1-01
B/W
(F)
3W
B1-03
B1-02
2M
GLOW
PLUG
RELAY
LG
(EM)
BR/B
(EM)
23
22
L
(EM)
FB-01
FB-03
L(E)
L
(E)
B1-05
X-09
3P
B1-01
B1-02
B
(E)
3R
B
B
(EM)
B1-04
GLOW
PLUG
Connector code
B1-01 PCM(EM)
1U
1S
1Q
W/R
L/B
W/G
W/L
V/W
1V
1T
1R
Y : Ground connector
A : Charging system/starting system
connectors
B : Engine control system connectors
C : Gauge control system connectors
D : Wiper system connectors
E : Lighting system connectors
F : Signal system connectors
G : Air-conditioning system connectors
H : Transmission control/Key interlock/
Shift-lock system connectors
I : Interior light system connectors
J : Audio/radio connectors
K : Power window/power door lock system
connectors
L : Remote control mirror system connectors
M : Sliding sunroof system connectors
O : Anti-lock brake system connectors
P : Power seat/seat warmer system connectors
Q : Auto cruise control system connectors
S : Passive shoulder belt control/Airbag system
connectors
T : Others
U : Data link connector
X : Common connectors
JB : Joint box connections
FB : Main fuse block
B/W
1M
L/W L/R
1K
1I
1G
1C
1A
2O
LG/R
R/Y
R/W
G/R
B/L
G/Y W/Y
1E
W/Y
G/W
1P
1N
1L
1J
1H
1F
2K
2I
2G
2E
2A
2M
1D
1B
2C
LG/B BR/W R/L
L/W
R
2P
2N
2L
2J
BR/Y L/Y
2H
2F
2D
Symbol
Harness
9
Unit
Sensor
O
2B
(SHORT CORD)
Ground numbers
4
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
1O
P/L
GI
System code
Multiplex communication
B-1a
DATA LINK
CONNECTOR(DLC)
(SECTION U)
B/W(D)
B(D)
1B
IG1 IG2
ENGINE
10A
14 JB-01
JB-04
G/Y
(EM)
W/Y
(EM)
R/W
(EM)
OFF
ENGINE SWITCH ST
X-06
16
X-03
ACC
X-03
Current symbol
L(D)
B/L(D)
AA
B/L
(EM)
B1-01
1F
1D
1I
1A
PCM
2C
2A
1S
2B
2E
R/Y
(EM)
SHIELD WIRE
W/R
(EM)
P/B
(EM)
O
(EM)
GY/R
(EM)
* Shielded wire :
Prevents signal disturbances from
electrical interference.
Wire is covered by a metal meshing for
grounding.
B1-07
INTAKE AIR
TEMPERATURE
SENSOR NO.1
B1-07
O
(EM)
B
(EM)
14
REFRIGERANT
PRESSURE SWITCH
(SECTION G-1)
B1-06
Connector symbols
BOOST SENSOR
3Y
3U
3W
B/W
3Q
3M
3K
3I
3S
V
LG BR/B Y/B
3X
3V
3T
3A
3G
R/B
L/R
R/L
3Z
3O
3R
3P
3N
3E
G/Y
3L
3J
3H
3F
3C
G/R
P/B GY/R
Circuit diagram
symbol
L/R
L
B/O
3D
Connector
diagram symbol
3B
Male
R/Y
Male
Female
L
Female
B Black
(F)
Striped wire
W/R
(F)
White
(base color)
Red(stripe)
5
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
GI
Routing diagram
The routing diagram shows where electrical components are on the system circuit diagram by call out line
and connector symbols.
Connector symbol
Component name
Ground symbol
(Example)
Connector
Symbol
Common connectors
X-19
System connectors
I-03
HARNESS SYMBOL :
(F)
(E)
(R)
INSTRUMENT
CLUSTER
VACUUM
SWITCH
C-01
C-05
6
(F)-(I)
X-02
(F)-(I)
X-02
C-06
PARKING BRAKE SWITCH
6
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
GI
Harness symbols
DESCRIPTION OF HARNESS
SYMBOL
DESCRIPTION OF HARNESS
SYMBOL
FRONT HARNESS
(F)
(DR1)
(F2)
(DR2)
ENGINE HARNESS
(E)
(DR3)
DASH HARNESS
(D)
(DR4)
REAR HARNESS
(R)
FLOOR HARNESS
(FR)
(R2)
(IN)
(R3)
A/C HARNESS
(AC)
(I)
INJECTION HARNESS
(INJ)
(HB)
EMISSION HARNESS
(EM)
(EM2)
(EM3)
7
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
GI
Symbols
Symbol
Meaning
Symbol
Meaning
Battery
Light
Ground (1)
1
Ground (2)
3.4W
Resistance
Motor
Pump
Cigarette lighter
Remarks
Current will not flow through a circuit if
ground is faulty.
Melts when current flow exceeds that
specified for circuit, interrupts current
flow.
Fuse (1)
Precautions
Do not replace with fuses exceeding
specified capacity.
(box)
Fuse (2)
<Blade type>
<Tube type>
Horn
(Cartridge)
Main fuse/
Fusible link
<Cartridge type>
<Fusible link>
Speaker
Transistor (1)
Collector (C)
Base (B)
NPN
Emitter (E)
B
E
Transistor (2)
C
EC B
Heater
E
B
Speed sensor
Ignition switch
Reading code.
Collector (C)
2 S C 828 A
Base (B)
PNP
Emitter (E)
Semiconductor
Number of
terminals
Revision mark
A:High-frequency PNP
B:Low-frequency PNP
C:High-frequency NPN
D:Low-frequency NPN
B2
IG2
8
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
B1
ST
OFF
IG1
OFF
ACC
Meaning
GI
Symbol
Meaning
Harness
Connection
D
B
Switch (2)
Selection
WITH ABS
A
Diversion point D
for the different
circuits according to the vehicles specification
is indicated by a
white dot.
Normally closed
(NC)
Relay (1)
WITHOUT ABS
C
Current flowing through coil produces electromagnetic force causing contact to open or close.
No current to coil
Current to coil
Flow
No flow
Current flowing through coil produces electromagnetic force causing contact to close.
No current to coil
Current to coil
Flow
No flow
Diode
Sensor
(thermistor)
Capacitor
Light-emitting
diode
(LED)
A K
A K
Cathode(K)
Anode(A)
Flow of electric current
Anode(A)
Cathode(K)
Anode(A)
Flow of current
Solenoid
9
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
Reference diode
(Zener diode)
GI
Symbol
Meaning
The wiring position can be exchanged freely within the
connector.
C
B
A
B
B
D
B
B
C
B
A
B
B
D
B
B
C
B
A
B
B
D
B
B
Third Gear
CCT
Circuit
4GR
Fourth Gear
CIGAR
Cigarette
Ampere
CIS
A/C
Air Conditioning
CKP
A/F
Air Fuel
CLS
A/R
Auto Reverse
CMP
AAS
COMBI
Combination
ABS
CON
Conditioner
ACC
Accessories
CONT
Control
ACV
CPU
ADD
Additional
CSD
AIR
CTP
AIS
DEF
Defroster
ALL
DI
Distributor Ignition
AM
Amplitude Modulation
DIS
AMP
Amplifier
DLC
ANT
Antenna
DLI
Distributorless Ignition
AP
Accelerator Pedal
DOHC
Double-Overhead Camshaft
AS
Autoshop
DTC
ASV
DTM
AT
Automatic Transmission
ECPS
ATX
Automatic Transaxle
ECT
B+
EGR
BAC
EI
Electronic Ignition
BARO
Barometric Pressure
ELEC
Electric
CAC
ELR
CARB
Carburetor
ETR
Electronic Tuner
10
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
Front
Power
F/I
Fuel Injector
P/S
Power Steering
FC
Fan Control
P/W CU
FICB
PAIR
FM
Frequency Modulation
PCM
FP
Fuel Pump
PNP
PRCV
Park/Neutral Position
GI
FPR
GEN
Generator
GND
Ground
PRG
H/D
Heater/Defroster
PSP
HEAT
Heater
PTC
HEI
High-Energy Ignition
QSS
Quick-Start System
HI
High
Rear
HO2S
REC
Recirculation
IAC
RF
Right Front
IAT
RH
Right Hand
ICM
RPM
Engine Speed
IG
Ignition
RR
Right Rear
ILLUMI
Illumination
SAPV
INT
Intermittent
SFI
JB
Joint Box
SOL
Solenoid
KS
Knock Sensor
SPV
Spill Valve
LCD
ST
Start
LF
Left Front
SW
Switch
LH
Left Hand
TC
Turbocharger
LO
Low
TCM
Transmission(Transaxle)Control Module
LR
Left Rear
TCS
Motor
TCV
MAF
TDC
MAP
TEMP
Temperature
MFI
TICS
MID
Middle
TP
MIL
TR
Transmission Range
MIN
Minute
TR
Transmission(Transaxle)Range
MIX
Mixture
TWS
MPX
Multiplex
Volt
MT
Manual Transmission
VAF
MTR
VENT
Ventilation
MTX
Manual Transaxle
VOL
Volume
NC
Normally Closed
VR
Voltage Regulator
NO
Normally Open
VRIS
O2S
Oxygen Sensor
VSS
OBD
On-board Diagnostic
Watt(s)
OFF
Switch Off
WOT
ON
Switch On
OSC
Oscillator
Valve
11
Form No.5561-1E-02H
5561-10-02H
F180-30-02H
Y-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
GROUND POINT
12
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
13
2
X-06
;
;;;;;
;;;;;
;;;;;
;;;;;
(F)-(FR)
X-06
(F)-(FR)
Y-a
Y-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
GROUND POINT
14
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;
;;;;;
;;;;;
;;;;;
;;;;;
[DOUBLE CAB]
13
9
X-04
(F)-(R)
10
15
(R)-(DR3)
X-28
11
(F)-(R)
X-04
13
X-29
(FR)-(DR4)
12
10
Y-b
W
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
16
A
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
18
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
(F)-(E)
[GRAY]
(F)-(E)
X-08
X-09
X-01
19
A-02
GENERATOR
[GRAY]
A-01
STARTER
A-02
GENERATOR
;
;;;;;
;;;;;
;;;;;
;;;;;
X-03
FUSE BLOCK
A-03
STARTER RELAY
X-02
ENGINE SWITCH
B-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
20
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
[BLACK]
EGR SOLENOID VALVE
(VACUUM)
[BLACK]
B-03
[GRAY]
(F)-(E)
B-03
B-07
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
X-08
[BROWN]
GLOW PLUG RELAY
[GRAY]
INJECTION PUMP
B-10
[GRAY]
(F)-(E)
X-09
B-08
[BLACK]
INTAKE SHUTTER
SOLENOID VALVE
B-06
NEUTRAL SWITCH
B-13
X-01
21
;
;;;;;
;;;;;
;;;;;
;;;;;
4
B-09
EGR CONTROL
SOLENOID VALVE
B-05
GLOW PLUG
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
B-01
PCM
X-30
JOINT CONNECTOR
B-02
PCM CONTROL RELAY
B-11
IDEL SWITCH
B-12
CLUTCH SWITCH
B-a
B-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
22
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
[GRAY]
(F)-(E)
[GRAY]
(F)-(E)
[GRAY]
ENGINE COOLANT
TEMPERATURE SENSOR
X-08
B-15
X-09
23
B-14
INJECTION PUMP
[GRAY]
B-16
INTAKE AIR
TEMPERATURE
SENSOR No.2
[BLACK]
B-17
B-18
EGR VALVE
BOOST SENSOR
POSITION SENSOR [BLACK]
[GRAY]
;
;;;;;
;;;;;
;;;;;
;;;;;
B-01
PCM
X-30
JOINT CONNECTOR
B-19
ACCELERATOR
POSITION SENSOR
[BLACK]
B-b
B-c
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
24
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
INJECTION PUMP
B-20
[GRAY]
TDC SENSOR
B-22
B-21
25
;
;;;;;
;;;;;
;;;;;
;;;;;
B-01
PCM
X-30
JOINT CONNECTOR
B-c
C-a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
INSTRUMENT CLUSTER
26
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
[GRAY]
(F)-(E)
X-08
[GRAY]
VEHICLE SPEEDOMETER SENSOR
2WD
(R)-(R2)
X-19
C-03
C-04
X-01
C-03
4WD
VEHICLE SPEEDOMETER SENSOR
[GRAY]
[DOUBLE CAB]
(F)-(R)
X-04
C-02
WATER TEMPERATURE
SENDER UNIT
27
(R)-(R2)
C-04
X-19
;
;;;;;
;;;;;
;;;;;
;;;;;
INSTRUMENT CLUSTER
C-01
[BLACK]
INSTRUMENT CLUSTER
C-01
(F)-(R)
X-04
X-03
FUSE BLOCK
X-04
(F)-(R)
X-02
ENGINE SWITCH
C-a
C-b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
INSTRUMENT CLUSTER
28
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
BRAKE FLUID
LEVEL SENSOR
SEDIMENTOR SWITCH
C-07
C-05
[GRAY]
(F)-(E)
X-09
29
;
;;;;;
;;;;;
;;;;;
;;;;;
INSTRUMENT CLUSTER
C-01
[BLACK]
INSTRUMENT CLUSTER
C-01
(F)-SHORT CORD
C-06
OIL PRESSURE SWITCH
C-09
C-08
C-b
C-c
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
INSTRUMENT CLUSTER
30
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;
;;;;;;
;;;;;;
;;;;;;
;;;;;;
INSTRUMENT CLUSTER
C-01
[BLACK]
INSTRUMENT CLUSTER
31
6
C-01
C-c
D
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
32
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
WINDSHIELD
WIPER MOTOR
D-03
33
D-01
WINDSHIELD
WASHER MOTOR
;
;;;;;
;;;;;
;;;;;
;;;;;
5
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
D-02
WINDSHIELD
WIPER AND WASHER SWITCH
E-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
HEADLIGHT
34
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
[DOUBLE CAB]
(F)-(R)
HEADLIGHT RH
E1-03
X-04
E1-02
35
HEADLIGHT LH
;
;;;;;
;;;;;
;;;;;
;;;;;
X-04
E1-01
X-03
HEADLIGHT SWITCH
FUSE BLOCK
X-04
(F)-(R)
E-1
E-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
36
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
TAILLIGHT RH
E2-06
(R)-(R2)
[GRAY]
LICENSE PLATE LIGHT RH
X-19
7
E2-04
[GRAY]
LICENSE PLATE LIGHT LH
E2-07
E2-02
E2-05
TAILLIGHT LH
[DOUBLE CAB]
8
PARKING LIGHT RH
TAILLIGHT RH
37
E2-01
(R)-(R2)
PARKING LIGHT LH
E2-06
X-19
7
[GRAY]
LICENSE PLATE LIGHT RH
E2-04
[GRAY]
LICENSE PLATE LIGHT LH
E2-07
TAILLIGHT LH
E2-05
E-2
E-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
38
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
1
E3-03
HEADLIGHT
LEVELING
ACTUATOR RH
39
E3-02
;
;;;;;
;;;;;
;;;;;
;;;;;
5
HEADLIGHT
LEVELING
ACTUATOR LH
E3-01
HEADLIGHT
LEVELING SWITCH
E-3
E-4
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
40
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
(R)-(R2)
;
;;;;;
;;;;;
;;;;;
;;;;;
X-19
7
E4-03
E4-01
[DOUBLE CAB]
8
(F)-(R)
X-04
X-04
(F)-(R)
41
E4-02
(R)-(R2)
X-19
E4-03
X-04
E-4
F-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
42
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
F1-05
(R)-(R2)
E2-06
X-19
7
X-01
1
F1-03
[DOUBLE CAB]
E2-05
(F)-(R)
X-04
8
F1-06
FRONT SIDE TURN LIGHT LH
REAR TURN LIGHT RH
43
(R)-(R2)
F1-04
;
;;;;;
;;;;;
;;;;;
;;;;;
HAZARD
WARNING SWITCH
F1-02
7
REAR TURN LIGHT LH
FLASHER UNIT
X-19
E2-06
F1-01
(F)-(R)
E2-05
X-04
X-03
E1-01
TURN SWITCH
FUSE BLOCK
X-04
X-02
ENGINE SWITCH
(F)-(R)
F-1
F-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
BACK-UP LIGHT
44
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
BACK-UP LIGHT RH
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
(R)-(R2)
E2-06
X-19
7
[GRAY]
(F)-(E)
X-08
F2-01
X-01
E2-05
[DOUBLE CAB]
BACK-UP LIGHT LH
(F)-(R)
X-04
BACK-UP LIGHT RH
E2-06
45
(R)-(R2)
X-19
;
;;;;;
;;;;;
;;;;;
;;;;;
7
BACK-UP LIGHT LH
E2-05
X-04
X-03
FUSE BLOCK
X-04
(F)-(R)
X-02
ENGINE SWITCH
F-2
F-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
46
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
BRAKE LIGHT RH
(R)-(R2)
E2-06
X-19
7
X-01
[DOUBLE CAB]
E2-05
BRAKE LIGHT LH
(F)-(R)
X-04
8
F3-05
HORN RH
[BLACK]
47
BRAKE LIGHT RH
(R)-(R2)
F3-02
X-19
HORN LH
[BLACK]
;
;;;;;
;;;;;
;;;;;
;;;;;
HORN RELAY
F3-01
SHORT CONNECTOR
E2-06
7
BRAKE LIGHT LH
E2-05
X-04
S1-02
X-03
FUSE BLOCK
F3-04
HORN SWITCH
X-04
(F)-(R)
F3-03
BRAKE SWITCH
F-3
G
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
48
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[GRAY]
(F)-(E)
X-09
A/C RELAY
G-07
X-01
49
G-09
;
;;;;;
;;;;;
;;;;;
;;;;;
5
REFRIGERANT
PRESSURE SWITCH
[BLACK]
A/C SWITCH
G-11
G-08
RESISTOR
MAGNETIC CLUTCH
G-04
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
G-05
RESISTOR
G-01
CLIMATE
CONTROL UNIT
G-03
G-10
(F)-BLOWER UNIT
G-06
A/C AMPLIFIER
BLOWER MOTOR
H
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
50
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
[GRAY]
(F)-(E)
X-09
[GRAY]
(F)-(E)
X-08
[BLUE]
LOCK SOLENOID
H-02
FREE SOLENOID
H-03
[BLACK]
TRANSFER NEUTRAL SWITCH
H-07
[BLACK]
4 4 INDICATOR SWITCH
H-06
X-01
51
;
;;;;;
;;;;;
;;;;;
;;;;;
5
H-05
RFW SWITCH
[BLACK]
X-03
X-02
FUSE BLOCK
ENGINE SWITCH
H-04
H-01
RFW CONTROL
MODULE
I-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
52
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[BLACK]
FILAMENT
I1-03
X-01
[DOUBLE CAB]
(F)-(R)
X-04
I1-03
FILAMENT
[BLACK]
13
53
[BLACK]
FILAMENT
I1-03
;
;;;;;
;;;;;
;;;;;
;;;;;
REAR WINDOW
DEFROSTER SWITCH
I1-05
[BLACK]
OUTLET
I1-02
6
X-04
(F)-(R)
I1-01
(F)-(R)
X-04
I1-03
X-03
FUSE BLOCK
13
FILAMENT
[BLACK]
X-02
ENGINE SWITCH
I1-04
REAR WINDOW
DEFROSTER RELAY
CIGARETTE LIGHTER
[BLACK]
I-1
I-2
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
54
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
HAZARD
WARNING SWITCH
ILLUMINATION
55
;
;;;;;
;;;;;
;;;;;
;;;;;
F1-02
AUDIO UNIT
ILLUMINATION
(OPTION)
CLOCK
[BLACK]
INSTRUMENT CLUSTER
ILLUMINATION
C-01
I2-01 C-01
J-01
INSTRUMENT CLUSTER
ILLUMINATION
X-03
FUSE BLOCK
I2-02
X-02
ENGINE SWITCH
PANEL LIGHT
CONTROL SWITCH
I2-03
HEATER CONTROL
ILLUMINATION
I-2
I-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
INTERIOR LIGHT
56
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
INTERIOR LIGHT
I3-01
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[BLACK]
DOOR SWITCH RF
I3-02
X-01
[DOUBLE CAB]
X-10
I3-04
DOOR SWITCH RR
[BLACK]
(F)-(IN)
X-04
I3-05
(F)-(R)
I3-06
DOOR SWITCH LR
[BLACK]
(FR)-SHORT CORD
I3-03
DOOR SWITCH LF
[BLACK]
X-06
(F)-(FR)
57
(R)-(DR3)
;
;;;;;
;;;;;
;;;;;
;;;;;
[BLACK]
FREESTYLE CAB/
DOOR SWITCH RF
STRETCH CAB
(WITH REAR ACCESS SYSTEM)
[BLACK]
EXCEPT FREESTYLE CAB/
DOOR SWITCH RF
STRETCH CAB
(WITH REAR ACCESS SYSTEM)
X-28
I3-02
(F)-(IN)
X-10
INTERIOR LIGHT
I3-01
I3-02
X-10
X-03
FUSE BLOCK
X-04
(F)-(R)
X-04
(F)-(R)
X-29
(FR)-(DR4)
I3-03
DOOR SWITCH LF
[BLACK]
X-06
(F)-(FR)
X-06
(F)-(FR)
FREESTYLE CAB/
STRETCH CAB
(WITH REAR ACCESS SYSTEM)
I3-03
DOOR SWITCH LF
[BLACK]
I-3
I-4
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
KEYLESS UNIT
58
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
59
;
;;;;;
;;;;;
;;;;;
;;;;;
5
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
I4-01
KEYLESS UNIT
I-4
J
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
AUDIO SYSTEM
60
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
REAR DOOR
SPEAKER RH
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
J-04
(R)-(DR3)
X-22
[DOUBLE CAB]
X-01
(F)-(DR1)
X-13
FRONT DOOR
SPEAKER RH
J-03
REAR DOOR
SPEAKER LH
(F)-(R)
J-05
X-04
X-25
(FR)-(DR4)
J-02
FRONT DOOR
SPEAKER LH
X-16
(F)-(DR2)
61
X-06
(F)-(FR)
;
;;;;;
;;;;;
;;;;;
;;;;;
(R)-(DR3)
(F)-(DR1)
X-13
AUDIO UNIT
(OPTION)
J-01
(F)-(DR2)
X-16
(F)-(DR1)
X-13
REAR DOOR
SPEAKER RH
X-28
J-04
FRONT DOOR
SPEAKER RH
J-03
(F)-(R)
X-04
X-03
FUSE BLOCK
X-04
(F)-(R)
X-02
X-29
ENGINE SWITCH
J-05
(FR)-(DR4)
REAR DOOR
SPEAKER LH
J-02
FRONT DOOR
SPEAKER LH
X-06
(F)-(FR)
X-16
(F)-(DR2)
X-06
(F)-(FR)
K-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
62
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
POWER WINDOW
SUBSWITCH RR
(R)-(DR3)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
POWER WINDOW
SUBSWITCH LR
K1-03
X-22
K1-04
(R)-(DR3)
[BLUE]
FRONT POWER
WINDOW
REGULATOR RH
X-01
POWER WINDOW
MAIN SWITCH
X-23
REAR POWER
WINDOW REGULATOR LH
K1-01
K1-08
K1-05
[DOUBLE CAB]
X-13
(F)-(DR1)
X-26
(FR)-(DR4)
X-15
(F)-(DR1)
X-25
(FR)-(DR4)
K1-02
POWER WINDOW
SUBSWITCH LF
X-04
K1-06
(F)-(R)
FRONT POWER
WINDOW
REGULATOR LH
[BLUE]
X-05
(F)-(R)
X-16
K1-09
(F)-(DR2)
X-18
63
(F)-(DR2)
POWER WINDOW
MAIN SWITCHFRONT POWER WINDOW
REGULATOR RH
(F)-(FR)
K1-07
REAR POWER
WINDOW REGULATOR RH
X-07
(F)-(FR)
X-06
;
;;;;;
;;;;;
;;;;;
;;;;;
4
(F)-(DR2)
X-16
X-05
(F)-(R)
X-18
POWER WINDOW
MAIN SWITCH[BLUE]
FRONT POWER WINDOW
FRONT POWER
WINDOW REGULATOR RH REGULATOR RH
(F)-(DR1)
X-13
K1-05
POWER WINDOW
MAIN SWITCH
K1-01
K1-09
(F)-(DR1)
X-15
(F)-(DR1)
[REGULAR CAB,STRETCH CAB
(WITHOUT REAR ACCESS SYSTEM), X-13
FREESTYLE CAB/STRETCH CAB
(WITH REAR ACCESS SYSTEM)]
X-02
ENGINE SWITCH
X-03
FUSE BLOCK
X-04
(F)-(R)
X-15
K1-02
(F)-(DR1)
POWER WINDOW
SUBSWITCH LF
(F)-(DR2)
K1-06
X-06
FRONT POWER
WINDOW REGULATOR LH
[BLUE]
X-16
(F)-(FR)
(F)-(DR2)
X-07
(F)-(FR)
X-18
(F)-(DR2)
K-1
K-2a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
64
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
K2-02
(F)-(DR1)
X-15
[DOUBLE CAB]
65
;
;;;;;
;;;;;
;;;;;
;;;;;
DOOR LOCK
TIMER UNIT
K2-01
(F)-(DR1)
X-15
(F)-(DR1)
X-15
X-03
FUSE BLOCK
K-2a
K-2b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
66
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;
;;;;;
;;;;;
;;;;;
;;;;;
DOOR LOCK
ACTUATOR RR
K2-04
K2-01
(R)-(DR3)
(F)-(DR1)
X-23
DOOR LOCK
ACTUATOR RF
X-15
K2-02
(F)-(DR1)
X-15
[DOUBLE CAB]
X-05
(F)-(R)
K2-05
X-26
X-18
(F)-(DR2)
DOOR LOCK
ACTUATOR LR
(FR)-(DR4)
K2-03
X-05
DOOR LOCK
ACTUATOR LF
(F)-(R)
X-07
(F)-(FR)
67
X-18
(F)-(DR2)
X-07
(F)-(FR)
DOOR LOCK
ACTUATOR RF
K2-02
(F)-(DR1)
K2-03
DOOR LOCK
ACTUATOR LF
X-18
(F)-(DR2)
K-2b
L
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
68
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
POWER OUTSIDE
MIRROR RH
L-02
(F)-(DR1)
X-14
X-01
[DOUBLE CAB]
L-03
POWER
OUTSIDE MIRROR LH
69
X-17
(F)-(DR2)
;
;;;;;
;;;;;
;;;;;
;;;;;
5
X-17
(F)-(DR1)
X-14
POWER OUTSIDE
MIRROR RH
L-02
(F)-(DR1)
X-14
L-01
POWER OUTSIDE
MIRROR SWITCH
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
L-03
POWER
OUTSIDE MIRROR LH
(F)-(DR2)
X-17
(F)-(DR2)
O
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
70
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
(R)-(R2)
X-20
[GRAY]
ABS HU/CM
O-01
[GRAY]
ABS WHEEL-SPEED
SENSOR RR
O-05
X-01
[GRAY]
ABS WHEELSPEED SENSOR RF
O-03
(R)-(F2)
X-21
(F)-(R)
X-04
[DOUBLE CAB]
O-04
ABS WHEEL-SPEED
SENSOR LR
[GRAY]
O-06
71
G SENSOR
[BLACK]
(R)-(R2)
O-02
ABS WHEELSPEED SENSOR LF
[GRAY]
;
;;;;;
;;;;;
;;;;;
;;;;;
(F)-(F2)
X-12
(F)-(F2)
X-20
X-11
[GRAY]
ABS WHEEL-SPEED
SENSOR RR
O-05
(R)-(F2)
X-21
ENGINE SWITCH
X-02
(F)-(R)
FUSE BLOCK
X-04
O-04
X-03
ABS WHEEL-SPEED
SENSOR LR
[GRAY]
X-21
(R)-(F2)
X-04
(F)-(R)
O-06
G SENSOR
[BLACK]
S
AIR BAG SYSTEM
SERVICE WARNINGS
Component Disassembly
RIGHT
WRONG
RIGHT
WRONG
*The references in this section can be found in B Series Workshop Manual [1644-10-99A (1999-1)] or
RANGER Repair Manual [F161-10-99A (1999-1)]
72
Form No. 5561-1E-02H
5561-10-02H
F180-30-02H
S
SAS Unit Handling
Disconnecting the SAS unit connector or removing
the SAS unit with the ignition switch at ON position
can cause the air bag modules to deploy, which
may seriously injure you. Before disconnecting the
SAS unit connector or removing the SAS unit, turn
the ignition switch to LOCK position, then
disconnect the negative battery cable and wait for
more than 1 minute to allow the backup power
supply of the SAS unit to deplete its stored power.
Connecting the SAS unit connector without firmly
installing the SAS unit to the vehicle is dangerous.
The crash sensor inside the unit may send an
electrical signal to the air bag modules. This will
deploy the air bag modules, which may result in
serious injury. Therefore, before connecting the
connector, firmly mount the unit to the vehicle.
For vehicles with a single point sensor, once an air
bag is deployed due to an accident or other causes,
the SAS unit must be replaced with a new one even
if the used one does not have any external signs of
damage. The used SAS unit may have been
damaged internally which may cause improper
operation, resulting in major injuries or even death.
The used single point SAS unit cannot be benchchecked or self-checked.
Component Handling
Oil, grease, water, etc on components may cause
the air bag modules to fail to deploy in an accident,
which may cause serious injury. Do not allow oil,
grease, water, etc on components.
Inserting a screwdriver, etc into the connector of
an air bag module may damage the connector and
cause the air bag module to deploy improperly,
which may cause serious injury. Do not insert any
foreign objects into the connector.
Component Reusing
Even if an air bag madule does not deploy in a
collision and does not have any external signs of
damage, it may have been damaged internally,
which may cause improper operation. Improper
operation may cause serious injury. Always selfcheck the undamaged air bag module to determine
whether it can be reused. (Refer to ON-BOARD
DIAGNOSTIC FUNCTION, AIR BAG SYSTEM.)
*The references in this section can be found in B Series Workshop Manual [1644-10-99A (1999-1)] or
RANGER Repair Manual [F161-10-99A (1999-1)]
73
Form No. 5561-1E-02H
5561-10-02H
F180-30-02H
S-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
74
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
MAIN FUSE BLOCK
X-01
75
;
;;;;;
;;;;;
;;;;;
;;;;;
[YELLOW]
(F)-CLOCK SPRING
[YELLOW]
PASSENGER-SIDE
AIR BAG MODULE
S1-04
6
S1-03
SHORT CONNECTOR
S1-02
X-03
FUSE BLOCK
S1-05
DRIVER-SIDE
AIR BAG MODULE
X-02
ENGINE SWITCH
S1-01
SAS UNIT
S-1
T-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
IMMOBILIZER SYSTEM
76
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
X-01
77
;
;;;;;
;;;;;
;;;;;
;;;;;
IMMOBILIZER UNIT
T1-01
COIL
T1-02
X-03
FUSE BLOCK
T1-03
KEY REMINDER
SWITCH
X-02
ENGINE SWITCH
X-30
JOINT CONNECTOR
T-1
T-2a
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
THEFT-DETERRENT SYSTEM
78
;
;
;
(F)
HARNESS SYMBOL:
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
[BLACK]
BONNET SWITCH
T2-05
DOOR KEY
CYLINDER SWITCH RF
T2-06
X-01
(F)-(DR1)
X-15
[DOUBLE CAB]
T2-07
DOOR KEY
CYLINDER SWITCH LF
79
X-18
(F)-(DR2)
;
;;;;;
;;;;;
;;;;;
;;;;;
THEFT-DETERRENT
CONTROL MODULE
T2-01
(F)-(DR1)
(F)-(DR1)
X-15
X-15
DOOR KEY
CYLINDER SWITCH RF
T2-06
X-03
T2-07
DOOR KEY
CYLINDER SWITCH LF
FUSE BLOCK
T2-01
THEFT-DETERRENT
CONTROL MODULE
[BLACK]
X-02
ENGINE SWITCH
X-18
(F)-(DR2)
X-18
(F)-(DR2)
T-2a
T-2b
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
THEFT-DETERRENT SYSTEM
80
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
DOOR LOCK-LINK
SWITCH RR
K2-04
(R)-(DR3)
X-01
X-24
(F)-(R)
X-04
K2-05
X-27
DOOR LOCK-LINK
SWITCH LR
(FR)-(DR4)
T2-03
THEFT-DETERRENT HORN RELAY
X-05
10
(F)-(R)
81
T2-04
THEFT-DETERRENT HORN
;
;;;;;
;;;;;
;;;;;
;;;;;
THEFT-DETERRENT
CONTROL MODULE
X-07
(F)-(FR)
T2-01
X-05
X-03
FUSE BLOCK
X-04
(F)-(R)
T2-01
THEFT-DETERRENT
CONTROL MODULE
[BLACK]
(F)-(R)
X-07
(F)-(FR)
T-2b
U
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
82
;
;
;
HARNESS SYMBOL:
(F)
(E)
(R)
;;;;;;;
;
;;;;;;;
;;;;;;;
;;;;;;;
;;;;;;;
3
X-01
[GRAY]
DATA LINK CONNECTOR
U-01
83
;
;;;;;
;;;;;
;;;;;
;;;;;
X-03
FUSE BLOCK
X-02
ENGINE SWITCH
X-1
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
84
85
X-2
X-3
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
86
87
X-4
PARTS INDEX
4
A
A/C AMPLIFIER ................................................... 48
A/C RELAY ........................................................... 48
A/C SWITCH ........................................................ 48
ABS HU/CM ......................................................... 70
ABS WHEEL-SPEED SENSOR ........................... 70
ACCELERATOR POSITION SENSOR ................. 22
AUDIO UNIT ......................................................... 60
I
IDLE SWITCH ...................................................... 20
ILLUMINATION
AUDIO UNIT ....................................................... 54
HAZARD WARNING SWITCH ........................... 54
HEATER CONTROL .......................................... 54
INSTRUMENT CLUSTER .................................. 54
IMMOBILIZER UNIT ............................................. 76
INJECTION PUMP ................................... 20, 22, 24
INSTRUMENT CLUSTER ........................ 26, 28, 30
INTAKE AIR TEMPERATURE SENSOR ........ 22, 24
INTAKE SHUTER SOLENOID VALVE .................. 20
INTERIOR LIGHT ................................................. 56
B
BACK-UP LIGHT .................................................. 44
BACK-UP LIGHT SWITCH ................................... 44
BLOWER MOTOR ................................................ 48
BONNET SWITCH ............................................... 78
BOOST SENSOR ................................................. 22
BRAKE FLUID LEVEL SENSOR ......................... 28
BRAKE LIGHT ...................................................... 46
BRAKE SWITCH .................................................. 46
K
KEYLESS UNIT .................................................... 58
KEY REMINDER SWITCH ................................... 76
C
CIGARETTE LIGHTER ........................................ 52
CLIMATE CONTROL UNIT .................................. 48
CLUTCH SWITCH ................................................ 20
CLOCK ................................................................. 54
COIL ..................................................................... 76
L
LICENSE PLATE LIGHT ...................................... 36
LOCK SOLENOID ................................................ 50
M
D
DATA LINK CONNECTOR .................................... 82
DOOR KEY CYLINDER SWITCH ........................ 78
DOOR LOCK ACTUATOR .................................... 66
DOOR LOCK TIMER UNIT ............................ 64, 66
DOOR LOCK-LINK SWITCH ......................... 64, 80
DOOR SWITCH ................................................... 56
DRIVER-SIDE AIR BAG MODULE ...................... 74
N
NEUTRAL SWITCH ............................................. 20
O
OIL PRESSURE SWITCH .................................... 28
OUTLET ............................................................... 52
E
EGR CONTROL SOLENOID VALVE .................... 20
EGR SOLENOID VALVE ...................................... 20
EGR VALVE POSITION SENSOR ........................ 22
ENGINE COOLANT TEMPERATURE
SENSOR ............................................................ 22
P
PANEL LIGHT CONTROL SWITCH ..................... 54
PARKING BRAKE SWITCH ................................. 28
PARKING LIGHT .................................................. 36
PASSENGER-SIDE AIR BAG MODULE .............. 74
PCM ......................................................... 20, 22, 24
PCM CONTROL RELAY ...................................... 20
POWER OUTSIDE MIRROR ............................... 68
POWER OUTSIDE MIRROR SWITCH ................ 68
POWER WINDOW MAIN SWITCH ...................... 62
POWER WINDOW SUBSWITCH ......................... 62
F
FILAMENT ............................................................ 52
FLASHER UNIT ................................................... 42
FREE SOLENOID ................................................ 50
FRONT DOOR SPEAKER ................................... 60
FRONT POWER WINDOW REGULATOR ........... 62
FRONT SIDE TURN LIGHT ................................. 42
FRONT TURN LIGHT ........................................... 42
FUEL GAUGE SENDER UNIT ............................. 26
G
G SENSOR .......................................................... 70
GENERATOR ....................................................... 18
GLOW PLUG ........................................................ 20
GLOW PLUG RELAY ........................................... 20
H
HAZARD WARNING SWITCH ............................. 42
HEADLIGHT ......................................................... 34
HEADLIGHT LEVELING ACTUATOR .................. 38
88
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H
R
REAR DOOR SPEAKER ...................................... 60
REAR FOG LIGHT ............................................... 40
REAR FOG LIGHT RELAY ................................... 40
REAR FOG LIGHT SWITCH ................................ 40
REAR POWER WINDOW REGULATOR .............. 62
REAR TURN LIGHT ............................................. 42
REAR WINDOW DEFROSTER RELAY ............... 52
REAR WINDOW DEFROSTER SWITCH ............. 52
REFRIGERANT PRESSURE SWITCH ................ 48
RESISTOR ........................................................... 48
RFW CONTROL MODULE .................................. 50
RFW MAIN SWITCH ............................................ 50
RFW SWITCH ...................................................... 50
PARTS INDEX
S
SAS UNIT ............................................................. 74
SEDIMENTOR SWITCH ...................................... 28
STARTER ............................................................. 18
STARTER RELAY ................................................. 18
T
TAILLIGHT ............................................................ 36
TDC SENSOR ...................................................... 24
THEFT-DETERRENT
CONTROL MODULE ................................... 78, 80
THEFT-DETERRENT HORN ................................ 80
THEFT-DETERRENT HORN RELAY ................... 80
TRANSFER NEUTRAL SWITCH ......................... 50
TURN SWITCH .................................................... 42
V
VEHICLE SPEEDOMETER SENSOR ................. 26
W
WATER TEMPERATURE
SENDER UNIT ................................................... 26
WINDSHIELD WASHER MOTOR ........................ 32
WINDSHIELD WIPER AND
WASHER SWITCH ............................................ 32
WINDSHIELD WIPER MOTOR ............................ 32
89
Form No. 5561-1E-02H
Form No. 5561-10-02H
Form No. F180-30-02H